OLED First Electrode Etching Unit for Residual Pattern Removal
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Solution Overview
Problem
Residual patterns on the first electrode of organic light emitting display apparatuses can cause defects such as dark spots, affecting image quality due to incomplete patterning during manufacturing.
Innovation Solution
Incorporating an etching unit on the first electrode, which is crystallized and formed using oxalic acid, to remove impurities like silver (Ag) and prevent damage to the electrode's edges and surfaces, thereby improving image quality by ensuring complete removal of residual patterns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional patterning is used to form the first electrode, then the manufacturing process is simple, but residual patterns remain on the electrode surface causing dark spots and poor image quality
Solution Approach 1:
The first electrode is segmented into two functional parts: a patterned conductive region for electrical function and an etching unit for surface cleaning. This segmentation allows the electrode to simultaneously achieve complete patterning (removing residual patterns) and maintain structural integrity, resolving the contradiction between patterning completeness and structural complexity.
Solution Approach 2:
The etching unit acts as an intermediary component between the patterned electrode and the organic emission layer. It provides a controlled etched surface that prevents residual pattern formation while maintaining electrical connectivity, serving as a mediator that resolves the conflict between simple patterning and complete pattern removal.
2Manufacturing precision
If aggressive etching is used to remove all residual patterns, then image quality improves, but the electrode edges and surfaces may be damaged
Solution Approach 1:
The etching process is applied locally only to specific regions where residual patterns form, rather than uniformly across the entire electrode. The etching unit is strategically positioned to provide localized surface treatment, removing contaminants while preserving the overall structural integrity and strength of the electrode.
Solution Approach 2:
The etching unit is pre-formed on the electrode surface before the organic emission layer is deposited. This preliminary action prepares the surface in advance to prevent residual pattern formation during subsequent manufacturing steps, ensuring complete pattern removal without requiring aggressive post-processing that could damage the electrode.
3Productivity
If the first electrode surface is left as-is after patterning, then the manufacturing process is fast, but residual patterns cause dark spots affecting image quality
Solution Approach 1:
The etching unit is incorporated into the electrode structure during the patterning process itself, rather than requiring a separate post-processing step. This preliminary action ensures surface cleanliness is built-in during manufacturing, maintaining both high productivity and manufacturing precision simultaneously.
Solution Approach 2:
The etching function is merged with the electrode structure by forming the etching unit as an integrated part of the first electrode. This combination eliminates the need for separate surface treatment steps, maintaining manufacturing speed while ensuring complete residual pattern removal for high image quality.
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 etching unit effectively removes residual silver (Ag) and crystallized ITO, enhancing the adhesive strength between the electrodes and intermediate layers, thus preventing defects and improving image quality and electrical characteristics.
Implementation Method 1
the etching unit is formed by wet etching the first electrode... the etching unit may be formed by an oxalic acid
Implementation Method 2
an area of the first electrode having the etching unit may be crystallized... an area of the first electrode having the etching unit may include crystallized ITO... the crystallizing of the first electrode comprises crystallizing ITO
Data Source
AI summary
An organic light emitting display apparatus and method of manufacturing the same to improve an image quality of the organic light emitting display apparatus. The organic light emitting display apparatus includes: a first electrode formed on a substrate; an intermediate layer disposed on the first electrode, the intermediate layer having an organic emission layer; and a second electrode formed on the intermediate layer, wherein the first electrode includes an etching unit facing the intermediate layer.