Organic Light Emitting Display Mask Support Spacer
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Solution Overview
Problem
The manufacturing process of high-resolution organic light emitting display apparatuses faces challenges in preventing the collapse of mask layers, leading to dispersion of slit widths and shadow effects, which affects the reliability and quality of the final product.
Innovation Solution
The use of spacers with an island shape, made of organic materials, is introduced to support the mask layer and prevent its collapse during the deposition process, while an auxiliary electrode seals the spacer to maintain the integrity of the organic light emitting diode structure, allowing for easier removal of lift-off and mask layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask is used in close contact with the substrate to reduce shadow effect and improve resolution, then the shadow effect is reduced and resolution is improved, but the mask layer may collapse during the deposition process
Solution Approach 1:
The mask structure is segmented into multiple functional layers: a support layer, a lift-off layer, and a patterned mask layer. This segmentation allows each layer to perform its specific function independently, with the support layer providing structural stability and the patterned mask layer defining the precise slit patterns for high-resolution deposition
Solution Approach 2:
Different regions of the mask structure have different properties: the support layer has high mechanical strength to prevent collapse, the lift-off layer has specific adhesion characteristics to enable easy removal, and the patterned mask layer has precise geometric features for defining slit widths. This local differentiation of properties allows the mask to simultaneously achieve stability and precision
2Manufacturing precision
If the resolution of the display apparatus is increased by reducing the open slit width, then the resolution is improved, but the dispersion of slit widths increases due to mask collapse
Solution Approach 1:
The support layer is formed in advance before the patterned mask layer is deposited. This preliminary action provides a stable foundation that prevents mask collapse during subsequent deposition processes, ensuring that the narrow slits maintain their intended dimensions and uniformity throughout manufacturing
Solution Approach 2:
The lift-off layer acts as an intermediary between the support layer and the patterned mask layer. It provides controlled adhesion that allows the mask to be stable during deposition but enables easy removal afterward, preventing mask collapse while maintaining slit width consistency
3Object-generated harmful factors
If the mask layer is made thinner to reduce shadow effect, then the shadow effect is reduced, but the mask layer becomes more prone to collapse
Solution Approach 1:
The mask system is divided into a thin patterned mask layer for minimizing shadow effects and a separate support layer for providing mechanical strength. This segmentation allows the patterned layer to be optimally thin for reduced shadowing while the support layer compensates for the reduced strength
Solution Approach 2:
The mask structure uses composite construction with multiple materials having different properties: the support layer material provides high mechanical strength, the lift-off layer material provides controlled adhesion, and the patterned mask layer material provides precise patterning with minimal shadowing. This composite approach allows optimization of each layer for its specific function
Data Source
AI summary
A display apparatus includes a substrate, a pixel defining layer, a spacer, an auxiliary electrode, and an organic light emitting diode. The substrate includes a light emitting area and a non-light emitting area adjacent to the light emitting area. The pixel defining layer is disposed on the non-light emitting area of the substrate. The spacer is disposed on the pixel defining layer. The auxiliary electrode is disposed on the spacer. The organic light emitting diode is disposed on the substrate, and at least a portion thereof is disposed in the light emitting area. The organic light emitting diode includes a pixel electrode, an intermediate layer disposed on the pixel electrode and including an organic light emitting layer, and an opposite electrode disposed on the intermediate layer and electrically connected to the auxiliary electrode.