Deposition Mask Indentation Prevents OLED Organic Film Damage
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Solution Overview
Problem
The existing deposition masks for organic light emitting displays (OLEDs) can damage the organic film by contacting already deposited emission layers during the manufacturing process, leading to chemical transitions and defects in the final product, particularly due to the vulnerability of the organic film to moisture and the risk of particles falling on light emission regions.
Innovation Solution
A deposition mask with a planar portion and an indentation on the side facing the substrate, which prevents contact with the already deposited organic emission layer, ensuring that only the opening contacts the substrate, thereby avoiding damage and chemical transitions, and is designed to be manufactured using a simple method that does not require additional processes, improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a deposition mask is used to deposit organic emission layers in separate colors, then full color display is achieved, but the blocked-off portions of the mask contact and damage the already deposited organic film
Solution Approach 1:
The patent introduces a vertical dimension by forming an indentation (recess) in the mask structure. This dimensional change creates a spatial separation where the mask's blocked-off portions are positioned at a lower level than the deposited organic film, preventing contact while maintaining the mask's patterning function for full color display
Solution Approach 2:
The indentation acts as an intermediary space between the mask and the organic film. This intermediate structure allows the mask to perform its blocking function while the recessed portion prevents direct contact with the organic emission layers, thereby protecting the film from damage
2Manufacturing precision
If photolithography is used to pattern the first electrode, then precise patterning is achieved, but the organic film is exposed to moisture during resist exfoliation or etching
Solution Approach 1:
The patent extracts the patterning function from the photolithography process that exposes the organic film to moisture. Instead, a deposition mask is used to define the patterns of subsequent layers, eliminating the need for photolithography steps that would require moisture exposure and protect the organic film throughout the manufacturing process
3Adaptability or versatility
If separate masks are used for each color (red, green, blue), then independent deposition is achieved, but the manufacturing process complexity increases
Solution Approach 1:
The patent merges multiple separate color-specific masks into a single integrated deposition mask. This unified mask contains all the necessary opening patterns for red, green, and blue emission layers, allowing independent color deposition while simplifying the mask system and reducing manufacturing complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively prevents damage to the organic film and chemical transitions, ensuring the integrity of the OLEDs while simplifying the manufacturing process and enhancing productivity by ensuring the mask does not touch the already deposited emission layers, thus maintaining the quality and reliability of the organic light emitting displays.
Implementation Method 1
the organic film and the second electrode layer may be manufactured by vacuum deposition using a mask having a predetermined pattern
Data Source
AI summary
A deposition mask for manufacturing an organic light emitting display (OLED) using the same are provided. The deposition mask is intended for preventing an organic film from being damaged due to touching of a blocked-off portion of the mask to an emission layer (EML), or chemical transition from being generated at the organic film. For that purpose, the deposition mask stuck to a substrate of the OLED to deposit an organic EML includes an opening and an indentation. The opening is opened so as to deposit the organic EML. The indentation is indented a predetermined depth from a plane facing the substrate.