OLED Deposition Mask Through-Hole Layout for Uniform Pixel Deposition
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Solution Overview
Problem
Existing deposition masks for OLED pixel deposition face challenges with reduced deposition efficiency and rigidity due to varying through-hole angles and heights, leading to non-uniform deposition and potential bending.
Innovation Solution
A deposition mask with unit through-holes featuring different widths and heights in multiple directions, accompanied by ribs and island portions to stabilize the mask and ensure uniform deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the through-hole height is made uniform in all directions, then the manufacturing process is simplified, but deposition efficiency is reduced due to non-optimal material flow angles
Solution Approach 1:
The patent applies local quality by making the through-hole height direction-dependent: the through-hole has a first height in a first direction and a second height in a second direction perpendicular to the first direction. This allows optimization of deposition efficiency in different directions while maintaining manufacturing feasibility through a systematic approach.
2Productivity
If the through-hole height varies in different directions to optimize deposition, then deposition efficiency improves, but the mask strength becomes non-uniform causing bending
Solution Approach 1:
The patent introduces asymmetry in the through-hole structure by setting different heights in different directions. The first height in the first direction and the second height in the second direction are deliberately made different to optimize deposition efficiency. This asymmetric design is compensated by corresponding asymmetric adjustments in the first and second widths to maintain overall structural balance and prevent mask bending.
Solution Approach 2:
The patent changes multiple geometric parameters of the through-hole simultaneously: first height, second height, first width, and second width. By coordinating changes in these parameters, the patent optimizes deposition efficiency while maintaining mask structural stability. The width adjustments compensate for the height asymmetry to prevent bending.
3Productivity
If the through-hole width is increased to improve material flow, then deposition efficiency improves, but the mask structural strength is reduced
Solution Approach 1:
The patent optimizes the balance between deposition efficiency and structural strength by carefully controlling the first width and second width of the through-hole. The width parameters are set to provide sufficient material flow paths while maintaining adequate mask structural integrity. The width adjustments are coordinated with height changes to achieve overall optimization.
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
The mask achieves improved deposition efficiency and reliability by maintaining consistent strength and uniformity across different directions, preventing bending and ensuring accurate pixel formation.
Implementation Method 1
The organic material is deposited on the deposition substrate using a large surface hole as an inlet and the small surface hole as an outlet
Data Source
AI summary
A deposition mask comprising; a metal plate including a deposition region and a non-deposition region, wherein the deposition region includes at least one effective portion; wherein the effective portion includes a plurality of unit through-holes, wherein the unit through-holes include a small surface hole formed on a first surface of the metal plate; a large surface hole formed on a second surface of the metal plate; and a connecting portion connecting the small surface hole and the large surface hole, wherein the unit through-hole includes a first width defined as a width in a first direction; and a second width defined as a width in a second direction, wherein the first width and the second width are different, wherein a rib is disposed between unit through-holes adjacent in the first direction, wherein an island portion is disposed between the unit through-holes adjacent in the second direction, wherein a height of the small surface hole of the unit through-hole in the second direction is smaller than a height of the small surface hole of the unit through-hole in the first direction.