Organic Light-Emitting Display Lift-Off Manufacturing
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Solution Overview
Problem
The manufacturing costs of organic light-emitting display apparatuses are high due to complex and costly processes involved in forming patterns and layers.
Innovation Solution
A method involving the formation of a lift-off layer with fluoropolymer on a substrate, followed by a roll-to-roll stamp process to create patterns, etching with fluorine-based solvents, and subsequent removal of the lift-off layer using fluorine-containing solvents, allowing for the deposition of organic functional layers and a cathode, thereby simplifying the process and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional manufacturing processes are used for organic light-emitting display apparatuses, then the required manufacturing precision and quality can be achieved, but the manufacturing costs become high due to complex processes
Solution Approach 1:
The patent combines multiple manufacturing steps into a single integrated process. Specifically, the pixel-defining layer and lift-off layer are formed in one coating step, and the pattern transfer is achieved through a single etching process using the organic functional layer as etchant, eliminating the need for separate photolithography and development steps.
Solution Approach 2:
The patent introduces an organic functional layer that serves dual purposes: as the light-emitting functional layer and as the etchant for pattern transfer. This intermediary material enables the lift-off process without requiring additional etching chemicals or complex processing steps.
2Manufacturing precision
If conventional photolithography processes are used for pattern formation, then manufacturing precision can be maintained, but misalignment issues and increased process complexity occur
Solution Approach 1:
The patent extracts and eliminates the photolithography step from the conventional manufacturing process. Instead of using photoresist coating, exposure, and development steps, the invention directly forms patterns through etching with the organic functional layer as the etchant, removing the source of misalignment issues.
Solution Approach 2:
The organic functional layer serves its own dual purpose: it functions as the light-emitting layer and simultaneously acts as the etchant for pattern transfer. This self-service approach eliminates the need for separate patterning materials and processes, ensuring perfect alignment between functional layers and patterns.
3Manufacturing precision
If multiple separate layers are formed for pixel definition and lift-off, then manufacturing precision can be maintained, but the number of process steps increases
Solution Approach 1:
The patent merges the pixel-defining layer and lift-off layer into a single multi-functional layer structure. This combined layer is formed in one coating step and performs both functions: defining the pixel pattern and enabling the lift-off process, thereby reducing the total number of process steps.
Solution Approach 2:
The combined pixel-defining/lift-off layer serves multiple functions simultaneously: it acts as the pixel pattern definition layer, the lift-off layer for removing excess material, and the etchant source for pattern transfer. This multi-functionality eliminates the need for separate dedicated layers for each function.
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 method reduces manufacturing costs by streamlining the process and preventing misalignment issues, while maintaining the quality of organic light-emitting layers, enabling the production of displays with different colored subpixels.
Implementation Method 1
etching a first portion of the lift-off layer corresponding to the pattern using a first solvent including fluorine
Implementation Method 2
removing the lift-off layer using a second solvent including fluorine
Data Source
AI summary
A method of manufacturing an organic light-emitting display apparatus including forming an anode on a substrate, forming a lift-off layer on the substrate including the anode, the lift-off layer including a fluoropolymer, forming a pattern on a first portion the lift-off layer overlapping the anode using a roll-to-roll stamp process, forming an organic functional layer including a light-emitting layer on the anode and on a second portion of the lift-off layer not formed with the pattern, removing the lift-off layer using a solvent including fluorine, and forming a cathode on the organic functional layer.