Maskless AMOLED Panel Manufacturing via Digital Light Projection
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Solution Overview
Problem
The existing AMOLED display panel manufacturing processes face issues with poor uniformity in film layers, material waste, and low deposition rates due to the use of masks, which affect precision and efficiency, especially for small-sized panels.
Innovation Solution
An AMOLED display panel manufacturing method and apparatus that collects substrate size parameters, constructs a model to determine spray data for organic vapor materials, and controls spraying devices to form the panel without a mask, ensuring precise and efficient film layer formation in a normal manufacturing environment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deposition or evaporation process with mask is used, then film layers can be formed, but manufacturing precision deteriorates due to mask deviations
Solution Approach 1:
The patent removes the mask from the deposition process entirely, using direct digital light processing to pattern the organic vapor materials without any physical mask, thereby eliminating mask-related precision deviations and simplifying the device structure
Solution Approach 2:
The patent replaces the mechanical mask system with a digital light processing system that uses projected patterns to control where organic vapor materials are deposited, achieving precise patterning without mechanical components
2Manufacturing precision
If mask is used for pattern formation, then desired patterns can be created, but material waste increases
Solution Approach 1:
By removing the mask entirely and using direct digital projection, the patent eliminates the material waste that occurs with mask-based methods where excess material deposits on the mask and is discarded
Solution Approach 2:
The digital light processing system directly patterns the organic vapor materials in their intended locations without requiring a mask to define the pattern, allowing materials to be deposited only where needed
3Manufacturing precision
If deposition process with mask is used, then film layers can be formed, but deposition rate decreases
Solution Approach 1:
The patent replaces the slow mask-based deposition process with a faster digital light processing method that can rapidly pattern multiple areas simultaneously through projected images, significantly increasing deposition rate while maintaining uniformity
Solution Approach 2:
The patent transitions from sequential mask-based deposition to parallel digital projection that can address multiple pattern areas simultaneously through different projected images, increasing overall deposition efficiency
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 eliminates the need for masks, improving precision and reducing material waste while allowing for adjustable spraying, resulting in enhanced film layer formation efficiency and reduced environmental requirements.
Implementation Method 1
controlling corresponding spraying devices to spray the respective organic vapor materials on the substrate successively
Data Source
AI summary
The present disclosure discloses an AMOLED display panel manufacturing method, apparatus and system. The method comprises: collecting size parameters of a substrate, constructing an AMOLED display panel model based on the size parameters, and determining spray data of respective organic vapor materials; controlling corresponding spraying devices to spray the respective organic vapor materials on the substrate successively according to the determined spray data of the respective organic vapor materials, to form an AMOLED display panel.