Process for fabricating metal bus lines for OLED lighting panels
First Claim
1. A method of manufacturing a light emitting panel with a plurality of bus lines, the method comprising:
- forming a first electrode layer;
forming an organic layer stack over the first electrode layer;
forming a second electrode layer over the organic layer stack; and
patterning a plurality of bus lines by vapor deposition through a shadow mask,wherein, the plurality of bus lines are formed in electrical contact with at least one of the first electrode layer and the second electrode layer, anda final profile shape of the bus lines corresponds to a profile shape of the bus lines as deposited.
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Abstract
Systems and methods for the design and fabrication of OLEDs, including high-performance large-area OLEDs, are provided. Variously described fabrication processes may be used to deposit and pattern bus lines with a smooth profile and a gradual sidewall transition. Such smooth profiles may, for example, reduce the probability of electrical shorting at the bus lines. Accordingly, in certain circumstances, an insulating layer may no longer be considered essential, and may be optionally avoided altogether. In cases where an insulating layer is not used, further enhancements in the emissive area and shelf life of the device may be achieved as well. According to aspects of the invention, bus lines such as those described herein may be deposited, and patterned, using vapor deposition such as vacuum thermal evaporation (VTE) through a shadow mask, and may avoid multiple photolithography steps. Other vapor deposition systems and methods may include, among others, sputter deposition, e-beam evaporation and chemical vapor deposition (CVD). A final profile of the bus line may substantially correspond to the profile as deposited.
88 Citations
19 Claims
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1. A method of manufacturing a light emitting panel with a plurality of bus lines, the method comprising:
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forming a first electrode layer; forming an organic layer stack over the first electrode layer; forming a second electrode layer over the organic layer stack; and patterning a plurality of bus lines by vapor deposition through a shadow mask, wherein, the plurality of bus lines are formed in electrical contact with at least one of the first electrode layer and the second electrode layer, and a final profile shape of the bus lines corresponds to a profile shape of the bus lines as deposited. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19)
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Specification