Angled Mask Plate Openings for Stronger Pixel Evaporation
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Solution Overview
Problem
The increasing density of pixel openings in display panel manufacturing challenges the strength of mask plates, leading to precision issues and uneven color development during the evaporation process, as conventional methods to enhance strength are limited and difficult to implement effectively.
Innovation Solution
The mask plate design features second openings arranged at a predetermined angle θ to the horizontal or vertical direction, increasing the area between openings and distributing connecting stress evenly, thereby enhancing the mask plate's strength without altering opening density or shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional mask plate with flat surface is used, then the structure is simple and manufacturing is easy, but particles settle on the bottom surface causing defects in the lower portion of the display panel
Solution Approach 1:
The mask plate employs an asymmetric convex structure where the upper surface has a different curvature radius than the lower surface. The upper surface has a smaller curvature radius than the lower surface, creating an inclined profile that prevents particle settlement while maintaining structural feasibility. This asymmetric design ensures uniform particle distribution and thin film formation across the coating area.
Solution Approach 2:
The mask plate features convex curved surfaces on both the upper and lower surfaces, replacing the conventional flat surface. The upper surface has a first curvature radius and the lower surface has a second curvature radius, with the upper surface having a smaller curvature radius. This curvature design prevents particles from settling on the bottom surface while enabling uniform coating material deposition.
2Strength
If the curvature radius of the mask plate is increased to reduce stress concentration, then stress is reduced, but the mask plate strength decreases
Solution Approach 1:
The mask plate uses asymmetric curvature radii where the upper surface has a smaller curvature radius and the lower surface has a larger curvature radius. This asymmetric configuration balances stress distribution - the larger lower curvature radius reduces stress concentration at the bottom, while the overall convex structure maintains sufficient structural strength.
Solution Approach 2:
The convex curved surfaces on the mask plate reduce stress concentration compared to sharp edges or flat surfaces with abrupt transitions. The smooth curvature distributes stress more evenly across the mask plate structure, preventing stress concentration while maintaining adequate strength through optimized curvature radius selection.
3Manufacturing precision
If the curvature radius of the mask plate is decreased to improve coating uniformity, then coating uniformity improves, but stress concentration increases
Solution Approach 1:
The mask plate employs different curvature radii for the upper and lower surfaces to simultaneously achieve coating uniformity and stress reduction. The upper surface has a smaller curvature radius that ensures uniform coating material deposition and particle distribution, while the lower surface has a larger curvature radius that reduces stress concentration, resolving the trade-off between coating quality and structural integrity.
Data Source
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AI summary
A display panel and a mask plate for fabricating the display panel. The mask plate (100) includes a plurality of through holes (110) spaced apart from each other; a first surface (200); and a second surface (300) opposite to the first surface (200). The through hole (110) forms a first opening (210) on the first surface (200), and the through hole (110) forms a second opening (310) on the second surface (300). An area of the second opening (310) is larger than an area of the first opening (210). The second openings (310) are arranged in parallel in a first predetermined direction. The first predetermined direction is at a predetermined angle to a horizontal direction or a vertical direction of the mask plate (100), and the predetermined angle does not include 90°.