Selective Mask Coating for Display Pad Isolation
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Solution Overview
Problem
Display devices experience reliability issues due to increased driving voltage, which can degrade their performance.
Innovation Solution
A mask with a frame and coating layer is used during manufacturing to deposit an inorganic insulating film, ensuring it does not overlap with pad portions, thereby preventing contact and enhancing the encapsulation layer's coverage without contacting the pads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the inorganic insulating film is deposited to cover the pad portion for improved encapsulation, then the encapsulation reliability is improved, but the pad functionality is compromised due to contact
Solution Approach 1:
The mask introduces a coating layer with spatially varying properties: it is opaque in the pad portion area (preventing film deposition on pads) and transparent in the display area (allowing film deposition for encapsulation). This local quality differentiation enables selective film formation that simultaneously achieves encapsulation reliability and pad functionality.
Solution Approach 2:
The mask with the coating layer serves as an intermediary tool during the deposition process. It mediates between the deposition source and the substrate, controlling where the inorganic insulating film is deposited by blocking or permitting material transport through its selectively transparent/opaque coating regions.
2Ease of manufacture
If a conventional mask without selective coating is used, then the manufacturing process is simpler, but the inorganic insulating film contacts the pad causing reliability issues
Solution Approach 1:
The mask incorporates a coating layer with spatially differentiated optical properties (opaque vs. transparent regions) to enable selective film deposition. This local quality approach allows a single mask structure to perform multiple functions: protecting pad areas from film deposition while permitting encapsulation film formation on the display area.
3Area of stationary object
If the encapsulation layer is extended to cover the pad area, then the overall coverage is improved, but the driving voltage increases causing reliability degradation
Solution Approach 1:
The solution extracts the pad portion from the encapsulation coverage area by using the mask's opaque coating layer to block film deposition specifically over the pad region. This separation allows the encapsulation layer to cover the display area without extending onto the pad, thereby maintaining reliability while achieving adequate coverage protection.
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 method improves the reliability of display devices by maintaining the integrity of the encapsulation layer and preventing direct contact with pads, thus enhancing the overall performance and longevity of the display device.
Implementation Method 1
depositing an inorganic insulating film on the base panel, wherein the mask includes a frame including ribs defining an opening; and a coating layer arranged on the frame
Data Source
AI summary
A method of manufacturing a display device is provided. The method includes: placing a mask on a base substrate, the base substrate including a base panel having a display area and a pad portion on a side of the display area and in which a pad is located; and depositing an inorganic insulating film on the base panel, wherein the mask includes a frame including ribs defining an opening; and a coating layer on the frame, and wherein the placing of the mask includes placing the mask so that the opening of the mask overlaps the base panel in a plan view and the coating layer overlaps the pad portion in a plan view.