Recess Region and Barrier Layer for OLED Short Circuit Prevention

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional organic light-emitting display devices face issues with contamination by undesired particles and surface defects during manufacturing, leading to short circuits and image defects, which reduce production yield and increase costs.

Innovation Solution

The implementation of a recess region with a barrier layer between the light-emitting element and the substrate, where the light-emitting element's first electrode is disposed, separated from the substrate by a barrier layer, and the switch element is electrically connected to the light-emitting element, ensuring that any particles or protrusions formed during manufacturing are removed, preventing short circuits and improving display quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional manufacturing processes are used for organic light-emitting display devices, then production efficiency is maintained, but particles and impurities contaminate the display device causing short circuits and image defects

Engineering Contradiction:

Improvedevice reliabilityVSAvoidparticle contamination

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention extracts and removes particles and impurities from the manufacturing environment by implementing cleanroom facilities with controlled particle levels, HEPA filters, and particle removal systems that actively extract contaminants from the air and processing areas

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The invention introduces intermediary protective measures including cleanroom environments as an intermediate space between the external environment and the display device manufacturing area, and uses protective coverings and barriers as intermediary layers to prevent particle contact with the device

Inventive Principle:

Principle #24Intermediary (Mediator)

2Productivity

If manufacturing processes continue without interruption, then productivity is maintained, but particles accumulate and attach to the light-emitting area causing image defects

Engineering Contradiction:

Improveproduction yieldVSAvoidparticle accumulation

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The invention performs preliminary actions by implementing particle removal systems and cleanroom maintenance procedures before particles can accumulate to problematic levels, and by pre-coating surfaces with protective layers that prevent particle adhesion before contamination occurs

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The invention maintains continuous particle removal and environmental control throughout the manufacturing process, ensuring that cleanroom filtration and particle monitoring operate continuously without interruption to prevent particle accumulation while maintaining productivity

Inventive Principle:

Principle #20Continuity of useful action

3Manufacturing precision

If quality control measures are intensified to reduce particles, then display quality improves, but manufacturing complexity and costs increase

Engineering Contradiction:

Improvedisplay qualityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention implements multi-functional cleanroom systems that combine particle filtration, environmental monitoring, pressure control, and contamination prevention in integrated facilities, reducing the need for separate specialized systems and thereby managing complexity while maintaining high manufacturing precision

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively prevents short circuits and enhances display quality by ensuring a smooth surface and reducing defects, thereby improving production yield and reducing manufacturing costs.

Implementation Method 1

a barrier layer between the light-emitting element and the substrate, where the light-emitting element's first electrode is disposed, separated from the substrate by a barrier layer

Methodology Applied

Scientific EffectPhysical barrier isolation:

Data Source

PatentUS7576364B2Display device and method of manufacturing the same

Publication Date: 2009.08.18 INNOLUX CORP

AI summary

A display device and its method of manufacture. The display device is formed to include a substrate having an upper surface, a recess region having a bottom surface and sidewalls, a light-emitting element and a switch element. The light-emitting element includes a first electrode disposed on the recess region, a light-emitting layer disposed on the first electrode, and a second electrode disposed on the light-emitting layer. The switch element is disposed on the substrate and electrically connected to the light-emitting element. The bottom surface of the recess region is lower than the bottom surface of the active layer.