Organic Material Deposition for Display Intermediate Layer
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Solution Overview
Problem
Existing display apparatus manufacturing methods face challenges in maintaining consistent concentration ratios of organic materials with different phase transition temperatures, leading to potential defects in display quality such as altered brightness or resolution over time.
Innovation Solution
A display apparatus manufacturing method involving a chamber where at least two organic materials with phase transition temperatures differing by no more than 5°C at a saturated vapor pressure between 5×10−4 Torr to 3×10−2 Torr are deposited on a substrate to form an intermediate layer, ensuring a consistent concentration ratio and minimizing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If organic materials with different phase transition temperatures are deposited using conventional methods, then deposition can be performed, but the concentration ratio becomes inconsistent leading to display quality defects
Solution Approach 1:
The patent applies parameter changes by precisely controlling the saturated vapor pressure (5×10^-4 to 3×10^-2 Torr) and phase transition temperature difference (≤5°C) of organic materials during deposition. This controlled parameter range ensures that materials with different phase transition temperatures deposit at consistent concentration ratios, resolving the contradiction between manufacturing precision and reliability
Solution Approach 2:
The patent utilizes phase transitions by selecting organic materials whose phase transition temperatures differ by no more than 5°C at the specified saturated vapor pressure range. This phase transition control mechanism ensures simultaneous and uniform deposition of multiple organic materials, maintaining concentration ratio consistency and preventing display quality defects
2Productivity
If the phase transition temperature difference between organic materials is large, then deposition can occur at different rates, but the concentration ratio varies over time causing display defects
Solution Approach 1:
The patent changes the temperature parameter by limiting the phase transition temperature difference to 5°C or less, while maintaining the saturated vapor pressure within 5×10^-4 to 3×10^-2 Torr. This parameter optimization allows all organic materials to deposit at comparable rates simultaneously, ensuring consistent concentration ratios without compromising productivity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach maintains the concentration ratio of organic materials within a margin of error, ensuring high-quality display apparatus production with minimized defects and consistent performance over time.
Implementation Method 1
depositing the at least two organic materials on the first substrate to form an intermediate layer
Implementation Method 2
the at least two organic materials have different phase transition temperatures at a first saturated vapor pressure
Data Source
AI summary
A display apparatus includes an emission portion disposed on a substrate and comprising an intermediate layer; and an encapsulation portion sealing the emission portion by overlapping the emission portion, wherein the intermediate layer comprises at least two organic materials, the organic materials having different phase transition temperatures at a first saturated vapor pressure in a range from 5×10−4 Torr to 3×10−2 Torr, and the difference between the phase transition temperatures being less than or equal to 5° C.