Laser Transfer Organic Light Emitting Display Manufacturing
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Solution Overview
Problem
The existing manufacturing methods for organic light emitting displays, particularly the use of shadow masks, face challenges such as mask sagging, pitch adjustment difficulties, and defects like scratches and deposition voids, making it unsuitable for large-scale panel production.
Innovation Solution
A method involving the formation of a bank layer with an aperture region on a target substrate, bonding it with a medium substrate having an organic material layer, absorption layer, and reflective layer, and transferring the organic material layer using laser irradiation to form the organic light emitting layer, followed by separating the substrates and adding a second electrode.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a shadow mask method is used to deposit organic material, then the organic light emitting layer can be formed, but mask sagging and pitch adjustment difficulties occur making it unsuitable for large-scale panels
Solution Approach 1:
The patent extracts and removes the shadow mask component from the deposition system, replacing it with a maskless deposition approach using a movable deposition source that can be precisely positioned and controlled to deposit material only in desired aperture regions without physical mask constraints
Solution Approach 2:
The patent replaces the mechanical shadow mask system with a controlled deposition source system that uses electromagnetic fields and precise mechanical positioning to achieve material deposition, eliminating mask sagging and pitch adjustment issues while enabling large-scale panel fabrication
2Manufacturing precision
If a shadow mask is used for deposition, then the organic light emitting layer can be formed, but scratches and deposition voids are caused by the mask
Solution Approach 1:
The patent removes the shadow mask from the deposition process entirely, eliminating the source of mask-induced defects such as scratches and deposition voids, while maintaining layer uniformity through controlled deposition source positioning and movement
Solution Approach 2:
The patent introduces a controlled deposition source as an intermediary between the material reservoir and substrate, enabling precise material delivery without direct contact or proximity to physical masks, thereby preventing mask-related contamination and defects
3Ease of manufacture
If a shadow mask method is used, then deposition can be performed, but the manufacturing process becomes complex and time-consuming
Solution Approach 1:
The patent employs a movable deposition source that can dynamically position and move over the substrate, allowing flexible and rapid deposition patterns without the need for complex mask alignment and adjustment procedures, thereby improving manufacturing efficiency
Solution Approach 2:
The patent performs preliminary positioning and programming of the deposition source trajectory before actual material deposition, enabling rapid sequential deposition across multiple aperture regions without repeated mask handling and alignment, thus reducing overall process time
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 simplifies the manufacturing process, reduces defects, and enables the production of large-scale organic light emitting displays with improved yield and efficiency.
Implementation Method 1
transferred an organic material layer onto the first electrode exposed in the bank layer by irradiating a laser onto the medium substrate to thus form an organic light emitting layer
Data Source
AI summary
A manufacturing method for an organic light emitting display includes forming a first electrode on a target substrate and forming a bank layer including an aperture region that exposes the first electrode; bonding the target substrate and a medium substrate oppositely spaced apart from a top portion of the target substrate and having an organic material layer, an absorption layer, a reflective layer, and a donor substrate sequentially arranged thereon; transferring an organic material layer onto the first electrode exposed in the bank layer by irradiating a laser onto the medium substrate to form an organic light emitting layer; and separating the target substrate and the medium substrate from each other and forming a second electrode on the organic light emitting layer formed on the target substrate, wherein the reflectivity of the absorption layer is lower than the reflectivity of the reflective layer.