Evaporation Mask Layout for OLED Display Panels
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Solution Overview
Problem
Current mask structures for organic material functional layers in OLED displays have low layout density, leading to inefficient utilization of the evaporation substrate and reduced production of display panels.
Innovation Solution
A method of mask layout that includes a frame with preset areas, positioning areas, and fixed areas, where the evaporation mask is accurately placed and fixed according to specific distances and conditions, reducing the gap between adjacent masks and improving masking accuracy, allowing for a higher number of masks in a mask assembly and increased yield of display panels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mask structure uses conventional layout with larger gaps between masks, then the masking accuracy is maintained, but the layout density is low and production efficiency is reduced
Solution Approach 1:
The mask assembly is segmented into multiple independent mask units, each with its own positioning and fixation areas. This segmentation allows for precise control of each mask while maintaining high overall density. The frame is divided into multiple fixed areas that can independently hold masks at optimized positions.
Solution Approach 2:
Positioning areas are pre-defined in the frame structure before mask installation. These positioning areas include positioning holes and fixation features that are prepared in advance, ensuring that masks can be quickly and accurately positioned without requiring complex alignment procedures during assembly.
2Productivity
If the gap between adjacent masks is reduced to increase layout density, then more panels can be produced, but the masking accuracy may be compromised
Solution Approach 1:
Positioning areas act as intermediary structures between adjacent masks, providing physical references and fixation points that ensure precise spacing. The positioning holes and fixation features in these intermediary areas maintain consistent gaps while enabling tight packing of mask units.
Solution Approach 2:
The distance parameters between masks are precisely controlled and standardized. By defining specific distance relationships in the positioning areas and fixed areas, the system achieves optimal balance between gap size and layout density, allowing maximum number of masks per frame while maintaining required masking precision.
3Manufacturing precision
If more positioning and fixation features are added to improve masking accuracy, then the manufacturing complexity increases
Solution Approach 1:
The positioning areas serve multiple functions simultaneously: they provide positioning references, fixation points, and spacing control. The fixation areas integrate both positioning and securing functions. This multi-functionality reduces the need for separate complex positioning and fixation mechanisms for each mask.
Solution Approach 2:
Different regions of the frame structure have different properties optimized for their specific functions. Positioning areas have precise geometric features for alignment, while fixation areas have structural features for secure mounting. This localized optimization achieves high overall precision without requiring the entire structure to be equally complex.
Data Source
AI summary
The present disclosure relates to a method of a mask layout, including: providing a frame with preset areas arranged at intervals, a positioning area between two adjacent preset areas, and a fixed area provided to offset from the positioning area and each of the preset areas, and a distance between two adjacent preset areas being a first predetermined distance L1; providing a cover mask corresponding to the positioning area, and a distance between an edge of the cover mask and the center of the positioning area being a second predetermined distance L2; and providing an evaporation mask on the fixed area according to preset conditions, a distance between two adjacent fixed areas being a third predetermined distance L3, and the third predetermined distance L3 being equal to a difference between the first predetermined distance L1 and the second predetermined distance L2.