Integrated OLED Electrode Stack With Hillock-Free Alloy Contacts
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Solution Overview
Problem
Current display devices face challenges in manufacturing efficiency and reliability, particularly in the integration of conductive patterns and electrodes, which affect the overall performance and production processes.
Innovation Solution
A display device design featuring a substrate with defined emission and non-emission areas, including a conductive pattern and first electrode stacked on an insulating layer, where the conductive pattern and first electrode are integrally formed with different layers, including an aluminum-nickel-lanthanum-based alloy as the second layer, improving electrical connections and reducing manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate processes are used for forming conductive patterns and electrodes, then manufacturing precision can be maintained, but manufacturing efficiency decreases and device complexity increases
Solution Approach 1:
The patent merges the formation of conductive patterns and electrodes into a single integrated process. The conductive pattern and first electrode are formed simultaneously through one coating step, eliminating the need for separate formation processes. This integration directly improves manufacturing efficiency while reducing process complexity, as the conductive pattern serves dual functions as both electrical connection and electrode structure.
2Reliability
If aluminum-based alloy is used for the second layer, then electrical conductivity is improved, but hillock formation may occur reducing reliability
Solution Approach 1:
The patent employs a composite aluminum-based alloy material for the second layer, specifically comprising aluminum, nickel, and lanthanum elements. This composite material formulation maintains the high electrical conductivity required for reliable electrical connections while the specific alloy composition prevents hillock formation that typically occurs with pure aluminum. The nickel and lanthanum additives modify the material properties to eliminate the harmful hillock effect during annealing processes.
Solution Approach 2:
The patent changes the material parameters by using a specific aluminum-based alloy composition with controlled proportions of aluminum, nickel, and lanthanum. This parameter modification transforms the material behavior during thermal processing, preventing the hillock formation that would otherwise occur with standard aluminum materials while maintaining the necessary electrical conductivity for reliable device operation.
3Reliability
If multiple layers are stacked for conductive pattern and electrode, then electrical conductivity improves, but manufacturing complexity increases
Solution Approach 1:
The patent combines multiple functional layers into a single integrated coating process. The conductive pattern and first electrode are formed together in one step, and the second layer with aluminum-based alloy is applied simultaneously or in close sequence. This merging approach maintains the beneficial multi-layer structure for electrical conductivity while simplifying the manufacturing process by reducing the number of discrete deposition steps.
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 manufacturing efficiency by eliminating separate processes for forming electrodes and improves reliability by using a hillock-free aluminum-nickel-lanthanum-based alloy, leading to improved electrical connections and reduced defects.
Implementation Method 1
the second layer may include an aluminum-nickel-lanthanum-based alloy
Data Source
AI summary
A display device includes: a substrate having an emission area and a non-emission area; an insulating layer covering a circuit element on the substrate, the insulating layer including a contact part exposing a portion of the circuit element; a conductive pattern on the insulating layer and electrically connected to the circuit element through the contact part; a first electrode on the insulating layer and integrally formed with the conductive pattern; a pixel defining layer over the first electrode, the pixel defining layer including an opening exposing a portion of the first electrode; a light emitting layer on the first electrode; and a second electrode on the light emitting layer, wherein the conductive pattern and the first electrode include a first layer, a second layer, and a third layer, which are sequentially stacked on one surface of the insulating layer, and wherein the second layer includes an aluminum-nickel-lanthanum-based alloy.