Masked Pulse-Light Functional Layer Removal in Display Manufacturing
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Solution Overview
Problem
Existing methods for manufacturing display devices face challenges in efficiently removing functional layers while preventing side leakage current, which affects the reliability and efficiency of the manufacturing process.
Innovation Solution
A method involving positioning a substrate, forming a pixel definition layer with openings for pixel electrodes, creating a mask with openings aligned with the pixel definition layer, and radiating pulse light through the mask openings to remove the functional layers, thereby improving manufacturing efficiency and reducing side leakage current.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If functional layers are removed using conventional methods, then manufacturing time is reduced, but side leakage current increases affecting device reliability
Solution Approach 1:
The patent applies local quality by selectively removing functional layers only in non-pixel regions while preserving them in pixel regions. The mask is designed with openings positioned only in non-pixel regions, allowing pulse light to remove functional layers locally where needed for preventing side leakage current, while maintaining functional layers in pixel regions for proper device operation.
Solution Approach 2:
The patent introduces a mask as an intermediary component between the pulse light source and the functional layers. The mask with specifically positioned openings controls where pulse light reaches the functional layers, enabling selective removal in non-pixel regions while protecting pixel regions. This intermediary structure resolves the contradiction by providing spatial selectivity.
2Reliability
If functional layers are completely removed to prevent side leakage current, then device reliability improves, but manufacturing complexity increases
Solution Approach 1:
Instead of completely removing functional layers, the patent applies local quality by removing them only in non-pixel regions where side leakage current occurs. This selective approach maintains device reliability by preventing leakage while avoiding the complexity of complete removal and subsequent re-deposition processes.
Solution Approach 2:
The patent extracts or removes only the necessary portions of functional layers from non-pixel regions using pulse light through a mask. This extraction approach prevents side leakage current without requiring complete removal of functional layers, thereby simplifying the manufacturing process compared to full removal and re-deposition methods.
3Productivity
If pulse light is radiated through mask openings to remove functional layers, then manufacturing efficiency improves, but precision requirements increase
Solution Approach 1:
The mask serves as an intermediary that simplifies the precision requirement by providing a physical template with pre-defined openings. The mask positioning structure aligns the mask openings with non-pixel regions, allowing pulse light to automatically achieve the correct pattern without requiring ultra-precise direct positioning of the light source on each feature.
Solution Approach 2:
The mask creates a copied or replicated pattern of openings that defines the removal regions. This copying approach transfers the precision requirement from the light source positioning to the mask fabrication, where a single master mask can be reused multiple times, improving overall manufacturing efficiency while maintaining consistent precision across production batches.
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 method enhances the manufacturing efficiency of display devices by effectively removing functional layers without damaging the display device, thereby improving the reliability and reducing the time required for the manufacturing process.
Implementation Method 1
radiating pulse light including a plurality of pulses through the opening of the mask, and removing the functional layer to which the pulse light is radiated
Data Source
AI summary
In a method of manufacturing a display device, the method includes: positioning a substrate; forming a functional layer on the substrate; forming a mask including an opening in the functional layer; radiating pulse light including a plurality of pulses through the opening of the mask; and removing the functional layer to which the pulse light is radiated.