Conductive Substrate With Crystalline And Amorphous ITO Layers
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Solution Overview
Problem
Current methods for preparing conducting substrates are complex and costly, involving multiple processes and high resistance losses, particularly in the formation of secondary electrodes for organic light emitting devices and solar cells.
Innovation Solution
A method involving the formation of a crystalline transparent conducting layer, followed by an amorphous transparent conducting layer, patterning to expose the crystalline layer, and deposition of a metal layer in the patterned regions, minimizing resistance loss and reducing the number of processing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a secondary electrode is formed by depositing and patterning metal on fully deposited ITO, then optical efficiency loss is prevented, but the number of processes increases and substrate cost increases
Solution Approach 1:
The transparent conducting layer is divided into two segments: a crystalline ITO layer deposited first, followed by an amorphous ITO layer deposited second. This segmentation allows the amorphous layer to be patterned more easily while maintaining good adhesion to the crystalline layer, reducing the complexity of the overall patterning process while preventing optical efficiency loss.
Solution Approach 2:
The patent uses a composite structure of crystalline ITO and amorphous ITO layers. The crystalline layer provides stable adhesion to the substrate, while the amorphous layer offers easier patterning characteristics. This composite material approach resolves the contradiction between maintaining reliability and reducing process complexity.
2Area of stationary object
If ITO is fully deposited on substrate to form primary electrode, then coverage is ensured, but resistance loss increases
Solution Approach 1:
The patent applies different qualities to different regions of the transparent conducting layer. The crystalline ITO layer provides broad coverage with stable adhesion, while the amorphous ITO layer is selectively patterned in specific regions to reduce resistance loss. This local differentiation allows full coverage where needed while minimizing resistance in critical areas.
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 results in an efficient conducting substrate with reduced process complexity and cost, achieved through the integration of an amorphous transparent conducting layer and a metal layer, which minimizes resistance loss and eliminates the need for additional insulating layers.
Implementation Method 1
forming a crystalline transparent conducting layer on a substrate
Implementation Method 2
forming an amorphous transparent conducting layer on the crystalline transparent conducting layer
Implementation Method 3
forming a metal layer in the at least one pattern open region
Data Source
AI summary
An exemplary embodiment of the present invention comprises: 1) forming a crystalline transparent conducting layer on a substrate; 2) forming an amorphous transparent conducting layer on the crystalline transparent conducting layer; 3) forming at least one pattern open region so as to expose a part of the crystalline transparent conducting layer by patterning the amorphous transparent conducting layer; and 4) forming a metal layer in the at least one pattern open region.