Patterned Mask for Flexible Display Encapsulation
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Solution Overview
Problem
The challenge in manufacturing flexible display apparatuses lies in achieving uniform coating of the organic layer on the inorganic layer, which affects the performance of the thin film encapsulation layer, particularly in the stack structure of the inorganic and organic layers used in portable electronic devices.
Innovation Solution
The apparatus and method involve a deposition gas supplying unit and masks with specific openings to form patterned inorganic layers on the substrate, followed by the deposition of lithium fluoride and organic layers using inkjet printing, ensuring uniform coverage and improved encapsulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a thin film encapsulation layer is used to implement flexible display apparatus, then the display can be bent to have a certain angle in a flat state, but the performance of the encapsulation layer deteriorates due to non-uniform coating of the organic layer on the inorganic layer
Solution Approach 1:
The mask is divided into multiple separate opening portions corresponding to different pixel regions (red, green, blue sub-pixels). Each opening portion is independently positioned and sized to match the specific geometry of the underlying inorganic layer patterns, allowing precise control of deposition material distribution across the flexible substrate
Solution Approach 2:
Different regions of the mask have different opening sizes, shapes, and positions tailored to the local requirements of each pixel region. The first opening portion for red sub-pixels, second opening portion for green sub-pixels, and third opening portion for blue sub-pixels are each optimized for their respective local areas, ensuring uniform coating thickness despite the flexible substrate's curvature
2Reliability
If the organic layer is coated on the inorganic layer in a stack structure, then the thin film encapsulation layer is formed, but non-uniform coating occurs due to the stacked configuration affecting material distribution
Solution Approach 1:
The mask is pre-configured with opening portions positioned exactly over the inorganic layer patterns before deposition begins. The mask openings are designed in advance to match the pixel electrode and emission layer geometries, ensuring that material is deposited only where needed and with uniform thickness across the stacked inorganic-organic layer structure
Solution Approach 2:
The mask serves as an intermediary component between the deposition source and the stacked inorganic-organic layers. It mediates the material distribution by allowing deposition flux to pass through its openings, creating uniform coating on the underlying stack structure while preventing deposition in unwanted areas
3Adaptability or versatility
If multiple pixel regions with different sub-pixels are present on the substrate, then various colors can be displayed, but the mask structure becomes complex requiring multiple opening portions for each pixel region
Solution Approach 1:
The mask is segmented into multiple opening portions (first, second, third opening portions) corresponding to red, green, and blue sub-pixels respectively. Each segment is positioned and sized independently to match its corresponding sub-pixel region, allowing the mask to handle complex multi-color display requirements through modular segmentation rather than a single complex opening
Solution Approach 2:
The mask structure performs multiple functions simultaneously: it defines the pattern for all three color sub-pixels, controls material distribution across different pixel regions, and maintains alignment with the underlying inorganic layers. This multi-functional design reduces the need for multiple separate masks while achieving full color display capability
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 approach enhances the uniformity and performance of the thin film encapsulation layer, increasing the lifespan of the display apparatus by effectively blocking moisture and oxygen, while reducing manufacturing time and cost.
Implementation Method 1
spraying a deposition gas onto the substrate from a deposition gas supplying unit through at least two openings of a first mask, such that a first inorganic layer is formed
Implementation Method 2
forming a first organic layer on the second inorganic layer using an inkjet printing process
Data Source
AI summary
An apparatus for manufacturing a display apparatus includes a stage supporting a substrate, a deposition gas supplying unit above the substrate, the deposition gas supplying unit spraying a deposition gas onto the substrate, and a first mask between the stage and the deposition gas supplying unit, the first mask including at least two first openings through which the deposition gas selectively passes.