Adjustable Mask Frame Assembly for Precise Display Deposition
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Solution Overview
Problem
Deposition quality in display apparatuses is compromised due to deformation of mask sheets and frames, causing the deposition material to be misplaced on the substrate.
Innovation Solution
A mask assembly with a mask frame featuring adjustable sides through gap portions and adjustment portions, allowing for precise alignment and adjustment of the mask sheet to maintain deposition accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mask sheet and mask frame are fixed without adjustment capability, then the manufacturing process is simple, but deformation occurs causing poor deposition quality
Solution Approach 1:
The mask frame incorporates gap portions that enable dynamic adjustment of the mask sheet position. The gap adjustment portions allow the mask frame to be modified in real-time to compensate for deformation, transforming a static structure into a dynamic one that can adapt to maintain deposition precision.
Solution Approach 2:
The invention changes the physical parameters of the mask frame by introducing gap portions with adjustable dimensions. By modifying the gap size and position through gap adjustment portions, the mask frame can compensate for deformation and maintain optimal deposition conditions without requiring complete replacement or complex realignment systems.
2Manufacturing precision
If the mask sheet deforms during deposition, then alignment is lost requiring removal and re-welding, but this increases manufacturing time and cost
Solution Approach 1:
The gap portions are pre-designed into the mask frame structure before deposition begins. This preliminary configuration allows for quick adjustments if deformation occurs, eliminating the need for time-consuming removal and re-welding operations. The adjustment mechanism is prepared in advance to enable rapid response to alignment issues.
Solution Approach 2:
The mask frame includes self-adjustment capabilities through the gap adjustment portions that can be modified without removing the mask sheet. This self-service feature allows operators to correct alignment issues directly on the assembled structure, avoiding the need to disassemble and reassemble components, thereby maintaining high manufacturing efficiency.
3Manufacturing precision
If the mask frame lacks adjustment capability, then the structure is simple and cost-effective, but deposition material cannot be placed at desired positions
Solution Approach 1:
The mask frame is segmented into multiple sections with gap portions that can be independently adjusted. This segmentation allows for localized adjustments to specific areas of the mask frame without affecting the entire structure, enabling precise material placement while keeping the manufacturing process relatively simple and modular.
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
Enhances deposition quality by enabling realignment of the mask sheet without removing and re-welding, reducing manufacturing costs and time, and ensuring precise material placement on the substrate.
Implementation Method 1
a gap adjustment portion tensile-welded to the mask frame across the gap portion
Data Source
AI summary
A mask assembly includes: a mask frame having a plurality of sides including a first side extending in a first direction, and an opening area defined by the plurality of sides; a gap portion recessed in the first side in a second direction crossing the first direction; a mask sheet covering the opening area; and a gap adjustment portion tensile-welded to the mask frame across the gap portion.