Organic Light Emitting Device Mask Reduction via Electrode Merging
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Solution Overview
Problem
The manufacturing process of organic light emitting devices is complex and costly due to the requirement of multiple mask processes, which increases manufacturing time and costs.
Innovation Solution
A method that reduces the number of mask processes by simultaneously forming source and drain electrodes using the same material, eliminating the need for a via hole and additional insulating layers, and using a half-tone mask process to define electrode areas, thereby simplifying the layer stacking and etching processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple mask processes are used to form gate electrode, amorphous silicon layer, ohmic layers, source and drain electrodes, via holes, and openings separately, then the manufacturing precision and device performance are improved, but the manufacturing time and cost increase significantly
Solution Approach 1:
The patent combines the formation of source and drain electrodes into a single mask process step. By using the same mask pattern to define both electrodes simultaneously, the manufacturing process reduces the number of separate mask steps required, thereby decreasing manufacturing time and cost while maintaining the precision needed for proper device performance
Solution Approach 2:
The patent employs a multi-functional mask that serves multiple purposes: it defines the source electrode area, defines the drain electrode area, and establishes the relative positioning between these electrodes. This universal mask approach eliminates the need for separate masks for each electrode formation step, reducing overall process complexity and time
2Manufacturing precision
If multiple mask processes are used to form gate electrode, amorphous silicon layer, ohmic layers, source and drain electrodes, via holes, and openings separately, then the manufacturing precision and device performance are improved, but the manufacturing cost increases
Solution Approach 1:
The patent merges the formation of source and drain electrodes into a single mask process step. By using the same mask pattern to define both electrodes simultaneously, the manufacturing process reduces the number of separate mask steps required, thereby decreasing manufacturing time and cost while maintaining the precision needed for proper device performance
Solution Approach 2:
The patent eliminates the need for via holes by directly forming the anode on the substrate in contact with the drain electrode. This discards the via hole formation step and the associated mask process, recovering process steps and reducing manufacturing cost
3Reliability
If via holes and additional insulating layers are used to connect electrodes, then the electrical connection reliability is improved, but the device complexity and manufacturing steps increase
Solution Approach 1:
The patent extracts and eliminates the via hole formation step from the manufacturing process. By directly forming the anode on the substrate in contact with the drain electrode, the design removes the need for via holes and the associated insulating layers, thereby reducing device complexity and manufacturing steps while maintaining electrical connection reliability through direct contact
Data Source
AI summary
A light emitting device and a method of manufacturing the same are provided. The light emitting device comprises a substrate, a gate electrode positioned on the substrate, a first insulating layer positioned on the substrate comprising the gate electrode, an amorphous silicon layer positioned on the first insulating layer so that a predetermined area thereof corresponds to the gate electrode, ohmic layers that positioned on a predetermined area of the amorphous silicon layer, the ohmic layers defining a source area and a drain area, a source electrode or a drain electrode electrically connected to any one of the ohmic layers and a cathode that is electrically connected to the other one of the ohmic layers, a second insulating layer positioned on the substrate comprising the source electrode or the drain electrode and the cathode, the second insulating layer comprising an opening exposing a portion of the cathode, an emitting layer positioned within the opening, and an anode positioned on the substrate comprising the emitting layer.