OLED Substrate Segmentation for Mask Bending and Alignment
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Solution Overview
Problem
The deposition method using a fine metal mask (FMM) for manufacturing organic light-emitting display devices faces challenges with large substrates, as the mask can bend due to gravitational pull, distorting patterns and requiring time-consuming alignment and separation processes, leading to low production efficiency and difficulty in achieving high-definition patterns.
Innovation Solution
The organic light-emitting display apparatus features a substrate with independently formed pixel electrodes and multiple organic light-emitting layers, utilizing a refraction conversion layer and semi-transparent reflective layers to enhance luminescent efficiency and productivity, and a method involving continuous deposition processes with spaced-apart deposition assemblies to simplify the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large fine metal mask is used for deposition on large substrates, then the pattern coverage is improved, but the mask bends due to gravitational pull causing pattern distortion
Solution Approach 1:
The patent divides the substrate into multiple smaller substrates and processes them separately using a smaller fine metal mask. This segmentation approach allows the mask to maintain its structural integrity and pattern precision while still achieving coverage of the overall large area through multiple processing steps.
Solution Approach 2:
The patent transitions from processing a single large substrate in one step to processing multiple smaller substrates in sequence, effectively adding a temporal dimension to the manufacturing process. This allows the use of a smaller, more precise mask while achieving coverage of the same total area.
2Manufacturing precision
If a fine metal mask is used for deposition, then the organic layer pattern is formed, but the alignment and separation processes are time-consuming
Solution Approach 1:
By dividing the large substrate into multiple smaller substrates, the patent reduces the complexity and time required for mask alignment and separation operations. Each smaller substrate requires less precise alignment and faster separation, thereby improving overall production efficiency while maintaining pattern formation capability.
Solution Approach 2:
The patent performs preliminary processing by dividing the substrate into smaller units before the deposition process. This preliminary action simplifies subsequent mask alignment and separation operations, reducing the time required for these critical steps and improving production efficiency.
3Illumination intensity
If multiple masks are used for different organic light-emitting layers, then the color luminescence is optimized, but the manufacturing complexity increases
Solution Approach 1:
The patent segments the manufacturing process into separate deposition steps for different organic light-emitting layers, each using a dedicated fine metal mask. This segmentation allows optimization of color luminescence for each layer while managing complexity through systematic process organization and repeated use of the same mask design.
Solution Approach 2:
The patent employs the same fine metal mask design for multiple different organic light-emitting layers, making the mask a universal tool that serves multiple functions. This universality reduces manufacturing complexity by eliminating the need for different mask designs for different layers, while still allowing optimization of color luminescence through material selection.
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 increases luminescent efficiency, lifetime, and productivity by reducing the need for multiple masks, optimizing color luminescence, preventing total reflection, and improving device properties, while allowing for faster processing and reduced production time.
Implementation Method 1
a refraction conversion layer disposed between the substrate and the pixel electrodes
Implementation Method 2
semi-transparent reflective layers to enhance luminescent efficiency
Data Source
AI summary
An organic light-emitting display apparatus includes a substrate comprising pixels, each of which comprises a first sub-pixel, a second sub-pixel, and a third sub-pixel, and a plurality of pixel electrodes independently formed for respective sub-pixels; a first common layer commonly formed on the pixels; first lines covering first sub-pixels arranged in a first direction, wherein the first lines comprise a first organic light-emitting layer; a plurality of second lines covering second sub-pixels arranged in the first direction, wherein the second lines comprise a second organic light-emitting layer differing from the first organic light-emitting layer; a second common layer commonly formed on the plurality of pixels, wherein the second common layer comprises a third organic light-emitting layer differing from the first organic light-emitting layer and the second organic light-emitting layer; a third common layer commonly formed on the pixels; and an opposite electrode commonly formed on the pixels.