WO-2026096210-A1 - ASYMMETRIC AUXILIARY ELECTRODE CONFIGURATION FOR ORGANIC LIGHT EMITTING DIODE DISPLAY

Abstract

Embodiments of the present disclosure generally relate to a display. More specifically, 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 overhang structures, each overhang structure including a first structure having a first portion opposing a second portion, a second structure disposed over the first structure, wherein an overhang of the second structure extends laterally past an upper surface of the first structure to define the overhang, and an auxiliary electrode is disposed partially under the second portion, and a plurality of sub-pixels defined by the plurality of overhang structures, each sub-pixel including an OLE material, and a cathode disposed over the OLE material, the cathode under the overhang disposed over the second portion of the first structure contacts the auxiliary electrode.

Inventors

• CHEN, CHUNG-CHIA
• LIN, YU-HSIN
• CHOUNG, JI YOUNG
• WANG, Sheng-wen

Assignees

• APPLIED MATERIALS, INC.

Dates

Publication Date

20260507

Application Date

20251016

Priority Date

20241031

Claims (20)

1. 1 . A device, comprising: a plurality of overhang structures, each overhang structure of the plurality of overhang structures comprising: a first structure having a first portion opposing a second portion; a second structure disposed over the first structure, wherein: an overhang of the second structure extends laterally past an upper surface of the first structure to define the overhang; and an auxiliary electrode is disposed partially under the second portion; and a plurality of sub-pixels defined by the plurality of overhang structures, each sub-pixel comprising: an organic light emitting (OLE) material; and a cathode disposed over the OLE material, the cathode under the overhang disposed over the second portion of the first structure contacts the auxiliary electrode.
2. 2. The device of claim 1 , further comprising adjacent pixel-defining layer (PDL) structures which define a sub-pixel, wherein each overhang of the plurality of overhang structures is disposed over each PDL structure of the adjacent PDL structures and the auxiliary electrode is disposed between the PDL structure and the first structure.
3. 3. The device of claim 1 , wherein the cathode disposed under the overhang contacts the auxiliary electrode and the first structure of the second portion.
4. 4. The device of claim 1 , wherein the second structure of the second portion is higher than the second structure of the first portion.
5. 5. The device of claim 4, wherein a height difference between the first portion and the second portion is about 10 nm to about 300 nm.
6. 6. The device of claim 1 , wherein the first portion and the second portion comprise half of each overhang structure of the plurality of overhang structures.
7. 7. The device of claim 1 , wherein the auxiliary electrode comprises a conductive material.
8. 8. The device of claim 7, wherein the conductive material comprises transparent conductive oxide material, aluminum, titanium, molybdenum, copper, silver, or combinations thereof.
9. 9. A device, comprising: a first sub-pixel defined by a first overhang structure and a second overhang structure; a second sub-pixel, the second sub-pixel is defined by the second overhang structure and a third overhang structure, each overhang structure of a plurality of overhang structures comprises: a first structure; and a second structure disposed over the first structure, wherein: an overhang of the second structure extends laterally past an upper surface of the first structure to define the overhang; and the second overhang structure has an auxiliary electrode disposed under the first structure; and wherein each of the first sub-pixel and the second sub-pixel include: an organic light emitting (OLE) material; and a cathode disposed over the OLE material, the cathode contacts the auxiliary electrode of the second overhang structure.
10. 10. The device of claim 9, further comprising adjacent pixel-defining layer (PDL) structures which define a sub-pixel, wherein each overhang of the plurality of overhang structures is disposed over each PDL structure of the adjacent PDL structures and the auxiliary electrode is disposed between the PDL structure and the first structure.
11. 11 . The device of claim 9, wherein the cathode contacts a sidewall of the first structure of the second overhang structure and the cathode contacts the auxiliary electrode.
12. 12. The device of claim 9, wherein the cathode under the overhang of the second overhang structure has an end point further than under the first overhang structure and the third overhang structure.
13. 13. The device of claim 9, wherein the first structure is disposed over a pixel defining layer (PDL) structure.
14. 14. The device of claim 13, wherein the second overhang structure has different height from a substrate than the first overhang structure a different height than the first overhang of the plurality of overhang structures.
15. 15. The device of claim 9, wherein the auxiliary electrode comprises a conductive material.
16. 16. A device comprising a plurality of sub-pixels, each sub-pixel of the plurality of sub-pixels defined by adjacent pixel-defining layer (PDL) structures with a plurality of overhang structures disposed over a plurality of PDL structures, each sub-pixel of the plurality of sub-pixels having an anode, an auxiliary electrode, an organic light-emitting (OLE) material disposed on the anode, and a cathode disposed on the OLE material, wherein the device is made by a process comprising the steps of: depositing the OLE material using evaporation deposition over a substrate, the OLE material disposed over and in contact with the anode; depositing the cathode using evaporation deposition, the cathode disposed over the OLE material and extending under the overhang structures adjacent to each sub-pixel of the plurality of sub-pixels; and depositing an encapsulation layer disposed over the cathode, the encapsulation layer extending under at least a portion of the overhang structures and along a sidewall of the overhang structures.
17. 17. The device of claim 16 further comprising: each overhang structure of the plurality of overhang structures comprising: a first structure having a first portion opposing a second portion; a second structure disposed over the first structure, wherein: an overhang of the second structure extends laterally past an upper surface of the first structure to define the overhang; and the auxiliary electrode is disposed partially under the second portion; and wherein the cathode contacts the auxiliary electrode.
18. 18. The device of claim 16, further comprising: a first sub-pixel defined by a first overhang structure and a second overhang structure; a second sub-pixel, the second sub-pixel is defined by the second overhang structure and a third overhang structure, each overhang structure of the plurality of overhang structures comprises: a first structure; and a second structure disposed over the first structure, wherein: an overhang of the second structure extends laterally past an upper surface of the first structure to define the overhang; and the second overhang structure has the auxiliary electrode disposed under the first structure; and wherein each of the first sub-pixel and the second sub-pixel include: an organic light emitting (OLE) material; and the cathode disposed over the OLE material, the cathode contacts the auxiliary electrode of the second overhang structure.
19. 19. The device of claim 18, wherein the cathode contacts the sidewall of the first structure of the second overhang structure and the cathode contacts the auxiliary electrode and wherein the cathode under the overhang of the second overhang structure has an end point further than under the first overhang structure and the third overhang structure.
20. 20. The device of claim 16, wherein the auxiliary electrode comprises a conductive material.

