OLED Pixel-Defining Layer via Single Mask Merging
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Solution Overview
Problem
Current organic light-emitting display apparatuses face challenges in achieving high-quality displays at low costs while maintaining structural integrity and efficiency in manufacturing processes.
Innovation Solution
The proposed solution involves an organic light-emitting display apparatus with a specific structure including a substrate, thin film transistor, via-insulating layer, pixel electrode, organic emission layer, counter electrode, and spacers, along with a method of manufacturing that involves forming layers using a half-tone mask and reflowing insulating materials to create a pixel-defining layer and wire-protection layer, reducing the number of masks needed and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used in the manufacturing process to form pixel-defining layers and wire-protection layers, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines the pixel-defining layer and wire-protection layer into a single insulating layer that is formed using one mask. This insulating layer is then selectively removed to expose both the pixel electrode and wire areas that need to be exposed, eliminating the need for multiple masks and reducing manufacturing complexity while maintaining precision
Solution Approach 2:
The insulating layer is divided into different regions with different thicknesses: a first insulating layer region covering the pixel electrode area and a second insulating layer region covering the wire area. This segmentation allows selective removal of appropriate portions to expose the underlying structures with high precision
2Manufacturing precision
If multiple masks are used in the manufacturing process, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent merges the functions of multiple masks into a single mask design that defines both the pixel-defining layer and wire-protection layer regions. This reduces mask fabrication costs, alignment costs, and process complexity while maintaining the precision required for layer formation
3Device complexity
If the insulating layer is made thinner to reduce manufacturing steps, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The insulating layer is segmented into regions of different thicknesses, with the first insulating layer region having a first thickness and the second insulating layer region having a second thickness. This segmentation allows the layer to be thin overall while maintaining sufficient thickness in critical areas for precise pattern definition and selective 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
This approach enables high-quality displays at reduced manufacturing costs and complexity, with improved structural integrity and efficiency in the production process.
Implementation Method 1
excitons, which are generated by holes injected from the hole injection electrode and electrons injected from the electron injection electrode being united in the organic emission layer, emit light by falling from an excited state to a ground state
Implementation Method 2
The spacer area may have a greater width than the non-spacer area
Data Source
AI summary
Provided are an organic light-emitting display apparatus and a method of manufacturing the same. The organic light-emitting display apparatus includes: a substrate on which a display area is defined, wherein an image is displayed on the display area; a thin film transistor arranged on the display area of the substrate; a via-insulating layer covering the thin film transistor; a pixel electrode arranged on the via-insulating layer and electrically connected to the thin film transistor; a pixel-defining layer including an opening exposing a central portion of the pixel electrode, and covering an edge of the pixel electrode; a counter electrode facing the pixel electrode; an organic emission layer arranged between the pixel electrode and the counter electrode; a wire arranged on the via-insulating layer to be spaced apart from the pixel electrode and including a spacer area and a non-spacer area; and a spacer arranged on the spacer area.