Undulated Mask Opening End Prevents Spacer Contact
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Solution Overview
Problem
The position shift of masks during the manufacturing of display devices due to magnetic forces and misalignment issues leads to contact between the common metal mask's opening end and mask spacers, causing foreign substances to stick and degrade the reliability of the display device by increasing contact resistance and forming dark spots.
Innovation Solution
The implementation of pixel-region and frame-region mask spacers with a common layer having undulations in plan view, preventing contact between the mask opening end and spacers even when shifted, and reducing the uncovered area between spacers, thus enhancing the reliability of the display device.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the CMM opening end is made flush and linear in plan view, then the common layer can be formed uniformly, but the opening end is more easily bent toward the substrate by magnetic force or its own weight, causing contact with mask spacers and foreign substance transfer
Solution Approach 1:
The patent applies curvature to the mask opening end by forming undulations (protrusions and recesses) in the plan view, replacing the traditional flat linear shape. This curved configuration increases the distance between the opening end and mask spacers, preventing contact and foreign substance transfer while maintaining uniform common layer formation.
2Area of stationary object
If the mask opening end is positioned close to the pixel region, then the common layer covers the entire pixel region uniformly, but any position shift causes the opening end to contact mask spacers and transfer foreign substances
Solution Approach 1:
The patent incorporates undulations in the mask opening end configuration before the film formation process. These pre-formed protrusions and recesses create inherent spacing that prevents contact between the opening end and mask spacers even when position shifts occur during manufacturing, thereby maintaining manufacturing precision without requiring additional alignment steps.
3Productivity
If the CMM is used to form common layers, then the entire pixel region can be covered with a single mask, but the large opening area makes the mask more susceptible to position shifts and bending toward the substrate
Solution Approach 1:
The patent applies undulations to the large opening area of the CMM, creating a wavy pattern that increases the effective distance between the opening end and the mask spacer boundaries. This curvature design maintains the large opening area for efficient film formation while preventing the opening end from contacting mask spacers even when position shifts occur.
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 configuration prevents foreign substances from sticking to the spacers and maintains contact between electrodes and wires, resulting in a more reliable display device with improved manufacturing reliability.
Implementation Method 1
the substrate and each mask are joined together closely by a magnetic force from a magnetic-force generating source, such as a magnet on the substrate backside
Data Source
AI summary
A display device includes: a plurality of pixel-region mask spacers disposed in a pixel region where a plurality of pixels are disposed; a plurality of frame-region mask spacers disposed in a frame region outside the pixel region so as to surround the pixel region; and a common layer disposed on the plurality of pixel-region mask spacers, the common layer being common to the plurality of pixels, wherein the common layer comprises an end that has undulations in a plan view.