OLED Mask Edge Slope Control for Uniform Metal Deposition
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Solution Overview
Problem
Conventional OLED display panels face issues with edge slope corners of organic layers being formed at approximately a right angle, leading to uneven metal layer thickness and resistance problems during the fabrication process.
Innovation Solution
An OLED display panel with a second film layer featuring an edge slope corner at an acute angle less than a predetermined value, formed using a mask with specific opaque and transparent areas and non-transparent stripes to control the edge slope, ensuring the metal layer thickness is uniform across the panel.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If edge slope angle is maintained at right angle, then photolithography process is simple, but metal layer thickness varies significantly causing resistance problems
Solution Approach 1:
The patent changes the edge slope angle parameter from 90 degrees to an acute angle, which modifies the metal layer deposition behavior. This parameter change ensures uniform metal layer thickness and consistent resistance characteristics while maintaining manufacturing feasibility through controlled organic layer formation processes.
2Ease of manufacture
If edge slope angle is right angle, then organic layer formation is straightforward, but etching residues occur due to excessive metal layer thickness at edges
Solution Approach 1:
The patent changes the edge slope angle from a right angle to an acute angle, which prevents excessive metal layer accumulation at the edges during deposition. This parameter change eliminates the root cause of etching residues by ensuring uniform metal layer thickness, thereby improving etching cleanliness while keeping organic layer formation straightforward.
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 mitigates the issue of uneven metal layer thickness and resistance by forming edge slope corners at acute angles, thereby improving panel yield and reducing the risk of short circuits and electrostatic discharge.
Implementation Method 1
it is often necessary to perform a photolithography process on organic layers to form desired patterns
Implementation Method 2
the opaque film has a light opacity for light of a predetermined color greater than or equal to a first predetermined threshold; the transparent substrate has a light transmittance for the light of the predetermined color greater than a second predetermined threshold
Implementation Method 3
after photolithography of an organic layer M1, an edge slope angle a of the organic layer is a right angle, or approximately a right angle. On this basis, various problems occur when depositing a metal layer M2
Data Source
AI summary
An organic light-emitting diode (OLED) display panel and a mask are disclosed. The OLED display panel includes a first film layer, and a second film layer disposed on the first film layer and made of an organic material. The second film layer includes an edge slope corner formed at an acute angle less than a predetermined value. Since the edge slope corner of the second film layer is formed at the acute angle less than a predetermined value, a technical problem existing in conventional OLED display panels that edge slope corners of organic layers are formed at approximately a right angle can be mitigated.