OLED Cathode Separator Manufacturing Process
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Solution Overview
Problem
Existing manufacturing processes for OLED display panels result in low stability of cathode separators due to their inverted-trapezoid shape, which affects the display quality and is prone to IR drop issues.
Innovation Solution
A manufacturing process for OLED display panels involving the formation of cathode separators through successive deposition of thin-film layers with increasing compactness, followed by dry-etching to achieve an inverted trapezoid shape, enhancing stability and patterning uniformity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional photoresist application and development is used to form cathode separators, then the manufacturing process is simple, but the stability of cathode separators is low
Solution Approach 1:
The cathode separator is divided into multiple thin-film layers with different compactness values, where each layer contributes to the overall stability. The segmentation allows the separator to maintain structural integrity while achieving the desired inverted trapezoid shape through differential etching rates between layers.
Solution Approach 2:
The compactness parameter of the thin-film layers is systematically varied, with compactness increasing from bottom to top. This parameter change creates different etching rates for each layer during the dry-etching process, enabling precise control over the final shape and stability of the cathode separator.
2Manufacturing precision
If inverted-trapezoid shape is formed by controlling process parameters, then the shape is achieved, but the manufacturing stability is low
Solution Approach 1:
By changing the compactness parameter across different thin-film layers, the invention achieves consistent inverted trapezoid shapes with high manufacturing stability. The gradient in compactness ensures uniform etching behavior across different batches and conditions.
Solution Approach 2:
The cathode separator is constructed as a composite structure of multiple thin-film layers with different compactness properties. This composite approach enables precise control over the etching process and final shape, achieving both high precision and stability.
3Reliability
If multiple thin-film layers with increasing compactness are deposited, then the stability and uniformity of cathode separators are improved, but the manufacturing process complexity increases
Solution Approach 1:
The systematic variation of compactness parameter across thin-film layers creates a self-organizing structure that simplifies the overall manufacturing control. The gradient structure ensures that each layer contributes predictably to the final shape, reducing the need for complex process adjustments.
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 process improves the stability and uniformity of cathode separators, simplifying the manufacturing process and reducing IR drop effects, thereby enhancing display quality and efficiency.
Implementation Method 1
successively depositing a plurality of thin-film layers on the auxiliary electrode layer by chemical vapor deposition
Implementation Method 2
dry-etching the plurality of thin-film layers so that the width of a single thin-film layer among the plurality of thin-film layers gradually increases from bottom to top
Data Source
AI summary
The present disclosure provides a display panel and a manufacturing process of the display panel. The manufacturing process of the display panel includes: successively depositing a plurality of thin-film layers on an auxiliary electrode layer, the compactness of a single thin-film layer among the plurality of thin-film layers gradually increasing from bottom to top; forming a preset pattern by the plurality of thin-film layers having a same width; dry-etching the plurality of thin-film layers so that the width of a single thin-film layer among the plurality of thin-film layers gradually increases from bottom to top, to form a plurality of cathode separators having an inverted trapezoid shape. The manufacturing process of the cathode separator is highly stable.