Organic Light-Emitting Display Masking to Prevent Solvent Damage
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Solution Overview
Problem
Manufacturing organic light-emitting display devices faces challenges in reducing defects during the formation of intermediate layers, particularly due to thermal damage from residual solvents in masking layers.
Innovation Solution
A method involving the use of resins with orthogonal material properties for masking layers and partitioning walls, where the partitioning walls are baked at a temperature above the thermal damage threshold to remove solvents, preventing damage to intermediate layers, and separate masking layers are used to avoid solvent exposure during intermediate layer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If partitioning walls are formed with resin containing solvent and baked to remove solvent, then solvent is effectively removed, but thermal damage may occur to intermediate layers if temperature is not controlled
Solution Approach 1:
The partitioning walls are formed and baked to remove solvent BEFORE the intermediate layer is deposited. This preliminary removal of solvent prevents subsequent thermal damage during intermediate layer formation, as the harmful solvent is already eliminated before the temperature-sensitive intermediate layer is introduced to the system.
Solution Approach 2:
The manufacturing process is divided into distinct sequential steps: first forming and baking partitioning walls to remove their solvent, then depositing the intermediate layer. This segmentation allows independent optimization of each step's parameters without compromising the other, enabling effective solvent removal while protecting the intermediate layer from thermal damage.
2Device complexity
If a single masking layer is used for all pixel electrodes, then the process is simpler, but residual solvent in the masking layer can damage intermediate layers during formation
Solution Approach 1:
The masking process is segmented into separate masking layers for different pixel electrodes. Each masking layer is applied, the intermediate layer is formed, then the masking layer is removed before proceeding to the next pixel electrode. This segmentation eliminates the problem of residual solvent in a single prolonged masking layer damaging the intermediate layer.
Solution Approach 2:
Each masking layer is removed immediately after the intermediate layer is formed on that specific pixel electrode, before the next masking layer is applied. This preliminary removal prevents accumulation of residual solvent that could damage the intermediate layer, while maintaining a relatively simple overall process structure.
3Reliability
If masking layers are removed immediately after intermediate layer formation, then solvent damage is prevented, but additional process steps are required
Solution Approach 1:
The process is segmented into rapid cycles of: apply masking layer → form intermediate layer → remove masking layer → repeat for next pixel. This segmentation allows the masking layer to be present only for the brief duration needed for intermediate layer formation, minimizing solvent exposure time while protecting the intermediate layer, and enables continuous progression through multiple pixel electrodes.
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 reduces defects in intermediate layer formation, enhancing the reliability and performance of organic light-emitting display devices by preventing solvent-induced damage and ensuring precise control over the manufacturing process.
Implementation Method 1
removing a solvent in the partitioning walls by baking the partitioning walls
Implementation Method 2
An organic light-emitting display device, which is a self-luminescent display device, may be driven at a low voltage
Data Source
AI summary
A method of manufacturing an organic light-emitting display device includes: preparing a substrate including pixel electrodes; forming a pixel defining layer on the substrate, the pixel defining layer exposing a central portion of each of the pixel electrodes and covering an edge portion of each of the pixel electrodes; forming partitioning walls in correspondence with at least a portion of an upper surface of the pixel defining layer, the partitioning walls including a first resin; removing a solvent in the partitioning walls by baking the partitioning walls; forming a first mask layer filling a space between the partitioning walls and exposing a first pixel electrode among the pixel electrodes, the first mask layer including a second resin; and forming a first intermediate layer on the first pixel electrode.