Mask assembly, display panel, and display apparatus

Abstract

Provided are a mask assembly, a display panel, and a display apparatus. The mask assembly comprises a mask frame and a plurality of mask sheets. The mask frame comprises at least one mask opening and a frame part surrounding the mask opening. The plurality of mask sheets overlap on the mask frame. Each mask sheet comprises a plurality of evaporation regions and a separation portion surrounding the plurality of evaporation regions, the plurality of evaporation regions of the mask sheet overlapping with the mask opening. The mask opening extends in a first direction, the size of the mask opening in the first direction is greater than the size of the mask opening in a second direction, and the first direction intersects with the second direction. Each mask sheet extends in the first direction, and the size of each evaporation region in the first direction is greater than the size of the evaporation region in the second direction. According to the mask assembly, the utilization rate of the mask frame can be increased to have high layout efficiency, thereby greatly increasing production capacity.

Description

Mask assembly, display panel and display device

[0001] Cross-reference to related applications

[0002] This application claims priority to Chinese Patent Application No. 202411746532.X, filed on November 29, 2024, the disclosure of which is incorporated herein by reference in its entirety. Technical Field

[0003] At least one embodiment of this disclosure relates to a mask assembly, a display panel, and a display device. Background Technology

[0004] Organic light-emitting diode (OLED) displays are the next generation of displays after liquid crystal displays (LCDs), and they have advantages such as wide color gamut, fast response speed, and foldability. Summary of the Invention

[0005] At least one embodiment of this disclosure provides a mask assembly including a mask frame and a plurality of mask sheets. The mask frame includes at least one mask opening and a border portion surrounding the mask opening. The plurality of mask sheets overlap the mask frame. Each mask sheet includes a plurality of vapor deposition areas and a partition portion surrounding the plurality of vapor deposition areas. The plurality of vapor deposition areas of the mask sheet overlap with the mask opening. The mask opening extends along a first direction, and the size of the mask opening in the first direction is larger than its size in a second direction. The first direction intersects the second direction. The mask sheets extend along the first direction, and the size of each vapor deposition area in the first direction is larger than its size in the second direction.

[0006] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the sum of the dimensions of a plurality of vapor-deposited regions located in the mask opening in the first direction is greater than the sum of the dimensions of a plurality of vapor-deposited regions located in the mask opening in the second direction.

[0007] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the minimum distance between the vapor deposition area of ​​the mask sheet and the edge of the mask opening is not greater than the distance between adjacent vapor deposition areas.

[0008] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the minimum distance between the vapor deposition area of ​​the mask sheet and the edge of the mask opening in the first direction is 15 mm to 20 mm, and the minimum distance between the vapor deposition area of ​​the mask sheet and the edge of the mask opening in the second direction is 30 mm.

[0009] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the size of the mask opening in the first direction is 1400 mm to 1600 mm, and the size of the mask opening in the second direction is 800 mm to 1000 mm.

[0010] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the ratio of the size of the mask sheet in the first direction to the size of the mask opening in the first direction is greater than 1 and less than 1.5.

[0011] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the plurality of vapor-deposited regions of the mask sheet are arranged sequentially at intervals in the mask opening, and the ratio between the sum of the dimensions of the plurality of vapor-deposited regions of the mask sheet in the first direction and the dimension of the mask opening in the first direction is greater than 0.5 and less than 1.

[0012] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the ratio between the dimension of the mask sheet in the second direction and the dimension of the mask opening in the second direction is greater than 0.05 and less than 0.6.

[0013] For example, according to at least one embodiment of the present disclosure, the mask sheet includes fixing portions located at both ends of the mask sheet, the fixing portions being fixed to the edge portion of the mask frame, wherein the fixing portion includes a clamping area, the clamping area including a main body portion and a plurality of protrusions, the plurality of protrusions being located on the side of the main body portion away from the mask frame, and the protrusions being connected to the main body portion, the plurality of protrusions being sequentially spaced along the second direction, and the number of the plurality of protrusions in the clamping area being greater than 3.

[0014] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the number of the plurality of protrusions in the clamping area is 3 to 8.

[0015] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, in the second direction, the size of the vapor deposition area of ​​the mask sheet corresponding to the middle portion of the mask sheet in the first direction is larger than the average size of the vapor deposition area.

[0016] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the plurality of vapor deposition regions of the mask sheet are sequentially spaced apart in the first direction, the partition portion of the mask sheet includes a first support portion located between adjacent vapor deposition regions, the mask frame includes a plurality of mask openings, and the mask assembly further includes at least one second support portion located between adjacent mask openings, and at least a portion of the first support portion overlaps with at least a portion of the second support portion.

[0017] For example, in a mask assembly provided according to at least one embodiment of the present disclosure, the first support portion, the second support portion, and the mask frame of the mask sheet are stacked sequentially.

[0018] At least one embodiment of this disclosure provides a display panel, at least a portion of the structure of which is fabricated using a mask assembly as provided in any embodiment of this disclosure.

[0019] For example, a display panel provided according to at least one embodiment of the present disclosure has a size in the first direction that is larger than its size in the second direction, the display panel comprising a plurality of sub-pixels, wherein the spacing between adjacent sub-pixels is not equal in the second direction.

