Organic Light-Emitting Component Contact Layer Structuring
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Solution Overview
Problem
Conventional methods for producing organic light-emitting components often result in undesired luminance distributions due to the lack of consideration for the electrical properties of different organic functional layers, leading to inhomogeneities in light emission, which can be costly to address with separate lithography masks for each type of component.
Innovation Solution
A method involving the formation of a carrier with a first electrode and organic functional layer structure, followed by a second electrode, where an electrically conductive contact layer is structured using a laser beam to create insulated contact sections, allowing for flexible and cost-effective production of organic light-emitting components with predetermined luminance distributions by modifying the current path and cross-sectional areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a separate lithography mask is used for each type of organic functional layer to account for different electrical properties, then the luminance distribution is improved, but the device complexity and production cost increase
Solution Approach 1:
The contact layer is segmented into multiple contact sections with different cross-sectional areas. The structuring element divides the originally continuous contact layer into discrete sections, allowing different current path lengths and cross-sectional areas in different regions. This enables tailored current distribution to compensate for variations in electrical properties of different organic functional layers without requiring separate lithography masks for each component type.
Solution Approach 2:
The contact layer is designed with spatially varying properties - different cross-sectional areas and path lengths in different regions. The structuring element creates local variations in the contact layer geometry, where contact sections closer to the light-emitting region have different characteristics than those farther away. This local differentiation allows optimization of current distribution for each region based on the electrical properties of the underlying organic functional layer.
2Ease of manufacture
If the same lithography mask is used for all organic light-emitting components, then the production cost is reduced, but the luminance distribution becomes inhomogeneous
Solution Approach 1:
The contact layer is pre-structured with a pattern of contact sections and varying cross-sectional areas before the organic functional layer is deposited. This preliminary structuring of the contact layer establishes the current distribution pattern in advance, which then works in conjunction with different organic functional layer types to achieve uniform luminance. The structuring element is applied once to create this preliminary geometry that will accommodate various organic layer configurations.
Solution Approach 2:
The contact layer structure with its varying cross-sectional areas and contact sections serves multiple functions: it provides electrical contact, controls current distribution, and compensates for electrical property variations in different organic functional layers. This universal structure can work with different types of organic functional layers (red, green, blue, white) without requiring mask changes, making the same lithography mask and contact layer design applicable across multiple component types.
3Ease of manufacture
If contact sections are formed with equal cross-sectional areas, then the manufacturing process is simplified, but the electrical stress distribution becomes non-uniform
Solution Approach 1:
The contact layer is designed with spatially varying cross-sectional areas rather than uniform dimensions. Contact sections at different positions have different widths or thicknesses, creating local variations in electrical resistance. This local differentiation ensures that regions with higher current density have larger cross-sectional areas, while regions with lower current density have smaller areas, distributing electrical stress uniformly across the contact layer despite the manufacturing complexity.
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 approach enables the production of organic light-emitting components with homogeneous or inhomogeneous luminance distributions, improving yield and product quality by accounting for the electrical properties of various organic functional layers, while reducing production costs and extending the lifetime by distributing electrical stress uniformly.
Implementation Method 1
The electrically conductive contact layer is subsequently structured by means of a laser beam. At least one further contact section, which is electrically insulated from the second contact layer, is formed by means of the structuring in the electrically conductive contact layer.
Data Source
AI summary
A method for producing an organic light-emitting component is disclosed with providing a carrier, forming a first electrode over the carrier, forming an organic functional layer structure over the first electrode, and forming a second electrode over the functional layer structure. The first and second electrodes and the functional layer structure overlap in an optically active region which extends in the lateral direction and is embodied to generate light. In an optically inactive region extending over the carrier in the lateral direction, an electrically conductive contact layer is formed over the carrier, so that it is in direct physical and electrical contact with the first electrode and/or the second electrode. A first contact section and at least one second contact section of the layer are separated from one another by a lithographic process, so that they are electrically insulated from one another. The layer is structured by a laser beam.