OLED Pixel Opening Offset for Mask Tension Misalignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing display apparatus manufacturing methods face challenges in achieving precise alignment of the mask sheet with the display substrate, leading to misalignment of the opening portions, which results in incomplete coverage of the organic emission layer over the pixel electrode, affecting the clarity of the image produced.
Innovation Solution
The method involves shifting the opening areas of the pixel definition layer to align with the centers of the pixel electrodes, ensuring accurate positioning of the organic emission layer to cover the entire opening area, even when the mask sheet is tensioned, thereby ensuring complete coverage and clear light emission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a mask sheet is tensioned and used for forming the organic emission layer, then the manufacturing process can be completed, but the position of the opening portion of the mask sheet deviates from the designed position, resulting in misalignment
Solution Approach 1:
The pixel definition layer is designed with opening areas that are pre-positioned to account for the expected deviation when the mask sheet is tensioned. By performing the design adjustment beforehand, the patent ensures that even though the mask sheet opening portions will deviate during tensioning, the organic emission layer will still be deposited at the correct positions relative to the pixel electrodes.
2Productivity
If the opening portions of the mask sheet are misaligned with the pixel electrodes, then the manufacturing process continues, but the organic emission layer does not completely cover the pixel electrode, affecting image clarity
Solution Approach 1:
The pixel definition layer opening areas are designed in advance to compensate for mask sheet tensioning deviations. This preliminary design adjustment ensures that when deposition occurs, the organic emission layer achieves complete coverage of the pixel electrode despite the mask sheet opening portions being positioned differently from the original design coordinates.
3Adaptability or versatility
If the center of the opening area and the center of the organic emission layer are at different positions, then the structure can accommodate mask sheet tensioning, but the light emission clarity is reduced
Solution Approach 1:
The opening areas of the pixel definition layer are pre-positioned to account for mask sheet tensioning effects. This advance design ensures that the organic emission layer, when deposited through the mask sheet opening portions, will be correctly positioned relative to the pixel electrodes, maintaining clear light emission despite the centers being at different positions due to tensioning accommodation.
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 ensures that each subpixel emits clear light by accurately depositing the organic emission layer over the pixel electrode, enhancing image clarity and reducing manufacturing defects and costs.
Implementation Method 1
depositing a deposition material that passed through an opening portion of the mask sheet, in an opening area of the pixel definition layer
Data Source
AI summary
A display apparatus includes a substrate, a pixel definition layer arranged over the substrate and including at least one opening area, and an organic emission layer arranged over the pixel definition layer and covering the opening area, wherein a center of the opening area and a center of the organic emission layer are arranged at different positions in a plan view.