[0020] At least one embodiment of this disclosure provides a display device, which includes a display panel provided in any embodiment of this disclosure. Attached Figure Description

[0021] To more clearly illustrate the technical solutions of the embodiments of this disclosure, the accompanying drawings of the embodiments will be briefly described below. Obviously, the drawings described below only relate to some embodiments of this disclosure and are not intended to limit this disclosure.

[0022] Figure 1 is a schematic diagram of a partial structure of a display panel.

[0023] Figure 2 is a schematic diagram of the mask assembly corresponding to the display panel shown in Figure 1.

[0024] Figure 3 is a partial structural diagram of another type of display panel.

[0025] Figure 4 is a schematic diagram of the mask assembly corresponding to the display panel shown in Figure 3.

[0026] Figure 5 is a schematic diagram of a mask assembly provided in at least one embodiment of the present disclosure.

[0027] Figure 6 is a schematic diagram of the mask frame of the mask assembly shown in Figure 5.

[0028] Figure 7 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure.

[0029] Figure 8 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure.

[0030] Figure 9 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure.

[0031] Figure 10 is a schematic diagram of the mechanical simulation results of a mask assembly provided by at least one embodiment of the present disclosure.

[0032] Figure 11 is a schematic diagram of a mask.

[0033] Figure 12 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure.

[0034] Figure 13 is a schematic diagram of the distribution of multiple sub-pixels in a display panel formed according to the mask assembly in Figure 12.

[0035] Figure 14 is a partial structural schematic diagram of a mask sheet provided in at least one embodiment of the present disclosure.

[0036] Figure 15 is a schematic diagram of the compensation effect of a mask sheet provided in at least one embodiment of the present disclosure.

[0037] Figure 16 is a schematic diagram of a mask sheet provided in at least one embodiment of the present disclosure.

[0038] Figure 17 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure. Detailed Implementation

[0039] To make the objectives, technical solutions, and advantages of the embodiments of this disclosure clearer, the technical solutions of the embodiments of this disclosure will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this disclosure. Based on the described embodiments of this disclosure, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this disclosure.

[0040] Unless otherwise defined, the technical or scientific terms used in this disclosure shall have the ordinary meaning understood by one of ordinary skill in the art to which this disclosure pertains. The terms “first,” “second,” and similar terms used in this disclosure do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as “comprising” or “including” mean that an element or object preceding the word encompasses the elements or objects listed following the word and their equivalents, without excluding other elements or objects.

[0041] The features "perpendicular," "parallel," and "identical" used in this disclosure include features in the strict sense of "perpendicular," "parallel," and "identical," as well as cases where "approximately perpendicular," "approximately parallel," and "approximately identical" include certain errors. Considering measurement and errors associated with the measurement of a specific quantity (i.e., limitations of the measurement system), they represent the acceptable deviation range for a specific value as determined by a person skilled in the art. The "center" in this disclosure can include a strictly geometrically central location and a roughly central location within a small area surrounding the geometrically central location.

[0042] With the continuous development of OLED display technology, users' pursuit of immersive experiences on large-screen displays is becoming increasingly apparent. Larger screens enhance the visual effects of in-vehicle displays and make the interface design and interaction methods of smart cockpits more intuitive and user-friendly. Through large screens, users can more easily browse and select the functions and information they need, thereby improving the quality of the immersive experience.

[0043] As display screen sizes gradually increase, the shipment volume of display panels needs to be continuously increased to meet performance requirements such as higher resolution, wider color gamut, and faster response speed, in order to bring a better visual experience.

[0044] Figure 1 is a partial structural schematic diagram of a display panel; Figure 2 is a schematic diagram of a mask assembly corresponding to the display panel shown in Figure 1.

[0045] For example, as shown in Figure 1, the display panel 01 includes a display area 10 and a bezel area 20. The display area 10 is configured for display, and the bezel area 20 surrounds the display area 10. The display panel 01 also includes a bonding area located on one side of the display area 10, which is an area for connecting a flexible printed circuit (FPC) or a printed circuit board (PCB). For example, the display area 10 is generally rectangular, and the ratio of the dimensions of adjacent first and second edges is approximately 16:9. For example, the first edge of the display area 10 has a dimension of 467 mm, and the second edge has a dimension of 263 mm. For example, the display panel 01 is a 21-inch display panel. For example, the resolution of the display panel 01 is 3840 × 2160 pixels, which can be referred to as 4K resolution or Ultra High Definition (UHD) resolution.

[0046] For example, as shown in FIG2, the mask assembly 010 is used to fabricate the display panel 01 shown in FIG1. ​​For example, the mask assembly 010 includes a mask frame 0100 and multiple mask sheets 0200, which are located on the mask frame 0100 and arranged sequentially at intervals in a first direction X. The opening area of ​​the mask frame 0100 in the first direction X is larger than its size in the second direction Y. For example, the opening area of ​​the mask frame 0100 in the first direction X is 1500 mm, and the opening area of ​​the mask frame 0100 in the second direction Y is 925 mm. For example, the mask sheet 0200 includes a vapor deposition area 0201 for forming the display panel 01, and the size of the vapor deposition area 0201 in the second direction Y is larger than its size in the first direction X. For example, one vapor deposition area 0201 of the mask sheet 0200 is used to form a display panel. Figure 2 only schematically shows the opening area of ​​the mask frame 0100. The border portion of the mask frame 0100 is not shown and is not limited here.

