Two-Layered Mask Plate for OLED Manufacturing
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Solution Overview
Problem
The existing mask plates for OLED manufacturing are single-layered and require multiple variations for different display panel shapes and sizes, leading to high manufacturing complexity and cost due to the need for precise opening formation.
Innovation Solution
A two-layered mask plate structure comprising a first sub-mask plate with openings matching the target display panel and a second sub-mask plate with a covering opening region containing multiple openings, allowing for assembly with existing sub-mask plates to form new mask plates with varying shapes and sizes, reducing the need for complex opening formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single-layered mask plate is used with openings corresponding to target display panels, then the mask plate can form pixel patterns accurately, but manufacturing complexity and cost increase when different shapes and sizes are required
Solution Approach 1:
The mask plate is divided into a first sub-mask plate with a first opening and a second sub-mask plate with a second opening region containing multiple second openings. This segmentation allows the first sub-mask plate to define the overall display panel shape while the second sub-mask plate creates the pixel patterns, separating the manufacturing functions and reducing complexity for different display configurations
Solution Approach 2:
The second sub-mask plate with multiple second openings can be reused across different display panel configurations. By combining this universal second sub-mask plate with different first sub-mask plates, the same second sub-mask plate serves multiple functions for various display shapes and sizes, reducing the need to manufacture entirely new mask plates
2Adaptability or versatility
If various mask plates with different shapes and sizes are manufactured to meet diverse display requirements, then adaptability improves, but manufacturing cost increases due to complicated processes and high accuracy requirements
Solution Approach 1:
By segmenting the mask plate into modular first and second sub-mask plates, the system achieves adaptability through combination rather than manufacturing entirely new plates. The first sub-mask plate adapts to different display shapes while the second sub-mask plate provides universal pixel patterning capability
Solution Approach 2:
The second sub-mask plate with multiple second openings is positioned within the first opening of the first sub-mask plate, creating a nested structure. This nesting allows the universal second sub-mask plate to be contained within different first sub-mask plates, enabling adaptability while reusing the same second sub-mask plate across multiple configurations
3Device complexity
If a single-layered mask plate structure is used, then the structure is simple, but it requires high manufacturing accuracy and complicated processes leading to high costs
Solution Approach 1:
The mask plate is segmented into two functional sub-plates: the first sub-mask plate provides the display panel contour and the second sub-mask plate provides the pixel pattern. This segmentation distributes the manufacturing requirements, allowing each sub-plate to be manufactured with less stringent accuracy requirements than a single integrated plate, while the overall structure remains relatively simple
Solution Approach 2:
The first opening in the first sub-mask plate is preliminarily formed to match the target display panel shape and size before the second sub-mask plate is introduced. This preliminary action establishes the boundary conditions, allowing the second sub-mask plate to be subsequently positioned and used for pixel patterning without requiring complete re-manufacturing for different configurations
Data Source
AI summary
A mask plate and a method for manufacturing the same are provided. The mask plate comprises a first sub-mask plate and a second sub-mask plate stacked with each other, the first sub-mask plate is provided with at least one first opening therein, a size and a shape of the first opening correspond to those of a target display panel; the second sub-mask plate is provided with a second opening region, which covers at least one of the at least one first opening and includes a plurality of second openings. Since it is only required to ensure that the sizes and shapes of the first openings are the same as those of the target display panels respectively, and it is unnecessary to further manufacture openings for forming pixel patterns, comparing with the existing mask plate, the manufacturing process of the present disclosure is more simple and the manufacturing cost is lower.