OLED Pixel Definer Formation Without First Electrode Damage
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Solution Overview
Problem
Existing manufacturing processes for organic light-emitting diode (OLED) display devices can damage electrodes, leading to reduced lifespan and image quality defects.
Innovation Solution
A method involving a metal pattern with a specific etching selection ratio is used to protect the first electrode during the manufacturing process, combined with a pixel definer that covers the electrode's end portion, preventing damage and ensuring a smooth manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing manufacturing processes are used for OLED display devices, then the manufacturing process can be completed, but the electrodes may be damaged leading to reduced lifespan and image quality defects
Solution Approach 1:
A metal pattern layer is introduced as an intermediary protective layer between the pixel definer material layer and the first electrode. This metal pattern serves as a mediator that prevents direct contact and potential damage from etching processes, while still allowing the pixel definer to be formed. The metal pattern is selectively removed after serving its protective function, leaving the electrode intact.
Solution Approach 2:
The metal pattern layer is formed on the first electrode before the pixel definer material layer is deposited. This preliminary protective layer is in place before any potentially harmful etching processes occur, preventing electrode damage in advance. The metal pattern is removed only after it has fulfilled its protective role during the pixel definer formation process.
2Reliability
If a metal pattern layer is added to protect the electrode, then electrode damage is prevented, but the device structure and manufacturing process become more complex
Solution Approach 1:
The metal pattern layer serves multiple functions: it acts as a protective barrier during etching processes, provides a foundation for pixel definer formation, and can be selectively removed after serving its purpose. This multi-functionality justifies the additional layer by consolidating multiple roles into a single structural element.
Solution Approach 2:
The metal pattern layer is intentionally designed as a temporary protective element that is discarded after fulfilling its protective function. It is removed via selective etching after the pixel definer is successfully formed, leaving no permanent trace. This temporary addition is recovered (removed) once its purpose is achieved, minimizing long-term structural complexity.
3Ease of manufacture
If the pixel definer material layer is directly etched to form the pixel definer, then the manufacturing process is simplified, but the first electrode is damaged
Solution Approach 1:
The metal pattern layer acts as an intermediary protective barrier during the etching process. It allows the pixel definer material layer to be etched and formed while preventing the etchant from reaching and damaging the first electrode. The metal pattern is selectively removed after the pixel definer formation is complete.
Solution Approach 2:
The metal pattern layer is deposited on the first electrode before the pixel definer material layer is formed. This preliminary protective layer is in place before etching begins, preventing electrode damage in advance while allowing the pixel definer formation process to proceed as intended.
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
The method prevents electrode damage, simplifies manufacturing, and enhances the lifespan and image quality of OLED devices by using a metal pattern and pixel definer configuration.
Implementation Method 1
A pixel definer is generated by heat treating the pixel definer material layer remaining on the first electrode and the metal pattern
Data Source
AI summary
An organic light emitting device includes: a substrate; a first electrode provided on the substrate; a metal pattern provided along an edge of the first electrode; and a pixel definer provided on the metal pattern. The pixel definer covers an end portion of the first electrode and an end portion of the metal pattern. The pixel definer includes an opening exposing the first electrode.