Description

ASYMMETRIC AUXILIARY ELECTRODE CONFIGURATION FOR ORGANIC LIGHT EMITTING DIODE DISPLAY BACKGROUND Field [0001] Embodiments of the present disclosure generally relate to a display. More specifically, 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 lightemitting diode (OLED) display. Description of the Related Art [0002] Input devices including display devices may be used in a variety of electronic systems. An organic light-emitting diode (OLED) is a light-emitting diode (LED) in which the emissive electroluminescent layer is a film of an organic compound that emits light in response to an electric current. OLED devices are classified as bottom emission devices if light emitted passes through the transparent or semitransparent bottom electrode and substrate on which the panel was manufactured. Top emission devices are classified based on whether or not the light emitted from the OLED device exits through the lid that is added following the fabrication of the device. OLEDs are used to create display devices in many electronics today. Today’s electronics manufacturers are pushing these display devices to shrink in size while providing higher resolution than just a few years ago. [0003] OLED pixel patterning is currently based on a process that restricts panel size, pixel resolution, and substrate size. Rather than utilizing a fine metal mask, photo lithography should be used to pattern pixels. Currently, OLED pixel patterning requires lifting off organic material after the patterning process. When lifted off, the organic material leaves behind a particle issue that disrupts OLED performance. [0004] Accordingly, what is needed in the art are OLED pixels and method of forming OLED pixels to increase pixel-per-inch and provide improved OLED performance. SUMMARY [0005] In a first embodiment, a device is disclosed. The device includes a plurality of overhang structures, each overhang structure of the plurality of overhang structures including a first structure having a first portion opposing a second portion, a second structure disposed over the first structure, wherein an overhang of the second structure extends laterally past an upper surface of the first structure to define the overhang, and an auxiliary electrode is disposed partially under the second portion, and a plurality of sub-pixels defined by the plurality of overhang structures, each subpixel including an organic light emitting (OLE) material, and a cathode disposed over the OLE material, the cathode under the overhang disposed over the second portion of the first structure contacts the auxiliary electrode. [0006] In another embodiment, a device is disclosed. The device includes a first sub-pixel defined by a first overhang structure and a second overhang structure, a second sub-pixel, the second sub-pixel is defined by the second overhang structure and a third overhang structure, each overhang structure of a plurality of overhang structures include a first structure and a second structure disposed over the first structure, wherein an overhang of the second structure extends laterally past an upper surface of the first structure to define the overhang and the second overhang structure has an auxiliary electrode disposed under the first structure and wherein each of the first sub-pixel and the second sub-pixel include an organic light emitting (OLE) material and a cathode disposed over the OLE material, the cathode contacts the auxiliary electrode of the second overhang structure. [0007] In another embodiment, a device is disclosed. 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 a plurality of overhang structures disposed over a plurality of PDL structures, each sub-pixel of the plurality of sub-pixels having an anode, an auxiliary electrode, an organic light-emitting (OLE) material disposed on the anode, and a cathode disposed on the OLE material, wherein the device is made by a process comprising the steps of: depositing the OLE material using evaporation deposition over a substrate, the OLE material disposed over and in contact with the anode, depositing the cathode using evaporation deposition, the cathode disposed over the OLE material and extending under the overhang structures adjacent to each sub-pixel of the plurality of sub-pixels, and depositing an encapsulation layer disposed over the cathode, the encapsulation layer extending under at least a portion of the overhang structures and along a sidewall of the overhang structures. BRIEF DESCRIPTION OF THE DRAWINGS [0008] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the disclosure, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the append