Organic Light Emitting Device Maskless Electrode Deposition
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Solution Overview
Problem
The existing processes for manufacturing organic light emitting devices are complex and costly due to the need for multiple masks and equipment in the deposition of organic material and metal electrodes, leading to low productivity and high preparation costs.
Innovation Solution
An organic light emitting device structure is developed with a substrate, a first electrode, an auxiliary electrode on a partial region, an insulating layer with a wider overhang structure, and a second electrode that is electrically short-circuited without direct contact, allowing for maskless patterning and reduced process costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks and equipment are used for deposition of organic material and metal electrodes, then manufacturing precision can be improved, but device complexity and preparation costs increase significantly
Solution Approach 1:
The patent extracts and eliminates the mask component from the deposition process. By designing the electrode structure to self-align during deposition, the mask is completely removed from the manufacturing process, reducing device complexity while maintaining deposition precision through the self-aligning electrode geometry
Solution Approach 2:
The patent merges the alignment function previously performed by masks into the electrode structure itself. The first and second electrodes are designed with overlapping regions that inherently provide alignment during deposition, combining the electrode formation and alignment functions into a single integrated structure
2Manufacturing precision
If multiple masks and equipment are used for deposition of organic material and metal electrodes, then manufacturing precision can be improved, but productivity decreases due to complex processes
Solution Approach 1:
By removing the mask from the process, the number of deposition steps is reduced. The maskless deposition process eliminates time-consuming mask alignment and replacement operations, directly improving manufacturing efficiency while maintaining precision through the self-aligning electrode design
Solution Approach 2:
The electrode structures are pre-designed with specific geometric configurations (overlapping regions, width relationships) that automatically provide alignment during deposition. This preliminary structural design eliminates the need for real-time alignment adjustments, speeding up the manufacturing process
3Manufacturing precision
If masks are used for pattern formation, then manufacturing precision can be maintained, but preparation costs increase
Solution Approach 1:
The patent completely removes the mask component from the manufacturing system. The cost of masks, their handling, alignment, and disposal is eliminated, reducing preparation costs while pattern precision is maintained through the self-aligning electrode geometry that inherently defines the pattern during deposition
4Ease of manufacture
If the insulating layer is in direct contact with the first electrode, then manufacturing process is simplified, but electrical isolation cannot be achieved
Solution Approach 1:
The patent introduces a vertical dimension to achieve electrical isolation. By forming the insulating layer to extend laterally beyond the auxiliary electrode (creating an overhang structure), electrical isolation is achieved in the horizontal dimension while maintaining simple vertical deposition processes. The insulating layer protrudes sideways to prevent electrical contact between adjacent electrode structures
Data Source
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AI summary
The present invention relates to an organic light emitting device. An organic light emitting device according to the present application includes: a substrate; a first electrode provided on the substrate; an auxiliary electrode provided on at least a partial region of the first electrode; an insulating layer provided on the auxiliary electrode, and having an overhang structure in which the insulating layer has a greater width than that of the auxiliary electrode; and a second electrode provided on the first electrode and the insulating layer, in which the second electrode provided on the first electrode and the second electrode provided on the insulating layer have an electrode structure with an electrically short-circuited form.