Conductive Planarization Layer for OLED Array Substrates

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Solution Overview

Problem

The complexity of manufacturing OLED electrodes on color filters leads to increased manufacturing difficulty and reduced production yield due to line breakage and defects, necessitating a planarization protective layer to ensure smooth conduction and protection.

Innovation Solution

A conductive planarization protective layer is electrically connected with the drain electrode of the TFT unit, formed using resin with specific viscosity, which also acts as a pixel electrode, reducing the need for sputtering and simplifying the manufacturing process while ensuring safety and productivity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a planarization protective layer is added to protect underlying structures and provide conductive path, then reliability and safety are improved, but device complexity and manufacturing difficulty increase

Engineering Contradiction:

ImprovesafetyVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The planarization protective layer is designed to serve multiple functions simultaneously: it provides mechanical protection to underlying structures, establishes electrical connection between TFT drain electrode and color filter, enables smooth conduction for OLED electrode formation, and acts as a pixel electrode. This multi-functionality resolves the contradiction by improving reliability through comprehensive protection while avoiding the need for separate protective components that would increase complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The patent merges the protective function, conductive function, and pixel electrode function into a single integrated planarization protective layer structure. By combining these functions that were previously performed by separate components, the solution improves safety and reliability without proportionally increasing device complexity.

Inventive Principle:

Principle #5Merging (Combining)

2Manufacturing precision

If traditional sputtering method is used to form OLED electrodes on color filters, then manufacturing precision can be maintained, but productivity decreases due to line breakage and defects

Engineering Contradiction:

Improveelectrode conduction qualityVSAvoidproduction yield

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The planarization protective layer is formed in advance before OLED electrode deposition, creating a smooth planarized surface that prevents line breakage and defects during subsequent electrode formation. This preliminary action resolves the contradiction by ensuring manufacturing precision is maintained while avoiding productivity losses from defects.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The planarization protective layer acts as an intermediary between the TFT drain electrode and the OLED electrode, providing a smooth intermediate surface that facilitates reliable electrical connection and prevents conduction issues. This intermediary structure maintains manufacturing precision while improving production yield by eliminating defect-prone direct deposition on irregular surfaces.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Productivity

If a conductive planarization protective layer is used to provide electrical connection, then productivity is improved by reducing sputtering steps, but manufacturing precision requirements increase

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidconductive layer quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent replaces the traditional sputtering mechanical deposition process with a coating-based formation method for the conductive planarization protective layer. This substitution improves productivity by eliminating complex sputtering steps while the coating process inherently provides uniform thickness and quality, maintaining manufacturing precision without the productivity penalties of traditional methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 solution enhances safety and productivity by providing a conductive path for electrical signals and protecting underlying structures, improving the display device's resolution, transmittance, and reducing light leakage, thus ensuring better display effects.

Implementation Method 1

the planarization protective layer is electrically connected with a drain electrode of the TFT unit, and the planarization protective layer is conductive

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Implementation Method 2

formed using resin with specific viscosity

Methodology Applied

Scientific EffectDeposition: Deposition (physical)

Data Source

PatentUS9484393B2Array substrate of a display device, manufacturing method thereof

Publication Date: 2016.11.01 BOE TECHNOLOGY GROUP CO LTD

AI summary

An array substrate, a manufacturing method thereof and a display device are disclosed. The array substrate comprises a base substrate and a thin-film transistor (TFT) unit, a color filter and a planarization protective layer disposed on the base substrate. The planarization protective layer is electrically connected with a drain electrode of the TFT unit and is conductive. The array substrate has the advantages of simplifying the layer structures of the array substrate, reducing the manufacturing difficulty of the array substrate, and improving the production yield of the array substrate.