OLED Deposition Mask Structure for Uniform Pixel Through-Holes
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Solution Overview
Problem
Existing deposition masks for OLED pixel deposition face challenges in achieving uniformity and reliability due to non-uniform shape and size of through-holes, leading to variations in deposition patterns and reduced efficiency.
Innovation Solution
A deposition mask with a metal plate design featuring unit through-holes, small and large area holes connected by a connecting portion, and island portions between adjacent holes, which control the shape and size of the through-holes to ensure uniformity and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If a fine metal mask with through-holes is used to form RGB light emitting layer, then light efficiency is improved by eliminating the need for color filters, but manufacturing complexity increases due to multi-step deposition and alignment requirements
Solution Approach 1:
The mask is divided into multiple effective portions, each containing unit through-holes for specific pixel patterns. This segmentation allows different regions of the mask to be optimized for different deposition requirements, enabling RGB color formation without complex multi-step processes while maintaining high light efficiency
Solution Approach 2:
The mask structure integrates multiple functions into a single component: it provides alignment features, defines through-hole patterns for color deposition, and includes isolation regions for precise pixel formation. This multi-functionality eliminates the need for separate color filters while simplifying the manufacturing process
2Ease of manufacture
If through-holes in the metal mask are non-uniform in shape and size, then manufacturing ease is improved, but deposition reliability decreases due to variations in deposition patterns
Solution Approach 1:
The mask includes alignment features with specific geometric properties (such as reference holes with defined dimensions and positions) that provide local quality control. These features ensure uniform through-hole formation while maintaining ease of manufacturing by providing clear fabrication guidelines for each region of the mask
Solution Approach 2:
The mask design specifies precise parameter ranges for through-holes including diameter, depth, spacing, and positional tolerances. By controlling these parameters within defined ranges, the mask achieves both manufacturability and deposition reliability, ensuring consistent pixel pattern formation across the entire mask surface
3Ease of manufacture
If the inclination angle and height of through-holes vary, then manufacturing simplicity is maintained, but deposition precision deteriorates due to non-uniform deposition patterns
Solution Approach 1:
The mask includes pre-formed alignment features and reference structures that establish the geometric framework before through-hole formation. This preliminary action ensures that subsequent through-hole fabrication maintains uniform inclination angles and heights, achieving precise deposition patterns while preserving manufacturing simplicity through a structured fabrication sequence
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 design improves deposition efficiency and reliability by ensuring uniform thickness and shape of deposition patterns, reducing deviations in inclination angles and heights of through-holes, thereby enhancing the overall deposition process.
Implementation Method 1
The organic material is deposited on the deposition substrate using a deposition mask
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 area hole formed on a first surface of the metal plate; a large area hole formed on a second surface of the metal plate; and a connecting portion connecting the small area hole and the large area hole, 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 the island portion includes a first island portion and a second island portion spaced apart from each other, wherein the first island portion contacts the rib, wherein the second island portion is spaced apart from the rib