[0047] Figure 3 is a partial structural diagram of another display panel; Figure 4 is a schematic diagram of the mask assembly corresponding to the display panel shown in Figure 3.

[0048] For example, as shown in Figure 3, the difference between display panel 02 and display panel 01 shown in Figure 1 lies in their size and resolution. For example, the size ratio of the adjacent first edge E1 and second edge E2 in display panel 02 is approximately 32.5:9. For example, the size of the first edge E1 of display area 10 is 712 mm, and the size of the second edge E2 is 197 mm. For example, display panel 02 is a 29-inch display panel. For example, the resolution of display panel 02 is 6300 × 1740 pixels.

[0049] For example, as shown in Figure 4, the difference between the mask assembly 020 and the mask assembly 010 shown in Figure 2 is that the size of the vapor deposition area 0201 of the mask sheet 0200 is different, so as to form the display panel 02; the rest of the structure is the same.

[0050] However, as shown in Figures 2 and 4, the longer edge (i.e., the edge extending along the second direction Y) of the vapor deposition area 0201 of the mask 0200 is arranged parallel to the shorter edge (i.e., the edge extending along the second direction Y) of the mask opening 0100. This arrangement results in a smaller total number of vapor deposition areas 0201 in the mask assembly, leading to fewer display panels that can be produced. Therefore, the structural utilization rate of the mask assembly (such as the utilization rate of the mask frame) is low, which in turn leads to lower production capacity and product yield, which is not conducive to reducing manufacturing costs.

[0051] For example, for the display panel shown in Figure 1, when the bonding area is 6.5mm in the first direction X, the number of masks in the corresponding mask assembly is 10, and the mask frame utilization rate is approximately 46.70%; when the bonding area is 4mm in the first direction X, the number of masks in the corresponding mask assembly is 10, and the mask frame utilization rate is approximately 47.64%. For example, for the display panel shown in Figure 3, when the bonding area is 6.5mm in the first direction X, the number of masks in the corresponding mask assembly is 12, and the mask frame utilization rate is approximately 64.59%; when the bonding area is 4mm in the first direction X, the number of masks in the corresponding mask assembly is 12, and the mask frame utilization rate is approximately 66.30%.

[0052] Therefore, it is particularly important to design a mask assembly with high output capacity.

[0053] At least one embodiment of this disclosure provides a mask assembly, including: a mask frame and a plurality of mask sheets. The mask frame includes at least one mask opening and a border portion surrounding the mask opening. The plurality of mask sheets overlap the mask frame. Each mask sheet includes a plurality of vapor deposition areas and a partition portion surrounding the plurality of vapor deposition areas. The plurality of vapor deposition areas of the mask sheet overlap with the mask opening. The mask opening extends along a first direction. The size of the mask opening in the first direction is larger than the size in a second direction, and the first direction intersects the second direction. The mask sheets extend along the first direction, and the size of each vapor deposition area in the first direction is larger than the size of the vapor deposition area in the second direction.

[0054] In at least one embodiment of the mask assembly provided in this disclosure, by arranging the longer edge (i.e., the edge extending along the first direction X) of the evaporation area of ​​the mask sheet parallel to the longer edge (i.e., the edge extending along the first direction X) of the mask opening, this arrangement can result in a larger total number of evaporation areas in the mask assembly, thereby enabling the production of more display panels. This can improve the structural utilization rate of the mask assembly (such as the utilization rate of the mask frame), which in turn helps to significantly increase production capacity and product yield, and reduces manufacturing costs.

[0055] At least one embodiment of this disclosure also provides a display panel, at least a portion of which is fabricated using a mask assembly as provided in any embodiment of this disclosure.

[0056] At least one embodiment of this disclosure also provides a display device, which includes a display panel provided in any embodiment of this disclosure.

[0057] Figure 5 is a schematic diagram of a mask assembly provided in at least one embodiment of the present disclosure; Figure 6 is a schematic diagram of the mask frame of the mask assembly shown in Figure 5.

[0058] As shown in Figures 5 and 6, the mask assembly includes a mask frame 100 and a plurality of mask sheets 200. The mask frame 100 includes at least one mask opening 110 and a border portion 120 surrounding the mask opening 110. For example, at least a portion of the border portion 120 is located outside the mask opening 110. This embodiment is described using a mask assembly including one mask opening 110 as an example, but is not limited thereto. For example, the mask assembly may include a plurality of mask openings 110, with a portion of the border portion 120 between adjacent mask openings 110.

[0059] As shown in Figures 5 and 6, multiple mask sheets 200 are overlapped on the mask frame 100. Each mask sheet 200 includes multiple vapor deposition areas 210 and a partition 220 surrounding the multiple vapor deposition areas 210. The multiple vapor deposition areas 210 of the mask sheet 200 are located in the mask opening 110. Thus, the partition 220 can separate the multiple vapor deposition areas 210.

