OLED Shadow Mask with Alternating Column Tension
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Solution Overview
Problem
The existing shadow masks used in OLED display fabrication tend to sag due to gravity, leading to irregular formation of the organic light-emitting layer, which can result in larger or smaller sizes than desired, and require additional apparatuses like magnetic forces to prevent sagging, increasing fabrication costs.
Innovation Solution
A shadow mask design featuring alternately arranged columns with transmission parts having different open directions, either within columns or across rows, to create a balanced tension that prevents sagging, allowing for precise formation of the organic light-emitting layer without additional equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional shadow mask is used in OLED fabrication, then the fabrication process is simple, but the shadow mask sags due to gravity causing irregular formation of the organic light-emitting layer
Solution Approach 1:
The shadow mask is divided into multiple columns, with each column containing transmission parts arranged in different directions. This segmentation allows each column to independently manage tension forces, preventing overall sagging while maintaining fabrication simplicity
Solution Approach 2:
Different columns of the shadow mask have transmission parts with different open directions (e.g., first column has horizontal openings, second column has vertical openings). This local variation in quality creates balanced tension distribution across the mask structure, preventing sagging without complicating the overall fabrication process
2Stability of the object's composition
If additional apparatuses like magnetic forces are used to prevent shadow mask sagging, then the shadow mask position stability is improved, but the fabrication cost increases
Solution Approach 1:
The shadow mask structure itself provides the solution to its sagging problem through its alternating column design. The mask's own geometric configuration creates internal tension balance that automatically prevents sagging, eliminating the need for external magnetic apparatuses or other complex stabilization equipment
3Ease of manufacture
If transmission parts in shadow mask are arranged in the same direction, then the manufacturing process is simple, but the shadow mask sags more severely
Solution Approach 1:
Adjacent columns of transmission parts are arranged asymmetrically in different directions (e.g., horizontal in one column, vertical in the next). This asymmetric arrangement prevents uniform stress distribution that would cause sagging, while still maintaining relatively simple manufacturing processes
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 solution effectively prevents sagging of the shadow mask during evaporation deposition, ensuring the organic light-emitting layer is formed accurately and consistently, reducing fabrication costs by eliminating the need for additional apparatuses to apply magnetic forces.
Implementation Method 1
A shadow mask design featuring alternately arranged columns with transmission parts having different open directions, either within columns or across rows, to create a balanced tension that prevents sagging
Implementation Method 2
forming an organic light-emitting layer by supplying an organic light-emitting material layer from an organic light-emitting material supplier positioned below the shadow mask to the substrate through the transmission parts of shadow mask
Data Source
AI summary
A shadow mask and a method of fabricating an OLED display using the same is disclosed, wherein the shadow mask is not sagging, and the shadow mask includes a plurality of columns, each column including a plurality of first or second cell-forming parts, wherein the first and second cell-forming parts are alternately arranged in the columns, and the first and second cell-forming parts provided in the adjacent columns include transmission parts having the different open directions.