Organic EL Second Electrode Laser Removal
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Solution Overview
Problem
Conventional methods for manufacturing organic EL elements face challenges in correcting defective portions due to laser beam reflection from conductor networks in the first electrode layer, which prevents effective removal of the second electrode layer in defective areas.
Innovation Solution
A method involving the formation of organic EL elements with a first electrode layer, an organic functional layer, and a second electrode layer, where the second electrode layer is removed by irradiating it with a laser beam from the second electrode layer side, allowing for effective correction of defective portions without reflection issues.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser beam is applied from the first electrode layer side to remove a defective portion of the second electrode layer, then the first electrode layer and second electrode layer can be electrically isolated to remove short circuit, but the laser beam may be reflected by the conductor having a network structure causing the defective portion to not be irradiated and thus cannot be corrected
Solution Approach 1:
The patent applies the laser beam from the opposite side (second electrode layer side) rather than from the first electrode layer side. This inversion of the laser application direction eliminates the reflection problem caused by the conductor network structure while still achieving effective removal of the defective second electrode layer portion and electrical isolation.
2Ease of manufacture
If the laser beam is applied from the first electrode layer side, then the process can be performed in the conventional manner, but the conductor network structure reflects the laser beam preventing effective irradiation of the defective portion
Solution Approach 1:
By inverting the laser application direction to approach from the second electrode layer side, the patent maintains process simplicity while dramatically improving manufacturing precision. The laser beam directly reaches the defective portion without being reflected by the conductor network, enabling precise removal and correction.
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 ensures satisfactory removal of the second electrode layer in defective areas, preventing short circuits and maintaining the integrity of the first electrode layer, thereby enhancing the reliability of the organic EL element manufacturing process.
Implementation Method 1
a step of removing the second electrode layer in the defective portion by irradiating the defective portion with a laser beam from the second electrode layer side when the defective portion has been detected
Data Source
AI summary
A method of manufacturing an organic EL element (1) includes: a step of forming a first electrode layer (5), an organic functional layer (7), and a second electrode layer (9) on a substrate (3), a step of detecting a defective portion after forming the second electrode layer (9), a step of removing the second electrode layer (9) in the defective portion by irradiating the defective portion with a laser beam (L) from the second electrode layer (9) side when the defective portion has been detected, and a step of forming a sealing layer (11) after removing the second electrode layer 9 in the defective portion.