Organic Layer Deposition Apparatus with Heated Blocking Member
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Solution Overview
Problem
Conventional organic light-emitting display apparatuses face challenges in achieving high light-emission efficiency and patterning fine organic thin layers, particularly for large-area displays, due to difficulties in forming uniform organic layers with satisfactory driving voltage, current density, brightness, color purity, and lifespan.
Innovation Solution
An organic layer deposition apparatus is designed with a deposition source, a patterning slit sheet, and a blocking member with a heating member, allowing for precise deposition and patterning of organic layers on a substrate, enabling the formation of large-sized organic light-emitting display apparatuses with improved manufacturing yield and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional organic layer deposition apparatus is used to deposit organic thin layers, then the deposition process can be performed, but the manufacturing precision deteriorates due to difficulty in forming fine patterns and uniform layers across large areas
Solution Approach 1:
The patent divides the deposition apparatus into multiple independent deposition source units, each capable of depositing material onto a specific region of the substrate. This segmentation allows precise control over material deposition patterns and enables formation of fine patterns across large areas by coordinating multiple deposition sources, thereby improving manufacturing precision without requiring a single overly complex apparatus
Solution Approach 2:
The patent employs movable components including a movable blocking member and adjustable deposition source positions, allowing dynamic control over the deposition process. This enables precise patterning by moving blocking members to define regions and adjusting source positions to optimize deposition uniformity across the substrate, resolving the contradiction between precision and complexity
2Area of stationary object
If the substrate area is increased to manufacture large-sized display apparatuses, then the display area is expanded, but the manufacturing precision deteriorates due to difficulty in forming uniform organic layers across large areas
Solution Approach 1:
The deposition apparatus is segmented into multiple deposition source units distributed across the substrate area, with each source contributing to a specific region. This allows uniform material deposition across large substrates by coordinating multiple sources, avoiding the uniformity problems associated with single-source deposition over large distances
Solution Approach 2:
The patent introduces a blocking member as an intermediary component that controls material flow and deposition patterns. By strategically positioning and moving this blocking member, the apparatus ensures uniform organic layer formation across large substrate areas, mediating between the deposition sources and the substrate to maintain precision despite the increased area
3Reliability
If intermediate layers are added between the emission layer and electrodes to improve light-emission efficiency, then the device performance is improved, but the manufacturing precision deteriorates due to difficulty in patterning multiple organic thin layers
Solution Approach 1:
The patent segments the deposition process into multiple sequential steps, with each deposition source unit responsible for depositing specific intermediate layers or the emission layer in defined regions. This segmentation enables precise patterning of multiple organic thin layers by controlling which source deposits material when and where, improving both light-emission efficiency and manufacturing precision
Solution Approach 2:
The patent employs dynamic control of deposition sources and blocking members to precisely define the spatial and temporal deposition of each intermediate layer. By moving blocking members and adjusting source positions between deposition steps, the apparatus achieves accurate multi-layer patterning, resolving the contradiction between improving device performance with intermediate layers and maintaining manufacturing precision
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
The apparatus enables the efficient deposition of organic layers on a large scale, enhancing manufacturing yield and deposition efficiency while preventing material deposition on non-layer formation regions, thus improving the overall performance and longevity of organic light-emitting displays.
Implementation Method 1
a heating member on the blocking member and configured to heat the blocking member
Implementation Method 2
a deposition source configured to discharge a deposition material
Data Source
AI summary
An organic layer deposition apparatus including: a deposition source configured to discharge a deposition material; a deposition source nozzle unit arranged at a side of the deposition source and including a plurality of deposition source nozzles; a patterning slit sheet facing the deposition source nozzle unit and including a plurality of patterning slits, the patterning slit sheet being smaller than the substrate in at least one of a first direction or a second direction perpendicular to the first direction; a blocking member configured to be disposed between the substrate and the deposition source to block at least a portion of the substrate; and a heating member on the blocking member and configured to heat the blocking member, and the substrate is spaced apart from the organic layer deposition apparatus by a predetermined distance, and the substrate or the organic layer deposition apparatus is movable relative to the other.