Additively Manufactured Shadow Masks With Elevated Crossbeams
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Traditional shadow masks are limited in design capabilities due to their singular solid structure, which restricts the creation of 'island' type masking and is costly and tedious to produce, especially when dealing with complex geometries and non-planar substrates.
Innovation Solution
A shadow mask system featuring a frame with island mask features and crossbeams that allow for additive manufacturing, enabling the creation of complex mask structures and deposition on non-planar surfaces by coupling island features to the frame and allowing material deposition underneath the crossbeams.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional shadow masks are manufactured as singular solid members, then manufacturing simplicity is maintained, but design capabilities are limited and island type masking is problematic
Solution Approach 1:
The shadow mask is divided into multiple discrete components including a frame, multiple island mask features, and crossbeams. These segmented parts are manufactured separately and then assembled together, enabling complex island-type masking patterns that would be impossible with a traditional solid mask while maintaining manufacturing feasibility through modular construction
Solution Approach 2:
The island mask features are positioned within the frame structure, with crossbeams connecting the islands to the frame at elevated positions. This nested arrangement allows multiple functional elements (frame, islands, crossbeams) to be integrated in a hierarchical structure that provides both design versatility and structural stability
2Stability of the object's composition
If crossbeams are added to couple island mask features to the frame, then structural stability is improved, but material deposition is blocked in additional areas
Solution Approach 1:
The crossbeams are positioned at an elevation above the substrate surface, creating a three-dimensional structure. This vertical dimensionality allows the crossbeams to provide structural support and coupling between islands and frame while permitting material deposition to occur in the space underneath the crossbeams, thus maintaining deposition area despite added structural elements
3Ease of manufacture
If additive manufacturing is used to produce shadow masks, then manufacturing cost and complexity are reduced, but precision for traditional solid mask requirements may be compromised
Solution Approach 1:
By segmenting the mask into discrete additively manufactured components (frame, islands, crossbeams, posts), each part can be manufactured with optimized tolerances for its specific function. The modular nature of additive manufacturing makes it particularly suitable for producing these complex geometric shapes that would be difficult or expensive to manufacture using traditional subtractive methods
Solution Approach 2:
Additive manufacturing enables precise control over geometric parameters such as crossbeam elevation, island positioning, and post heights. The layer-by-layer construction process allows for accurate reproduction of complex three-dimensional features while maintaining the precision needed for functional performance in material deposition applications
4Manufacturing precision
If island mask features are used to block deposition on specific areas, then selective deposition control is improved, but manufacturing complexity increases
Solution Approach 1:
The mask structure is segmented into a frame, multiple independent island features, and connecting crossbeams. This segmentation enables precise control over which areas block deposition (the islands) while allowing material to deposit in other areas, achieving selective deposition control through the strategic placement of discrete masking elements rather than requiring a completely solid mask with complex cutouts
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
Enables the production of complex mask structures and deposition on non-planar surfaces, expanding design capabilities and reducing costs by using additive manufacturing and allowing for more efficient material deposition processes like physical vapor deposition and chemical vapor deposition.
Implementation Method 1
the deposition of the material upon the surface of the substrate is configured as a physical vapor deposition or sputtered deposition
Implementation Method 2
the deposition of the material upon the surface of the substrate is configured as a physical vapor deposition or sputtered deposition
Implementation Method 3
the deposition of the material upon the surface of the substrate is configured as a chemical vapor deposition or photolithography
Data Source
AI summary
A shadow mask for a substrate is disclosed. The shadow mask includes a frame circumscribing a surface of the substrate. The shadow mask further includes one or more island mask features within the surface of the substrate, configured to block a deposition of a material onto at least a portion of the surface of the substrate. The shadow mask further includes one or more crossbeams coupling one or more island mask features to the frame at an elevation relative to the substrate. The one or more cross beams are configured to permit deposition of a material onto the substrate surface underneath the one or more crossbeams. In some instances, the shadow mask is manufactured through an additive manufacturing process.