Organic Light-Emitting Display Bus Electrode Exposure via Laser Ablation
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Solution Overview
Problem
Existing methods for manufacturing organic light-emitting display apparatuses face challenges in efficiently exposing bus electrodes while preventing particle accumulation, which can lead to defects and black spots due to the integration of intermediate layers and opposite electrodes.
Innovation Solution
A method involving the formation of pixel and bus electrodes on the same layer, with a pixel-defining layer and intermediate layers, where the intermediate layer is selectively removed using a laser beam from underneath to expose the bus electrodes, allowing the opposite electrode to contact the bus electrodes directly, thereby improving manufacturing efficiency and preventing particle accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the intermediate layer is formed to cover the bus electrode, then the structural integrity is improved, but the manufacturing complexity increases due to the need for precise patterning and alignment
Solution Approach 1:
The patent extracts the intermediate layer material from the bus electrode region by forming openings, separating the continuous intermediate layer into discrete regions. This allows the intermediate layer to maintain structural integrity in pixel areas while exposing bus electrodes for electrical connection, resolving the contradiction between structural integrity and manufacturing complexity
Solution Approach 2:
The intermediate layer is segmented into multiple regions: continuous coverage over pixel electrodes and discrete openings over bus electrodes. This segmentation enables different functional requirements to be met simultaneously - structural integrity where needed and electrical access where required - without requiring complex overall manufacturing processes
2Reliability
If the intermediate layer is removed to expose the bus electrode, then the electrical connection is improved, but particle accumulation occurs leading to defects
Solution Approach 1:
The opening in the intermediate layer acts as an intermediary structure that enables electrical connection between the opposite electrode and bus electrode while preventing direct exposure that would cause particle accumulation. The opening provides a controlled pathway for electrical contact while the surrounding intermediate layer material prevents particle generation and accumulation
Solution Approach 2:
The intermediate layer is formed to cover the bus electrode before the opening is created, establishing a protective barrier in advance. This preliminary coverage prevents particle accumulation during subsequent manufacturing steps, and the controlled removal process ensures electrical connection is established without exposing the bus electrode to harmful particles
3Productivity
If the laser beam is emitted continuously to remove the intermediate layer, then the manufacturing speed is improved, but the precision of opening formation deteriorates
Solution Approach 1:
The laser beam is emitted in periodic pulses rather than continuously, with each pulse removing a small amount of material. This periodic action allows heat dissipation between pulses, preventing excessive heat accumulation that would reduce precision, while the rapid repetition of pulses maintains high manufacturing speed. The pulsed laser also enables better control over opening dimensions and shapes
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 and stability of organic light-emitting display apparatuses by ensuring proper exposure of bus electrodes and minimizing defects, leading to improved emission stability and reduced brightness deviations across pixels.
Implementation Method 1
forming an opening in the intermediate layer by irradiating the intermediate layer with a laser beam from underneath the intermediate layer to remove the intermediate layer on the bus electrode
Data Source
AI summary
A method of manufacturing an organic light-emitting display apparatus includes forming a pixel electrode, a bus electrode and a pixel defining layer on a same layer on a substrate, the pixel defining layer exposing a center of the pixel electrode and a portion of the bus electrode, forming an intermediate layer on the pixel-defining layer and on the pixel electrode and the bus electrode, orienting the substrate such that the intermediate layer is located underneath the substrate, forming an opening in the intermediate layer by irradiating the intermediate layer with a laser beam from underneath the intermediate layer to remove the intermediate layer on the bus electrode, exposing at least a portion of the bus electrode, and forming an opposite electrode such that the opposite electrode contacts the bus electrode via the opening in the intermediate layer.