Organic Light Emitting Display Device Laser Patterning
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Solution Overview
Problem
Conventional methods for manufacturing organic light emitting display devices face challenges in forming precise organic light emitting layers due to mask bending and contamination, leading to complex processes and high defect rates, especially in full-color displays where multiple mask alignments and depositions are required.
Innovation Solution
The method involves forming organic light emitting layers in a substantially rectangular shape using a laser and a mask with openings to expose the entire pixel region, allowing for precise patterning and selective removal of layers, reducing manufacturing costs and defect rates by using a single mask for red, green, and blue layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a shadow mask is used for selective deposition of organic material, then the organic light emitting layer can be formed, but the mask bends when thin causing imprecise patterning or fails to deposit material when thick due to evaporation angle
Solution Approach 1:
The patent extracts the shadow mask from the deposition process entirely and replaces it with a pixel defining layer formed by photolithography. This layer defines the light emitting region by having openings that expose the electrode, allowing organic material to be deposited only in the desired areas without using a shadow mask during deposition.
Solution Approach 2:
The patent replaces the mechanical shadow mask system with a photolithographic patterning system. Instead of using a physical mask that blocks deposition, the method uses a patterned pixel defining layer created through photoresist coating, exposure, and development processes to control where organic material is deposited.
2Adaptability or versatility
If multiple mask alignments and depositions are performed to form red, green and blue light emitting layers, then full-color display is achieved, but the manufacturing process becomes complicated and contamination defects increase
Solution Approach 1:
The patent merges the formation of red, green, and blue light emitting layers into a single deposition step. By forming a composite organic layer containing all three emissive materials simultaneously and then selectively removing portions using the pixel defining layer as a mask, the process eliminates multiple separate depositions and alignments.
Solution Approach 2:
Instead of forming red, green, and blue layers separately and adding them up, the patent inverts the approach by forming all layers together and then subtracting the unwanted portions. This reverse engineering approach simplifies the process by eliminating the need for precise multiple alignments.
3Adaptability or versatility
If multiple depositions are performed for different colors, then full-color display is achieved, but contamination defects are produced
Solution Approach 1:
The patent combines the deposition of red, green, and blue organic materials into a single vacuum deposition step, eliminating the need for multiple separate deposition chambers and transfers. This single-step process prevents contamination that would occur during multiple deposition cycles.
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 enables easy formation of organic light emitting layers with reduced defect rates and simplified manufacturing processes, saving costs and improving the precision of layer formation in organic light emitting display devices.
Implementation Method 1
forming organic light emitting layers in a substantially rectangular shape using a laser and a mask with openings
Data Source
AI summary
An organic light emitting display device and a method of manufacturing the same are disclosed. The organic light emitting display device includes a substrate on which first, second and third pixel units are arranged in row and column directions. To simplify manufacturing and reduce defects, the first, second and third pixel units are arranged so that each column of the display is formed of only one of the first, second, and third pixel units.