Display Panel Emission Layer Uniformity via Segmented Mask Alignment
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Solution Overview
Problem
Current methods for manufacturing display panels face challenges in uniformly forming emission layers across varying substrate sizes and shapes, leading to inefficiencies in aperture ratio and production complexity.
Innovation Solution
A method involving a substrate with alignmarks and a mask with specific pattern parts is used to form first and second emission layers on divided substrate regions, allowing for precise alignment and uniform coating, even on substrates with different sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single mask is used to form emission layers on the entire substrate, then the process is simple, but uniformity of emission layer formation across varying substrate sizes and shapes deteriorates
Solution Approach 1:
The substrate is divided into multiple regions (first region and second region), and a single mask is sequentially positioned on different regions to form emission layers. This segmentation approach maintains process simplicity while achieving uniform emission layer formation across varying substrate sizes and shapes by treating each region individually with precise alignment.
2Manufacturing precision
If multiple masks are used to form emission layers on different substrate regions, then emission layer uniformity improves, but device complexity increases
Solution Approach 1:
A single mask is designed to serve multiple functions by being sequentially positioned on different regions of the substrate. The mask forms emission layers for both the first region and the second region, eliminating the need for multiple dedicated masks while maintaining uniformity. This multi-functional approach reduces device complexity while preserving manufacturing precision.
3Area of stationary object
If large masks are used to cover entire substrates, then complete coverage is achieved, but space usability in manufacturing equipment deteriorates
Solution Approach 1:
Instead of using one large mask to cover the entire substrate, the substrate is divided into multiple regions that are processed sequentially with a smaller mask. This segmentation reduces the mask size, improving space usability in manufacturing equipment while maintaining complete coverage of the substrate through multiple positioning steps.
4Measurement precision
If alignment marks are increased for precise positioning, then alignment precision improves, but manufacturing complexity increases
Solution Approach 1:
Multiple alignment marks (at least five, including corner and center regions) are integrated into a unified alignment system that works together to achieve precise positioning. The alignment marks are combined with the mask design and substrate structure, creating a cohesive alignment approach that improves precision without proportionally increasing manufacturing complexity.
Data Source
AI summary
A method of manufacturing a display panel includes forming a pixel-defining layer on a substrate, disposing a mask on the pixel-defining layer on a first region of the substrate, and forming a first emission layer, and disposing the mask on the pixel-defining layer on a second region of the substrate, and forming a second emission layer.