OLED Mask Plate Blocking Walls Prevent Vapor Color Mixing
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Solution Overview
Problem
OLED display devices face poor color mixing due to organic light-emitting material vapor flow into unintended pixel defining layer openings during the evaporation process, affecting display quality.
Innovation Solution
A mask plate with a matrix of openings and blocking walls, where the blocking walls are strategically placed between adjacent rows or columns to prevent vapor flow into other openings, supporting the mask plate and limiting organic light-emitting material vapor to specific pixel regions during evaporation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If organic light-emitting material is evaporated to form light-emitting layer, then light-emitting function is achieved, but vapor flow causes poor color mixing in adjacent pixels
Solution Approach 1:
The patent introduces a blocking wall as an intermediary structure between adjacent pixel openings. This blocking wall physically intercepts the vapor flow of organic light-emitting material, preventing it from reaching unintended pixel regions. The blocking wall acts as a mediator that allows the evaporation process to continue while controlling the path of material deposition, thereby solving the color mixing problem without stopping the light-emitting layer formation.
Solution Approach 2:
The patent segments the opening regions by introducing blocking walls that divide the continuous vapor flow path into separate zones for each pixel. These blocking walls create distinct deposition zones, ensuring that material evaporated for one pixel does not contaminate adjacent pixels. This segmentation approach maintains the integrity of each pixel's color while allowing efficient material deposition.
2Manufacturing precision
If blocking walls are added to prevent vapor flow, then color mixing is improved, but device structure complexity increases
Solution Approach 1:
The patent applies local quality by adding blocking walls only in specific locations where vapor flow control is needed, rather than uniformly across the entire mask plate. The blocking walls are strategically positioned between adjacent pixel openings where color mixing occurs, while leaving other areas simple. This localized approach improves color mixing precision without unnecessarily complicating the overall device structure.
3Shape
If no spacer layer is used to reduce thickness, then substrate flatness is improved, but mask plate support and positioning become difficult
Solution Approach 1:
The blocking wall serves multiple functions simultaneously: it acts as a vapor flow barrier to prevent color mixing, and it also serves as a support structure and positioning reference for the mask plate. By making the blocking wall multi-functional, the patent eliminates the need for a separate spacer layer, maintaining substrate flatness while providing adequate support and positioning capabilities.
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 enhances display quality by preventing poor color mixing, reduces material usage and spacer layer thickness, and improves substrate flatness, thereby minimizing the risk of cathode layer breakage and packaging film issues.
Implementation Method 1
an organic light-emitting material vapor flow is likely to flow to other PDL opening regions during the evaporating process
Data Source
AI summary
A mask plate, an OLED display substrate, a display device and a manufacturing method thereof are provided. The mask plate includes: a mask plate body and a first blocking wall arranged on the mask plate body, where the mask plate body is provided with a plurality of openings, the plurality of openings are arranged in a matrix; the first blocking wall is arranged to close to the plurality of openings, and at least one part of the first blocking wall is arranged between two adjacent rows or adjacent columns of openings.