OLED Deposition Mask Assembly with Dummy Openings Against Deformation
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Solution Overview
Problem
The existing mask assemblies for depositing organic light emitting layers face deformation issues due to differences in the number of openings per unit area in the display and module regions, leading to inaccurate formation of organic light emitting layers.
Innovation Solution
A mask assembly with dummy opening regions and opening regions, where the number and arrangement of openings are symmetrical and fewer than in the pattern region, along with a blocking stick and support sticks, ensures accurate deposition without deformation, preventing the deposition material from passing through non-display regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the mask is stretched and fixed to a frame, then the mask can be used for deposition, but deformation occurs due to different numbers of openings per unit area in different regions
Solution Approach 1:
The patent changes the physical parameters of the mask by adding dummy openings to modify the overall opening distribution. This transforms the mask structure from one with uneven opening density to one with uniform opening density, allowing it to withstand stretching without deformation that would misalign openings with sub-pixel regions.
Solution Approach 2:
The patent creates a copy of the opening pattern by adding dummy openings that replicate the structural characteristics of real openings. These dummy openings are positioned to mirror the opening distribution, creating a symmetrical pattern that balances the mask structure and prevents deformation during installation.
2Manufacturing precision
If the number of openings per unit area is uniform across the mask, then deformation is prevented, but the module region requires fewer openings due to transmission windows
Solution Approach 1:
The patent introduces dummy openings as intermediary elements that do not perform the primary function of depositing organic light emitting layers (unlike real openings), but serve as structural placeholders. These dummy openings act as mediators that maintain the mask's structural integrity and uniform opening distribution without interfering with the actual deposition process in the display region.
Solution Approach 2:
The patent segments the mask functionality by distinguishing between real openings (for deposition in display region) and dummy openings (for structural support in module region). This segmentation allows different regions of the mask to serve different purposes while maintaining overall structural uniformity, with dummy openings providing structural balance without compromising deposition efficiency in the display region.
Data Source
AI summary
A mask assembly includes a mask and a blocking stick. The mask includes a pattern region formed therein with openings and extends in a first direction. The blocking stick is disposed under the mask and overlaps a first side portion of the mask. The mask further includes dummy opening regions and opening regions. The dummy opening regions are arranged in the first direction in the first side portion of the mask, and are formed therein with openings. The opening regions are arranged in the first direction in a second side portion which is opposite to the first side portion of the mask and correspond to the dummy opening regions, respectively. The number of the openings per a unit area in each of the dummy opening region and the opening region is smaller than the number of the openings per a unit area in the pattern region.