OLED Cathode Bridge Patterning With Low-Resistance Layer
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Solution Overview
Problem
The existing manufacturing processes for OLED display panels are complicated and costly due to the need for multiple mask plates and high contact resistance between the cathode layer, electron injection layer, and electron transport layer, which complicates the formation of these layers and increases production costs.
Innovation Solution
A display panel design that includes a resistance reduction layer between the cathode voltage line and the electron transport layer, allowing for simultaneous patterning of the cathode, electron injection, and electron transport layers using a single mask plate, reducing the number of mask plates needed and lowering contact resistance, while also using metal oxide layers to enhance conductivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple mask plates are used to form the cathode layer, electron injection layer, and electron transport layer separately, then the electrical connection between the cathode voltage line and the cathode layer is improved, but the manufacturing process becomes complicated and costs increase
Solution Approach 1:
The patent merges the cathode layer, electron injection layer, and electron transport layer into a single integrated cathode assembly that is patterned using one mask plate. This combining approach maintains electrical connection reliability while significantly simplifying the manufacturing process by eliminating the need for multiple separate patterning operations and multiple mask plates.
Solution Approach 2:
The single mask plate design serves multiple functions by simultaneously defining the patterns for the cathode layer, electron injection layer, and electron transport layer. This universal approach allows one mask plate to accomplish what previously required multiple specialized mask plates, reducing process complexity while maintaining the necessary electrical connections.
2Ease of manufacture
If the film formation region of the electron transport layer and electron injection layer is reduced to enable direct cathode bridging to the cathode voltage line, then the manufacturing process is simplified, but the contact resistance increases
Solution Approach 1:
The patent introduces a conductive bridge structure that acts as an intermediary between the cathode voltage line and the cathode layer. This conductive bridge maintains low contact resistance by providing a dedicated electrical pathway, while allowing the electron transport layer and electron injection layer to be extended to the edge of the substrate for simplified manufacturing.
Solution Approach 2:
The patent extends the cathode layer, electron injection layer, and electron transport layer to the edge of the substrate in a dimensional extension approach. This allows the layers to be formed in a single patterning step while the conductive bridge provides the necessary electrical connection in a different spatial configuration, effectively separating the electrical connection function from the layer formation process.
3Reliability
If evaporation or sputtering processes are used to deposit the electron transport layer, electron injection layer, and cathode layer, then the layer quality is improved, but the manufacturing cost increases compared to ink jet printing
Solution Approach 1:
The patent combines the deposition of electron transport layer, electron injection layer, and cathode layer into a single evaporation or sputtering process step. By patterning all three layers simultaneously using one mask plate, the patent reduces the number of high-cost vacuum process steps required, thereby lowering manufacturing costs while maintaining layer quality through the use of evaporation or sputtering deposition.
Data Source
AI summary
An embodiment of the present invention discloses a display panel and a manufacturing method thereof. The display panel includes a driver wiring layer, an electron transport layer, an electron injection layer, and a cathode layer. The driver wiring layer includes a cathode voltage line, and the electron transport layer is connected to the cathode voltage line. The cathode layer is connected to the electron injection layer. Patterns of the electron transport layer and the electron injection layer are the same as a pattern of the cathode layer. The display panel further includes a resistance reduction layer located between the cathode voltage line and the electron transport layer. The present invention simultaneously patterns the cathode layer, the electron injection layer, and the electron transport layer by a mask plate and forms the same patterns.