OLED Anode Auxiliary Electrode Single Mask Process
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Solution Overview
Problem
The manufacturing process of organic light-emitting devices is complex and costly due to the need for multiple mask processes, leading to increased production time and failure rates, which negatively impacts yield and efficiency.
Innovation Solution
The formation of an auxiliary electrode via the same mask process as the anode electrode, along with a bank covering the side and upper surfaces of both electrodes, simplifies the structure and manufacturing process, reducing the number of mask processes and preventing short-circuit failures and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple mask processes are used to manufacture the organic light-emitting device, then the manufacturing precision and structural complexity are improved, but the manufacturing time, production costs, and failure rates increase
Solution Approach 1:
The patent combines the formation of the auxiliary electrode and the emission pattern definition into a single mask process. The mask layer is formed to define both the auxiliary electrode pattern and the emission pattern simultaneously, eliminating the need for separate mask processes that were previously required for each structure.
Solution Approach 2:
The mask layer serves multiple functions: it defines the auxiliary electrode pattern, defines the emission pattern, and protects underlying structures during etching. This multi-functional approach consolidates what would traditionally require multiple specialized mask processes into a single operation.
2Manufacturing precision
If multiple mask processes are used to manufacture the organic light-emitting device, then the manufacturing precision and structural complexity are improved, but the production costs and failure rates increase
Solution Approach 1:
The patent combines the formation of the auxiliary electrode and the emission pattern definition into a single mask process. The mask layer is formed to define both the auxiliary electrode pattern and the emission pattern simultaneously, eliminating the need for separate mask processes that were previously required for each structure.
Solution Approach 2:
The mask layer is formed, used for patterning both the auxiliary electrode and emission regions, then selectively removed in specific areas to expose underlying structures. This controlled discarding of the mask layer after its protective and definitional functions are complete eliminates the need for additional mask processes.
3Device complexity
If the auxiliary electrode is formed via the same mask process as the anode electrode, then the manufacturing process is simplified, but the risk of damage to the electrodes increases
Solution Approach 1:
The mask layer is formed beforehand to define the patterns of both the auxiliary electrode and the emission regions. This preliminary protective layer is in place before any etching or material deposition occurs, preventing accidental damage to the electrodes during subsequent manufacturing steps.
Solution Approach 2:
The mask layer acts as an intermediary protective element between the manufacturing processes and the delicate electrode structures. It mediates the interaction by providing a sacrificial layer that can be selectively removed without damaging the underlying electrodes, thus simplifying the process while maintaining reliability.
Data Source
AI summary
Disclosed are an organic light-emitting device and a method of manufacturing the same. In the organic light-emitting device, an auxiliary electrode is formed on anode electrode to come into contact with the anode electrode via the same mask process as the anode electrode, which results in a simplified structure and simplified processing. In addition, a bank is disposed to cover a side surface and an upper surface of the auxiliary electrode and a side surface of the anode electrode, whereby damage to the auxiliary electrode and the anode electrode is prevented.