Organic Electronic Device Patterning via Electrode Masking
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Solution Overview
Problem
The conventional production of organic electronic devices using masks is prone to imprecise imaging due to vapor creepage, mask distortions, and high costs, leading to inefficient and defective components, with complex and costly quality monitoring required to mitigate these issues.
Innovation Solution
A method for producing organic electronic devices that applies organic material over a large area without masks, using electrode materials to pattern and post-pattern the organic material, reducing the need for multiple masks and enhancing design freedom while maintaining processability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If masks are used for patterned application of organic layers and electrodes, then precise patterning is achieved, but vapor creepage occurs leading to imprecise imaging and defects
Solution Approach 1:
Instead of using masks to define patterns during deposition, the patent inverts the approach by depositing organic material over entire electrode patterns and then removing excess material. The electrodes serve as the defining structure, and the organic layer is subsequently patterned by removal rather than by selective deposition, eliminating vapor creepage issues entirely.
Solution Approach 2:
The patent performs preliminary deposition of organic material covering the entire electrode area before performing selective removal. This preliminary action ensures complete coverage during deposition without requiring masks, and the subsequent removal step creates the precise patterns needed, separating the deposition and patterning functions.
2Manufacturing precision
If masks are used for patterned application, then multiple masks are required for different layers, but this increases cost and handling complexity
Solution Approach 1:
The patent extracts the masking step entirely from the deposition process. Instead of requiring separate masks for organic layers and electrodes, the method uses the electrode patterns themselves as the reference structure and performs unmasked deposition followed by selective removal of organic material, eliminating mask-related complexity.
Solution Approach 2:
The electrode patterns serve multiple functions: they are both the functional electrical components and the reference structure for defining the organic layer patterns. This multi-functionality eliminates the need for separate masking layers, reducing the number of components and simplifying the overall process.
3Manufacturing precision
If masks are used for patterning, then alignment tolerances must be maintained, but this restricts design freedom and packing density
Solution Approach 1:
The patent inverts the reference relationship: instead of using masks as the reference and aligning electrodes to them, the electrodes serve as the reference structure and the organic layer patterns are defined relative to them. This eliminates alignment tolerance constraints and maximizes design freedom.
4Reliability
If complex quality monitoring of masks is implemented, then vapor creepage is reduced, but costs and process complexity increase
Solution Approach 1:
The patent extracts the quality monitoring requirement entirely from the process by eliminating masks. Since no masks are used, there is nothing to monitor for quality issues such as undulations, distortion, or misalignment, thereby eliminating the need for complex quality monitoring systems while maintaining or improving reliability.
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 reduces costs and defects, increases design freedom, and ensures precise patterning of organic electronic devices by using electrode materials as masks for post-processing, thereby improving the efficiency and quality of the production process.
Implementation Method 1
Application of the organic material may accordingly proceed, for example, by means of physical vapor deposition, for instance by means of vacuum evaporation
Implementation Method 2
Application of the electrode material may proceed, for example, by means of physical vapor deposition such as for instance vacuum evaporation and/or sputtering
Implementation Method 3
organic material is removed in regions which are free of, i.e., not covered by, the electrode material applied patterned to the at least one organic functional layer
Data Source
AI summary
A method for producing an organic electronic device is disclosed. In an embodiment the method includes applying an organic material to a substrate to form at least one organic functional layer, applying a patterned electrode material to the at least one organic functional layer by a first mask, and removing the organic material from regions which are free of the electrode material.