Organic EL Element Continuous Electrodes Inkjet Printing

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Solution Overview

Problem

The existing manufacturing methods for organic electroluminescent (EL) elements are costly due to the need for masks corresponding to each emission pattern, which increases production costs and complexity.

Innovation Solution

The method involves forming continuous electrodes and light emitting layers with different materials and thicknesses in various regions, allowing for the creation of predetermined emission patterns without the need for patterned masks, using techniques like inkjet printing to apply coating liquids with specific viscosities and overlapping boundaries to enhance visibility and reduce blurring.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If photolithography process, etching process, or evaporation process is used to form patterned electrodes, then the emission pattern can be obtained, but the manufacturing cost increases due to the need for masks

Engineering Contradiction:

Improveemission pattern precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent extracts the masking step from the manufacturing process by using continuous electrodes without patterns. The emission pattern is achieved not through patterned electrodes but through selective formation of light emitting layers in specific regions, thereby eliminating the need for masks and reducing manufacturing cost while maintaining emission pattern precision

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

Instead of forming patterned electrodes to achieve emission patterns, the patent inverts the approach by using continuous electrodes and creating patterns through the light emitting layers alone. This reverse methodology achieves the same functional result (patterned emission) through a different mechanism that eliminates masking requirements

Inventive Principle:

Principle #13The other way round (Inversion)

2Adaptability or versatility

If masks are manufactured for each emission pattern, then the desired emission pattern can be achieved, but the manufacturing complexity increases

Engineering Contradiction:

Improveemission pattern varietyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The continuous electrodes serve a universal function across different emission patterns. The same simple electrode structure can support multiple different emission patterns by changing only the light emitting layer configuration, thereby providing versatility in emission patterns while reducing manufacturing process complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent performs preliminary action by forming continuous electrodes before forming the light emitting layers. This sequence allows the electrodes to remain simple and unpatterned, while the subsequent light emitting layer formation creates the desired patterns, thereby reducing overall manufacturing complexity while maintaining adaptability

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If coating liquids are applied to form light emitting layers in different regions, then distinct emission colors can be achieved, but boundary blurring may occur

Engineering Contradiction:

Improveemission color distinctionVSAvoidboundary sharpness

Core Design Contradiction:

Manufacturing precisionVSMeasurement precision

Solution Approach 1:

The patent applies local quality by using different light emitting materials in different regions of the light emitting layer. Each region has locally optimized material properties that provide distinct emission colors, thereby achieving emission color distinction while managing boundary characteristics through material selection and application control

Inventive Principle:

Principle #3Local quality

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 simplifies and reduces the manufacturing cost by eliminating the need for masks and achieving distinct emission colors and luminances across regions, improving visibility and enabling three-dimensional visual effects through controlled layer thickness and material combinations.

Implementation Method 1

an organic EL element that emits light in a predetermined emission pattern... an organic light emitting film arranged between these anode and cathode

Methodology Applied

Scientific EffectElectroluminescence: Electroluminescence

Implementation Method 2

applying coating liquids containing respective different light emitting materials in respective patterns to the respective light emitting regions to form coating films in patterns; and solidifying the coating films to form the light emitting layer

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentEP2999020B1Organic el element, and organic el element manufacturing method

Publication Date: 2020.01.22 SUMITOMO CHEM CO LTD

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AI summary

An organic EL element 1 according to one embodiment of the present invention is an organic EL element comprising: a continuous first electrode 20; a continuous second electrode 70; and a light emitting layer 50 arranged between the first electrode 20 and the second electrode 70, wherein the light emitting layer 50 has two light emitting regions 51, 52 and wherein the two light emitting regions 51, 52 are different in at least one of emission color and emission luminance.