[0060] For example, a display panel includes a display area and a peripheral area surrounding the display area. The display area includes multiple sub-pixels arranged in an array, such as red sub-pixels emitting red light, green sub-pixels emitting green light, and blue sub-pixels emitting blue light. The display area is configured to display images. For example, each vapor deposition area of ​​the mask corresponds to a main display area, but the embodiments of this disclosure do not limit the specific size of each vapor deposition area. For example, the shape of the vapor deposition area can be set according to the shape of the main display area. For example, multiple vapor deposition areas in the mask can have different shapes, and the embodiments of this disclosure do not limit this. For example, each vapor deposition area of ​​the mask can serve as an opening for forming an encapsulation layer in the display panel. The encapsulation layer can include inorganic materials such as silicon nitride and silicon oxide, and the embodiments of this disclosure do not limit this. For example, each vapor deposition area of ​​the mask can also serve as an opening for forming a common layer in the display panel, such as a hole transport layer, an electron transport layer, or other entire film layer.

[0061] As shown in Figures 5 and 6, the mask opening 110 extends along a first direction X, and the size of the mask opening 110 in the first direction X is larger than its size in the second direction Y, where the first direction X intersects the second direction Y. For example, the mask opening 110 is generally rectangular, but not limited thereto. The mask sheet 200 extends along the first direction X, and the size of each vapor deposition region 210 in the first direction X is larger than its size in the second direction Y. For example, multiple mask sheets 200 are arranged sequentially along the second direction Y. For example, multiple vapor deposition regions 210 located in the mask opening 110 are arranged in an array. Each mask sheet 200 includes at least two vapor deposition regions 210.

[0062] In at least one embodiment of the mask assembly provided in this disclosure, by arranging the longer edge (i.e., the edge extending along the first direction X) of the evaporation area of ​​the mask sheet parallel to the longer edge (i.e., the edge extending along the first direction X) of the mask opening, this arrangement can result in a larger total number of evaporation areas in the mask assembly, thereby enabling the production of more display panels. This can improve the structural utilization rate of the mask assembly (such as the utilization rate of the mask frame), which in turn helps to increase production capacity and product yield, and reduces manufacturing costs.

[0063] For example, as shown in FIG5, the sum of the dimensions of the plurality of vapor deposition regions 210 (10 vapor deposition regions shown in FIG5) located in the mask opening 110 in the first direction X is greater than the sum of the dimensions of the plurality of vapor deposition regions 210 in the mask opening 110 in the second direction Y. For example, the vapor deposition regions 210 are generally rectangular.

[0064] This configuration helps to increase the total number of vapor deposition areas located in the mask openings and improves the utilization rate of the mask frame.

[0065] For example, as shown in Figure 5, the minimum distance L between the vapor deposition area 210 of the mask 200 and the edge of the mask opening 110 is not greater than the distance between adjacent vapor deposition areas 210. For example, the minimum distance L between the vapor deposition area 210 of the mask 200 and the edge of the mask opening 110 is substantially equal to the distance between adjacent vapor deposition areas 210. For example, the minimum distance between the vapor deposition area 210 of the mask 200 and the edge of the mask opening 110 in the first direction X is 15mm to 20mm, such as 15mm to 18mm, 16mm to 19mm, or 17mm to 20mm, but the embodiments of this disclosure are not limited to this. For example, the minimum distance between the vapor deposition area 210 of the mask 200 and the edge of the mask opening 110 in the second direction Y is 30mm, such as 30mm to 35mm, 32mm to 36mm, or 34mm to 38mm, and the embodiments of this disclosure are not limited to this.

[0066] Therefore, while meeting the size requirements of the vapor deposition area, the number of vapor deposition areas located in the mask opening can be increased as much as possible, thereby improving the utilization rate of the mask frame.

[0067] For example, as shown in FIG5, the dimension M1 of the mask opening 110 in the first direction X is 1400mm to 1600mm, such as 1450mm to 1500mm, 1500mm to 1550mm, 1550mm to 1600mm, or other values ​​among 1400mm to 1600mm. The embodiments of this disclosure do not limit this. For example, the dimension M2 of the mask opening 110 in the second direction Y is 800mm to 1000mm, such as 800mm to 850mm, 850mm to 900mm, 950mm to 1000mm, or other values ​​among 800mm to 1000mm. The embodiments of this disclosure do not limit this.

[0068] By ensuring that the dimensions of the mask openings in the first and second directions are within the aforementioned range, it is beneficial to increase the total number of mask openings in a plurality of mask sheets arranged sequentially along the second direction. For example, it can be made greater than the total number of mask openings when the plurality of mask sheets are arranged sequentially along the first direction, thereby improving the utilization rate of the mask frame and thus improving production capacity and product yield.

[0069] For example, as shown in Figure 5, the ratio of the dimension H1 of the mask 200 in the first direction X to the dimension M1 of the mask opening 110 in the first direction X is greater than 1 and less than 1.5. For example, in the first direction X, the dimension H1 of the mask 200 in the first direction X is larger than the dimension of the mask opening 110. For example, the dimension H1 of the mask 200 in the first direction X can be 1500mm to 2000mm, such as at least one of 1500mm to 1600mm, 1600mm to 1700mm, 1700mm to 1800mm, 1800mm to 1900mm, and 1900mm to 2000mm, or other values ​​in the range of 1500mm to 2000mm. The embodiments of this disclosure do not limit this.

