OLEDoS Pixel Electrode Layout With Single-Mask Patterning

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Solution Overview

Problem

Existing head-mounted displays (HMDs) face challenges in achieving high-resolution images due to the complexity and cost of manufacturing high-resolution organic light-emitting diode on silicon (OLEDoS) display devices.

Innovation Solution

The display device includes a substrate with specific layer configurations and manufacturing methods that reduce the number of mask processes, allowing for efficient patterning of connection electrodes, reflective electrodes, and optical auxiliary films using a single mask, thereby reducing manufacturing costs and increasing efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If high-resolution organic light-emitting diode on silicon (OLEDoS) display devices are used to achieve high-resolution images, then image resolution is improved, but manufacturing complexity and cost increase

Engineering Contradiction:
Improveimage resolutionVSAvoidmanufacturing complexity
Core Design Contradiction:
Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent merges the patterning of connection electrodes, reflective electrodes, and optical auxiliary films into a single mask process. Multiple layers are patterned simultaneously through one mask, reducing the number of separate manufacturing steps while maintaining high-resolution requirements. This combines multiple patterning operations that would traditionally require separate masks and processes into a unified step.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The single mask serves multiple functions by simultaneously defining the patterns for connection electrodes, reflective electrodes, and optical auxiliary films. This universal mask approach allows one component to perform multiple patterning tasks that would traditionally require separate dedicated masks for each layer, simplifying the manufacturing process while achieving high-resolution patterns.

Inventive Principle:
Principle #6Universality (Multi-functionality)

2Manufacturing precision

If multiple mask processes are used for patterning connection electrodes, reflective electrodes, and optical auxiliary films, then manufacturing precision is maintained, but manufacturing time and cost increase

Engineering Contradiction:
Improvepatterning precisionVSAvoidmanufacturing efficiency
Core Design Contradiction:
Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines multiple sequential mask processes into a single integrated mask process. The connection electrodes, reflective electrodes, and optical auxiliary films are all patterned in one step rather than through multiple separate masking operations, reducing manufacturing time and increasing productivity while preserving patterning precision through careful mask design.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The single mask is designed in advance to accommodate all necessary patterning requirements for multiple layers. By performing preliminary design and preparation of a comprehensive mask that covers all patterning needs, the process eliminates the need for multiple sequential masking steps, thereby improving manufacturing efficiency without sacrificing precision.

Inventive Principle:
Principle #10Preliminary action

3Manufacturing precision

If traditional multi-step patterning processes are used, then manufacturing precision is achieved, but manufacturing cost increases

Engineering Contradiction:
Improvepatterning precisionVSAvoidmanufacturing cost
Core Design Contradiction:
Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent merges multiple patterning steps into a single mask process, reducing the total number of manufacturing operations required. This consolidation decreases material consumption, reduces equipment usage time, and lowers labor costs while maintaining the necessary patterning precision through optimized mask design and single-step processing.

Inventive Principle:
Principle #5Merging (Combining)

Solution Approach 2:

The single mask serves as a master template that simultaneously copies the required patterns onto multiple layers (connection electrodes, reflective electrodes, and optical auxiliary films). This copying approach allows one mask to produce multiple identical or related patterns across different layers, reducing the need for multiple unique masks and associated costs.

Inventive Principle:
Principle #26Copying

Data Source

PatentUS20250359460A1Display device, method for manufacturing the display device, and head mounted display including the display device
Publication Date: 2025.11.20 SAMSUNG DISPLAY CO LTD
  • US20250359460A1 patent drawing
  • US20250359460A1 patent drawing
  • US20250359460A1 patent drawing

AI summary

A display device includes: a substrate; an insulating film on the substrate; a connection electrode on the insulating film; a reflective electrode on the connection electrode; an optical auxiliary film on the reflective electrode; a first electrode on a side surface of the connection electrode, a side surface of the reflective electrode, and a side surface and a top surface of the optical auxiliary film; a pixel defining film exposing a partial area of a top surface of the first electrode; at least one light-emitting layer on a partial area of the top surface of the first electrode exposed by the pixel defining film; and a second electrode on the at least one light-emitting layer.