OLED Panel Arbitrary Shape Fabrication via Segmented Cutting
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Solution Overview
Problem
Existing OLED fabrication techniques are limited in producing panels of arbitrary shapes, as they often require pre-defined external electrical connections and specific designs, which restrict customization and increase manufacturing complexity and costs.
Innovation Solution
A method for fabricating OLED panels with arbitrary shapes by making cuts in the panels that do not extend through all layers initially, allowing for external electrical connections to be defined later, and using techniques like laser ablation or dry etching to isolate the cathode and anode, enabling flexible shape customization post-fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If OLED panels are fabricated with pre-defined external electrical connections and specific designs, then manufacturing process is simplified, but shape customization is restricted and device versatility is reduced
Solution Approach 1:
The fabrication process is segmented into two distinct stages: (1) bulk fabrication of OLED panels with standard rectangular shapes and pre-defined electrical connections on a common substrate, and (2) post-fabrication customization where individual panels are cut into arbitrary shapes and electrical connections are defined later. This segmentation allows standardization of the complex fabrication process while enabling flexibility in final product shapes.
Solution Approach 2:
The patent applies preliminary action by fabricating the complete OLED structure including electrodes, organic layers, and encapsulation on a common substrate before any shape customization or electrical connection definition. This preliminary fabrication establishes a standardized base that can later be adapted to various shapes without requiring complex re-engineering of the core device structure.
2Adaptability or versatility
If OLED panels are fabricated with arbitrary shapes using post-fabrication cutting, then shape customization is enabled, but manufacturing precision and electrical integrity may be compromised
Solution Approach 1:
Encapsulation layers are deposited over the entire common substrate including all electrode regions before cutting. This preliminary encapsulation creates a protective barrier that maintains electrical integrity during the subsequent cutting process, ensuring that arbitrary shape customization does not compromise the precision of electrical connections.
Solution Approach 2:
The patent introduces an intermediary encapsulation layer that mediates between the cutting process and the electrical connections. This encapsulation layer protects the electrical connections from damage during cutting while allowing precise definition of external connections after the shape is established, thus maintaining manufacturing precision despite shape variability.
3Productivity
If multiple OLED panels share a common substrate, then manufacturing efficiency and productivity are improved, but device isolation and individual customization become more difficult
Solution Approach 1:
The patent segments the device isolation process into two stages: (1) bulk processing of multiple panels on a common substrate for efficient manufacturing, and (2) post-fabrication separation where individual panels are cut apart and can be independently customized. This segmentation maintains high productivity during fabrication while simplifying subsequent device isolation and customization.
Solution Approach 2:
Encapsulation and electrical connection definition are performed preliminarily on the common substrate before device separation. This preliminary action on multiple panels simultaneously reduces the complexity of subsequent isolation steps, as the devices are already protected and electrically defined before being separated for individual customization.
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 allows for the production of OLED panels with unique shapes while maintaining electrical integrity, reducing manufacturing complexity and costs by allowing shape customization near the end of the production process, and enabling the use of thin film encapsulation for protection.
Implementation Method 1
using techniques like laser ablation or dry etching to isolate the cathode and anode
Implementation Method 2
using techniques like laser ablation or dry etching to isolate the cathode and anode
Data Source
AI summary
OLED panels and techniques for fabricating OLED panels are provided. Multiple cuts may be made in an OLED panel to define a desired shape, as well as the location and shape of external electrical contacts. The panel may be encapsulated before or after being cut to a desired shape, allowing for greater flexibility and efficiency during manufacture.