[0070] This allows the mask to be large enough in the first direction, and facilitates a large number of vapor deposition areas located in the mask opening, thereby maximizing the utilization of the mask frame.

[0071] For example, as shown in FIG5, a plurality of vapor deposition regions 210 of the mask 200 are arranged sequentially at intervals in the mask opening 110, and the ratio between the sum of the dimensions of the plurality of vapor deposition regions 210 of the mask 200 in the first direction X and the dimension M1 of the mask opening 110 in the first direction X is greater than 0.5 and less than 1. For example, the sum of the dimensions of the plurality of vapor deposition regions 210 of the mask 200 in the first direction X can be 800mm to 1500mm, such as at least one of 800mm to 900mm, 900mm to 1000mm, 1000mm to 1100mm, 1100mm to 1200mm, 1200mm to 1300mm, 1300mm to 1400mm, and 1400mm to 1500mm, or other values ​​in the range of 800mm to 1500mm. The embodiments of this disclosure do not limit this.

[0072] This configuration maximizes the density of multiple vapor deposition areas in the first direction, which in turn increases the number of vapor deposition areas located in the mask opening, thereby improving the utilization rate of the mask frame.

[0073] For example, as shown in FIG5, the ratio between the dimension H2 of the mask 200 in the second direction Y and the dimension M2 of the mask opening 110 in the second direction Y is greater than 0.05 and less than 0.6. For example, the dimension H2 of the mask 200 in the second direction Y can be 50mm to 500mm, such as at least one of 50mm to 100mm, 100mm to 200mm, 200mm to 300mm, 300mm to 400mm, and 400mm to 500mm, or other values ​​in the range of 50mm to 500mm. The embodiments of this disclosure do not limit this.

[0074] This arrangement helps to increase the number of masks arranged in the second direction, thereby increasing the total number of vapor deposition areas located in the mask openings.

[0075] Figure 7 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure.

[0076] For example, compared to the mask assembly shown in Figure 5, the mask assembly in Figure 7 differs in the structure of the mask sheet, while the rest of the structure (e.g., the mask frame) is the same, and will not be described in detail here.

[0077] For example, as shown in Figure 7, the vapor deposition region 210 has a large size in the second direction Y; for example, the mask 200 has a size of 270 mm in the second direction Y. For example, the vapor deposition region 210 has a size of 263 mm in the second direction Y and is used to fabricate a 21-inch display panel.

[0078] For example, compared to the layout shown in Figure 2, in the mask assembly shown in Figure 7, multiple vapor deposition areas 210 in the mask sheet 200 are arranged sequentially at intervals in the first direction X, thereby increasing the total number of vapor deposition areas in the mask opening 110. For example, it can be made greater than the total number in the mask opening when multiple masks are arranged sequentially along the first direction as shown in Figure 2. This can improve the utilization rate of the mask frame, which in turn helps to improve production capacity and product yield.

[0079] For example, for the display panel shown in Figure 5, when the bonding area is 6.5mm in the first direction X, the number of masks in the corresponding mask assembly is 18, and the utilization rate of the mask frame is approximately 80%; when the bonding area is 4mm in the first direction X, the number of masks in the corresponding mask assembly is 18, and the utilization rate of the mask frame is approximately 84% (an improvement of approximately 80%). For example, for the display panel shown in Figure 7, when the bonding area is 6.5mm in the first direction X, the number of masks in the corresponding mask assembly is 16, and the utilization rate of the mask frame is approximately 83%; when the bonding area is 4mm in the first direction X, the number of masks in the corresponding mask assembly is 16, and the utilization rate of the mask frame is approximately 86% (an improvement of approximately 33%).

[0080] Therefore, the layout method in the mask assembly provided by the embodiments of this disclosure can effectively increase the number of mask sheets and significantly improve the utilization rate of the mask frame.

[0081] Figure 8 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure.

[0082] For example, as shown in Figure 8, the mask 200 includes fixing portions 230 located at both ends of the mask 200, which are fixed to the frame portion 120 of the mask frame 100. For example, the fixing portion 230 of the mask 200 can be the part of the mask 200 located outside the mask opening 110. The fixing portion 230 of the mask 200 can cooperate with and be fixed to the frame portion 120 of the mask frame 100. It should be noted that Figure 8 only schematically shows the cooperation relationship between the components and does not represent their actual dimensions. The specific dimensions can be set according to the actual design requirements.

[0083] For example, as shown in FIG8, the fixing part 230 includes a clamping area 2310, which includes a main body 2301 and a plurality of protrusions 2302. The plurality of protrusions 2302 are located on the side of the main body 2301 away from the mask opening 110, and the protrusions 2302 are connected to the main body 2301. For example, the plurality of protrusions 2302 and the main body 2301 can be an integral structure. The plurality of protrusions 2302 are arranged sequentially at intervals along the second direction Y, and the number of the plurality of protrusions 2302 in the clamping area 2310 is greater than 3. For example, the number of protrusions 2302 can be 2 to 8, such as 2 to 4, 3 to 5, 4 to 6, or 5 to 8, and the embodiments of this disclosure are not limited thereto. For example, when the mask sheet is stretched and placed on the mask frame, it can be clamped on the plurality of protrusions by a clamping device.

