Dual Panel OLED Reverse-Taper Walls for Isolation
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Solution Overview
Problem
The dual panel type organic electroluminescent display (OLED) devices face issues with brightness due to particle problems and thermal degradation of the organic emitting layer, and require additional mask processes for spacer formation, leading to increased contact risks and reduced lifetime.
Innovation Solution
A dual panel type OLED device with first and second substrates featuring reverse-taper shaped walls and patterns for isolating the organic emitting layer, eliminating the need for column spacers and allowing for controlled contact areas, and a method of fabricating this device involving the formation of insulating material walls and photoresist patterns to achieve uniform height and improved connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If column spacers are used for isolating the organic emitting layer, then the structural support is improved, but the fabrication complexity increases due to additional mask processes and contact risks increase
Solution Approach 1:
The invention extracts and eliminates the column spacer component from the device structure. Instead of using separate column spacers for isolation, the patent forms integrated walls directly from the insulating material layer that perform both the isolation and structural support functions, thereby removing the need for additional mask processes and reducing fabrication complexity
Solution Approach 2:
The invention merges the isolation function and structural support function into a single integrated wall structure. The walls are formed from the insulating material layer that simultaneously provides electrical isolation for the organic emitting layer and mechanical structural support, eliminating the need for separate column spacers
2Manufacturing precision
If additional mask processes are performed for spacer formation, then the isolation precision is improved, but the production time increases and contact risks are reduced
Solution Approach 1:
The invention removes the additional mask processes from the fabrication sequence by integrating the isolation structure into the existing insulating material layer formation process, maintaining precision while reducing production steps and time
Solution Approach 2:
The isolation walls are formed preliminarily during the insulating material layer formation process itself, rather than requiring subsequent separate mask and etch processes. This preliminary action maintains precise isolation while reducing overall production time
3Shape
If the organic emitting layer is exposed to gas from the planarization layer during heating, then the planarization function is achieved, but thermal degradation occurs reducing device lifetime
Solution Approach 1:
The invention converts the harmful thermal degradation effect into a beneficial process by controlling the thermal treatment to remove volatile components from the insulating material layer without degrading the organic emitting layer. The controlled heating process eliminates gas generation that would cause thermal degradation while maintaining the planarization function
Solution Approach 2:
The invention applies a protective measure beforehand by forming a barrier or controlling the heating process to prevent direct exposure of the organic emitting layer to gases from the insulating material layer, thus cushioning against thermal degradation while achieving planarization
4Reliability
If walls with reverse-taper shape are formed, then the isolation effectiveness is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The invention changes the geometric parameters of the walls by forming them with a reverse-taper shape, where the width at the top surface is greater than the width at the bottom surface. This parameter change improves isolation effectiveness by providing better coverage and mechanical stability while the formation process is designed to achieve this shape with controlled precision
Data Source
AI summary
The present invention relates to an organic electroluminescent display (OELD) device, more particularly, to a dual panel type OELD device and a method of fabricating the same. The OLED structure has first and second barrier walls having a reverse-taper shape with respect to the first substrate and first and second side surfaces, wherein the walls define novel polymer patterns with varying heights relative to each other.