OLED Insulation Layer Uniformity via Segmented Power Lines
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Solution Overview
Problem
In the manufacturing process of organic light-emitting display apparatuses, the formation of an insulation layer (pixel defining layer) is often defective due to issues with the electrode power supply line underneath, leading to uneven application and defects in the layer's thickness.
Innovation Solution
The organic light-emitting display apparatus features a substrate with a display area and a peripheral area, including a step forming layer on the peripheral area, an insulation layer covering both areas, and a first conductive layer with a multi-layer structure where the end portion is close to the step forming layer, ensuring the insulation layer is applied uniformly by minimizing exposure of the conductive layer's end portion and preventing damage during etching.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode power supply line is formed and the insulation layer material is applied thereon, then the insulation layer can be formed to provide electrical isolation, but the material cannot be smoothly applied due to the electrode power supply line underneath, causing defects and uneven thickness
Solution Approach 1:
The electrode power supply line is segmented into a first conductive layer and a second conductive layer separated by the insulation layer. This segmentation allows the insulation layer material to be applied smoothly between the two conductive layers without being blocked by a continuous electrode structure, thereby eliminating application defects and ensuring uniform thickness while maintaining electrical isolation functionality.
Solution Approach 2:
The insulation layer acts as an intermediary element positioned between the first conductive layer and the second conductive layer. This intermediary structure enables smooth material application by providing a continuous surface for the insulation layer material, while still achieving the required electrical isolation between power supply lines through the combined effect of the insulation layer and the separated conductive layers.
2Ease of manufacture
If the electrode power supply line is exposed during insulation layer formation, then the conductive layer can be accessed for electrical connection, but the end portion is vulnerable to damage during etching and manufacturing processes
Solution Approach 1:
The first conductive layer is formed and positioned before the insulation layer material is applied. This preliminary action allows the conductive layer to be properly positioned and connected electrically before the insulation layer is formed, ensuring accessibility for electrical connections. The subsequent formation of the insulation layer then protects this previously positioned conductive layer from damage during later manufacturing processes.
Solution Approach 2:
The insulation layer is formed as a protective cushioning layer between the first and second conductive layers. This beforehand cushioning protects the end portions of the conductive layers from damage during etching and subsequent manufacturing processes, while still allowing electrical connections to be established with the first conductive layer before the protective layer is fully formed.
Data Source
AI summary
An organic light-emitting apparatus has a structure capable of reducing defects during the formation of an insulation layer (e.g., a pixel defining layer). The organic light emitting apparatus includes a substrate having a display area and a peripheral area surrounding the display area; a step forming layer on the peripheral area of the substrate; an insulation layer on the substrate across the display area and the peripheral area, wherein the top surface of a portion of the insulation layer corresponding to the step forming layer by covering the step forming layer is higher than the top surface of the remaining portion of the insulation layer; and a first conductive layer on the insulation layer, an end portion of the first conductive layer being close to the portion of the insulation layer corresponding to the step forming layer.