Alternating Mask Frame Assembly for Thin Film Deposition
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Solution Overview
Problem
As the size of display devices using organic light emitting elements increases, thin film deposition masks tend to droop and become spaced apart due to their rectangular shape, leading to connectivity issues during the deposition process.
Innovation Solution
A mask frame assembly design where first and second masks are alternately placed and connected, featuring overlapping and non-overlapping portions that overlap at connectors, with the connector's width being greater than the openings' width, and extended in a vertical direction to prevent drooping and spacing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If thin film deposition masks are made larger to accommodate increasing display device sizes, then the coverage area increases, but the masks droop and become spaced apart due to their rectangular shape
Solution Approach 1:
The mask assembly is divided into multiple individual masks arranged in an alternating pattern (first masks and second masks). Each mask is a smaller rectangular unit, but collectively they form a large coverage area. The masks are connected through overlapped portions at connector regions, creating a segmented yet integrated structure that maintains stability while achieving large area coverage.
Solution Approach 2:
The masks are arranged in an alternating pattern across multiple dimensions rather than a simple linear or grid arrangement. First masks and second masks alternate in position, creating a staggered configuration that enhances structural stability. The connector regions extend in a direction vertical to the main mask plane, adding dimensional complexity that prevents drooping.
2Ease of manufacture
If rectangular masks are used for simplicity of manufacture, then manufacturing ease increases, but the masks droop and connectors become spaced apart over time
Solution Approach 1:
The connector structure incorporates nested overlapped portions where connectors are embedded within the mask bodies. The first and second overlapped portions of each mask nest with corresponding portions of adjacent masks at the connector regions. This nesting creates interlocking connections that maintain reliability while using simple rectangular mask shapes that are easy to manufacture.
Solution Approach 2:
The mask assembly uses composite structural elements combining mask bodies with integrated connector portions. The overlapped portions create composite regions where material from adjacent masks interlocks, forming a unified structure that maintains connection reliability. This composite approach allows simple rectangular masks to be manufactured while achieving reliable connections through the composite connector regions.
3Device complexity
If masks are connected through simple adjacent placement, then assembly complexity decreases, but individual masks droop and become spaced apart
Solution Approach 1:
Adjacent masks are merged through overlapped portions at connector regions. The first overlapped portion of one mask combines with the second overlapped portion of the adjacent mask, creating a merged connector structure. This merging increases connection strength and prevents drooping while maintaining relatively simple assembly procedures. The edge portions of masks are designed to overlap and merge with adjacent masks, forming integrated connection zones.
Solution Approach 2:
The mask assembly design incorporates pre-configured overlapped portions and connector regions that are prepared in advance during mask fabrication. The first and second overlapped portions are pre-formed on each mask before assembly, allowing for preliminary preparation that simplifies the final assembly process. This preliminary action ensures that when masks are connected, the connector regions are already configured to provide strong, droop-resistant connections.
Data Source
AI summary
A mask frame assembly for thin film deposition and manufacturing method thereof are disclosed. One inventive aspect includes a mask frame, a plurality of first masks and a plurality of second masks. The first and second masks are alternately formed in a first direction. Two overlapped portions of each of the first and second masks are connected to both sides of the non-overlapped portion of each of the first and second mask, respectively. In addition, one overlapped portion of each first mask and one overlapped portion of each second mask overlap each other at a connection area.