Auxiliary Layer for Selective Organic Material Removal in OLED Substrates
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Solution Overview
Problem
The manufacturing of OLED display devices faces challenges in large-scale and mass production due to issues with uniform deposition rates and the difficulty in cleaning organic materials from non-display areas without damaging substrate structures, particularly with methods like vacuum thermal evaporation and inkjet printing.
Innovation Solution
A method involving the formation of a display substrate with an auxiliary layer in the non-display area, made from heat-absorbing or thermoplastic materials, which changes properties upon heating, allowing for easy removal of the organic material layer through heating processes, thereby improving manufacturing efficiency and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If vacuum thermal evaporation or inkjet printing is used to deposit organic material layers, then OLEDs can be formed in the display area, but organic materials cannot be easily removed from the non-display area without damaging substrate structures
Solution Approach 1:
The patent divides the substrate into display area and non-display area, and further divides the non-display area into regions with different auxiliary layers. Different auxiliary layers (first auxiliary layer below TFT layer, second auxiliary layer on PDL) are selectively placed in different segments of the non-display area, allowing targeted removal of organic materials without affecting the display area or damaging substrate structures.
Solution Approach 2:
The patent introduces auxiliary layers as intermediary structures between the substrate and organic material layer in the non-display area. These auxiliary layers (made from heat-absorbing materials, thermoplastic polymers, or thermal expansion materials) serve as mediators that facilitate selective removal of organic materials through heating processes, while protecting the underlying substrate structures from damage.
2Productivity
If organic material layer is formed simultaneously in display area and non-display area, then manufacturing process is simplified, but cleaning organic materials from non-display area becomes difficult and time-consuming
Solution Approach 1:
The patent performs preliminary action by forming auxiliary layers in the non-display area before depositing the organic material layer. These pre-formed auxiliary layers are designed to enable easy removal of organic materials later through heating, thus facilitating the cleaning process without requiring additional time-consuming manual removal steps after OLED formation.
Solution Approach 2:
The patent utilizes parameter changes in the auxiliary layers through heating processes. The auxiliary layers are made from materials that undergo significant property changes (heat absorption, thermal expansion, or thermoplastic deformation) when heated, allowing the organic material layer to be selectively removed from the non-display area by changing the temperature parameter, thereby reducing cleaning time while maintaining manufacturing efficiency.
3Ease of manufacture
If conventional cleaning methods are used to remove organic materials from non-display area, then manufacturing costs increase and manufacturing precision decreases
Solution Approach 1:
The patent replaces mechanical or chemical cleaning methods with a thermal field-based removal method. By using heating processes that exploit the thermal properties of the auxiliary layers (heat absorption, thermal expansion, or thermoplastic deformation), the organic material layer is selectively removed from the non-display area without requiring contact-based mechanical removal or chemical etching, thus reducing manufacturing costs and improving precision.
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 effectively and rapidly removes organic material layers from non-display areas, enhancing manufacturing efficiency and reducing costs while maintaining the integrity of the substrate, thus addressing the limitations of existing technologies.
Implementation Method 1
the auxiliary layer is made from heat-absorbing material and formed below the TFT layer in the non-display area
Implementation Method 2
the auxiliary layer is made from material of which the temperature is raised after heating or which is deformed after heating
Implementation Method 3
a step of removing a portion of the organic material layer corresponding to the auxiliary layer by a heating process
Data Source
AI summary
A method of manufacturing a display substrate, a display substrate and a display device are provided. The manufacturing method includes: forming an organic material layer in a display area (10) and a non-display area (11); forming an auxiliary layer (24, 25) in the non-display area (11) before forming the organic material layer. The performances of the auxiliary layer (24, 25) are changed after heating, to allow a portion of the organic material layer corresponding to the auxiliary layer (24, 25) can be easily stripped off. The method further includes removing the portions of the organic material layer corresponding to the auxiliary layer by a heating process.