[0084] This configuration can increase the tensile stress of the mask sheet through multiple protrusions in the clamping area, thereby reducing the sag of the mask sheet. For example, it can also reduce the shrinkage of the mask sheet in the second direction, which helps to ensure that the product formed using the mask sheet meets the target size.

[0085] For example, as shown in FIG8, the fixing part 230 also includes a transition region 2320, which is located on the side of the main body 2301 away from the protrusion 2302. For example, the provision of the transition region 2320 can balance the stress between the clamping region 2310 and the portion of the mask sheet 200 located in the mask opening 110, so as to further reduce the deformation of the mask sheet.

[0086] Figure 9 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure.

[0087] For example, as shown in FIG9, the clamping area 2310 of the mask assembly includes a main body 2301 and a plurality of protrusions 2302, which are located on the side of the main body 2301 away from the mask opening 110. The size of the protrusions 2302 in the first direction X is larger than the size of the main body 2301 in the first direction X, and the number of protrusions 2302 in the clamping area 2310 is 6. For example, the vapor deposition area 210 of the mask sheet 200 includes a plurality of vapor deposition openings 2101, which are configured to form a material layer for sub-pixels in the display panel.

[0088] By making the size of the protrusion in the first direction larger than the size of the main body, and by connecting the protrusion directly to the part of the mask located in the mask opening through the main body, the stress of the mask can be balanced directly through multiple protrusions. In addition, since the number of protrusions is large, the ability to balance the force can be further enhanced during the clamping process of the protrusions at different positions, and the risk of deformation such as inward shrinkage of the mask in the second direction can be reduced.

[0089] Figure 10 is a schematic diagram of the mechanical simulation results of a mask assembly provided by at least one embodiment of the present disclosure.

[0090] For example, as shown in Figure 10, the clamping area of ​​this mask assembly includes four protrusions. The stress in the central region of the mask sheet located at the mask opening is relatively high, while the stress gradually decreases from the central region to the edge region. Under this design, the sag force in the aforementioned central region is relatively small, approximately 1 N. Therefore, increasing the number of protrusions in the clamping area helps to make the stress distribution of the mask sheet more uniform, thereby reducing sag. For example, the area where the mask opening is located can be considered the effective area of ​​the mask frame.

[0091] Therefore, it can be seen that the number of protrusions in the clamping area of ​​the mask sheet provided in the embodiments of this disclosure is greater than 3, for example, 3 to 8, so as to reduce the sag of the mask sheet while balancing the stress distribution.

[0092] For the structure of the mask assembly in Figure 10, please refer to the relevant description of Figure 8 in the above embodiments, which will not be repeated here.

[0093] Figure 11 is a schematic diagram of a mask.

[0094] As shown in Figure 11, after the mask is stretched, the first edge 210-1 and the second edge 210-2 of the vapor deposition area of ​​the mask extending along the first direction X may shrink inward. For example, the first edge 210-1 may change into the third edge 210-3, and the second edge 210-2 may change into the fourth edge 210-4. In this case, in the display panel formed by the mask, some sub-pixels (e.g., sub-pixels located in the middle in the first direction X) have a smaller spacing in the second direction Y, while multiple sub-pixels near the protrusion 2302 of the mask 200 have a larger spacing in the second direction Y, thereby affecting the uniformity of the display effect of the display panel.

[0095] Figure 12 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure. Figure 13 is a schematic diagram of the distribution of a plurality of sub-pixels in a display panel formed according to the mask assembly in Figure 12.

[0096] For example, as shown in FIG12, in this mask assembly, the mask sheet 200 extends along a first direction X and includes two vapor deposition regions 210 spaced apart along the first direction X. For example, each vapor deposition region 210 corresponds to a display panel. For example, FIG12 also schematically shows region B located in the middle of the vapor deposition region 210, and regions A and C located at opposite ends of the vapor deposition region 210 in the first direction X.

[0097] For example, as shown in Figures 12 and 13, after the mask 200 is set, regions A, B, and C in the vapor deposition region 210 have different degrees of inward shrinkage. For example, the edge portions of vapor deposition region 210 corresponding to region A and region C are closer to the target curve, while the edge portion of vapor deposition region 210 corresponding to region B moves away from the target curve in a direction away from the center of vapor deposition region 210. For example, there is a shaded area S between the edge of vapor deposition region 210 and the target curve, and the portions of shaded area S corresponding to regions A, B, and C have different dimensions in the second direction Y. For example, the dimensions of the portions of shaded area S corresponding to regions A and C in the second direction Y are smaller than the dimensions of the portion corresponding to region B in the second direction Y.

[0098] For example, as shown in Figure 13, in region B, the spacing between adjacent sub-pixels in the same row along the second direction Y is non-uniformly distributed. For example, the spacing between adjacent sub-pixels in the middle is smaller, while the spacing between adjacent sub-pixels near the edge is larger, which may affect the display uniformity of the display panel.

[0099] Figure 14 is a partial structural schematic diagram of a mask sheet provided in at least one embodiment of the present disclosure.

