OLED Passivation Layer Exposure and Filling Method
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The manufacturing process of organic light-emitting display apparatuses faces challenges in improving the reliability of the intermediate layers, particularly due to damage caused by the repeated removal and reformation of the passivation layer, which affects the emission layers during the exposure and filling processes.
Innovation Solution
A method involving the formation of exposure portions in the passivation layer to expose pixel electrodes, followed by the deposition of intermediate layers, and subsequent filling with the same material as the passivation layer, with a single removal step for the passivation layer to reduce contact time with stripping solutions and minimize damage to the intermediate layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the passivation layer is repeatedly removed and reformed during the manufacturing process, then the pixel electrodes can be exposed for intermediate layer formation, but the intermediate layers (emission layers) are damaged by repeated exposure to stripping solutions
Solution Approach 1:
The passivation layer is removed in advance before forming each intermediate layer, allowing the emission layers to be formed without subsequent exposure to stripping solutions. This preliminary removal action prevents the harmful effect of repeated stripping solution exposure on the intermediate layers.
Solution Approach 2:
The method skips the reformation of the passivation layer between intermediate layer formations. Instead of removing and reforming the passivation layer multiple times, the process rushes through by forming each intermediate layer sequentially on exposed pixel electrodes without restoring the passivation layer in between, thereby minimizing exposure to stripping solutions.
2Reliability
If the passivation layer is kept intact to protect pixel electrodes, then intermediate layers cannot be formed on exposed pixel electrodes
Solution Approach 1:
The passivation layer is selectively removed only at specific regions where pixel electrodes need to be exposed for intermediate layer formation. This segmentation allows the passivation layer to remain intact in other regions, providing protection where needed while enabling intermediate layer formation where required.
Solution Approach 2:
The passivation layer is removed locally at specific positions to expose pixel electrodes for intermediate layer formation, while maintaining the passivation layer in other areas. This local quality approach ensures that the passivation layer provides protection where needed while allowing intermediate layers to be formed on exposed pixel electrodes in specific regions.
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 enhances the reliability of the organic light-emitting display apparatus by reducing the exposure of intermediate layers to stripping solutions, thereby preventing damage and improving the overall manufacturing process efficiency.
Implementation Method 1
forming a first photoresist layer on the passivation layer; partially exposing and etching the first photoresist layer to form a first opening
Implementation Method 2
etching the passivation layer through the first opening
Data Source
AI summary
Provided is a method of manufacturing an organic light-emitting display apparatus. The method includes: forming a passivation layer on a substrate, on which pixel electrodes are formed, to cover the pixel electrodes; forming a first exposure portion in the passivation layer to expose a first pixel electrode among the pixel electrodes; forming a first intermediate layer on the exposed first pixel electrode; filling the first exposure portion with the same material as the passivation layer; forming a second exposure portion in the passivation layer to expose a second pixel electrode among the pixel electrodes; forming a second intermediate layer on the exposed second pixel electrode; filling the second exposure portion with the same material as the passivation layer; forming a third exposure portion in the passivation layer to expose a third pixel electrode among the pixel electrodes; and forming a third intermediate layer on the exposed third pixel electrode.