OLED Display Metal Pattern Fabrication Without Shadow Masks
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Solution Overview
Problem
Conventional organic light emitting diode display devices require complex and costly manufacturing processes due to the need for shadow masks in forming metal patterns and organic layers, which increases resistance and fabrication complexity.
Innovation Solution
A method that simplifies the manufacturing process by forming a photoresist pattern over the metal pattern to expose specific areas, allowing for the formation of hole and electron common layers without a shadow mask, and subsequently removing these layers to connect the metal pattern to the second electrode, reducing resistance and fabrication costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shadow masks are used to form metal patterns and organic layers, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent extracts and removes the shadow mask component from the manufacturing process. Instead of using shadow masks to define patterns, the invention forms organic layers and metal patterns through sequential deposition and selective removal processes, eliminating the complex shadow mask fabrication and alignment steps while maintaining pattern formation precision
Solution Approach 2:
The patent applies preliminary action by forming the organic light emitting layer and common layers before forming the metal pattern. This sequence allows the metal pattern to be deposited over the organic structure, and subsequent selective removal exposes precise metal regions without requiring shadow masks during the patterning process
2Manufacturing precision
If shadow masks are used to form metal patterns, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The shadow mask is extracted and removed from the manufacturing process. The patent achieves pattern formation through a maskless approach where organic layers are deposited first, followed by metal pattern deposition, and selective removal of organic layers to expose metal regions, eliminating the high cost associated with shadow mask fabrication and disposal
Solution Approach 2:
The patent discards the shadow mask approach entirely and recovers cost by using standard deposition techniques without specialized masking equipment. The process uses commonly available materials and methods, reducing manufacturing cost while maintaining precision through controlled deposition and removal sequences
3Manufacturing precision
If metal patterns are formed in the same layer as organic layers using shadow masks, then manufacturing precision is improved, but ease of manufacture deteriorates
Solution Approach 1:
The organic light emitting layer and common layers are formed in advance before the metal pattern is deposited. This preliminary formation of organic structures provides a template that guides subsequent metal deposition, allowing precise alignment without shadow masks and simplifying the overall fabrication process
Solution Approach 2:
The conventional sequence is inverted: instead of forming metal patterns first with shadow masks and then depositing organic layers, the patent forms organic layers first and then deposits metal patterns. This inversion eliminates the need for shadow masks and simplifies the manufacturing process while maintaining layer alignment precision
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 simplifies the manufacturing process, reduces manufacturing costs, and maintains low resistance in large area organic light emitting diode display devices by eliminating the need for shadow masks and using fluorine-containing materials to prevent damage to the organic light emitting layer.
Implementation Method 1
forming a photoresist pattern exposing the electrode common layer to correspond to the metal pattern and removing the hole common layer and the electron common layer using the photoresist pattern as a mask
Implementation Method 2
utilizing an electroluminescence phenomenon in which light energy is released through recombination of the electrons and holes
Data Source
AI summary
A method of fabricating an organic light emitting diode display device, which include forming a thin film transistor in a display region of a substrate, forming a metal pattern on the substrate in the display region, forming a first electrode on the substrate connected to the thin film transistor, forming a bank on the substrate to expose a portion of the first electrode and a portion of the metal pattern, forming a hole common layer, an organic light emitting layer, and an electron common layer sequentially over the entire surface of the substrate provided with the first electrode, the bank and the metal pattern, forming a photoresist pattern covering the electrode common layer and removing the hole common layer, the organic light emitting layer and the electron common layer using the photoresist pattern as a mask, removing the photoresist pattern, and forming a second electrode on the electron common layer connected to the metal pattern.