Organic Light Emitting Display Electrode Patterning via Sacrificial Layer
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Solution Overview
Problem
During the manufacturing of organic light emitting display devices, the formation of reflective and transmissive anode patterns can be damaged due to etching operations, leading to inefficiencies and reduced light emitting efficiency.
Innovation Solution
A method involving the formation of a sacrificial layer with inclined sidewalls to create openings, allowing for the independent formation of first and second electrodes without damaging each other, followed by the deposition of an organic emitting layer and a third electrode, ensuring precise patterning and maintaining light emitting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If etching operations are used to form reflective and transmissive anode patterns, then the electrode patterns can be formed, but the patterns can be damaged leading to reduced light emitting efficiency
Solution Approach 1:
A sacrificial layer is formed in advance to cover and protect the first electrode pattern before the etching operation for the second electrode pattern. This preliminary protective action prevents the etching process from damaging the already-formed electrode patterns, thereby maintaining manufacturing precision while enabling ease of manufacture.
Solution Approach 2:
The sacrificial layer acts as an intermediary protective element between the etching operation and the first electrode pattern. It serves as a temporary barrier that shields the sensitive electrode patterns from the harmful effects of the etching process, allowing both electrode patterns to be formed without mutual damage.
2Productivity
If reflective and transmissive anode patterns are formed simultaneously, then manufacturing steps are reduced, but the patterns interfere with and damage each other
Solution Approach 1:
The manufacturing process is segmented into distinct sequential steps: first forming the first electrode pattern, then forming the sacrificial layer,接着 forming the second electrode pattern through etching, and finally removing the sacrificial layer. This segmentation prevents interference between electrode patterns while maintaining productivity through efficient process sequencing.
Solution Approach 2:
The sacrificial layer is formed in advance as a protective measure before the second electrode pattern formation. This preliminary action enables the etching operation to proceed without damaging the first electrode pattern, thereby maintaining electrode pattern integrity while allowing efficient sequential manufacturing.
3Manufacturing precision
If a sacrificial layer is used to protect electrodes during etching, then electrode damage is prevented, but the manufacturing process becomes more complex
Solution Approach 1:
The sacrificial layer is formed temporarily to provide protection during the etching operation, then systematically removed in a final cleaning step. This approach adds only one additional process step while achieving effective electrode protection, as the sacrificial layer is discarded after serving its protective function, thereby minimizing the increase in manufacturing process complexity.
Data Source
AI summary
A method of manufacturing an organic light emitting display device includes defining pixels on a substrate, each of the pixels including a first area in which light is emitted in a first direction and a second area in which light is emitted in a second direction opposite the first direction; forming first electrodes respectively disposed in the first area of each of the pixels; forming a sacrificial layer in the first area and the second area of each pixel to cover the first electrodes; forming openings in the sacrificial layer to open a patterning area in the respective second area of each of the pixels; forming a conductive layer on the patterning areas and the sacrificial layer; removing the sacrificial layer; forming an intermediate layer including an organic emitting layer; and forming a third electrode on the intermediate layer.