Organic EL Buffer Layer Coverage via Ink Flood
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Solution Overview
Problem
In organic electroluminescent element manufacturing, the buffer layer is often incompletely covered by the light emitting layer due to ink discharge variations, leading to leakage current and increased manufacturing costs, as existing methods require iterative testing to ensure complete coverage.
Innovation Solution
The method involves discharging a light emitting layer forming ink with a volume larger than its maximum retention volume by surface tension onto the buffer layer, ensuring complete coverage and suppression of leakage current, calculated using the surface area and surface tension of the ink and buffer layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the discharge amount of light emitting layer forming ink is increased to ensure complete coverage of the buffer layer, then the coverage reliability is improved, but the manufacturing cost increases due to repeated testing
Solution Approach 1:
The patent applies preliminary action by establishing the ink discharge amount before actual manufacturing based on theoretical calculations. The maximum retention volume is calculated using surface tension parameters and buffer layer area, allowing the optimal discharge amount to be determined in advance without repeated manufacturing tests. This preliminary determination of parameters resolves the contradiction by enabling reliable coverage while avoiding the cost of iterative experimentation.
Solution Approach 2:
The patent applies self-service by using the inherent surface tension properties of the ink to automatically achieve complete coverage. By setting the discharge amount based on the calculated maximum retention volume, the ink naturally spreads to cover the entire buffer layer without requiring additional control mechanisms or repeated testing. The system uses its own physical properties to ensure reliable coverage.
2Reliability
If the discharge amount of light emitting layer forming ink is increased to ensure complete coverage, then the leakage current suppression is improved, but the time required for manufacturing increases due to iterative testing
Solution Approach 1:
The patent determines the optimal ink discharge amount in advance through calculation rather than through iterative testing during manufacturing. By calculating the maximum retention volume based on surface tension and buffer layer area before production, the process eliminates time-consuming trial-and-error cycles while ensuring complete coverage and effective leakage current suppression.
Solution Approach 2:
The patent replaces the mechanical trial-and-error testing process with a theoretical calculation system. Instead of physically manufacturing multiple test samples to determine the correct discharge amount, the system uses mathematical calculations involving surface tension parameters and geometric measurements to determine the optimal discharge amount, significantly reducing the time required.
3Reliability
If the film formation region of the light emitting layer is made larger than the buffer layer by increasing ink discharge amount, then the complete coverage is achieved, but the manufacturing precision decreases due to variability in ink discharge
Solution Approach 1:
The patent applies parameter changes by using surface tension as a controlling parameter to determine the optimal ink discharge amount. By calculating the maximum retention volume based on surface tension characteristics and buffer layer area, the method establishes a precise discharge amount that ensures complete coverage while maintaining manufacturing precision. This parameter-based approach replaces variable discharge amounts with a calculated optimal value.
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 reliably covers the buffer layer with the light emitting layer, reducing manufacturing costs and time by eliminating the need for iterative testing, while maintaining high light emitting efficiency and aperture ratio.
Implementation Method 1
a maximum volume where the ink is retained by the surface tension thereof on the top surface of a buffer layer
Implementation Method 2
the ink discharged on the buffer layer inevitably floods and spreads over the buffer layer
Implementation Method 3
obtaining the light emitting layer by drying the ink discharged on the buffer layer
Data Source
AI summary
An ink containing an electroluminescent light emitting material is discharged onto a buffer layer. The discharge amount of the ink is larger than a maximum volume where the ink is retained by the surface tension thereof on the top surface of the buffer layer.