Laser Mask System for Organic Light-Emitting Display Deposition
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Solution Overview
Problem
Traditional methods for manufacturing organic light-emitting displays using metal masks and plates increase costs and complicate the washing process, necessitating the development of a more efficient deposition method.
Innovation Solution
An evaporation device with a laser mask system that forms a laser mask between a substrate and a stage, allowing for precise deposition of material without the need for metal masks, thereby reducing manufacturing costs and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If metal masks and plates are used in the mask assembly, then deposition precision is maintained, but manufacturing cost increases and device complexity increases
Solution Approach 1:
The patent replaces the mechanical mask assembly system (metal masks and plates) with a laser-based system. The laser mask uses light fields instead of physical masks to define deposition patterns, eliminating the need for mechanical mask components while maintaining deposition precision through optical control.
Solution Approach 2:
The patent creates a virtual copy of the mask function using laser patterns instead of physical masks. The laser mask system projects optical patterns that replicate the masking function without requiring actual mask plates, thereby simplifying the device structure while preserving patterning capability.
2Stability of the object's composition
If metal masks are welded to the mask assembly, then structural stability is improved, but manufacturing cost increases and ease of manufacture deteriorates
Solution Approach 1:
The patent eliminates the mechanical welding process by replacing the physical mask assembly with a laser-based system. The laser mask requires no assembly or welding operations, as the optical components are positioned and configured without permanent mechanical connections, dramatically simplifying manufacturing.
Solution Approach 2:
The laser mask system uses temporary, non-permanent optical configurations instead of permanent welded metal masks. The laser patterns can be adjusted and reconfigured without permanent modifications, allowing for flexible manufacturing processes that do not require complex assembly operations.
3Reliability
If welding equipment is stored onsite for mask assembly, then reliability is improved, but device complexity increases and space requirements increase
Solution Approach 1:
The patent replaces the need for welding equipment with a laser-based mask system. The optical components and laser delivery system eliminate the requirement for onsite welding equipment, reducing facility requirements and equipment complexity while maintaining assembly reliability through precision optical positioning.
4Manufacturing precision
If metal masks are used, then deposition precision is maintained, but washing process complexity increases
Solution Approach 1:
The patent replaces physical metal masks with a laser optical system that does not require cleaning or washing. The laser patterns are generated electronically and do not accumulate contaminants, eliminating the washing process entirely while maintaining precise deposition patterning 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
The evaporation device enables cost-effective and efficient deposition of organic light-emitting layers, eliminating the need for metal masks and associated equipment, and simplifying the manufacturing process.
Implementation Method 1
a laser mask system configured to form a laser mask between the substrate and the stage
Implementation Method 2
a deposition source configured to discharge material toward the substrate
Data Source
AI summary
A deposition device including a chamber configured to accommodate a substrate supported on a stage, a deposition source configured to discharge material toward the substrate, and a laser mask system configured to form a laser mask between the substrate and the stage.