Quantum Dot Light-Emitting Layer Patterning via Integrated Mask Etching

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Solution Overview

Problem

The existing methods for manufacturing display devices with quantum dot light-emitting diodes (QLEDs) or organic light-emitting diodes (OLEDs) involve a large number of steps due to the formation and subsequent removal of patterned photosensitive resin, which complicates the process.

Innovation Solution

A method is introduced that includes forming a charge transport layer, applying a mixture of quantum dots and photosensitive resin, pattern-exposing and curing the mixture to create a light-emitting layer, and using the light-emitting layer as a mask for etching the charge transport layer with an alkaline or organic solvent, reducing the number of steps by eliminating the need for forming and removing a patterned photosensitive resin.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a patterned photosensitive resin is formed and then removed to pattern the light-emitting layer, then the light-emitting layer can be precisely patterned, but the number of manufacturing steps increases

Engineering Contradiction:

Improvelight-emitting layer patterning precisionVSAvoidnumber of manufacturing steps

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent combines the photosensitive resin layer with the light-emitting layer into a single integrated layer. The photosensitive resin and light-emitting material are mixed together before application, so that one layer serves dual purposes: as the light-emitting layer and as the patterning mask. This eliminates the need for separate formation and removal of a patterned photosensitive resin layer, reducing manufacturing steps while maintaining patterning precision.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mixed layer performs multiple functions simultaneously: it serves as the light-emitting layer, the photosensitive layer for patterning, and the mask layer for protecting underlying structures during etching. This multi-functional design eliminates the need for separate dedicated layers for each function, thereby simplifying the manufacturing process.

Inventive Principle:

Principle #6Universality (Multi-functionality)

2Manufacturing precision

If a patterned photosensitive resin is formed as a mask, then the light-emitting layer can be patterned accurately, but additional materials not included in the finished product are required

Engineering Contradiction:

Improvelight-emitting layer patterning accuracyVSAvoidamount of photosensitive resin material

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent merges the photosensitive resin material with the light-emitting material into a single mixed layer. This eliminates the need for separate photosensitive resin material that would be applied, patterned, and then discarded. The photosensitive resin serves its patterning function while remaining part of the final light-emitting layer structure.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

In conventional methods, the patterned photosensitive resin is a temporary component that is formed and then removed. The patent eliminates this disposable component by integrating the photosensitive resin into the permanent light-emitting layer, so no material needs to be discarded after serving its patterning purpose.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

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 simplifies the manufacturing process by reducing the number of steps, improving the resolution and reliability of the display device, and enhancing color purity and luminous efficiency while minimizing power consumption.

Implementation Method 1

pattern-exposing the first mixture to cure a portion of the first mixture to be formed into the first light-emitting layer

Methodology Applied

Scientific EffectPhotopolymerization: Photopolymerisation

Implementation Method 2

etching the first charge transport layer with an etching solution using the first light-emitting layer as a mask, the etching solution being an alkaline solution or an organic solvent

Methodology Applied

Scientific EffectChemical etching:

Data Source

PatentUS20230157044A1Method for producing display device, and display device

Publication Date: 2023.05.18 SHARP KK

AI summary

A method for manufacturing a display device, including: a step of applying a first mixture obtained by mixing green quantum dots and a photosensitive resin on a green electron transport layer, an exposure step of pattern-exposing the first mixture to cure a portion of the first mixture, the portion being a green light-emitting layer; a development step of removing an uncured portion of the first mixture and developing the green light-emitting layer; and an etching step of etching the green electron transport layer with an etching solution that is an alkaline solution or an organic solvent using the green light-emitting layer as a mask.