[0100] For example, as shown in FIG14, in the second direction Y, the dimension P1 of the vapor deposition region 210 of the mask 200 corresponding to the middle of the mask 200 in the first direction X is larger than the average dimension of the vapor deposition region 210. For example, the first edge 210-1 and the second edge 210-2 of the vapor deposition region 210 both protrude relative to a direction away from its centerline C extending along the first direction X, thereby making the dimension P1 of the middle of the vapor deposition region 210 larger.

[0101] With this configuration, when the mask shrinks inward after being stretched, the deformation of the first and second edges of the vapor deposition area can be compensated. For example, the first and second edges can be made to extend as far as possible along the first direction after deformation, so as to get closer to the target position. This allows adjacent sub-pixels in the display panel formed by the mask to maintain a uniform distance in the second direction, thereby improving display uniformity.

[0102] Figure 15 is a schematic diagram of the compensation effect of a mask sheet provided in at least one embodiment of the present disclosure.

[0103] For example, as shown in Figure 15, before the mask shrinks inward, the first edge 210-1 and the second edge 210-2 of its vapor deposition region 210 can serve as compensation curves. After the mask shrinks inward after being stretched, the first edge 210-1 moves to the third edge 210-3, and the second edge 210-2 moves to the fourth edge 210-4. For example, the third edge 210-3 and the fourth edge 210-4 can substantially coincide with the target position to serve as the target curve.

[0104] Therefore, by making the central part of the vapor deposition area larger, it is beneficial to compensate for the deformation of the vapor deposition area of ​​the mask, so that the vapor deposition area obtained after deformation is more in line with the design goal.

[0105] In some embodiments of this disclosure, depending on the position of the vapor deposition area in the mask, the portion of the vapor deposition area other than the middle portion in the first direction may have a larger size in the second direction, so as to specifically compensate for the deformation at different positions of the vapor deposition area. The embodiments of this disclosure do not limit this.

[0106] Figure 16 is a schematic diagram of a mask sheet provided in at least one embodiment of the present disclosure; Figure 17 is a schematic diagram of another mask assembly provided in at least one embodiment of the present disclosure.

[0107] For example, as shown in Figure 16, multiple vapor deposition areas 210 of the mask 200 are arranged sequentially at intervals in the first direction X, and the partition portion 220 of the mask 200 includes a first support portion 2201 located between adjacent vapor deposition areas 210. The provision of the first support portion can reduce the sag of the mask and enhance the strength of the mask, thereby making it easier for the size of the vapor deposition area to better meet the design requirements.

[0108] For example, as shown in FIG17, the mask frame 100 includes a plurality of mask openings 110, and the mask assembly further includes at least one second support portion 2202, which is located between adjacent mask openings 110. At least a portion of the first support portion 2201 overlaps with at least a portion of the second support portion 2202. For example, the border portion 120 of the mask frame 100 includes a portion extending in the same direction as the second support portion 2202, and the second support portion 2202 can overlap this portion of the border portion 120. The first support portion 2201 of the mask sheet 200 is located on the side of the second support portion 2202 away from the border portion 120. That is, the first support portion 2201, the second support portion 2202 of the mask sheet 200, and the mask frame 100 are stacked sequentially.

[0109] By providing a second support between the first support and the mask frame, the mask can be further supported, thereby further reducing the sag of the mask.

[0110] In some embodiments, referring to FIG17, the second support portion 2202 may be a part of the frame portion 120. The extension direction of the first support portion 2201 and the extension direction of the second support portion 2202 are the same. The second support portion 2202 may provide stable support for the first support portion 2201 to reduce the sag of the mask sheet 200.

[0111] For example, as shown in FIG17, the mask assembly may include a plurality of second support portions 2202. For example, a second support portion 2202 is provided between adjacent vapor deposition regions 210. For example, a first support portion 2201 located between adjacent vapor deposition regions 210 has a first dimension N1 perpendicular to its extending direction, and a second support portion 2202 overlapping the first support portion 2201 and extending in the same direction has a second dimension N2, and the second dimension N2 is smaller than the first dimension N1.

[0112] This design helps to reduce the impact of the second support on the area of ​​the evaporation zone of the mask, thereby improving the utilization rate of the mask frame.

[0113] At least one embodiment of this disclosure also provides a display panel, at least a portion of which is fabricated using a mask assembly provided in any embodiment of this disclosure, thereby providing the display panel with the technical effects of the mask assembly described in any of the above embodiments corresponding to the display panel.

[0114] For example, referring to Figure 12, at least one film layer of the display panel, such as at least one film layer in the light-emitting functional layer, can be fabricated according to a mask assembly.

[0115] For example, referring to Figures 12 and 13, the size of the display panel in the first direction X is larger than its size in the second direction Y. The display panel includes multiple sub-pixels, and the spacing between adjacent sub-pixels in the second direction Y is not equal. For example, referring to Figure 11, in the actual process, the vapor deposition area of ​​the mask 200 may shrink to different degrees. After compensation using the mask 200 provided in the embodiments of this disclosure (for example, please refer to Figure 14), the size of the vapor deposition area may be very close to the target size. However, under the condition of meeting the process design requirements, it is inevitable that there will still be a certain deviation from the target size. Therefore, the spacing between the multiple sub-pixels in the display panel formed by the vapor deposition area in the second direction Y is non-uniform. For example, in multiple display panels formed by the mask assembly, the spacing between adjacent sub-pixels in at least one display panel is not equal in the second direction Y. The embodiments of this disclosure do not limit this.

