OLED Mask Grooves for Gap Control
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Solution Overview
Problem
In the manufacturing of OLED displays, the non-uniform drawing force on the mask during stretching leads to a larger gap between the raised portion and the substrate, affecting the design of the product and the encapsulation reliability of the formed film layer.
Innovation Solution
The mask design includes a plurality of grooves partially formed on the first surface of the raised portions, which adjusts the drawing force and reduces the gap between the raised portion and the substrate by transferring stress to the edges, improving the consistency between the mask pattern and the formed film layer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the mask is stretched during the film forming process, then the mask can be adapted to the substrate, but non-uniform drawing force creates a larger gap between the raised portion and the substrate
Solution Approach 1:
The patent applies local quality by creating grooves at specific locations on the raised portions of the mask. These grooves are not uniformly distributed but are strategically placed to address the non-uniform drawing force problem. The grooves modify the local mechanical properties of the raised portions, allowing them to better conform to the substrate under stretching while maintaining precise alignment. This localized structural modification enables the mask to adapt to the substrate without creating excessive gaps at critical areas.
2Device complexity
If the mask structure is simplified without raised portions, then the device complexity is reduced, but the encapsulation reliability of the formed film layer deteriorates
Solution Approach 1:
The patent applies segmentation by dividing the mask into distinct functional regions: shielding portions and raised portions with grooves. The raised portions are further segmented into side surfaces and groove regions. This segmentation allows each part to perform its specific function - the shielding portions block material deposition in certain areas, while the raised portions with grooves provide mechanical support and control the gap formation. The grooves themselves act as segmented features that distribute stress and improve conformance without requiring a completely complex overall structure.
3Manufacturing precision
If the gap between raised portion and substrate is reduced, then the consistency between mask pattern and film layer pattern is improved, but the drawing force distribution becomes more challenging
Solution Approach 1:
The patent applies parameter changes by modifying the physical structure of the raised portions through the addition of grooves. This structural parameter change alters the mechanical behavior of the raised portions during stretching. The grooves change the stress distribution parameters, allowing the raised portions to better withstand drawing forces while maintaining small gaps. By changing the geometric parameters of the raised portions (adding grooves with specific dimensions and positions), the mask achieves both good pattern consistency and reasonable force distribution.
Data Source
AI summary
A mask includes a shielding portion and a plurality of hollow regions. The shielding portion includes: a plurality of shielding strips, a plurality of raised portions and a plurality of grooves. Side surfaces of some of the plurality of shielding strips are sequentially connected to form one of the plurality of hollow regions. Each raised portion is disposed on a side surface of a corresponding one of the plurality of shielding strips close to a corresponding hollow region, and each raised portion is connected with the side surface of the shielding strip. Each groove is at least partially formed in a first surface of a corresponding one of the plurality of raised portions, and the first surface is parallel to a plate surface of the mask.