Magnetic Removal of Emission Layer on Auxiliary Cathode
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Solution Overview
Problem
The high resistance of the cathode electrode in large-size OLED displays leads to uneven brightness due to increased IR drop across the panel, restricting the development of large-size OLED displays.
Innovation Solution
A method of manufacturing an array substrate involving the formation of an auxiliary cathode with a layer of magnetic material, where the emission layer is deposited and then removed using an electromagnet, allowing direct contact between the cathode and the auxiliary cathode, thereby reducing cathode resistance and avoiding chemical reactions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the emission layer is deposited on the auxiliary cathode by evaporation, then the emission layer can be formed in the display area, but the emission layer remains on the auxiliary cathode causing high cathode resistance
Solution Approach 1:
The emission layer is segmented into two parts: one part remains on the auxiliary cathode in the non-display area (which will be removed), and another part is formed in the display area. This segmentation allows selective removal of the emission layer from the auxiliary cathode while preserving it in the display area, thereby achieving both complete emission layer formation and clean cathode contact.
Solution Approach 2:
The emission layer deposited on the auxiliary cathode is extracted/removed from the auxiliary cathode surface using a magnet. This extraction eliminates the insulating emission layer material from the cathode contact area, enabling direct contact between the cathode and auxiliary cathode, thus reducing cathode resistance and improving contact reliability.
2Manufacturing precision
If chemical methods are used to remove the emission layer, then the emission layer can be removed from the auxiliary cathode, but secondary pollution is generated
Solution Approach 1:
Chemical removal methods are replaced with a magnetic removal method. A magnet is used to attract and remove the emission layer material (which contains magnetic particles) from the auxiliary cathode. This mechanical/magnetic substitution eliminates the need for chemical solvents and reactions, thereby avoiding secondary pollution while achieving precise emission layer removal.
3Manufacturing precision
If the cathode resistance is high due to emission layer presence, then the emission layer provides complete coverage, but brightness uniformity deteriorates
Solution Approach 1:
The emission layer is preliminarily deposited on the entire auxiliary cathode surface including both the display area and non-display area. This preliminary complete coverage ensures that the display area has sufficient emission layer for operation, while the excess emission layer in the non-display area is subsequently removed by magnetic attraction, allowing the cathode to contact the auxiliary cathode directly and reduce resistance, thereby improving brightness uniformity.
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
The method effectively reduces cathode resistance, improves brightness uniformity, and avoids secondary pollution by performing the process in a vacuum environment, ensuring high success rate of cathode-auxiliary cathode contact.
Implementation Method 1
removing the part of the emission layer and the underneath layer of magnetic material from the first surface of the auxiliary cathode
Implementation Method 2
the emission layer (EL) material deposited by evaporation on the auxiliary cathode
Data Source
AI summary
The present disclosure is related to a method of manufacturing an array substrate. The method of manufacturing an array substrate may include forming an auxiliary cathode on a base substrate, forming a layer of magnetic material on a first surface of the auxiliary cathode, forming an emission layer in a display area of the array substrate, a part of the emission layer on the layer of the magnetic material on the first surface of the auxiliary cathode, and removing the part of the emission layer and the layer of magnetic material from the first surface of the auxiliary cathode.