Donor Mask Light-to-Heat Conversion Layer for OLED Emission Transfer
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Solution Overview
Problem
The manufacturing of organic light-emitting display apparatuses faces inefficiencies due to complex processes and excessive material usage in forming the emission layer, particularly in aligning and transferring layers accurately.
Innovation Solution
A donor mask with a base substrate, a light-to-heat conversion layer, and a reflection layer having varying thickness regions and alignment marks is used to efficiently transfer and align layers, allowing for precise deposition of the emission layer using a flash lamp or laser beam, thereby optimizing material usage and simplifying the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a general method is used to form the emission layer, then the emission layer can be formed, but the process becomes complex and excessive materials are used
Solution Approach 1:
The emission layer materials are pre-deposited on a donor mask substrate before the actual display apparatus assembly. This preliminary action allows the emission layer to be formed in advance and transferred later, simplifying the overall process and reducing material waste by enabling precise positioning and reuse of the donor mask.
Solution Approach 2:
A donor mask is introduced as an intermediary component to hold and transfer the emission layer materials. The donor mask acts as a mediator between the material deposition process and the final display apparatus assembly, enabling controlled transfer of materials and reducing direct material loss during the formation process.
2Object-affected harmful factors
If the reflection layer has greater thickness, then light blocking ability improves, but light transmittance decreases
Solution Approach 1:
The reflection layer is designed with spatially varying thickness: thicker regions in non-transfer areas provide strong light blocking, while thinner regions in transfer areas allow controlled light transmission. This local variation in thickness enables simultaneous optimization of both light blocking ability and light transmittance in different functional zones of the donor mask.
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
This method significantly increases material usage efficiency by allowing the transfer layer to be reused multiple times and reduces material waste, while ensuring accurate alignment and deposition of emission layers, thus streamlining the production of organic light-emitting display apparatuses.
Implementation Method 1
a light to heat conversion layer provided on the base substrate
Implementation Method 2
irradiating a flash lamp or a laser beam onto the base substrate of the donor mask, and evaporating, vaporizing, or sublimating the part of the transfer layer where the flash lamp or laser beam is irradiated
Implementation Method 3
irradiating a flash lamp or a laser beam onto the base substrate of the donor mask
Implementation Method 4
a reflection layer disposed between the base substrate and the light to heat conversion layer
Data Source
AI summary
A method of manufacturing an organic light emitting display apparatus using a donor mask. The donor mask includes a base substrate, a light to heat conversion layer provided on the base substrate, and a reflection layer disposed between the base substrate and the light to heat conversion layer and comprising a through hole corresponding to a first transfer region, a non-transfer region having a first thickness and a second transfer region having a second thickness smaller than the first thickness, and the organic light emitting display apparatus using the same.