Sacrificial Layer Fabrication for High-Resolution OLED Displays
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Solution Overview
Problem
Current display technologies face challenges in achieving high resolution, high display quality, and high contrast while maintaining a reliable and efficient manufacturing process, particularly in forming light-emitting devices without the use of metal masks which can lead to deviations in shape and position accuracy.
Innovation Solution
A method of fabricating display devices involves forming sacrificial layers and insulating layers around pixel electrodes and light-emitting layers, allowing for precise etching and deposition of light-emitting films without a metal mask, enabling the creation of high-resolution, high-aperture-ratio displays with improved reliability by inhibiting oxygen and moisture ingress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal masks are used to form light-emitting devices, then manufacturing process is simplified, but position accuracy and shape precision deteriorate due to deviations
Solution Approach 1:
The patent introduces sacrificial layers as intermediary structures that enable precise positioning of light-emitting devices without requiring metal masks. The sacrificial layers are formed at specific positions, undergo etching to create cavities, and guide the deposition of light-emitting films, thereby transferring the positioning function from metal masks to self-aligned sacrificial structures.
Solution Approach 2:
The patent replaces the mechanical metal mask system with a chemical etching-based system. Instead of using physical masks that require alignment and positioning, the invention uses sacrificial layers that are chemically etched to form cavities, which then guide film deposition through self-alignment, eliminating the need for mechanical mask positioning.
2Manufacturing precision
If higher resolution is achieved, then display quality improves, but manufacturing complexity increases
Solution Approach 1:
The patent performs preliminary actions by forming sacrificial layers and etching cavities before depositing the light-emitting films. This pre-preparation of the substrate structure with predetermined cavities and positioning elements simplifies subsequent high-resolution film formation, as the complex positioning work is already done in advance through the sacrificial layer structure.
Solution Approach 2:
The patent segments the manufacturing process into distinct stages: forming sacrificial layers, etching cavities, depositing light-emitting films, and removing sacrificial layers. This segmentation allows each step to be optimized independently, enabling high resolution in film deposition while keeping overall manufacturing complexity manageable through modular process design.
3Illumination intensity
If aperture ratio is increased, then display brightness improves, but manufacturing precision requirements increase
Solution Approach 1:
The sacrificial layers and etched cavities serve self-aligning functions, automatically guiding the deposition of light-emitting films to the correct positions without requiring external alignment tools or complex positioning systems. The cavity structure itself provides the positioning reference, making the system self-servicing in terms of alignment.
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 enables the production of display devices with resolutions exceeding 5000 ppi, achieving high display quality and contrast while reducing manufacturing complexity and improving yield, without the need for complex pixel arrangement methods like PenTile.
Implementation Method 1
a fourth step of etching the first sacrificial film to form a first sacrificial layer including a region overlapping with the first pixel electrode
Implementation Method 2
By voltage application to this device, light emission can be obtained from the light-emitting organic compound
Implementation Method 3
improving reliability by inhibiting oxygen and moisture ingress
Data Source
AI summary
A method of fabricating a display device with high resolution is provided. A display device having both high display quality and high resolution is provided. The method of fabricating a display device includes steps of forming a first EL film and a first sacrificial film over a first pixel electrode and a second pixel electrode; etching the first sacrificial film to form a first sacrificial layer; etching the first EL film to form a first EL layer and to expose the second pixel electrode; forming a second EL film and a second sacrificial film; etching the second sacrificial film to form a second sacrificial layer; etching the second EL film to form a second EL layer; forming an insulating film covering the first sacrificial layer, the first EL layer, the second sacrificial layer, and the second EL layer; and etching the insulating film to form an insulating layer including a region in contact with a side surface of the first EL layer and a region in contact with a side surface of the second EL layer.