OLED Backplate Alignment via Reflective Virtual Points
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Solution Overview
Problem
As OLED display devices increase in size, the fine metal mask (FMM) used for forming the organic light-emitting material layer becomes prone to deformation during alignment, making it difficult to achieve accurate alignment with the OLED backboard, thereby reducing the efficiency of the organic light-emitting material layer formation.
Innovation Solution
The OLED backboard features via holes with alignment modules containing reflective first alignment structures arranged in predefined traces, allowing for the determination of virtual alignment points and enabling correct alignment with a CCD camera system, which reduces the complexity and time required for aligning the FMM with the OLED backboard.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the FMM size is increased to match larger OLED display devices, then the coverage area is improved, but the FMM becomes more prone to deformation during alignment
Solution Approach 1:
The patent divides the large FMM into multiple smaller FMMs, each covering only a portion of the OLED backboard. This segmentation reduces the size of each individual FMM, making them less prone to deformation during alignment while still covering the entire display area when combined. The multiple small FMMs can be aligned and positioned independently on the backboard.
2Manufacturing precision
If traditional alignment pins and holes are used for aligning FMM with OLED backboard, then alignment is achieved, but multiple adjustments are needed reducing efficiency
Solution Approach 1:
The patent replaces the traditional mechanical alignment pin-and-hole system with an optical alignment system. Alignment marks are formed on the OLED backboard that can be optically detected, and the alignment process uses optical detection and image processing to achieve precise positioning. This substitution eliminates the need for multiple mechanical adjustments and significantly improves alignment efficiency.
3Manufacturing precision
If multiple adjustments are made to align FMM correctly, then alignment accuracy is achieved, but the time required for alignment increases
Solution Approach 1:
The patent incorporates alignment marks during the initial formation of the OLED backboard structure, so that alignment features are prepared in advance. The alignment marks are formed simultaneously with other backboard structures, eliminating the need for separate alignment preparation steps. This preliminary action enables quick and accurate alignment without requiring multiple adjustment iterations.
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 solution significantly reduces the time and complexity of aligning the FMM with the OLED backboard, enhancing the efficiency of forming the organic light-emitting material layer by providing clear, direct light reflection and improved pattern differentiation, thus facilitating accurate alignment and increased manufacturing efficiency.
Implementation Method 1
each of the alignment modules is suitable to reflect an incident light from the lower surface of the transparent substrate
Data Source
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AI summary
The present disclosure relates to a technical field of OLED display and discloses an OLED backboard, a method of manufacturing the same, an alignment system and an alignment method thereof, which aims to solve a problem of low efficiency in forming an organic light-emitting material layer on the OLED backboard. The OLED backboard comprises: a transparent substrate; at least two functional layers disposed on the upper surface of the transparent substrate and stacked on each other; at least two via holes formed in predefined areas of the at least two functional layers and extending through at least the upper one of the at least two functional layers; and at least two alignment modules located in the at least two via holes respectively, wherein each of the at least two alignment modules comprises at least three first alignment structures arranged in a predefined trace, and a virtual alignment point is allowed to be determined based on the relative position among all the first alignment structures in each of the alignment modules. The efficiency of forming the organic light-emitting material layer on the OLED backboard is thus increased by using the above OLED backboard.