Mask Frame Assembly for OLED Thin Film Deposition
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Solution Overview
Problem
Conventional mask frames for thin film deposition in organic light-emitting display devices face challenges in achieving high resolution and small-sized product manufacturing, particularly due to the difficulty in varying the pattern shapes and sizes of emission regions for red, green, and blue pixels, which require different light-emission efficiencies and area ratios.
Innovation Solution
A mask frame assembly with specific slit patterns, including stripe-shaped and dot-shaped slits, is used to deposit organic layers on a substrate, allowing for the formation of stripe-shaped and dot-shaped organic layers that cross each other, optimizing the arrangement of emission regions based on light-emission efficiency, enabling compact and high-resolution pixel formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional mask frames are used for thin film deposition, then the manufacturing process is simple, but high resolution and small-sized product cannot be achieved
Solution Approach 1:
The mask frame assembly is divided into multiple independent masks (first mask, second mask, third mask) that can be separately manufactured and precisely positioned. Each mask contains specific slit patterns (stripe-shaped or dot-shaped) that can be independently optimized, enabling high-resolution patterning while maintaining manufacturing simplicity through modular construction
Solution Approach 2:
The patent introduces a multi-dimensional mask arrangement where masks are positioned at different locations and orientations (first mask with stripes in first direction, second mask with stripes in second direction, third mask with dots). This spatial arrangement in multiple dimensions enables complex high-resolution patterns to be formed through material deposition through the slit patterns
2Adaptability or versatility
If uniform pattern shapes are used for all pixels, then manufacturing is easy, but different light-emission efficiencies of red, green, and blue pixels cannot be optimized
Solution Approach 1:
Different regions of the substrate receive different mask patterns tailored to the specific light-emission efficiency requirements of each color. Red pixels (lower efficiency) receive larger emission region patterns, green pixels (higher efficiency) receive smaller patterns, and blue pixels receive intermediate patterns. This local customization optimizes overall display efficiency while the modular mask system keeps manufacturing feasible
3Manufacturing precision
If large emission regions are used for all pixels, then manufacturing is simple, but high resolution cannot be achieved in small-sized products
Solution Approach 1:
The mask system enables dynamic adjustment of emission region sizes through different slit patterns and material deposition processes. By varying the slit dimensions and deposition parameters, the emission region area can be precisely controlled for each pixel type, achieving both high resolution and optimized light emission efficiency without fixed uniform sizes
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 allows for the efficient and compact arrangement of organic layers in different colors, facilitating the manufacture of high-resolution, small-sized organic light-emitting display devices by varying the sizes of emission regions according to their light-emission efficiencies, overcoming the limitations of conventional methods.
Implementation Method 1
a first mask having stripe-shaped first slits for providing a passage upon which material for forming strip-shaped first organic layers is deposited on the substrate
Data Source
AI summary
A mask frame assembly for thin film deposition, an organic light-emitting display device using the same, and a method of manufacturing the organic light-emitting display device. The organic light-emitting display device includes a first electrode and a second electrode patterned on a substrate to face each other, and a plurality of organic layers formed between the first and second electrodes. The plurality of organic layers include at least a plurality of stripe-shaped organic layers and a plurality of discontinuous dot-shaped organic layers.