OLED Panel Reflective Layer Same Material as Color Filter
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Solution Overview
Problem
The manufacturing process of conventional OLED panels is complicated due to the need for multiple photolithography processes in forming the color filter layer, which increases costs and process complexity.
Innovation Solution
The OLED panel design includes a color filter layer with a reflective layer of the same material as the first color filter layer, allowing for simultaneous fabrication in the same photolithography process, reducing the number of required processes and mask consumables.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a color filter layer is formed using conventional methods with multiple photolithography processes, then the color filter layer can be formed with proper color separation, but the manufacturing process becomes complicated and costly
Solution Approach 1:
The patent combines the formation of the color filter layer and the reflective layer into a single photolithography process. By using a dual-layer photoresist structure where the first photoresist forms the color filter patterns and the second photoresist forms the reflective layer patterns, both structures are created simultaneously in one exposure and development step, eliminating the need for separate photolithography processes
Solution Approach 2:
The photoresist material serves multiple functions in this invention. The same photoresist material is used to form both the color filter layer and the reflective layer, allowing a single photolithography process to accomplish what previously required multiple specialized processes. This multi-functional approach simplifies the manufacturing workflow while maintaining the distinct optical properties of each layer
2Manufacturing precision
If multiple photolithography processes are used to form the color filter layer and reflective layer separately, then each layer can be precisely controlled, but the manufacturing cost increases due to multiple mask consumables
Solution Approach 1:
The invention merges the formation of the color filter layer and reflective layer into one photolithography process using a dual-layer photoresist system. This single process uses one mask to define both the color filter patterns (through the first photoresist) and the reflective layer patterns (through the second photoresist), thereby eliminating the need for multiple masks and reducing material costs while preserving precise layer formation
3Manufacturing precision
If multiple photolithography processes are used for forming color filter layer and reflective layer, then each layer can be independently optimized, but the overall manufacturing time and process steps increase
Solution Approach 1:
The invention combines multiple sequential photolithography processes into a single simultaneous process. By applying one exposure pattern that defines both the color filter layer and reflective layer, and using a dual-layer photoresist that can be developed together, the manufacturing time is reduced while still allowing independent optimization of each layer's pattern design in the exposure mask
Data Source
AI summary
An organic light-emitting diode (OLED) panel and a manufacturing method thereof are provided, wherein a color filter layer of the OLED panel includes a first color filter layer, a second color filter layer, a third color filter layer, and a reflective layer disposed between the first color filter layer, the second color filter layer, and the third color filter layer, wherein material of the reflective layer is same as material of the first color filter layer. Because the first color filter layer and the reflective layer are the same material, consumable cost of the mask is saved.