OLED Mask Design for Variable Display Area Manufacturing
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Solution Overview
Problem
The existing manufacturing processes for organic light emitting diode (OLED) display devices require multiple masks, which can be costly and inefficient due to the need for separate masks for different process conditions, such as varying pixel sizes and resolutions.
Innovation Solution
A manufacturing method that uses a shared mask setup, where a mask support is positioned with a transmissive and non-transmissive area, allowing the light emitting layer to be formed in specific areas while avoiding others, enabling the same mask to be used across different display area sizes by adjusting the peripheral areas based on the mask's non-transmissive area width.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple masks are used for different process conditions, then manufacturing precision is maintained, but device complexity and cost increase
Solution Approach 1:
The patent applies universality by designing a single mask structure that can be used across different display area sizes and resolutions. The mask includes a display area portion and a peripheral area portion with a non-transmissive area that can be positioned at various locations, allowing the same mask to serve multiple manufacturing conditions without requiring separate masks for each configuration.
Solution Approach 2:
The patent implements dynamics through the movable positioning of the non-transmissive area within the peripheral area portion of the mask. This allows the mask to be dynamically adjusted to accommodate different display area sizes and resolutions, enabling one mask to adapt to multiple process conditions rather than requiring static, dedicated masks for each condition.
2Productivity
If mask size is increased to cover larger display areas, then productivity improves, but manufacturing precision for smaller areas decreases
Solution Approach 1:
The patent applies segmentation by dividing the mask into distinct functional portions: a display area portion for forming light emitting layers in active display regions, and a peripheral area portion containing a non-transmissive area for defining peripheral structures. This segmentation allows each portion to be optimized independently - the display area portion can be large for high productivity, while the peripheral area portion maintains precise alignment control.
Solution Approach 2:
The patent implements local quality by giving different regions of the mask different functional properties. The display area portion is designed for high-throughput deposition across large areas, while the peripheral area portion with the non-transmissive area provides localized precision control for defining specific peripheral structures, allowing each region to optimize its performance for its specific function.
3Manufacturing precision
If fixed mask positions are used, then manufacturing precision is maintained, but adaptability to different display configurations is reduced
Solution Approach 1:
The patent applies universality by designing a single mask structure that can be used across different display area sizes and resolutions. The mask includes a display area portion and a peripheral area portion with a non-transmissive area that can be positioned at various locations, allowing the same mask to serve multiple manufacturing conditions without requiring separate masks for each configuration.
Solution Approach 2:
The patent implements dynamics through the movable positioning of the non-transmissive area within the peripheral area portion of the mask. This allows the mask to be dynamically adjusted to accommodate different display area sizes and resolutions, enabling one mask to adapt to multiple process conditions rather than requiring static, dedicated masks for each condition.
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
This approach reduces the need for multiple masks and simplifies the manufacturing process, lowering costs and improving efficiency by allowing the same mask to be used regardless of display area size, thus reducing the complexity and expense of mask replacement.
Implementation Method 1
In the organic light emitting diode, organic layers and/or electrodes may be formed by a vacuum deposition method
Data Source
AI summary
A manufacturing method of a display device includes forming a mask support spaced apart from an edge of a substrate by a first distance, disposing a mask including a transmissive area and a non-transmissive area surrounding the transmissive area on the mask support, determining a display area and a peripheral area positioned at a side of the display area based on at least one of a size of the display area and a width of the non-transmissive area, and forming a light emitting layer in the display area corresponding to the transmissive area and a portion of the peripheral area using the mask.