Auxiliary Electrode Design for High-Resolution OLED Deposition

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Solution Overview

Problem

In the manufacturing of high-resolution organic light-emitting display devices, the deposition process with a mask can damage the pixel-defining layer due to close contact, and the use of spacers increases device thickness and adds complexity.

Innovation Solution

A display device design featuring a pixel electrode with a barrier portion, an auxiliary electrode, and an intermediate layer, where the auxiliary electrode has larger openings than the pixel electrode, allowing for a shadow layer and non-photosensitive layer to form an intermediate layer and opposite electrode without direct contact, reducing the risk of damage and thickness increase.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the deposition process is performed while the substrate and mask are in close contact with each other, then the manufacturing precision is improved, but the pixel-defining layer is damaged

Engineering Contradiction:

Improvedeposition precisionVSAvoiddamage to pixel-defining layer

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

A buffer layer is introduced as an intermediary component between the pixel electrode and the pixel-defining layer. This buffer layer absorbs the mechanical stress and damage that would otherwise be transmitted to the pixel-defining layer during the close-contact deposition process, thereby protecting the pixel-defining layer while maintaining deposition precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The buffer layer is pre-formed on the pixel electrode before the deposition process. This beforehand cushioning structure prevents damage to the pixel-defining layer by providing a protective interface that absorbs mechanical stress during subsequent close-contact deposition operations.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Object-affected harmful factors

If a spacer is arranged on the pixel-defining layer to prevent damage, then the pixel-defining layer is protected, but the device thickness increases and process complexity increases

Engineering Contradiction:

Improveprotection of pixel-defining layerVSAvoidprocess complexity

Core Design Contradiction:

Object-affected harmful factorsVSDevice complexity

Solution Approach 1:

The protective function is extracted from the pixel-defining layer itself and transferred to a separate buffer layer. This extraction allows the pixel-defining layer to focus on its primary function of defining pixel patterns, while the buffer layer independently provides mechanical protection, thereby simplifying the overall process design.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The buffer layer serves multiple functions: it protects the pixel-defining layer from damage during deposition, provides a suitable surface for subsequent electrode formation, and maintains the structural integrity of the device. This multi-functionality reduces the need for additional specialized components like spacers.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Object-affected harmful factors

If a spacer is arranged on the pixel-defining layer to prevent damage, then the pixel-defining layer is protected, but the device thickness increases

Engineering Contradiction:

Improveprotection of pixel-defining layerVSAvoiddevice thickness

Core Design Contradiction:

Object-affected harmful factorsVSLength of stationary object

Solution Approach 1:

The buffer layer is designed as a thin, sacrificial protective layer that can be formed with minimal thickness. Unlike permanent spacers that must maintain structural integrity throughout the device, the buffer layer provides temporary protection only during the deposition process, allowing it to be much thinner and thus not significantly increasing device thickness.

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 method prevents damage to the pixel electrode during deposition, maintains a thinner device structure, and simplifies the manufacturing process by avoiding direct contact between the pixel electrode and auxiliary electrode, thereby enhancing the production of high-resolution organic light-emitting display devices.

Implementation Method 1

a method in which a deposition process is performed while a substrate and a mask are in close contact with each other

Methodology Applied

Scientific EffectPhysical Vapour Deposition: Physical Vapour Deposition

Data Source

PatentUS11700750B2Display device and method of manufacturing the same

Publication Date: 2023.07.11 SAMSUNG DISPLAY CO LTD

AI summary

Provided are a display device and a method of manufacturing the same. The display device includes a substrate; a pixel electrode on the substrate; a pixel-defining layer having a first opening exposing a central portion of the pixel electrode and a barrier portion defining the first opening; an auxiliary electrode on the barrier portion; an intermediate layer on the pixel electrode; and an opposite electrode on the intermediate layer and in electrical contact with the auxiliary electrode.