Organic EL Device Fabrication via Mask Alignment
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Solution Overview
Problem
The roll-to-roll processes for fabricating organic electro-luminescent devices face significant alignment issues between stacked layers, leading to low yield rates due to mis-alignment, which complicates the mass production and increases fabrication costs.
Innovation Solution
A method involving the use of multiple masks with high adhesion viscosity to accurately pattern and align conductive layers and organic functional layers, ensuring precise exposure and shielding to prevent mis-alignment, and subsequent removal of masks to form connected electrodes, while maintaining sufficient adhesion for process integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If roll-to-roll processes are used for mass production of organic electro-luminescent devices, then productivity is improved, but manufacturing precision deteriorates due to mis-alignment between stacked layers
Solution Approach 1:
The patent introduces a mask layer as an intermediary component between the conductive layer and the organic functional layer. This mask layer with controlled adhesion viscosity serves as a mediator that enables precise alignment during roll-to-roll processing while maintaining the ability to be removed after patterning, thus resolving the contradiction between mass production capability and alignment precision.
Solution Approach 2:
The patent utilizes parameter changes in the adhesion viscosity of the mask layer to achieve different functional states. By controlling the adhesion viscosity to be substantially equal to or greater than 2000 g/inch, the mask layer maintains strong adhesion during the patterning process for precise alignment, then allows for clean removal after serving its purpose, enabling both high precision and productivity.
2Manufacturing precision
If multiple masks with high adhesion viscosity are used to ensure precise alignment, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The mask layer in the patent serves multiple functions: it provides alignment reference during patterning, maintains adhesion to prevent misalignment, and can be cleanly removed after use. This multi-functionality reduces the need for multiple separate mask layers, thereby improving alignment precision without proportionally increasing device complexity.
3Manufacturing precision
If masks are used to pattern layers with precise alignment, then manufacturing precision is improved, but ease of manufacture deteriorates due to additional process steps
Solution Approach 1:
The mask layer is formed with predetermined adhesion viscosity characteristics before the patterning process. This preliminary preparation ensures that the mask layer automatically maintains proper adhesion during rolling and patterning operations, eliminating the need for complex real-time alignment adjustments and simplifying the overall manufacturing process while maintaining high precision.
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 method effectively minimizes mis-alignment between layers, enhancing the yield rate of organic electro-luminescence devices and reducing fabrication costs by ensuring precise alignment and electrical connectivity during the roll-to-roll process.
Implementation Method 1
a viscosity of an adhesion film of the first mask being substantially equal to or greater than 2000 g/inch
Data Source
AI summary
A method for fabricating an organic electro-luminescence device, comprising: forming a first conductive layer comprising a first electrode and a contact pattern on a substrate; forming a first mask on the first conductive layer, the first mask comprising an opening for exposing a portion of the first electrode and a portion of the contact pattern; forming a patterned organic functional layer by shielding of a second mask, the patterned organic functional layer covering the first mask and the first electrode exposed by the first mask, and the second mask being disposed over the first mask to shield the portion of the contact pattern exposed by the opening; forming a second conductive layer and patterning the second conductive layer by removing the first mask and a portion of the second conductive layer on the first mask to form a second electrode electrically connected to the contact pattern.