Crystallized Metal Oxide Scattering Patterns for OLED Displays
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Solution Overview
Problem
The manufacturing of organic light-emitting displays with a non-resonance structure faces challenges in controlling the size and density of silver crystal particles for scattering structures, and patterning tungsten oxide due to silver's low chemical resistance and the lack of effective etchants.
Innovation Solution
The use of crystallized metal oxide scattering patterns, such as tin oxide, indium oxide, and zinc oxide, formed on a substrate with a method involving the deposition and crystallization of amorphous metal oxides at room temperature, allowing for adjustable particle size and easy patterning, and the inclusion of an insulating layer with a higher refractive index than the scattering patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If silver crystal particles are used to form scattering structures, then light scattering is achieved, but it is difficult to control the size and density of the particles
Solution Approach 1:
The patent changes the material parameter from silver to metal oxide (such as zinc oxide, tin oxide, indium oxide), which fundamentally alters the formation mechanism. Instead of relying on thermal agglomeration of metal particles whose size and density are difficult to control, the metal oxide layer is deposited with controllable thickness and then selectively removed to form scattering patterns with precise dimensions determined by the deposition parameters and etching process.
Solution Approach 2:
The patent uses metal oxide as a temporary scattering structure material that can be easily deposited and removed. The metal oxide layer serves its scattering function during device operation but can be selectively eliminated through etching processes, allowing for flexible manufacturing and pattern formation without the persistence issues of metal crystal particles.
2Ease of manufacture
If silver is exposed during manufacturing, then scattering structure formation is enabled, but low chemical resistance prevents further processing
Solution Approach 1:
The patent employs metal oxide as a sacrificial material that is easy to deposit and remove. The metal oxide layer is formed, used as the scattering structure, and then can be selectively removed by etchants without affecting other components. This disposable approach avoids the chemical resistance problems of exposed silver while maintaining the scattering function during critical processing steps.
Solution Approach 2:
The patent introduces metal oxide as an intermediary material between the substrate and the final device structure. This intermediary layer provides the necessary light scattering properties during manufacturing and operation, and its temporary presence enables processes that would be difficult or impossible with direct silver exposure, as it can be selectively removed when no longer needed.
3Manufacturing precision
If tungsten oxide is patterned using silver crystal particles as etch mask, then scattering patterns can be formed, but effective etchants are difficult to develop
Solution Approach 1:
The patent inverts the conventional approach by not using metal particles as masks to pattern metal oxide, but rather using deposited metal oxide layers that are then selectively removed. Instead of trying to find etchants that selectively remove tungsten oxide while preserving silver masks, the process is reversed: metal oxide is deposited and then selectively removed to form the scattering patterns, simplifying the chemistry requirements.
Solution Approach 2:
The patent uses metal oxide as a temporary structure that is easily removed after serving its purpose. The metal oxide layer is deposited, used to define scattering patterns through selective removal, and then the patterning is achieved without requiring complex etchant development for metal-metal oxide systems. The metal oxide serves as a disposable element that simplifies the overall manufacturing chemistry.
4Illumination intensity
If resonance structure is used in organic light-emitting display, then light emission is enhanced, but different resonance conditions for different colors require different organic layer thicknesses and independent masks
Solution Approach 1:
The patent extracts the scattering function from the color-specific resonance structure and implements it as a separate, color-independent metal oxide scattering layer. Instead of requiring different organic layer thicknesses and masks for each color to achieve resonance, a single scattering layer is deposited and patterned once, providing uniform light scattering for all colors without affecting the color-specific optical paths needed for resonance enhancement.
Solution Approach 2:
The patent creates a universal scattering structure using metal oxide that serves all color channels simultaneously. The single metal oxide layer with appropriate refractive index provides light scattering functionality for red, green, and blue emissions without requiring color-specific variations in thickness or patterning, thereby simplifying the manufacturing process while maintaining enhanced light emission for all colors.
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, improves lateral visibility by scattering light effectively, and reduces manufacturing costs by eliminating the need for complex masking and etching processes associated with silver and tungsten oxide.
Implementation Method 1
The scattering structure scatters light emitted from an organic layer, thereby preventing the occurrence of resonance within the organic light-emitting display.
Implementation Method 2
depositing amorphous metal oxide on the substrate, and crystallizing portions of the deposited amorphous metal oxide
Implementation Method 3
crystallizing portions of the deposited amorphous metal oxide
Data Source
AI summary
A display device and method of manufacturing the same, the display device having a substrate, a plurality of scattering patterns which are located on the substrate and comprise crystallized metal oxide, a first electrode which is located on the scattering patterns, an organic light-emitting layer which is located on the first electrode, and a second electrode which is located on the organic light-emitting layer.