OLED Pixel Electrode Formation via Source Drain Extension
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Solution Overview
Problem
Current organic light emitting display (OLED) manufacturing processes are complex, time-consuming, and prone to defects due to the need for precise photolithography and multiple stacked films, resulting in a relatively thick apparatus.
Innovation Solution
The OLED apparatus features a substrate with an active layer, insulated gate and source/drain electrodes, a pixel defining layer with an aperture exposing one electrode, an intermediate layer with an organic light emitting layer, and a facing electrode, where one source/drain electrode operates as a pixel electrode, and the process uses a single halftone mask for patterning, simplifying the manufacturing process and reducing thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If photolithography using mask is used to form patterns, then manufacturing precision can be achieved, but device complexity and manufacturing time increase significantly
Solution Approach 1:
The patent extracts and eliminates the mask layer and photolithography process from the manufacturing flow. Instead of using photolithography to define pixel electrodes, the invention directly forms pixel electrodes through electrode material deposition and patterning processes, removing the complex photo resist formation, exposure, developing, and etching operations while maintaining manufacturing precision.
Solution Approach 2:
The patent merges the pixel electrode formation process with the source/drain electrode formation process. By integrating these steps, the invention reduces the total number of separate manufacturing operations and eliminates the need for additional photolithography steps that would be required if pixel electrodes were formed separately using traditional methods.
2Manufacturing precision
If multiple stacked films are used to form patterns, then manufacturing precision can be achieved, but the total thickness of the apparatus increases
Solution Approach 1:
The patent removes unnecessary insulating films and intermediate layers that are typically required in traditional multi-layer OLED structures. By eliminating these redundant layers while maintaining precise pattern formation through direct electrode patterning, the invention achieves both thin profile and manufacturing precision simultaneously.
Solution Approach 2:
The invention employs thin film structures for the pixel defining layer and intermediate layer that provide sufficient functional separation and definition without adding excessive thickness. These thin films maintain the necessary precision for pattern formation while keeping the overall apparatus thickness minimal.
3Manufacturing precision
If photolithography processes are used, then patterns can be formed, but productivity decreases due to time-consuming operations
Solution Approach 1:
The patent extracts the time-consuming photolithography operations (photo resist formation, exposure, developing, etching) from the manufacturing process. By replacing these sequential operations with direct electrode material deposition and patterning, the invention maintains pattern formation capability while dramatically reducing manufacturing cycle time and improving productivity.
Solution Approach 2:
The invention performs electrode material deposition and patterning in advance during the electrode formation stage, rather than requiring subsequent photolithography steps. This preliminary action approach allows patterns to be defined early in the process flow, eliminating later time-consuming operations and improving overall manufacturing efficiency.
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 results in a thinner, simpler OLED apparatus with reduced manufacturing complexity and defect rates, enabling more efficient production while maintaining image quality.
Implementation Method 1
When a voltage is applied to the cathode and anode electrodes, the organic light emitting layer, which is connected to the cathode and anode electrodes, generates visible light.
Data Source
AI summary
An organic light emitting display (OLED) apparatus and a method of manufacturing the same, the OLED apparatus including: a substrate; an active layer formed on the substrate; a gate electrode insulated from the active layer; source and drain electrodes insulated from the gate electrode and electrically connected to the active layer; a pixel defining layer formed on the source and drain electrodes, having an aperture to expose one of the source and drain electrodes; an intermediate layer formed in the aperture and comprising an organic light emitting layer; and a facing electrode which is formed on the intermediate layer. One of the source and drain electrodes has an extension that operates as a pixel electrode. The aperture exposes the extended portion. The intermediate layer is formed on the extended portion.