Laser Removal of Organic Layers in Vacuum Display Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing display units with organic light emitting devices face challenges in maintaining a vacuum atmosphere for laser irradiation to remove organic layers from auxiliary electrodes, especially when using large substrates, leading to equipment complexity and increased costs.
Innovation Solution
A method involving a laminated structure with a projection structure as a spacer, allowing for vacuum maintenance even when taken out of the chamber, enabling laser irradiation to remove organic layers from auxiliary electrodes in a vacuum atmosphere, which simplifies equipment configuration and reduces costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a glass window is arranged in the vacuum chamber to transmit laser light from outside, then laser irradiation can be performed in vacuum atmosphere, but the glass window becomes jumboized and equipment complexity increases
Solution Approach 1:
Instead of bringing the laser source outside the vacuum chamber and transmitting light through a large glass window, the invention inverts the approach by placing the laser source inside the vacuum chamber. This eliminates the need for a jumboized glass window and simplifies the overall equipment configuration while maintaining the vacuum atmosphere for laser irradiation.
2Reliability
If the laser source and operating section are arranged in the vacuum chamber, then laser irradiation can be performed in vacuum atmosphere, but the configuration becomes complicated and grows in size
Solution Approach 1:
The invention integrates the laser source with the substrate support structure, making the support structure serve dual functions: holding the substrate and housing the laser source. This multi-functionality reduces the number of separate components needed in the vacuum chamber, simplifying the overall equipment configuration while maintaining vacuum atmosphere for laser irradiation.
3Area of stationary object
If a large substrate is used, then display unit production is enabled, but the glass window becomes jumboized and equipment cost increases
Solution Approach 1:
The invention extracts the laser source from the external environment and places it inside the vacuum chamber, eliminating the need for a large glass window that would be required to transmit laser light through the chamber wall. This allows large substrates to be processed without proportionally increasing the glass window size or equipment complexity.
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 effectively removes organic layers from auxiliary electrodes in a vacuum atmosphere, reducing luminance variations and thermal damage, while simplifying equipment design and reducing costs, enabling efficient production of display units with uniform luminance.
Implementation Method 1
irradiating a laser beam to the laminated structure thereby removing the organic layer
Data Source
AI summary
A laminated structure is formed by placing a cover substrate over a device substrate with a projection structure in between in the vacuum atmosphere. Next, the laminated structure is taken out into the air in a state that a space between the device substrate and the cover substrate is maintained in the vacuum atmosphere. Subsequently, the portion of the organic layer formed on the auxiliary electrode is removed by irradiating laser light to the laminated structure. Since the space between the device substrate and the cover substrate is maintained in the vacuum atmosphere, even if the laser light is emitted to the laminated structure taken out into the air, the laser light is emitted to the portion of the organic layer formed on the auxiliary electrode in the vacuum atmosphere.