Mask for Display Panel Organic Layer Boundary Control
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Solution Overview
Problem
During the manufacturing of display panels, the reflow phenomenon of liquid organic materials can lead to the oxidation of electrodes due to ashing processes, resulting in dark spots and reduced reliability, as gases like oxygen are generated, affecting the encapsulation layer and ultimately the display's performance.
Innovation Solution
A mask with specific blocking portions and openings is used to pretreat the inorganic layer, controlling the spread of organic materials and eliminating the need for the ashing process, thereby preventing electrode oxidation and improving the display panel's reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If an ashing process is used to remove the organic layer formed by reflow, then the organic layer spread issue is resolved, but oxygen gases are generated that oxidize the electrode and create dark spots
Solution Approach 1:
The patent applies preliminary action by forming a hydrophobic barrier layer on the inorganic layer before depositing the organic layer. This pretreatment prevents the organic material from spreading beyond the desired cell area during curing, eliminating the need for subsequent ashing processes that would generate harmful oxygen gases and oxidize the electrode.
Solution Approach 2:
The patent introduces an intermediary substance - a hydrophobic barrier layer - between the inorganic layer and the organic layer. This intermediate layer acts as a physical and chemical barrier that controls the spread of organic material while preventing direct contact between the organic layer and the electrode, thus avoiding oxidation without requiring ashing.
2Ease of manufacture
If the organic material is allowed to spread freely during curing, then the curing process is simple, but the organic layer flows over dams and reaches the end of the cell causing reflow
Solution Approach 1:
The patent applies preliminary action by forming a hydrophobic barrier layer on the inorganic layer before depositing the organic layer. This pretreatment prevents the organic material from spreading beyond the desired cell area during curing, eliminating the need for subsequent ashing processes that would generate harmful oxygen gases and oxidize the electrode.
Solution Approach 2:
The patent applies local quality by creating a hydrophobic barrier layer specifically at the interface between the inorganic layer and the organic layer, while leaving other areas unchanged. This localized modification provides precise control over organic material spread in critical areas without affecting the overall simplicity of the curing process.
3Manufacturing precision
If a mask with blocking portions and openings is used for pretreatment, then the spread of organic materials is controlled, but the mask structure becomes more complex
Solution Approach 1:
The patent applies segmentation by dividing the mask into distinct functional portions: blocking portions that prevent organic material spread and openings that allow plasma treatment. This segmented structure enables precise control over where the hydrophobic barrier layer is formed, achieving accurate organic layer boundary control while maintaining reasonable mask complexity through functional division.
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 solution effectively controls the organic layer's formation, reduces process time and costs, and prevents the generation of gases that could oxidize electrodes, enhancing the display panel's reliability and preventing dark spots.
Implementation Method 1
pretreating at least a portion of the first inorganic layer overlapping with the peripheral area through a plasma process using a first mask
Implementation Method 2
a surface of the first inorganic layer that is pretreated in areas overlapping with the first openings may have a hydrophobicity higher than a hydrophobicity of the surface of the first inorganic layer overlapping with the first portion
Data Source
AI summary
A mask includes: a first portion; and a second portion surrounding the first portion, and having a size smaller than a size of the first portion in a plan view, the second portion including: first blocking portions; and first openings alternately located with the first blocking portions along one direction in a plan view.