Multi-Directional OLED Spacers for Mask Support and Leakage Prevention
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Solution Overview
Problem
Conventional spacers in OLED displays provide limited support and often allow organic material to leak into adjacent pixel regions during deposition, and they can snag or catch fine metal masks during fabrication, leading to fabrication challenges.
Innovation Solution
The use of multi-directional spacers that extend in various directions between pixels, providing a robust support structure for the metal mask and preventing organic material from invading adjacent pixels by forming a substantial barrier against deposition shadows, while also facilitating easier and more stable mounting and transportation of the mask.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional spacers are used to support the metal mask, then the mask can be mounted during fabrication, but the spacers are sparsely spaced and have small area, allowing organic material to leak into adjacent pixel regions
Solution Approach 1:
The spacer structure is segmented into multiple directional components (first direction and second direction extensions) that radiate from a central region. This segmentation allows the spacer to block organic material leakage paths more effectively while maintaining a manageable structural complexity through modular radial arrangement.
Solution Approach 2:
The spacer extends in multiple directions (first direction and second direction) rather than solely in one direction, adding dimensional coverage. This multi-directional extension creates a more comprehensive barrier against organic material leakage from adjacent pixel regions while the central region provides a stable mounting platform.
2Manufacturing precision
If fine metal mask is used to define pixel regions, then deposition precision is improved, but the mask can get caught or snagged by conventional spacers during mounting or transport
Solution Approach 1:
The spacer is segmented into a central region for mounting and multiple extension portions in different directions. This segmentation allows the mask to be mounted on the stable central region while the extensions radiate outward to prevent snagging during transport, improving ease of operation without compromising pixel region definition precision.
Solution Approach 2:
The spacer transitions from a simple linear structure to a multi-dimensional radial structure with extensions in first and second directions. This dimensional expansion provides a larger mounting surface area on the central region for stable mask attachment and creates clearance zones that prevent the mask from getting caught during transport.
3Device complexity
If spacers are sparsely spaced with small area, then device complexity is reduced, but they provide limited support structure for the metal mask
Solution Approach 1:
The spacer is divided into a central region and multiple extension portions, where the central region concentrates support function for mask mounting while extensions provide structural reinforcement. This segmentation strengthens the support structure without requiring dense spacing of multiple spacers across the device.
Solution Approach 2:
The spacer extends in multiple directions (first and second directions) from the central region, creating a star-like or cross-shaped structure. This multi-dimensional extension distributes mechanical support forces more effectively and provides a larger overall support footprint without increasing the number of spacer locations.
Data Source
AI summary
Embodiments of the present disclosure provide an organic electroluminescence display device. The display device may include a set of multi-directional spacers that are interposed between the pixels of the display. In one embodiment, the spacers are positioned in both lengthwise and crosswise directions. In another embodiment, the spacers include a first portion that is extends lengthwise between pixels and one or more portions that extend laterally from the first portion between pixels. In yet another embodiment, the spacers include portions that extend in multiple directions between pixels. The spacers may substantially surround each of the pixels and may serve as a boundary, for example, that prevents organic material for one pixel from being incorrectly deposited in another pixel. The spacers can be configured as a support structure, such as, for a metal mask during fabrication of the display device. In addition, the multi-directional aspect of the spacers may be useful in protecting the pixels from damage, such as, when a metal mask is moved during mounting or during fabrication of the display device.