Spacer Extensions for Mask Alignment in Display Panels
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Solution Overview
Problem
Existing display panel manufacturing processes face challenges in achieving high manufacturing yield and reliability, particularly due to issues related to the deposition method using a mask and the support structures for the mask.
Innovation Solution
A display panel design that includes a circuit board with a pixel circuit and an element layer containing light emitting elements, a pixel defining layer with specific openings, and a spacer structure with extensions that support the mask and improve rigidity, thereby enhancing manufacturing precision and reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask deposition method is used to form the emissive layer, then manufacturing precision can be improved, but the reliability decreases due to potential mask damage and contamination
Solution Approach 1:
The patent removes the mask component from the deposition system entirely, replacing it with a direct thermal evaporation or atomic layer deposition method. This eliminates mask-related issues such as damage, contamination, and alignment problems while maintaining precise emissive layer formation through controlled deposition parameters and substrate temperature management
Solution Approach 2:
The mechanical mask system is replaced with a field-based control method where electric or magnetic fields are used to control the deposition process. This substitution eliminates mechanical wear and alignment issues inherent in mask-based systems while achieving comparable or superior precision through field-controlled material transport
2Device complexity
If the spacer structure is made thinner to reduce device complexity, then ease of manufacture improves, but the rigidity decreases leading to potential damage during processing
Solution Approach 1:
The spacer is constructed using composite materials combining polymer matrices with reinforcing fillers such as glass fibers, metal particles, or nanotubes. This composite structure achieves high rigidity and mechanical strength while maintaining a thin profile, thereby reducing device complexity without compromising structural integrity during processing
Solution Approach 2:
The spacer design transitions from a simple planar structure to a three-dimensional configuration with vertical pillars, arches, or truss-like geometries. This dimensional change provides enhanced rigidity and load-bearing capacity in the lateral direction while keeping the overall thickness minimal, thus reducing device complexity without sacrificing strength
3Reliability
If the extensions of the spacer are made longer to improve mask support, then reliability improves, but the risk of contamination to light emitting elements increases
Solution Approach 1:
The mask component is completely removed from the system, eliminating the need for spacer extensions to support it. The deposition process is conducted using maskless techniques such as direct thermal evaporation or atomic layer deposition, which inherently prevent contamination while maintaining reliable material transport to the substrate
Solution Approach 2:
An intermediary protective layer or shutter system is introduced between the deposition source and the substrate. This intermediary can be dynamically controlled to allow material transport only to intended areas, providing reliable deposition control without requiring long spacer extensions that could contaminate the light emitting elements
Data Source
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AI summary
A display panel includes a circuit board (100) and an element layer (200) disposed on the circuit board (100) and including a pixel defining layer (PDL) having a plurality of openings (OP-R, OP-G, OP-B), and a spacer (SPC) disposed on the pixel defining layer (PDL). The plurality of openings include a first opening (OP-R), a second opening (OP-G), and a third opening (OP-G) that are adjacent to the spacer (SPC). The spacer (SPC) includes a central portion (CP) disposed between the first, second, and third openings and a first extension (P1), a second extension (P2), and a third extension (P3) that protrude from the central portion (CP) in three directions, respectively. End portions of the first, second, and third extensions (P1-P3) are disposed in a region defined by virtual lines (AR) connecting a first center of the first opening (CP-R), a second center of the second opening (CP-G), and a third center of the third opening (CP-B).