Organic EL Display Maskless Patterning
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Solution Overview
Problem
The conventional active matrix type organic electroluminescent display devices with a dual-plate structure face challenges in manufacturing complexity and high costs due to the need for shadow masks in forming organic common layers, which prolongs the process time and increases costs.
Innovation Solution
The use of conductive polymers to form organic common layers on the second substrate without a mask simplifies the process, reducing manufacturing costs and time by eliminating the need for shadow masks and allowing for easier formation of organic common layers and electron injection layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If shadow masks are used to form organic common layers, then manufacturing precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The patent removes the shadow mask component from the manufacturing process entirely. Instead of using shadow masks to define patterns, the invention uses self-aligned formation methods where the organic common layer is formed directly over the electrode patterns through controlled deposition and patterning steps, extracting the problematic masking step while maintaining pattern precision.
Solution Approach 2:
The patent performs preliminary patterning of the electrode structures before forming the organic common layer. By pre-defining the electrode patterns and using them as alignment references, the organic common layer can be formed without requiring shadow masks, as the underlying electrode structure already provides the necessary pattern guidance.
2Manufacturing precision
If shadow masks are used to form organic common layers, then manufacturing precision is improved, but manufacturing time increases
Solution Approach 1:
The patent eliminates the shadow mask application, alignment, and removal steps from the manufacturing process. By using direct patterning methods where the organic common layer is formed through controlled deposition aligned with pre-formed electrode patterns, the time-consuming masking operations are extracted and replaced with more efficient single-step patterning approaches.
3Manufacturing precision
If shadow masks are used to form organic common layers, then manufacturing precision is improved, but manufacturing cost increases
Solution Approach 1:
The patent removes shadow masks and associated handling equipment from the manufacturing line. By implementing a maskless patterning approach that relies on pre-formed electrode patterns as alignment references, the invention eliminates the cost of shadow masks, mask alignment systems, and mask replacement procedures, significantly reducing manufacturing equipment investment and operational costs.
Solution Approach 2:
The patent replaces expensive, reusable shadow masks with a disposable-like approach where patterns are directly formed through deposition processes that use the underlying electrode structure as a template. This eliminates the need for costly, precision-machined shadow masks while achieving comparable pattern precision through material deposition control.
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 manufacturing costs and time while preventing lateral cross-talk and electrical connection defects, enabling efficient production of organic electroluminescent display devices with high resistance between pixels to prevent unwanted electrical connections.
Implementation Method 1
enabling efficient production of organic electroluminescent display devices with high resistance between pixels to prevent unwanted electrical connections
Data Source
AI summary
An organic electroluminescent display device according to an embodiment includes a connection electrode on a first substrate; and a luminescent element on a second substrate opposite to the first substrate, the luminescent element being connected to the connection electrode, the luminescent element having a contact part at least partially surrounded by a separator, wherein a first electrode, a second electrode and an organic common layer between the first electrode and the second electrode are located in the contact part.