OLED Spacer Arrangement Minimizing Mask Contact
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional OLED displays face issues with spacer interference and mask contact during subsequent processes, leading to dent defects and pixel defects due to the contact area between spacers and masks, which affects deposition reliability and image quality.
Innovation Solution
The OLED display features two or more spacers arranged at the center or vicinity of a virtual quadrangle, protruding in an island-like shape from the pixel definition layer, with symmetrical and varied shapes to minimize contact area with the mask and reduce interference, thereby enhancing deposition reliability and image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spacers are arranged in conventional positions, then structural support is provided, but mask contact and dent defects occur during deposition
Solution Approach 1:
The patent applies asymmetry by positioning spacers at non-conventional locations - specifically at the center point or vicinity of a virtual quadrangle formed by four electrode portions, rather than at symmetric corner positions. This asymmetric arrangement minimizes contact area with deposition masks and prevents dent defects while maintaining structural support function
Solution Approach 2:
The patent transitions from conventional two-dimensional spacer arrangements (at corners or edges) to a three-dimensional spatial optimization by placing spacers at the center point of the virtual quadrangle. This dimensional repositioning in the planar layout reduces mask contact area and eliminates dent defects during deposition processes
2Reliability
If spacers are positioned to minimize mask contact, then deposition reliability improves, but structural support may be compromised
Solution Approach 1:
The patent applies local quality by concentrating spacer support function at the center point of the virtual quadrangle formed by electrode portions, rather than distributing spacers uniformly at corners. This localized positioning provides adequate structural support while minimizing mask contact area, achieving both deposition reliability and structural integrity
3Ease of manufacture
If spacers are arranged symmetrically at corners, then manufacturing is simplified, but contact area with mask increases causing defects
Solution Approach 1:
The patent deliberately employs asymmetric spacer positioning at the center point of the virtual quadrangle rather than symmetric corner placement. This asymmetric arrangement reduces mask contact area and prevents pixel defects during deposition, while the center-point symmetry (radial symmetry) maintains ease of manufacturing through simple alignment procedures
Data Source
AI summary
An organic light emitting diode (OLED) display includes two or more spacers on a substrate, the two or more spacers being arranged at least at either one of a center point of a virtual quadrangle or a vicinity of the center point of the virtual quadrangle, an electrode portion at each apex of the virtual quadrangle, the electrode portion surrounding the two or more spacers, and a pixel definition layer on the electrode portion, the pixel definition layer including exposing the electrode portion.