Display Panel Spacer Layout for Mask Alignment and Emission Area
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Solution Overview
Problem
Existing display panels face challenges in manufacturing yield and reliability due to issues with spacer placement and mask alignment during the deposition of light emitting layers.
Innovation Solution
A display panel design featuring a first and second spacer with protruding portions arranged between them, allowing for increased area for emission areas and reducing spacer density, thereby improving mask alignment and reducing manufacturing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If spacers are placed densely to support the mask during deposition, then mask alignment is improved, but the area available for emission areas is reduced and manufacturing defects increase
Solution Approach 1:
The mask support function is segmented between two types of structures: spacers positioned at pixel boundaries and protruding portions positioned at emission area boundaries. This segmentation allows spacers to be spaced farther apart (reducing their density) while still maintaining proper mask alignment through the combined support system of both spacers and protruding portions.
Solution Approach 2:
Protruding portions serve as intermediary structures that work in conjunction with spacers to support the mask. The protruding portions are positioned between the spacers and the emission areas, providing additional mask support without requiring the spacers to be densely placed, thus preserving emission area while maintaining alignment precision.
2Manufacturing precision
If spacers are placed densely to support the mask during deposition, then mask alignment is improved, but manufacturing yield and reliability deteriorate due to increased defects
Solution Approach 1:
The mask support function is divided between spacers and protruding portions, allowing spacers to be spaced farther apart. This reduced spacer density minimizes the number of potential defect sites while the protruding portions provide complementary support, maintaining alignment precision and improving manufacturing yield.
Solution Approach 2:
Different structures serve different local functions: spacers are positioned at pixel boundaries to provide structural support, while protruding portions are positioned at emission area boundaries to provide localized mask support. This localized differentiation allows each structure to optimize its function while reducing overall defect density.
3Manufacturing precision
If spacers are placed close together to support the mask, then mask alignment during deposition is improved, but the lifespan of emission areas is reduced
Solution Approach 1:
The mask support function is segmented between spacers and protruding portions, allowing spacers to be spaced farther apart. This increased spacing reduces stress concentration and extends the operational lifespan of emission areas while maintaining alignment precision through the combined support system.
Solution Approach 2:
Protruding portions act as intermediary support structures that reduce the burden on spacers. By positioning protruding portions between spacers and emission areas, the system distributes mechanical stress more evenly, extending emission area lifespan while maintaining mask alignment through the combined support mechanism.
Data Source
AI summary
A display panel, in which a plurality of first emission areas, a plurality of second emission areas, and a plurality of third emission areas are defined, includes a first spacer spaced apart from one of the plurality of third emission areas in a first direction, a second spacer spaced apart from the first spacer in the first direction, and a plurality of protruding portions spaced apart from the plurality of third emission areas in a second direction crossing the first direction, wherein m third emission areas (m is an integer greater than or equal to 4) among the plurality of third emission areas are between the first spacer and the second spacer.