OLED Panel Cathode Contact Structure for Single-Mask Deposition
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Solution Overview
Problem
Current OLED display devices have low production efficiency due to the need for multiple masks to form the cathode electrode and electron injection/transport layers, which increases production costs and reduces conduction efficiency between the cathode layer and terminal.
Innovation Solution
An OLED display panel design featuring a conductive layer with a first conductive layer having higher metal mobility and oxidation rate, forming protrusions that disconnect the electron transport and injection layers, allowing the cathode layer to be connected to the terminal through these protrusions, thus enabling formation with a single mask and improving conduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If different masks are used for cathode electrode and electron injection/transport layer, then manufacturing precision is improved, but device complexity and production efficiency deteriorate
Solution Approach 1:
The patent merges the cathode electrode pattern and electron injection/transport layer pattern into a single mask design. The conductive layer is configured with a first region overlapping the electron injection layer and a second region overlapping the electron transport layer, allowing both layers to be formed simultaneously through one vapor deposition process, thereby eliminating the need for multiple masks while maintaining manufacturing precision
Solution Approach 2:
The single mask serves multiple functions: it defines both the cathode electrode pattern and the electron injection/transport layer pattern, and the conductive layer performs dual functions of electrical conduction and physical support for the organic light-emitting layers, reducing overall device complexity
2Manufacturing precision
If multiple masks are used for cathode electrode and electron injection/transport layer, then manufacturing precision is improved, but productivity deteriorates
Solution Approach 1:
The patent combines multiple patterning steps into a single vapor deposition process using one mask. The conductive layer is deposited in one continuous operation to form both the cathode electrode and electron injection/transport layer patterns, significantly reducing production time and improving productivity while maintaining pattern formation precision through careful mask design
Solution Approach 2:
The mask is pre-designed with optimized patterns that simultaneously define both the cathode electrode and electron injection/transport layer geometries. The conductive layer material is pre-selected to provide both electrical conduction and structural support functions, allowing single-step formation that improves productivity
3Reliability
If cathode electrode area is greater than electron injection layer area, then electrical conduction is improved, but device complexity increases
Solution Approach 1:
The conductive layer is segmented into distinct functional regions: a first region that overlaps with the electron injection layer to provide electrical conduction and support, and a second region that overlaps with the electron transport layer. This segmentation allows the conductive layer to serve multiple functions while maintaining a relatively simple overall structure
Solution Approach 2:
The conductive layer is designed to perform multiple functions: it serves as the cathode electrode for electrical conduction, provides physical support for the organic light-emitting layers, and defines the pattern for the electron injection layer. This multi-functionality reduces device complexity by eliminating the need for separate structural support layers
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 design enhances production efficiency by allowing the electron injection, transport, and cathode layers to be formed with one mask, improving conduction between the cathode layer and terminal, and reducing the complexity and cost of the manufacturing process.
Implementation Method 1
During a preparation process of the first conductive layer and the second conductive layer, the first conductive layer undergoes metal migration, thereby producing the protrusions
Implementation Method 2
the first conductive layer undergoes metal migration and/or oxidation, thereby producing the protrusions
Data Source
AI summary
An OLED display panel comprises an overlapping area, and further includes a driving circuit layer, a light-emitting functional layer, a cathode layer, and a conductive layer. In the overlapping area, a terminal of the driving circuit layer, a first conductive layer and a second conductive layer of the conductive layer, an electron transport layer and an electron injection layer of the light-emitting functional layer, and the cathode layer are disposed sequentially from bottom to top. The first conductive layer includes a plurality of protrusions. Each of the electron transport layer and the electron injection layer is disconnected at the protrusions, and the cathode layer is in contact with the protrusions.