OLED Anode and Active Layer Integration via Lyophilic Lyophobic Insulation
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Solution Overview
Problem
The manufacturing process of organic light emitting diode (OLED) array substrates is complex, and defects such as Mura can occur due to uneven spreading of organic light emitting material, leading to decreased yield and production efficiency.
Innovation Solution
A manufacturing method that forms the first electrode and active layer of the thin film transistor in the same layer, using a combination of lyophilic and lyophobic insulating layers to improve the flatness of the organic light emitting material layer, and includes an overexposure treatment to enhance conductivity, simplifying the process and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If many patterning processes are used to form gates, sources, drains, cathodes and anodes, then the OLED array substrate structure can be achieved, but the manufacturing process becomes complicated
Solution Approach 1:
The patent merges the formation of the anode and active layer into a single layer structure formed by one patterning process. The first electrode (anode) and active layer are created simultaneously from the same oxide semiconductor layer through a single pattern definition process, eliminating the need for separate patterning steps that would otherwise be required to form these structures individually.
Solution Approach 2:
The oxide semiconductor layer serves multiple functions: it forms both the active layer of the thin film transistor and the anode of the OLED. This multi-functional material layer replaces what would traditionally require separate material layers and processing steps, simplifying the overall manufacturing process while maintaining the required device functionality.
2Ease of manufacture
If inkjet printing technique is used to deposit organic light emitting material, then manufacturing flexibility is improved, but Mura defects occur when ink droplet does not spread evenly
Solution Approach 1:
The patent applies different surface properties to different regions of the insulating layer. The insulating layer is designed with a first region having a first surface property and a second region having a second surface property different from the first. This local differentiation of surface properties controls the spreading behavior of the inkjet-deposited organic light emitting material in different areas, ensuring uniform distribution while maintaining manufacturing flexibility.
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 simplifies the manufacturing process, improves the flatness of the organic light emitting material layer, and increases yield by reducing the number of patterning processes and avoiding defects like Mura, thereby enhancing the efficiency and quality of OLED array substrates.
Implementation Method 1
using a combination of lyophilic and lyophobic insulating layers to improve the flatness of the organic light emitting material layer
Implementation Method 2
performing an overexposure treatment on the first electrode formed in the same layer as the active layer through the accommodation cavity to improve conductivity thereof
Data Source
Figure 1(a)~1(d)
Figure 2~3
Figure 4~5
AI summary
The present invention discloses an OLED array substrate and a manufacturing method thereof, a display apparatus. The OLED array substrate includes a TFT and an OLED. The method includes: forming an oxide semiconductor layer by a film forming process, and performing one patterning process on the oxide semiconductor layer to form an active layer of the TFT and a first electrode of the OLED; sequentially forming a first insulating layer and a second insulating layer on the active layer and the first electrode of the OLED, the first insulating layer being a lyophilic layer, and the second insulating layer being a lyophobic layer; forming an accommodation cavity exposing the first electrode by performing a patterning process on the first and second insulating layers; and injecting, into the accommodation cavity, and drying a solution containing an organic light emitting material to form an organic light emitting material layer.