Organic Light Emitting Display Panel Manufacturing Process
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Solution Overview
Problem
Conventional organic electroluminescent display manufacturing processes face defects due to deformation of the deposition mask, leading to incorrect alignment and formation of protective insulating films in non-luminescent regions.
Innovation Solution
A method involving forming a substrate with luminescent and pad regions, simultaneously creating a light emitting cell and organic pattern, applying a protective insulating film, bonding with a sealing substrate, cutting to expose pad regions, and removing the protective insulating film and organic pattern using adhesive tapes, etchants, or laser irradiation to prevent pattern defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a deposition mask is used to form a protective insulating film, then the film can be formed in the luminescent region, but the mask deforms due to plasma and heat causing alignment defects
Solution Approach 1:
The patent removes the deposition mask from the process entirely. Instead of using a mask to define the protective insulating film pattern, the method forms a continuous insulating film over the entire substrate and then selectively removes portions using adhesive tapes and etchants. This extraction of the mask eliminates the source of deformation and alignment defects.
Solution Approach 2:
The protective insulating film is formed in advance as a continuous layer before substrate cutting. Adhesive tapes are applied to specific regions (luminescent regions) beforehand, and after the film is deposited, the tapes are removed to selectively expose and etch the pad regions. This preliminary formation of the complete film followed by selective removal avoids the need for mask alignment during deposition.
2Productivity
If the deposition mask is deformed, then alignment accuracy decreases, but the process continues without stopping
Solution Approach 1:
The deposition mask is completely removed from the manufacturing process. The protective insulating film is deposited as a continuous layer without any mask, eliminating the deformation problem entirely while maintaining manufacturing efficiency through a simplified process flow.
Solution Approach 2:
Instead of using a mask to prevent film deposition in certain areas (positive approach), the method deposits the film everywhere and then removes it from areas where it shouldn't be (negative approach). This inversion of the deposition strategy eliminates mask-related alignment issues while preserving productivity.
3Manufacturing precision
If the protective insulating film is formed without a mask, then alignment defects are prevented, but the film may form in pad regions as well
Solution Approach 1:
Adhesive tapes are applied to the luminescent regions before the protective insulating film is deposited. After deposition, the tapes are removed, exposing only the pad regions for selective etching. This preliminary masking with removable tapes ensures the film is retained where needed while allowing clean removal where not needed, minimizing material waste.
Solution Approach 2:
Adhesive tapes serve as an intermediary tool between the continuous film deposition and the selective removal process. The tapes temporarily protect the luminescent regions during deposition and are then cleanly removed to expose only the pad regions for etching, achieving precise pattern definition without mask deformation and minimizing material waste through controlled removal.
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
Enables the formation of protective insulating films solely in luminescent regions without causing pattern defects, improving manufacturing efficiency and reducing the need for specialized equipment, thus enhancing the quality and cost-effectiveness of organic light emitting display panels.
Implementation Method 1
bonding the substrate provided with the protective insulating film and the sealing substrate using an adhesive film formed in a region corresponding to the luminescent region
Implementation Method 2
removing the organic pattern in the exposed pad region by immersing the entire substrate from which the protective insulating film is removed or the pad region in an etchant
Implementation Method 3
removing the organic pattern of the pad region by immersing the entire substrate from which the protective insulating film is removed or the pad region in an etchant, which may include isopropyl alcohol
Implementation Method 4
irradiating a laser beam to the pad region
Data Source
AI summary
A method of manufacturing an organic light emitting display panel forming a protective insulating film in a luminescent region without causing defects in a pattern is disclosed. The method of manufacturing an organic light emitting display panel includes forming a substrate having a luminescent region and a pad region, simultaneously forming a light emitting cell in the luminescent region and an organic pattern in the pad region, forming a protective insulating film over the substrate, bonding the substrate provided with the protective insulating film and the sealing substrate using an adhesive film formed in a region corresponding to the luminescent region, cutting the bonded substrate provided with the protective insulating film and the sealing substrate into a plurality of unit panels to expose the pad region, and removing the protective insulating film and the organic pattern in the exposed pad region.