Polymer Layer Smoothing for OLED Light Emission Layers
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Solution Overview
Problem
The transfer method used in organic light emitting display device manufacturing often results in a rough, uneven surface of the light emission layer due to stripping, leading to protrusions, voids, and cracks, which can damage the thin film sealing layer and affect the device's quality.
Innovation Solution
A polymer layer, specifically a silicon-based, acryl-based, vinyl-based, rubber-based, or urethane-based polymer film, is applied over the second electrode to smooth out the surface irregularities, reducing non-uniformity and preventing damage to the sealing layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the transfer method is used to form the light emission layer, then the light emission layer can be formed on the electrode, but the surface becomes rough and non-uniform due to stripping
Solution Approach 1:
A polymer layer is introduced as an intermediary between the light emission layer and the sealing layer. This polymer layer acts as a mediator that compensates for surface irregularities caused by the transfer method, providing a smooth surface for the sealing layer while allowing the light emission layer to be formed using the transfer method.
Solution Approach 2:
The problem is solved by adding another dimensional layer (the polymer layer) between the light emission layer and sealing layer. This additional layer provides a new interface that smooths out surface irregularities from the transfer process, effectively separating the manufacturing requirements of the light emission layer from the sealing requirements.
2Productivity
If the light emission layer is formed by transfer method, then the layer can be deposited, but protrusions and voids are generated affecting electrode structure
Solution Approach 1:
The polymer layer is applied beforehand to compensate for surface irregularities before the sealing layer is formed. This cushioning layer prevents protrusions and voids from the transfer process from affecting the electrode structure and sealing layer quality.
3Ease of manufacture
If the thin film sealing layer is formed on the uneven electrode surface, then the sealing layer can be deposited, but cracks are generated and coating is poor
Solution Approach 1:
The polymer layer serves as an intermediary that provides a smooth, uniform surface for the sealing layer. This mediator layer eliminates the direct contact between the sealing layer and the irregular electrode surface, preventing cracks and ensuring proper coating while maintaining the ability to form the sealing layer.
4Device complexity
If no surface modification is performed, then the manufacturing process is simple, but device quality deteriorates
Solution Approach 1:
The polymer layer is a simple intermediary that can be applied through straightforward processes such as spin coating or dip coating. This single additional step provides significant quality improvement by smoothing the surface without substantially increasing manufacturing complexity.
Data Source
AI summary
In an embodiment of the present disclosure, a polymer layer is formed on a second electrode of an organic light emitting display device.