OLED Pixel Electrode Wet Cleansing for Resonance Structure
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Solution Overview
Problem
Existing organic light-emitting display apparatus manufacturing methods face challenges in efficiently forming a pixel electrode with a resonance structure, particularly in preventing damage from etchant solutions and ensuring material selection flexibility, while maintaining the structural integrity and functionality of the semi-transmissive mirror.
Innovation Solution
The method involves forming a reflection layer and a second transparent conductive layer as upper layers of the pixel electrode using a wet cleansing operation, with a cleansing solution jet pressure of 0.1 to 1 MPa, allowing for the easy formation of a pixel electrode with a resonance structure and preventing damage from etchant solutions, while enabling a broader material selection for the reflection layer and transparent conductive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional manufacturing methods are used to form pixel electrodes with resonance structures, then the structural integrity may be maintained, but the manufacturing efficiency is reduced and material selection is limited due to damage from etchant solutions
Solution Approach 1:
The patent extracts and removes the harmful etchant solution step from the manufacturing process by using a photolithography-based approach where a photoresist layer is patterned and then removed with a mild solvent, eliminating the need for harsh etchants that damage sensitive materials like ITO and silver layers
Solution Approach 2:
The patent changes the chemical parameters of the removal process by replacing strong etchants with mild solvents that can selectively remove photoresist without damaging the underlying functional layers, thereby protecting material integrity while maintaining manufacturing efficiency
2Adaptability or versatility
If conventional manufacturing methods are used, then material selection may be restricted, but the process complexity increases and manufacturing becomes less flexible
Solution Approach 1:
The patent applies a universal photolithography-based patterning approach that can be used with various transparent conductive materials (ITO, IZO, ZnO, etc.) and reflective materials (silver, aluminum, etc.), making the process adaptable to different material combinations without requiring complex specialized etching procedures for each material type
Solution Approach 2:
The photoresist layer serves multiple functions: it defines the pixel electrode pattern, protects underlying layers during processing, and can be easily removed with mild solvents, eliminating the need for separate etching steps and reducing overall process complexity
3Reliability
If the pixel electrode structure is formed with multiple layers including reflection layer and transparent conductive layers, then the resonance structure functionality is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent forms the complete multi-layer pixel electrode structure (transparent conductive layer, reflection layer, second transparent conductive layer) as a integrated unit using photolithography, where the photoresist pattern is formed first and then all subsequent layers are deposited and patterned in alignment with this master pattern, ensuring precise relative positioning without requiring multiple separate alignment steps
Solution Approach 2:
The photoresist layer acts as an intermediary that defines the final pixel electrode pattern and serves as a template for forming all subsequent layers, ensuring that the reflection layer and transparent conductive layers are precisely aligned relative to each other and to the pixel definition, thereby maintaining manufacturing precision
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 the efficient and flexible formation of a pixel electrode with a resonance structure, enhancing the manufacturing process by reducing material damage and expanding material options, thus improving the overall performance and reliability of the organic light-emitting display apparatus.
Implementation Method 1
forming a reflection layer and a second transparent conductive layer as upper layers of the pixel electrode using a wet cleansing operation
Data Source
AI summary
An organic light-emitting display apparatus including an active layer and a first insulating layer on a substrate; a gate electrode on first insulating layer and including a first transparent conductive layer and a first metal layer, a second insulating layer on the gate electrode and including contact holes exposing source and drain areas of the active layer; source and drain electrodes including a second metal layer in the contact holes and on the second insulating layer, a pixel electrode on the first insulating layer and including the first transparent conductive layer, a reflection layer, and a second transparent conductive layer, and a pixel-defining layer on the source and drain electrodes and exposing the pixel electrode. The pixel-defining layer covers upper edges of the first transparent conductive layer of the pixel electrode. The reflection layer and the second transparent conductive layer contact sides of the pixel-defining layer.