OLED Display Device Support Member for Vapor Deposition Stability

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Solution Overview

Problem

The use of vapor deposition masks in OLED display devices can lead to displacement and degradation of the organic layer, resulting in poor display quality due to potential damage and foreign matter adherence, especially when forming organic layers of different colors simultaneously.

Innovation Solution

The implementation of a display device configuration that includes a base with insulating layers, spacers, partitions, and a support member to maintain proper distance and prevent damage, along with a shield member to prevent light leakage, ensuring stable vapor deposition and minimizing display area distortion.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a vapor deposition mask is used to form organic layers in sub-pixels, then the organic layer can be formed in each sub-pixel, but displacement and degradation of the organic layer occur resulting in poor display quality

Engineering Contradiction:

Improveorganic layer formationVSAvoidorganic layer position accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The patent introduces a support member as an intermediary between the vapor deposition mask and the substrate. This support member maintains a precise distance from the substrate surface, preventing the mask from contacting and damaging the organic layer while still enabling effective vapor deposition. The support member acts as a mediator that resolves the conflict between manufacturing capability and precision.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The support member provides beforehand cushioning by pre-establishing a protective distance between the vapor deposition mask and the organic layer. This preventive measure ensures that during the vapor deposition process, the mask cannot come into contact with and damage the organic layer, thus preventing displacement and degradation before they can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Productivity

If the vapor deposition mask is positioned close to the substrate for precise deposition, then deposition efficiency improves, but the risk of mask contact and organic layer damage increases

Engineering Contradiction:

Improvevapor deposition efficiencyVSAvoidorganic layer integrity

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The support member serves as an intermediary that enables the vapor deposition mask to maintain an optimized distance from the substrate. This distance is sufficient to prevent contact and damage to the organic layer, yet close enough to ensure efficient vapor deposition. The support member mediates between the competing requirements of deposition efficiency and layer integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Loss of time

If multiple colors are formed simultaneously using vapor deposition mask, then production time is reduced, but foreign matter adherence and display quality degradation increase

Engineering Contradiction:

Improveproduction timeVSAvoidforeign matter adherence

Core Design Contradiction:

Loss of timeVSObject-affected harmful factors

Solution Approach 1:

The support member acts as a protective intermediary during simultaneous multi-color vapor deposition. By maintaining a consistent distance between the mask and substrate, it prevents foreign matter from adhering to the organic layer while allowing the vapor deposition process to proceed efficiently for multiple colors at once, thus reducing production time without compromising quality.

Inventive Principle:

Principle #24Intermediary (Mediator)

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 configuration stabilizes the vapor deposition process, reduces foreign matter adherence, and prevents display quality degradation by maintaining the integrity of the organic layer and sub-pixels, thereby enhancing the overall display performance.

Implementation Method 1

a display device with an organic light-emitting diode (OLED) applied thereto as a display element

Methodology Applied

Scientific EffectElectroluminescence: Electroluminescence

Implementation Method 2

the organic layer described above is formed in each of the sub-pixels using, for example, a vapor deposition mask

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS20230403916A1Display device

Publication Date: 2023.12.14 MAGNOLIA WHITE CORP

AI summary

According to one embodiment, a display device includes a base, a first insulating layer arranged on the base, a first electrode arranged on the first insulating layer overlapping with a pixel in a display area, a second insulating layer arranged on the first insulating layer and including an aperture overlapping with the first electrode, a first spacer partially arranged on the second insulating layer overlapping with the display area, a partition arranged on the second insulating layer and the first spacer, an organic layer in contact with the first electrode, a second electrode arranged on the organic layer, a second spacer partially arranged on the second insulating layer overlapping with a surrounding area, and a support member arranged on the second spacer.