Mask-Free OLED Deposition via Patterned Insulation
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Solution Overview
Problem
The high manufacturing costs and complexity of OLED lighting panels due to the need for multiple deposition steps and shadow masking in existing processes, which increase equipment costs and reduce manufacturing efficiency.
Innovation Solution
A method for manufacturing OLED lighting panels that minimizes the number of masking steps by patterning a first electrode layer and an inorganic insulation layer on a substrate, allowing for the deposition of organic layers without shadow masking, and subsequently removing organic layers from sealing regions to create a sealing region free from organic materials for encapsulation, enabling encapsulation directly on the continuous OLED web.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shadow masks are used for patterning during vapor deposition, then patterning precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the shadow mask component from the vapor deposition system. By using a different patterning approach that does not require physical masks, the system eliminates the complexity associated with mask handling, alignment, and maintenance while achieving the desired patterning precision through alternative means.
Solution Approach 2:
The patent replaces the mechanical shadow mask system with a non-mechanical patterning approach. Instead of using physical masks that require mechanical alignment and handling, the invention employs a method that achieves patterning through a different mechanism, thereby eliminating the mechanical complexity of the mask system.
2Manufacturing precision
If multiple deposition stations are used for different OLED layers, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent merges multiple deposition operations into a single continuous process. By implementing a method that allows sequential deposition of different OLED layers without requiring separate stations or interrupting the substrate flow, the system maintains layer deposition precision while significantly improving manufacturing throughput and productivity.
Solution Approach 2:
The patent ensures continuous deposition action throughout the manufacturing process. The method allows the substrate to move continuously through the deposition chamber while layers are deposited in sequence without stopping or repositioning, eliminating idle time between deposition steps and maintaining both precision and high productivity.
3Manufacturing precision
If high vacuum vapor deposition is used for organic layer deposition, then material purity is improved, but loss of substance increases
Solution Approach 1:
The patent changes the deposition parameters by using a method that reduces material waste while maintaining purity. The approach optimizes the deposition process to minimize excess material deposition and improve material utilization efficiency, thereby reducing substance loss while preserving the high purity characteristics necessary for OLED performance.
4Manufacturing precision
If shadow masks are used for cathode and organic layer patterning, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent extracts the shadow mask component from the manufacturing process entirely. By implementing a patterning method that does not rely on physical masks for either the organic layers or cathode, the invention eliminates the costs associated with mask fabrication, handling, and disposal while maintaining the necessary patterning accuracy through alternative techniques.
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 reduces manufacturing costs and complexity, enhances manufacturing yield, and allows for the production of OLED lighting panels without the need for shadow masking, making the process more efficient and cost-effective.
Implementation Method 1
One general method for depositing the organic OLED layers is by vapor deposition under high vacuum. Inorganic layers such as metal oxides or metals can generally be deposited by vapor deposition as well as sputtering techniques which also require high vacuum.
Implementation Method 2
Vapor deposition is based on heating the material(s) to be deposited under high vacuum and directing the resulting vaporized material onto the deposition surface.
Implementation Method 3
removing the at least one organic layer over a sealing region
Data Source
Figure 1a~1d
Figure 2a~2d
Figure 3a~3d
AI summary
A method for making an OLED lighting panel is disclosed. A patterned inorganic insulating layer is used to enclose an area over a first electrode layer leaving portions of the first electrode layer and substrate adjacent to the outside of the enclosure exposed. After uniform deposition of the organic layer(s), the organic layer(s) are selectively removed over the inorganic insulating layer and an adjacent portion of the substrate to form a sealing region. After uniform deposition of the second electrode, the enclosed area is encapsulated and any overlying layers over the first and second electrodes outside the enclosed area are removed resulting in an OLED within the enclosed area with electrode contact pads outside the enclosed area. The OLED can be manufactured at low cost with no or limited use of shadow masking and is suitable for roll-to-roll processes.