OLED Evaporation Mask Structure for Gap-Free Material Deposition
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Solution Overview
Problem
Existing masks used in the manufacturing of OLED displays suffer from gaps between the frame and shielding plate, leading to inaccurate deposition of luminescent materials and reduced yield due to evaporation material diffusing into unintended areas, necessitating additional shielding sheets and increased costs.
Innovation Solution
A mask design with a frame and shielding plate configuration where the inner edge of the frame is within the orthogonal projection of the shielding plate, eliminating gaps and ensuring precise material deposition by using a thickness difference between regions to align and fix the shielding plate and mask sheet without additional alignment sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask is used for OLED manufacturing, then luminescent material deposition can be achieved, but gaps between the frame and shielding plate cause material diffusion and reduce deposition accuracy
Solution Approach 1:
The patent transitions from a two-dimensional planar mask structure to a three-dimensional structure with varying thickness. The frame includes a first region with greater thickness that extends toward the shielding plate, creating a vertical dimension solution to the horizontal gap problem. This dimensional change allows the thicker first region to bridge the gap between the frame and shielding plate, preventing material diffusion while maintaining structural integrity.
Solution Approach 2:
The frame is designed with non-uniform thickness distribution, where the first region has greater thickness than the second region. This local quality variation concentrates the gap-filling function specifically in the first region where the gap exists, while the second region maintains its original thickness for other functions. The differentiated thickness structure optimizes material usage and prevents deformation while solving the deposition accuracy problem.
2Manufacturing precision
If additional shielding sheets are added to eliminate gaps, then deposition accuracy improves, but manufacturing cost and device complexity increase
Solution Approach 1:
The patent merges the gap-filling function with the existing frame structure by adding thickness to the first region, rather than adding a separate shielding sheet. This integration eliminates the need for additional components and simplifies the overall structure. The frame simultaneously provides structural support and gap-filling functions through its differentiated thickness design, reducing manufacturing steps and costs.
Solution Approach 2:
The patent extracts the gap-filling function from the concept of adding separate shielding sheets and instead implements it within the frame structure itself. By modifying the frame's thickness distribution, the solution removes the need for additional shielding components while achieving the same gap-elimination effect, thereby reducing manufacturing complexity and cost.
3Manufacturing precision
If the frame thickness is increased to fill gaps, then material deposition accuracy improves, but the mask structure becomes more complex and harder to manufacture
Solution Approach 1:
The frame is designed with non-uniform thickness distribution, where the first region has greater thickness than the second region. This local quality variation concentrates the gap-filling function specifically in the first region where the gap exists, while the second region maintains its original thickness for other functions. The differentiated thickness structure optimizes material usage and prevents deformation while solving the deposition accuracy problem.
Solution Approach 2:
The patent transitions from a two-dimensional planar mask structure to a three-dimensional structure with varying thickness. The frame includes a first region with greater thickness that extends toward the shielding plate, creating a vertical dimension solution to the horizontal gap problem. This dimensional change allows the thicker first region to bridge the gap between the frame and shielding plate, preventing material diffusion while maintaining structural integrity.
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
Achieves accurate evaporation material deposition on the substrate, enhancing yield and reducing costs by eliminating gaps and the need for extra shielding sheets, thus improving the manufacturing process efficiency.
Implementation Method 1
The self-luminous organic material is mainly deposited on a substrate by an evaporation method
Data Source
AI summary
A mask includes a frame, at least one mask sheet, and a shielding plate. The frame includes a plurality of borders. The borders are connected end to end in sequence to form the frame with a first hollow region. A mask sheet includes a pattern region and non-pattern regions. The pattern region includes at least one evaporation hole. The shielding plate includes a plurality of shielding strips. The plurality of shielding strips are arranged crosswise to form a plurality of second hollow regions. Orthogonal projections of the second hollow regions on a plane perpendicular to a thickness direction of the frame are located within a range of an orthogonal projection of the first hollow region on the plane. An inner edge of an orthogonal projection of the frame on the plane is located within a range of an orthogonal projection of the shielding plate on the plane.