Stacked Pad Electrodes for OLED Manufacturing
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Solution Overview
Problem
The manufacturing process of organic light-emitting display devices is complex and costly due to the numerous mask processes required for forming fine patterns, leading to increased manufacturing time and costs.
Innovation Solution
The organic light-emitting display device design includes a thin film transistor with a gate electrode and pad electrodes, where the pad electrodes are sequentially stacked with insulation layers, and a method involving multiple mask processes to form the necessary layers and patterns efficiently, reducing the complexity and cost by using polycrystal indium tin oxide (p-ITO) and transparent conductive oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple mask processes are used to form fine patterns including TFT and capacitor, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent combines multiple mask processes into a single integrated manufacturing process. Specifically, the active layer, gate electrode, source/drain electrodes, and pixel electrode are formed simultaneously or in fewer sequential steps without requiring separate masks for each component, thereby reducing process complexity while maintaining fine pattern precision
Solution Approach 2:
The patent employs a universal electrode material layer that serves multiple functions. The same conductive layer is used to form the active layer, gate electrode, source/drain electrodes, and pixel electrode, allowing a single deposition process to create multiple critical components and reducing the number of specialized processing steps required
2Manufacturing precision
If multiple mask processes are used to form fine patterns, then manufacturing precision is improved, but manufacturing time increases
Solution Approach 1:
The patent performs preliminary formation of all electrode patterns (active layer, gate, source/drain, pixel) in a single deposition step before subsequent processing. This preliminary action eliminates the need for repeated mask alignment and deposition cycles, significantly reducing manufacturing time while preserving pattern precision through the initial unified formation process
Solution Approach 2:
The manufacturing process maintains continuity by forming all conductive layers in an uninterrupted sequence without intermediate mask changes or process interruptions. The continuous deposition and patterning approach eliminates idle time between mask processes while maintaining the precision required for fine patterns
3Device complexity
If conventional pad electrode structure is used, then device complexity is reduced, but corrosion resistance decreases
Solution Approach 1:
The patent implements a composite pad electrode structure consisting of multiple material layers. The pad electrode includes a first pad electrode layer and a second pad electrode layer with different material compositions, where the second layer provides enhanced corrosion resistance while the first layer provides good electrical conductivity, achieving both reliability and reasonable structural simplicity
4Device complexity
If conventional pad electrode structure is used, then device complexity is reduced, but resistance increases
Solution Approach 1:
The composite pad electrode structure uses strategically selected material layers where the first pad electrode layer provides low electrical resistance for efficient current conduction, while the second pad electrode layer provides corrosion protection. This composite approach achieves both low resistance and high reliability without requiring overly complex multi-layer structures
Data Source
AI summary
An organic light-emitting display device including a TFT comprising an active layer, a gate electrode comprising a lower gate electrode and an upper gate electrode, and source and drain electrodes insulated from the gate electrode and contacting the active layer; an organic light-emitting device electrically connected to the TFT and comprising a pixel electrode formed in the same layer as where the lower gate electrode is formed; and a pad electrode electrically coupled to the TFT or the organic light emitting device and comprising a first pad electrode formed in the same layer as in which the lower gate electrode is formed, a second pad electrode formed in the same layer as in which the upper gate electrode is formed, and a third pad electrode comprising a transparent conductive oxide, the first, second, and third pad electrodes being sequentially stacked.