Maskless OLED Deposition via Light-Activated Organic Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current OLED display manufacturing methods using fine metal masks face limitations in achieving high resolution due to shadow areas and temperature-related precision issues, which restrict resolution to around 250 ppi and increase production costs.
Innovation Solution
A manufacturing method involving a substrate with alternating deposition and non-deposition regions, a mask with blocking and hollow regions, and a light source that selectively irradiates the non-deposition regions to prevent organic material deposition, eliminating the need for fine metal masks and reducing maintenance costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If vacuum evaporation with fine metal mask is used, then OLED display can be manufactured, but shadow areas are formed at edges of sub-pixels limiting resolution to around 250 ppi
Solution Approach 1:
The patent extracts and removes the fine metal mask from the vapor deposition system, eliminating the source of shadow areas. By using a maskless deposition approach with in-situ formed organic material patterns, the shadow effect caused by mask thickness and opening geometry is completely eliminated, enabling resolution beyond 250 ppi.
Solution Approach 2:
The patent replaces the mechanical fine metal mask system with a chemical/self-organizing system where organic material patterns are formed in-situ through controlled deposition and self-organization. This substitution eliminates mechanical shadow effects and enables higher resolution display manufacturing.
2Manufacturing precision
If fine metal mask is used during vapor deposition, then sub-pixel deposition can be controlled, but temperature increase causes PPA precision change and requires periodic cleaning and re-laying
Solution Approach 1:
The patent removes the fine metal mask from the deposition process, eliminating temperature-related mask instability and PPA (pixel position accuracy) changes. The maskless approach with in-situ pattern formation ensures consistent pixel positioning without thermal drift issues.
Solution Approach 2:
The patent enables continuous deposition without periodic mask cleaning and re-laying interruptions. The in-situ pattern formation method maintains continuous production flow, eliminating downtime for mask maintenance and ensuring consistent pixel position accuracy throughout the manufacturing process.
3Object-affected harmful factors
If sub-pixel width is increased to avoid shadow area influence, then display effect is improved, but resolution is limited
Solution Approach 1:
The patent eliminates the fine metal mask that causes shadow areas, allowing sub-pixels to be deposited with precise boundaries without the need to increase width for compensation. This enables high resolution display manufacturing with accurate pixel definition.
4Manufacturing precision
If fine metal mask is periodically cleaned and re-laid, then deposition quality is maintained, but production cost and maintenance cost increase
Solution Approach 1:
The patent removes the fine metal mask from the process, eliminating all associated maintenance costs including cleaning, re-laying, and mask replacement. The maskless deposition approach with in-situ pattern formation maintains deposition quality without any mask-related operational expenses.
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 method enables the production of high-resolution display panels by avoiding shadow areas and temperature-related precision shifts, allowing for resolutions beyond 300 ppi and reducing production costs.
Implementation Method 1
providing a light source to irradiate the mask, wherein the light source in the hollow region irradiates the non-deposition regions after passing through the hollow regions
Implementation Method 2
a light source selectively emits light onto the substrate to produce a thermal or photochemical effect in the regions irradiated by the light source which activates particles of organic material vapor
Implementation Method 3
generating an organic material vapor by an evaporation source, wherein the organic material vapor contacts the first surface to form an organic material block on each of the deposition regions
Implementation Method 4
The organic light-emitting materials are heated in crucibles and changes from a solid state to a gaseous state. The organic light-emitting materials are then deposited on an opening of a corresponding pixel definition layer
Data Source
AI summary
A manufacturing method of a display panel and a display panel are provided. The advantages thereof are that a shadow area of an edge of a pixel caused by an angle of evaporation can be avoided and reduced, a pixel position accuracy (PPA) shift caused by raising a temperature of a fine metal mask during a coating process can be prevented, and it is applicable to manufacture of high-resolution display panels.