Organic Film Overflow Detection via Pigmented Indicator Layer
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Solution Overview
Problem
In the production of light-emitting apparatuses like OLEDs and QLEDs, the intermediate organic encapsulation film fails to effectively block water and oxygen, leading to performance degradation and shortened lifespan due to overflow issues with colorless liquid organic materials, which are difficult to detect using conventional methods, resulting in increased production losses.
Innovation Solution
A method involving the formation of a pigment mixture layer outside the organic film region using a pigment liquid mixture, which includes a colorless, transparent second liquid organic material, and curing it to create an indicator film that can be observed for real-time overflow detection, along with barrier dams to prevent overflow, ensuring the organic film is completely covered by the second inorganic film.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If colorless liquid organic material is used for forming the organic film, then the organic film provides flexibility and covers impurity particles, but the liquid organic material tends to overflow and cannot be easily detected
Solution Approach 1:
The patent applies color change principle by forming an indicator film with pigmented liquid organic material that changes color when overflow occurs. The indicator film contains pigment particles that make the overflow visible, transforming the undetectable colorless overflow into a visually detectable colored indication, thus resolving the detection difficulty while maintaining the flexibility function of the organic film
2Manufacturing precision
If the organic film is formed to completely cover the display area, then it provides flexibility and covers impurity particles, but the organic material overflows to form an excessively large organic film
Solution Approach 1:
The patent introduces an indicator film as an intermediary element that mediates between the organic film formation process and the overflow control. The indicator film is formed with pigmented liquid organic material and serves as a visual indicator system that allows real-time monitoring of overflow, enabling operators to adjust manufacturing parameters to achieve precise coverage without excessive overflow
3Measurement precision
If conventional detection methods are used to observe the boundary of organic material, then overflow detection is possible, but it costs extra time and labor and requires preparing extra samples
Solution Approach 1:
The patent implements self-service detection principle where the indicator film automatically indicates overflow conditions through color changes visible to the naked eye or simple optical devices. The pigmented liquid organic material in the indicator film serves itself as the detection mechanism, eliminating the need for complex sample preparation, slice observation, or expensive scanning electron microscopy, thereby significantly improving production efficiency while maintaining detection accuracy
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 allows for real-time detection of organic material overflow, preventing defects and ensuring the organic film is completely covered, thereby enhancing the yield and lifespan of light-emitting apparatuses by facilitating timely adjustments in production parameters.
Implementation Method 1
Curing the pigment mixture layer and the liquid organic layer to form an indicator film and the organic film, respectively may be performed by ultraviolet light irradiation
Data Source
AI summary
The present disclosure relates to a method for preparing an organic film structure. The method for preparing the organic film structure may include forming a pigment mixture layer outside a region where an organic film is to be formed using a pigment liquid mixture, forming a liquid organic layer in the region where the organic film is to be formed with a first liquid organic material, and curing the pigment mixture layer and the liquid organic layer to form an indicator film and the organic film, respectively. The pigment mixture layer may include a pigment.