Mask Assembly Patterning for Multi-Resolution Display Alignment
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Solution Overview
Problem
The manufacturing of display devices with varying resolutions poses challenges due to high costs and difficulties in precise alignment of separate mask assemblies, leading to suboptimal quality and increased costs.
Innovation Solution
A display device design featuring a substrate with distinct display areas of different resolutions, utilizing a mask assembly with pattern holes of varying sizes and shapes, and a method for manufacturing this assembly using photoresists and etching solutions, allowing for efficient deposition of materials and precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If separate mask assemblies are manufactured for each display area with different resolutions, then the display device can be manufactured with varying resolutions, but the manufacturing cost increases and precise alignment becomes difficult
Solution Approach 1:
The patent applies universality by designing a single mask assembly that can serve multiple display areas with different resolutions. The mask assembly includes a first mask for a first display area and a second mask for a second display area, allowing one mask assembly to perform functions that would traditionally require separate mask assemblies, thereby reducing manufacturing complexity and cost while maintaining adaptability to different resolutions
2Manufacturing precision
If separate mask assemblies are used for different display areas, then each area can have its required resolution, but precise alignment between mask assemblies and substrate becomes difficult
Solution Approach 1:
The patent merges multiple mask functions into a single mask assembly structure. The first mask and second mask are integrated into one assembly that can be aligned with the substrate as a unified unit, eliminating the need for separate alignment processes for each mask assembly and thereby improving manufacturing precision while reducing alignment process complexity
3Reliability
If multiple mask assemblies are manufactured separately, then each can be optimized for its specific display area, but manufacturing cost increases
Solution Approach 1:
The patent implements universality by creating a single mask assembly that can be used across multiple display areas with different resolutions. This approach maintains the reliability and display quality needed for each specific area while significantly reducing manufacturing costs by eliminating the need to produce and manage multiple separate mask assemblies
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 enables the production of display devices with precise pixel patterns and varying resolutions using a single mask assembly, reducing manufacturing costs and improving alignment precision, thereby enhancing the quality and efficiency of the display device manufacturing process.
Implementation Method 1
a method of manufacturing the mask assembly
Data Source
AI summary
A display device includes: a substrate comprising a first display area and a second display area, the first display area comprising a transparent area and the second display area being arranged to surround at least a portion of the first display area; a first pixel in the first display area and comprising a first pixel electrode, a first intermediate layer, and a first opposite electrode; and a second pixel in the second display area and comprising a second pixel electrode, a second intermediate layer, and a second opposite electrode, wherein each of the first intermediate layer and the second intermediate layer comprises a first section having a portion where a thickness thereof is constant and a second section where the thickness thereof is variable.