[0116] The mask provided in the embodiments of this disclosure employs a compensation structure (see Figure 14), which effectively improves the spacing between multiple sub-pixels in the formed display panel, resulting in good uniformity and thus improving the quality of the displayed image.

[0117] At least one embodiment of this disclosure also provides a display device, which includes a display panel provided in the embodiments of this disclosure (e.g., the display panel described in the above embodiments). Therefore, the technical effects of the aforementioned display panel can also be reflected in this display device, and will not be repeated here.

[0118] For example, the display device can be an organic light-emitting diode display device or other display device, as well as any product or component with display function, such as a television, digital camera, mobile phone, watch, tablet computer, laptop computer, or navigator that includes the display device. This embodiment is not limited to this.

[0119] The following points need to be explained:

[0120] (1) The accompanying drawings of the embodiments of this disclosure only involve the structures involved in the embodiments of this disclosure, and other structures can be referred to the general design.

[0121] (2) Where there is no conflict, features of the same embodiment and different embodiments of this disclosure may be combined with each other.

[0122] The above description is merely an exemplary embodiment of this disclosure and is not intended to limit the scope of protection of this disclosure, which is determined by the appended claims.

Claims

1. A mask assembly, comprising: A mask frame includes at least one mask opening and a border portion surrounding the mask opening; as well as Multiple photomasks are overlapped on the photomask frame; Each of the aforementioned masks includes multiple vapor deposition areas and a partition surrounding the multiple vapor deposition areas, wherein the multiple vapor deposition areas of the mask overlap with the mask opening. The mask opening extends along a first direction, the size of the mask opening in the first direction is larger than the size in the second direction, and the first direction intersects the second direction. The mask extends along the first direction, and the size of each of the vapor deposition areas in the first direction is larger than the size of the vapor deposition area in the second direction.

2. The mask assembly according to claim 1, wherein, The sum of the dimensions of the plurality of vapor deposition regions located in the mask opening in the first direction is greater than the sum of the dimensions of the plurality of vapor deposition regions located in the mask opening in the second direction.

3. The mask assembly according to claim 1 or 2, wherein, The minimum distance between the vapor deposition area of ​​the mask and the edge of the mask opening is no greater than the distance between adjacent vapor deposition areas.

4. The mask assembly according to claim 3, wherein, The minimum distance between the vapor deposition area of ​​the mask and the edge of the mask opening in the first direction is 15mm to 20mm, and the minimum distance between the vapor deposition area of ​​the mask and the edge of the mask opening in the second direction is 30mm.

5. The mask assembly according to any one of claims 1-4, wherein, The size of the mask opening in the first direction is 1400mm to 1600mm, and the size of the mask opening in the second direction is 800mm to 1000mm.

6. The mask assembly according to any one of claims 1-5, wherein, The ratio of the size of the mask sheet in the first direction to the size of the mask opening in the first direction is greater than 1 and less than 1.

5.

7. The mask assembly according to any one of claims 1-6, wherein, The plurality of vapor deposition areas of the mask are arranged sequentially at intervals in the mask opening, and the ratio between the sum of the dimensions of the plurality of vapor deposition areas of the mask in the first direction and the dimension of the mask opening in the first direction is greater than 0.5 and less than 1.

8. The mask assembly according to any one of claims 1-7, wherein, The ratio between the dimension of the mask sheet in the second direction and the dimension of the mask opening in the second direction is greater than 0.05 and less than 0.

6.

9. The mask assembly according to any one of claims 1-8, wherein, The mask includes fixing portions located at both ends of the mask, and the fixing portions are fixed to the edge portion of the mask frame. The fixing part includes a clamping area, which includes a main body and a plurality of protrusions. The plurality of protrusions are located on the side of the main body away from the mask opening and are connected to the main body. The plurality of protrusions are arranged at intervals along the second direction, and the number of the plurality of protrusions in the clamping area is greater than 3.

10. The mask assembly according to claim 9, wherein, The number of the plurality of protrusions in the clamping area is 3 to 8.

11. The mask assembly according to any one of claims 1-5, wherein, In the second direction, the size of the vapor deposition area of ​​the mask corresponding to the center of the mask in the first direction is larger than the average size of the vapor deposition area.

12. The mask assembly according to any one of claims 1-5, wherein, The plurality of vapor deposition areas of the mask are arranged at intervals in the first direction, and the separating portion of the mask includes a first support portion located between adjacent vapor deposition areas. The mask frame includes a plurality of mask openings, and the mask assembly further includes at least one second support portion located between adjacent mask openings, wherein at least a portion of the first support portion overlaps with at least a portion of the second support portion.

13. The mask assembly according to claim 12, wherein, The first support portion, the second support portion, and the mask frame of the mask sheet are stacked in sequence.

14. A display panel, wherein, At least a portion of the structure of the display panel is fabricated using a mask assembly as described in any one of claims 1-13.

15. The display panel according to claim 14, wherein, The display panel is larger in size in the first direction than in size in the second direction. The display panel includes a plurality of sub-pixels, and the spacing between adjacent sub-pixels is not equal in the second direction.

16. A display device comprising the display panel as described in claim 14 or 15.

Images