Methods of fabricating oled panel with inorganic pixel encapsulating barrier

Patent metadata

Field	Value
Publication number	US-2025301876-A1
Application number	US-202519231118-A
Country	US
Kind code	A1
Filing date	Jun 6, 2025
Priority date	Sep 4, 2020
Publication date	Sep 25, 2025
Grant date	—

Abstract

Embodiments described herein relate to sub-pixel circuits and methods of forming sub-pixel circuits that may be utilized in a display such as an organic light-emitting diode (OLED) display. The device includes a plurality of sub-pixels, each sub-pixel of the plurality of sub-pixels defined by adjacent pixel-defining layer (PDL) structures with inorganic overhang structures disposed on the PDL structures, each sub-pixel having an anode, organic light-emitting diode (OLED) material disposed on the anode, and a cathode disposed on the OLED material. The device is made by a process including the steps of: depositing the OLED material and the cathode by evaporation deposition, and depositing an encapsulation layer disposed over the cathode.

First claim

What is claimed is:

1 . A device, comprising:
a substrate; pixel-defining layer (PDL) structures disposed over the substrate; overhang structures disposed on an upper surface of the PDL structures, the overhang structures having an upper portion that extends past a sidewall of a lower portion disposed over PDL structures; and a first sub-pixel and a second sub-pixel, each of the first sub-pixel and the second sub-pixel comprising:
an anode;
an organic light-emitting material; and
a cathode;
a first color filter disposed over the first sub-pixel; and a second color filter disposed over the second sub-pixel.

2 . The device of claim 1 , wherein at least one sub-pixel further comprises an encapsulation layer disposed over the cathode, wherein the encapsulation layer extends under at least a portion of the overhang structures contacts the sidewall of the lower portion and an underside surface of the upper portion of the overhang structures.

3 . The device of claim 2 , wherein a second encapsulation layer is over the first color filter and the second color filter.

4 . The device of claim 3 , wherein the second encapsulation layer is contacts a top surface of the upper portion of the overhang structures.

5 . The device of claim 2 , wherein the encapsulation layer of the first sub-pixel and the encapsulation layer of the second sub-pixel are separated from each other.

6 . The device of claim 2 , wherein the first color filter and the second color filter are disposed over the encapsulation layer.

7 . The device of claim 1 , further comprising a global passivation layer.

8 . The device of claim 7 , wherein the global passivation layer is disposed over the first color filter and the second color filter.

9 . The device of claim 1 , wherein the device comprises a dot-type architecture or a line-type architecture.

10 . The device of claim 1 , wherein:
the first color filter has a transmittance that is matched or substantially matched to the transmittance of the organic light-emitting material of the first sub-pixel; and the second color filter has a transmittance that is matched or substantially matched to the transmittance of the organic light-emitting material of the second sub-pixel.

11 . A device, comprising:
a substrate; pixel-defining layer (PDL) structures disposed over the substrate; overhang structures disposed on an upper surface of the PDL structures, the overhang structures having an upper portion that extends past a sidewall of a lower portion disposed over PDL structures; and a first sub-pixel and a second sub-pixel, each of the first sub-pixel and the second sub-pixel comprising:
an anode;
an organic light-emitting material, the organic light-emitting material of the first sub-pixel and the second sub-pixel emit different color light from each other when energized; and
a cathode;
a first color filter disposed over the first sub-pixel, the first color filter has a first transmittance that is matched or substantially matched to the transmittance of the organic light-emitting material of the first sub-pixel; and a second color filter disposed over the second sub-pixel, the second color filter has a second transmittance that is matched or substantially matched to the transmittance of the organic light-emitting material of the second sub-pixel.

12 . The device of claim 11 , wherein at least one sub-pixel further comprises an encapsulation layer disposed over the cathode, wherein the encapsulation layer extends under at least a portion of the overhang structures contacts the sidewall of the lower portion and an underside surface of the upper portion of the overhang structures.

13 . The device of claim 12 , wherein the encapsulation layer of the first sub-pixel and the encapsulation layer of the second sub-pixel are separated from each other.

14 . The device of claim 12 , wherein the first color filter and the second color filter are disposed over the encapsulation layer.

15 . The device of claim 12 , wherein a second encapsulation layer is over the first color filter and the second color filter.

16 . The device of claim 15 , wherein the second encapsulation layer is contacts a top surface of the upper portion of the overhang structures.

17 . The device of claim 12 , further comprising a global passivation layer.

18 . The device of claim 17 , wherein the global passivation layer is disposed over the first color filter and the second color filter.

19 . The device of claim 11 , wherein the device comprises a dot-type architecture or a line-type architecture.

20 . A device, comprising:
a substrate; pixel-defining layer (PDL) structures disposed over the substrate; overhang structures disposed on an upper surface of the PDL structures, the overhang structures having an upper portion that extends past a sidewall of a lower portion disposed over PDL structures; and a first sub-pixel and a second sub-pixel, each of the first sub-pixel and the second sub-pixel comprising:
an anode;
an organic light-emitting material, the organic light-emitting material of the first sub-pixel and the second sub-pixel emit different color light from each other when energized;
a cathode; and
at least one sub-pixel further comprises an encapsulation layer disposed over the cathode, wherein the encapsulation layer extends under at least a portion of the overhang structures contacts the sidewall of the lower portion and an underside surface of the upper portion of the overhang structures;
a first color filter disposed over the first sub-pixel; and a second color filter disposed over the second sub-pixel.

Assignees

• Applied Materials Inc

Inventors

• Choung Ji-Young
• Haas Dieter
• Lin Yu Hsin
• Lee Jungmin
• Yoo Seong Ho
• Kim Si Kyoung

Classifications

• H10K50/844 Primary

  Encapsulations · CPC title

• H10K71/00

  Manufacture or treatment specially adapted for the organic devices covered by this subclass · CPC title

• H10K50/84

  Passivation; Containers; Encapsulations · CPC title

• H10K59/1315

  comprising structures specially adapted for lowering the resistance · CPC title

• H10K59/80522

  combined with auxiliary electrodes · CPC title