OLED Inspection Patterns Eliminate Substrates
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Solution Overview
Problem
The existing manufacturing processes for organic light-emitting display (OLED) devices require additional inspection substrates for alignment inspection, increasing costs and complexity.
Innovation Solution
Incorporating inspection patterns and layers on a substrate with thin film transistors, allowing for alignment inspection without additional substrates, by using inspection pixels and keys in a non-display area to check the alignment of organic light-emitting and hole transporting layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If additional inspection substrates are used for alignment inspection, then alignment accuracy can be verified, but manufacturing cost increases and process complexity increases
Solution Approach 1:
The patent combines the inspection function with the display substrate itself by forming inspection patterns (inspection pixels and inspection keys) directly on the display substrate. This eliminates the need for separate inspection substrates, thereby reducing process complexity while maintaining alignment inspection accuracy. The inspection patterns are integrated into the same substrate where the actual display pixels are formed, allowing alignment verification to be performed on the final product substrate rather than requiring additional test substrates.
2Measurement precision
If additional inspection substrates are used for alignment inspection, then alignment accuracy can be verified, but manufacturing cost increases
Solution Approach 1:
The inspection patterns are merged with the display substrate manufacturing process. The same thin film transistors, organic light-emitting layers, and other structures are used for both display pixels and inspection pixels. This integration eliminates the need to manufacture separate inspection substrates, directly reducing material costs and manufacturing expenses while preserving the ability to perform accurate alignment inspection.
Solution Approach 2:
The display substrate is given dual functionality: it serves both as the final display product and as the inspection medium. The inspection patterns formed on the substrate allow the substrate itself to perform the alignment verification function, eliminating the need for dedicated inspection substrates and reducing overall manufacturing costs.
3Device complexity
If inspection patterns are incorporated on the substrate, then additional substrates can be eliminated, but the substrate area required increases
Solution Approach 1:
The inspection patterns are placed in specific localized regions of the substrate (non-display areas or peripheral regions) rather than distributing them uniformly across the entire substrate. This allows the inspection function to be performed while minimizing the impact on the display area and keeping the overall substrate area requirement reasonable.
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 reduces manufacturing costs and simplifies the process by eliminating the need for additional inspection substrates while ensuring accurate alignment of layers, thereby improving efficiency and reducing errors.
Implementation Method 1
when a high potential voltage is applied to the anode electrode, and a low potential voltage is applied to the cathode electrode, holes and electrons are respectively moved to the organic light-emitting layer via the hole transporting layer and the electron transporting layer, and are then combined to each other in the organic light-emitting layer to thereby emit light
Data Source
AI summary
Provided are an organic light-emitting display (OLED) device and a method of manufacturing the same. An OLED device includes: a substrate, a display area on the substrate, the display area including: a first pixel including a first organic light-emitting layer configured to emit first-colored light, a second pixel including a second organic light-emitting layer configured to emit second-colored light, and a third pixel including a third organic light-emitting layer configured to emit third-colored light, and an inspection pattern area in a non-display area on the substrate, the inspection pattern area including a first inspection pixel including a first inspection organic light-emitting layer including a same material as that of the first organic light-emitting layer.