Organic Layer Uniformity via Swelling and Drying
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Solution Overview
Problem
The solution-based printing method for forming organic layers in organic light emitting devices often results in non-uniform thickness and surface irregularities, leading to reduced reliability and lifespan due to concave or convex surfaces, causing non-uniform brightness and potential defects in the light emission area.
Innovation Solution
A method involving the supply of liquefied organic material on a base substrate, followed by drying to form an intermediate layer, then using solvents with specific boiling points to swell and dry the layer, forming a flat organic layer through inkjet or nozzle printing, with barrier walls defining the area to maintain uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a solution-based printing method is used to form the organic layer, then the patterning process is simplified and large-scale area coverage is achieved, but the thickness of the organic layer becomes non-uniform and the surface becomes concave or convex
Solution Approach 1:
The patent applies a preliminary swelling treatment to the intermediate organic layer before final drying. The swelling solution penetrates the layer and causes it to expand uniformly, creating a flat surface profile before the layer is completely dried. This preliminary action corrects thickness non-uniformities that would otherwise persist through the drying process.
Solution Approach 2:
The patent changes the physical-chemical parameters of the organic layer by introducing a swelling solution with specific solvent properties. The swelling solution has different evaporation rates and swelling capacities compared to the original casting solution, allowing the layer to transition from a non-uniform intermediate state to a uniform final state through controlled parameter changes during the two-stage drying process.
2Ease of manufacture
If a solution-based printing method is used to form the organic layer, then the patterning process is simplified and large-scale area coverage is achieved, but the surface of the organic layer becomes concave or convex
Solution Approach 1:
The patent applies a preliminary swelling treatment to the intermediate organic layer before final drying. The swelling solution penetrates the layer and causes it to expand uniformly, creating a flat surface profile before the layer is completely dried. This preliminary action corrects surface irregularities that would otherwise persist through the drying process.
Solution Approach 2:
The patent changes the physical-chemical parameters of the organic layer by introducing a swelling solution with specific solvent properties. The swelling solution has different evaporation rates and swelling capacities compared to the original casting solution, allowing the layer to transition from a non-uniform intermediate state to a uniform final state through controlled parameter changes during the two-stage drying process.
3Productivity
If the organic layer has non-uniform thickness and surface irregularities, then the solution-based printing method is used, but the reliability of the device decreases and lifespan is reduced
Solution Approach 1:
The patent applies a preliminary swelling treatment to the intermediate organic layer before final drying. The swelling solution penetrates the layer and causes it to expand uniformly, creating a flat surface profile before the layer is completely dried. This preliminary action corrects thickness non-uniformities that would otherwise persist through the drying process.
Solution Approach 2:
The patent changes the physical-chemical parameters of the organic layer by introducing a swelling solution with specific solvent properties. The swelling solution has different evaporation rates and swelling capacities compared to the original casting solution, allowing the layer to transition from a non-uniform intermediate state to a uniform final state through controlled parameter changes during the two-stage drying process.
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 ensures a uniform thickness and flat surface of the organic layer, enhancing the reliability of the organic light emitting device by uniformly forming an electric field across the pixel area, thus improving the device's lifespan and brightness consistency.
Implementation Method 1
supplying a solvent to the intermediate organic layer to form a swelled organic layer
Implementation Method 2
drying the swelled organic layer to form a flat organic layer
Data Source
AI summary
A method of forming an organic layer includes supplying a liquefied organic material, drying the liquefied organic material, supplying a solvent to an intermediate organic layer to swell the intermediate organic layer, and drying the swelled organic layer. The organic layer is formed to have a uniform thickness when the organic layer is formed by a solution-based printing method.