Mask Sheet Curvature Design for OLED Aperture Ratio
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Solution Overview
Problem
The manufacturing of fine metal masks (FMMs) for OLED display panels is complicated by non-uniform pixel designs, leading to alignment errors and color mixing due to wrinkles, which hinder high aperture ratio and pixel density achievements.
Innovation Solution
A mask sheet with mask openings larger than corresponding pixel openings, featuring curved edges with inner concave surfaces and mask edges with reduced curvature, allowing for non-proportional enlargement and simplified manufacturing, reducing the likelihood of wrinkles and color mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mask opening size is proportionally enlarged to match complex pixel designs, then the pixel density and aperture ratio are improved, but the mask sheet becomes difficult to manufacture and wrinkles are easily generated
Solution Approach 1:
The patent applies different curvature characteristics to different parts of the mask opening edges. Specifically, the mask opening edges have smaller curvatures compared to the pixel opening edges, creating a local differentiation in geometric properties. This allows the mask sheet to maintain manufacturing feasibility while still achieving the required alignment precision for complex pixel designs.
Solution Approach 2:
The patent changes the curvature parameter of the mask opening edges relative to the pixel opening edges. By reducing the curvature (making edges straighter) on the mask sheet compared to the pixel design, the mask becomes easier to manufacture without compromising alignment accuracy. This parameter modification resolves the contradiction between manufacturing ease and precision.
2Area of stationary object
If the mask opening size is proportionally enlarged, then the aperture ratio is improved, but wrinkles are easily generated during mask tension process causing alignment errors
Solution Approach 1:
The patent introduces local quality differentiation by making the mask opening edges have smaller curvatures than the pixel opening edges. This local modification at the edge regions allows the overall aperture ratio to be maintained or improved while preventing wrinkle formation during tensioning, thereby ensuring alignment reliability.
Solution Approach 2:
The patent applies preliminary anti-action by designing the mask opening edges with smaller curvatures in advance, before the tensioning process occurs. This pre-designed geometric feature prevents wrinkles from forming during the mask tension process, thereby maintaining alignment accuracy between the evaporated organic materials and the predetermined pixel positions.
3Manufacturing precision
If complex pixel designs are implemented for high resolution, then the pixel density is improved, but the FMM manufacturing becomes increasingly difficult
Solution Approach 1:
The patent applies local quality by differentiating the edge characteristics of mask openings from pixel openings. While the overall pixel design remains complex to achieve high density, the local modification of having straighter mask edges (smaller curvatures) simplifies the FMM manufacturing process without compromising the ability to form precise pixel patterns.
Data Source
AI summary
The disclosure provides a mask sheet and a pixel structure. The mask sheet includes a mask opening configured to manufacture a sub-pixel in a pixel opening of a display panel. An area of the mask opening is greater than an area of the pixel opening corresponding thereto. The pixel opening includes at least one curved edge with an inner concave surface, the mask opening includes at least one mask edge, and the at least one mask sheet is in one-to-one correspondence with the at least one curved edge. A curvature of each mask edge is less than a curvature of the curved edge corresponding thereto.