Stacked OLED Device Reducing Mask Complexity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current OLED display panel manufacturing processes are complex, costly, and have low yield rates due to the need for fine metal masks and high-precision alignment, making it difficult to improve pixel resolution and reduce costs.
Innovation Solution
A stacked OLED device structure comprising a first forward OLED structure, a first reverse OLED structure, and a second forward OLED structure, with a charge generation layer and transparent insulating layers, allowing for reduced precision mask requirements and improved pixel resolution by connecting anodes through a conductive layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If five fine metal masks (FMM) and high precision CCD alignment are used to achieve side by side RGB pixelation type OLED display, then pixel resolution can be improved, but manufacturing complexity increases, cost increases, and yield rate decreases
Solution Approach 1:
The patent divides the OLED display into multiple independent sub-pixels (red, green, blue) that are arranged in a stacked configuration rather than side-by-side. Each sub-pixel is formed through separate deposition processes, eliminating the need for complex fine metal masks and high-precision alignment systems while maintaining high pixel resolution.
Solution Approach 2:
The patent transitions from a two-dimensional side-by-side pixel arrangement to a three-dimensional stacked structure. By stacking sub-pixels vertically, the design achieves high pixel resolution without requiring the complex lateral alignment processes needed in traditional side-by-side configurations.
2Manufacturing precision
If five fine metal masks (FMM) and high precision CCD alignment are used to achieve side by side RGB pixelation type OLED display, then pixel resolution can be improved, but production cost increases
Solution Approach 1:
The patent extracts and eliminates the need for expensive fine metal masks and high-precision CCD alignment systems by采用ing a stacked pixel structure. This approach uses simpler, more cost-effective deposition processes while still achieving the desired pixel resolution through vertical stacking rather than lateral arrangement.
3Manufacturing precision
If five fine metal masks (FMM) and high precision CCD alignment are used to achieve side by side RGB pixelation type OLED display, then pixel resolution can be improved, but yield rate decreases
Solution Approach 1:
The patent segments the pixel formation process into independent vertical stacking steps for each sub-pixel color. This segmentation eliminates the cumulative alignment errors that occur in side-by-side processes, significantly improving yield rate while maintaining high pixel resolution through the stacked architecture.
Data Source
AI summary
The disclosure provides a stacked OLED device and a method thereof, wherein the device comprises a forward and reverse of a first OLED structure, and a second forward OLED structure stacked from bottom to top on a substrate sequentially; a charge generation layer disposed between the forward and reverse of the first OLED structure as a common cathode, and each organic functional layer in the forward and reverse of the first OLED structure are symmetrical with the charge generation layer; a transparent insulating layer disposed between the first reverse and the second forward OLED structure; an anode of the first and second forward OLED structure are connected through a conductive layer. The disclosure reduces the use of a precision mask so that a space occupied by three primary colors is reduced, greatly increases a pixel resolution, improves a product yield rate, saves the cost, and enhances a product competitiveness.