OLED Device Shadowing Pillars Electrode Patterning
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Solution Overview
Problem
Existing OLED devices face challenges in increasing resolution and improving lifetime, particularly in forming patterned electrodes and spacing vias, which can damage organic material layers and are limited in resolution, especially when using masks and photolithographic techniques.
Innovation Solution
A light-emitting diode device structure featuring a substrate with patterned first and second electrodes, shadowing pillars of varying heights, and multiple light-emitting layers, allowing for independent control of each light-emitting element and eliminating the need for precise patterning and masking during electrode deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masks and photolithographic techniques are used to pattern electrodes, then manufacturing precision is improved, but device complexity and difficulty of manufacture increase
Solution Approach 1:
The patent extracts and removes the masking step from the electrode patterning process. By using shadowing pillars that physically block deposition material during evaporation, the complex photolithographic masking process is eliminated, reducing device complexity while maintaining patterning precision
Solution Approach 2:
The patent introduces shadowing pillars as an intermediary structure between the substrate and the electrode deposition process. These pillars serve as physical masks during evaporation, simplifying the overall manufacturing process by replacing complex photolithographic techniques with a more straightforward shadow mask approach
2Duration of action of stationary object
If stacked light-emitting elements are used to improve lifetime, then device lifetime is improved, but manufacturing complexity increases
Solution Approach 1:
The patent segments the light-emitting function into multiple stacked elements, each with its own electrodes and light-emitting layer. This segmentation allows independent control and optimization of each element, improving overall device lifetime while managing complexity through modular architecture
Solution Approach 2:
The patent transitions from a planar single-layer structure to a three-dimensional stacked configuration. By adding the vertical dimension with multiple layers, the device achieves improved lifetime through redundant light-emitting elements while maintaining manageable complexity through systematic layering
3Measurement precision
If resolution is increased through finer patterning, then measurement precision is improved, but manufacturing difficulty increases
Solution Approach 1:
The patent replaces complex photolithographic mechanical systems with a simpler physical shadow masking approach. By using evaporated shadowing pillars as masks, the process achieves fine patterning for high resolution while significantly reducing manufacturing difficulty compared to traditional photolithography
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 structure enhances the resolution and lifetime of OLED devices by enabling independent control of light-emitting layers and reducing the complexity of electrode formation, while maintaining energy efficiency through complementary colored emitters and patterned color filters.
Implementation Method 1
Recombination of holes and electrons within a zone of the EL medium structure results in emission of light from this zone
Data Source
AI summary
A light-emitting diode device includes a substrate, and numerous first electrodes formed in a pattern over the substrate in a first dimension. Numerous first shadowing pillars, having a first height, are formed in a second dimension, orthogonal to the first dimension, and over the substrate. One-or-more first light-emitting layer(s) are formed over the first electrodes. Numerous second electrodes are formed in a pattern between the first shadowing pillars over the one-or-more first light-emitting layer(s). Numerous second shadowing pillars, having a second height, are formed in the first dimension over the substrate, wherein the second height is greater than the first height. One or more second light-emitting layer(s) are formed over the second electrodes; and numerous third electrodes are formed in a pattern over the first shadowing pillars, between the second shadowing pillars, and over the one-or-more second light-emitting layer(s).