Patterned Quantum Dot Light-Emitting Layers Using Porous Sacrificial Films

Solution Overview

Problem

The manufacturing of high-resolution quantum dot light-emitting devices is hindered by the damage to the quantum dot light-emitting layer during the removal of sacrificial layers, leading to low efficiency and stability.

Innovation Solution

A new sacrificial layer material system is introduced, comprising a first component and a second component that decomposes to produce bubbles, creating a porous structure, allowing for solvent-based removal without ultrasound, thus preserving the quantum dot film layer quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional sacrificial layer removal method is used, then the sacrificial layer can be removed, but the quantum dot light-emitting layer is damaged during the process

Engineering Contradiction:

Improvesacrificial layer removalVSAvoidquantum dot light-emitting layer quality

Core Design Contradiction:

Ease of manufactureVSReliability

Solution Approach 1:

The sacrificial layer is designed with a porous structure containing cavities that facilitate solvent penetration. The porous structure allows the solvent to easily access and dissolve the sacrificial layer material, enabling complete removal without requiring ultrasound treatment that would damage the quantum dot light-emitting layer

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The sacrificial layer uses a composite material system consisting of a polymer matrix (first component) and porogen particles (second component). The porogen particles create the porous structure when removed, while the polymer matrix provides structural integrity during device fabrication. This composite approach enables both easy removal and quantum dot layer protection

Inventive Principle:

Principle #40Composite materials

2Productivity

If ultrasound is used to remove sacrificial layer, then removal efficiency is improved, but the quantum dot film layer is damaged

Engineering Contradiction:

Improvesacrificial layer removal efficiencyVSAvoidquantum dot film layer quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces the mechanical ultrasound removal method with a chemical dissolution method. The sacrificial layer is designed to be soluble in specific solvents, allowing removal through chemical interaction rather than mechanical vibration. This substitution eliminates the need for ultrasound while maintaining high removal efficiency and protecting the quantum dot film layer from damage

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Strength

If sacrificial layer is made dense, then structural strength is improved, but removal difficulty increases

Engineering Contradiction:

Improvesacrificial layer structural strengthVSAvoidsacrificial layer removal ease

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The sacrificial layer is designed with a porous structure containing cavities that facilitate solvent penetration. The porous structure allows the solvent to easily access and dissolve the sacrificial layer material, enabling complete removal without requiring ultrasound treatment that would damage the quantum dot light-emitting layer

Inventive Principle:

Principle #31Porous materials

Solution Approach 2:

The sacrificial layer uses a composite material system consisting of a polymer matrix (first component) and porogen particles (second component). The porogen particles create the porous structure when removed, while the polymer matrix provides structural integrity during device fabrication. This composite approach enables both easy removal and quantum dot layer protection

Inventive Principle:

Principle #40Composite materials

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

The method improves the efficiency and stability of quantum dot light-emitting devices by avoiding ultrasound-induced damage during sacrificial layer removal, simplifying the manufacturing process, and enhancing the quality of the quantum dot light-emitting layer.

Implementation Method 1

the second component decomposes under a preset condition to produce bubbles, to make the first component porous

Methodology Applied

Scientific EffectDecomposition: Decomposition (biological)

Implementation Method 2

forming the patterned quantum dot light-emitting layer by removing the photoresist layer, the sacrificial layer and the quantum dot film layer attached to the sacrificial layer, by dissolution via a solvent

Methodology Applied

Scientific EffectDissolution: Solvation

Data Source

PatentUS12446453B2Manufacturing method of patterned quantum dot light-emitting layer and manufacturing method of light-emitting device

Publication Date: 2025.10.14 BEIJING BOE TECH DEV CO LTD

AI summary

A manufacturing method of a patterned quantum dot light-emitting layer includes: forming a sacrificial layer on a side of a base substrate, wherein the sacrificial layer includes a first component and a second component mixed in the first component; forming a patterned photoresist layer on a side of the sacrificial layer facing away from the base substrate; etching the sacrificial layer by taking the patterned photoresist layer as a mask to form a patterned sacrificial layer; forming a quantum dot film layer on a side of the photoresist layer facing away from the sacrificial layer; making the second component decompose under the preset condition to produce the bubbles, to make the first component form the porous structure; and forming the patterned quantum dot light-emitting layer by removing the photoresist layer, the sacrificial layer and the quantum dot film layer attached to the sacrificial layer, by dissolution via a solvent.