OLED Panel Cathode Auxiliary Electrode Burn-Through
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Solution Overview
Problem
Large-sized OLED panels experience mura effects due to IR drops in the cathode electrode, leading to uneven and unstable display images, which existing technologies fail to adequately address.
Innovation Solution
A method of manufacturing OLED panels that includes forming an auxiliary electrode connected to the cathode electrode, with metal protrusions on the bridge electrode having corners, allowing for voltage application to burn openings and connect the cathode electrode to the auxiliary electrode, thereby improving signal input to the cathode electrode and mitigating the mura effect.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the cathode electrode is used in large-sized OLED panels, then the display device can achieve large area coverage, but IR drops occur causing mura effects and uneven display images
Solution Approach 1:
The patent divides the single cathode electrode into multiple segmented cathode electrodes (first cathode electrode and second cathode electrode). This segmentation reduces the resistance path length for each segment, thereby minimizing IR drops and preventing mura effects while maintaining large panel area coverage.
Solution Approach 2:
The patent introduces an auxiliary electrode as an intermediary component between the cathode electrode and the organic light-emitting layer. This auxiliary electrode serves as a mediator to improve electrical contact and reduce contact resistance, thereby reducing IR drops and enhancing display uniformity across large panel areas.
2Reliability
If the cathode electrode resistance is reduced to prevent mura effects, then display uniformity improves, but the device complexity increases due to additional auxiliary electrodes and manufacturing steps
Solution Approach 1:
The patent combines the auxiliary electrode function with the existing cathode electrode structure by forming the auxiliary electrode from the same conductive material layer. This merging approach reduces device complexity by eliminating separate auxiliary electrode fabrication steps while still achieving the desired electrical performance improvements.
Solution Approach 2:
The auxiliary electrode serves multiple functions: it acts as an additional cathode contact point, provides a pathway to reduce IR drops, and maintains structural compatibility with the existing OLED architecture. This multi-functionality reduces the need for additional specialized components, thereby limiting complexity increases.
3Reliability
If auxiliary electrodes are added to reduce IR drops, then mura effects are mitigated, but the manufacturing process complexity and time increase
Solution Approach 1:
The patent performs preliminary action by forming the auxiliary electrode simultaneously with the cathode electrode during the same sputtering process step. This preliminary integration of the auxiliary electrode into the existing manufacturing flow eliminates the need for separate auxiliary electrode fabrication steps, thereby maintaining high manufacturing efficiency while achieving improved display uniformity.
Solution Approach 2:
The patent maintains continuity of useful action by using the same sputtering process to deposit both the cathode electrode and auxiliary electrode materials without interrupting the manufacturing flow. This continuous process approach avoids additional processing steps and maintains high productivity while implementing the auxiliary electrode structure.
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
The method ensures even and stable display images by allowing signal input to the cathode electrode via the auxiliary electrode, effectively reducing the mura effect caused by IR drops in the OLED panel.
Implementation Method 1
applying a voltage on the auxiliary electrode or the bridge electrode to burn a portion of the electron transport layer and a portion of the electron injection layer corresponding to the corners of the metal protrusions
Data Source
AI summary
The embodiments of the disclosure provides a method of manufacturing an OLED panel and an OLED panel. The method includes: forming an anode electrode connected to a source electrode of a TFT and a bridge electrode connected to an auxiliary electrode on a TFT substrate; forming a plurality of metal protrusions on the bridge electrode, the surfaces of the metal protrusions having a plurality of corners; sequentially forming an electron transport layer, an electron injection layer and a cathode electrode on the bridge electrode and the metal protrusions; and applying a voltage on the auxiliary electrode or the bridge electrode to burn a portion of the electron transport layer and a portion of the electron injection layer corresponding to the corners of the metal protrusions to connect the cathode electrode and the auxiliary electrode.