OLED Mask Plate Hollowed-Out Areas Single-Process Cathode Formation
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Solution Overview
Problem
The traditional OLED transparent display panel manufacturing process is complex, costly, and results in a low aperture ratio and transmittance due to the need for two deposition processes to communicate cathodes, leading to a large cathode area and high manufacturing time.
Innovation Solution
A mask plate with hollowed-out areas corresponding to cathode units on a substrate, allowing for a single patterning or evaporation process to form mutually connected cathode units, reducing manufacturing time and cost while improving aperture ratio and transmittance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If two deposition processes are used to communicate cathodes, then cathode communication is achieved, but manufacturing time increases and cost increases
Solution Approach 1:
The patent merges multiple deposition processes into a single deposition process by designing a mask plate with multiple hollowed-out areas that correspond to different cathode regions. This allows all cathode patterns to be formed simultaneously in one deposition step, eliminating the need for multiple sequential depositions and reducing manufacturing time while maintaining proper cathode communication.
Solution Approach 2:
The mask plate is segmented into multiple hollowed-out areas, each corresponding to a specific cathode unit or region. This segmentation allows the single deposition process to selectively deposit cathode material in multiple distinct locations simultaneously, achieving what previously required multiple sequential depositions.
2Reliability
If two deposition processes are used to communicate cathodes, then cathode communication is achieved, but manufacturing cost increases
Solution Approach 1:
By combining multiple deposition operations into a single deposition process using a multi-region mask plate, the patent reduces manufacturing cost. The single deposition process eliminates the need for multiple mask plates, multiple deposition chamber loadings, and intermediate handling steps, thereby reducing both material and operational costs while achieving complete cathode communication.
3Reliability
If traditional cathode layout is used, then cathode communication is achieved, but aperture ratio decreases and transmittance decreases
Solution Approach 1:
The mask plate design implements local quality by creating hollowed-out areas with specific geometries and distributions that optimize cathode material deposition in critical regions while minimizing material deposition in non-critical areas. This localized control allows for reduced overall cathode area while maintaining necessary communication pathways, thereby improving aperture ratio and transmittance.
4Reliability
If traditional cathode layout is used, then cathode communication is achieved, but transmittance decreases
Solution Approach 1:
The patent combines multiple cathode deposition regions into a single optimized deposition process that reduces total cathode material usage. By carefully designing the hollowed-out areas to overlap or connect only where necessary for electrical communication, the overall cathode area is minimized, allowing more light to pass through the display panel and improving transmittance while maintaining cathode functionality.
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
The solution enables a single-process cathode formation with improved communication and reduced area, resulting in enhanced transmittance and aperture ratio, and lower manufacturing costs compared to traditional methods.
Implementation Method 1
A mask plate with hollowed-out areas corresponding to cathode units on a substrate, allowing for a single patterning or evaporation process to form mutually connected cathode units
Data Source
AI summary
A mask plate for manufacturing an organic light-emitting diode (OLED) transparent display panel, the OLED transparent display panel and a manufacturing method thereof are disclosed. The mask plate includes a substrate and a plurality of hollowed-out areas and a plurality of opaque areas disposed on the substrate, and a pattern of the hollowed-out areas correspond to a pattern of a cathode of the OLED transparent display panel to be manufactured; and all the hollowed-out areas are communicated with each other.