Inkjet AMOLED Anode Cleaning via Spacer Layer Etching
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Solution Overview
Problem
The residue of hydrophobic PDL material in the pixel region of inkjet printing AMOLED display panels affects ink spreadability, leading to abnormal pixel function and display effects, as dry etching destroys the surface structure and causes thickness and line width loss of the PDL.
Innovation Solution
A manufacturing method involving a spacer layer etched by an etching solution to remove residual PDL material, allowing for even inkjet printing without damaging the surface structure or causing thickness loss, by forming a notch in the pixel definition layer to expose the spacer layer and then etching it away.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If dry etching process is used to remove PDL material residue, then the anode surface cleanliness is improved, but the surface structure of PDL is destroyed and thickness/line width are lost
Solution Approach 1:
The patent introduces a dedicated spacer layer as a separate component between the anode and PDL, which is selectively removed to clean the anode surface. This segments the cleaning function from the PDL structure itself, allowing residue removal without damaging the PDL's hydrophobic surface properties or dimensions.
Solution Approach 2:
The spacer layer acts as an intermediary sacrificial element that facilitates anode surface cleaning. By etching away the spacer layer through notches in the PDL, residual PDL material is removed from the anode surface without requiring direct etching of the PDL itself, thus preserving the PDL's structural integrity and hydrophobicity.
2Manufacturing precision
If dry etching is applied after PDL yellow light process, then PDL material residue is removed, but ink spread ability deteriorates due to loss of hydrophobicity
Solution Approach 1:
The patent extracts the cleaning function from the PDL layer itself and transfers it to the spacer layer. The spacer layer is selectively removed through controlled etching via notches, extracting residual PDL material from the anode surface while leaving the PDL layer's hydrophobic surface structure intact, thereby preserving ink spread ability.
Solution Approach 2:
The spacer layer serves as an intermediary that enables residue removal without compromising the PDL's hydrophobic properties. By using the spacer layer as the etching target rather than the PDL itself, the method removes residues while maintaining the PDL surface structure necessary for proper ink spreading.
3Manufacturing precision
If dry etching process is used, then residue cleanliness is improved, but manufacturing complexity increases due to additional process steps
Solution Approach 1:
The patent combines the spacer layer formation with the existing PDL patterning process. The spacer layer is formed before PDL deposition and is patterned simultaneously with the PDL, merging two functions into one process sequence. This integration reduces overall manufacturing complexity compared to adding a separate etching step after PDL formation.
Solution Approach 2:
The spacer layer is formed in advance before PDL deposition, and its pattern is pre-established to guide subsequent selective etching. This preliminary preparation enables targeted residue removal through simple wet etching of the exposed spacer layer, avoiding the need for complex post-PDL etching processes.
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
Improves the cleanliness of the anode surface, reduces residue, and ensures even spreading of the light-emitting layer, preventing display abnormalities while maintaining the surface integrity of the pixel definition layer.
Implementation Method 1
etching the spacer layer below the notch by an etching solution
Implementation Method 2
forming an ink layer on the anode by an inkjet printing method
Implementation Method 3
the residue of the hydrophobic PDL (Pixel Define Layer) material in the Bank region (pixel region) directly affects the spreading of the ink
Data Source
AI summary
A manufacturing method for an inkjet printing AMOLED display panel is disclosed. The method includes steps of: manufacturing a TFT backplane, and manufacturing an anode on the TFT backplane; manufacturing a spacer layer for isolating the anode from a pixel definition layer on the anode; manufacturing a pixel definition layer on the TFT backplane, and the pixel definition layer covers the spacer layer; patterning the pixel definition layer to form a notch on the pixel definition layer in order to expose the spacer layer; etching the spacer layer below the notch by an etching solution; and forming an ink layer on the anode by an inkjet printing method. The invention can improve the cleanliness of the anode surface in the AMOLED display panel, reduce the residue, and make the printed light-emitting layer easier to spread evenly, prevent the AMOLED display panel from displaying abnormality.