OLED Layer and Inspection Pattern Layout for Precise Mask Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing display devices face challenges in improving luminous efficiency and reliability due to complex layer deposition processes, particularly in aligning and managing multiple layers and inspection patterns, which can lead to inefficiencies and increased mask management burdens.
Innovation Solution
A display device design that includes overlapping first and second light emitting layers and inspection patterns in a plan view, using a charge generation layer to extend from the display area to the non-display area, and utilizing the same material for these layers to simplify mask management and reduce the non-display area, with a method of manufacturing that uses multiple masks to form these layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate masks are used to form different light emitting layers and inspection patterns, then each layer can be precisely controlled, but mask management complexity increases
Solution Approach 1:
The patent combines multiple masks into a single integrated mask structure that defines openings for both the first and second light emitting layers as well as inspection patterns. This merging approach maintains precise alignment control while significantly reducing mask management complexity and the number of separate mask components required
2Measurement precision
If the non-display area is enlarged to accommodate inspection patterns, then inspection accuracy improves, but the overall device area increases
Solution Approach 1:
The patent positions inspection patterns in the non-display area but designs them to overlap with light emitting layers in plan view, utilizing the vertical stacking dimension to achieve both inspection functionality and space efficiency. This dimensional approach allows accurate inspection without proportionally increasing the lateral device area
3Adaptability or versatility
If different materials are used for light emitting layers and inspection patterns, then material optimization for each function is achieved, but manufacturing process complexity increases
Solution Approach 1:
The patent uses the same material for both the light emitting layers and inspection patterns, forming them simultaneously through a single deposition process. This homogeneous material approach simplifies the manufacturing process while maintaining functional performance, avoiding the need for separate material deposition steps
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
Enhances reliability and simplifies mask management by minimizing the non-display area and ensuring precise alignment of light emitting layers and inspection patterns, thereby improving luminous efficiency and reducing manufacturing complexity.
Implementation Method 1
a charge generation layer disposed between the first light emitting layer and the second light emitting layer and between the first inspection pattern and the second inspection pattern. The charge generation layer may include a first semiconductor layer doped with n-type dopants and a second semiconductor layer doped with p-type dopants.
Implementation Method 2
a light emitting element disposed in the display area of the substrate and including a first light emitting layer and a second light emitting layer disposed on the first light emitting layer
Implementation Method 3
a deposition process of depositing various types of thin films may be performed. The deposition process may be performed by closely contacting a mask defining an opening having the same pattern as a deposition pattern of the light emitting layer, the metal layer, or the like on a target substrate on which deposition is to be performed.
Data Source
AI summary
A display device includes a substrate including a display area and a non-display area adjacent to the display area, a light emitting element disposed in the display area of the substrate and including a first light emitting layer and a second light emitting layer disposed on the first light emitting layer, and an inspection array disposed in the non-display area of the substrate and including a first inspection pattern and a second inspection pattern disposed on the first inspection pattern.