Coated Display Mask Structure for Laser Damage Reduction
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Solution Overview
Problem
Current mask manufacturing technologies for large-area display panels face challenges in reliability and cost efficiency, particularly in the precision and durability of the mask components during the laser processing stages.
Innovation Solution
A mask design featuring a base part with cell openings, a coating part made of materials like magnesium or aluminum that have a lower absorption rate for lasers, and a joining part that separates the coating and base parts, allowing for precise laser processing while minimizing damage to the base part, thereby improving reliability and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask is used for laser processing in large-area display panel manufacturing, then the mask enables precise patterning of light-emitting patterns, but the base part of the mask suffers from laser damage due to high absorption rate
Solution Approach 1:
The mask is constructed as a composite structure with a base part (high laser absorption rate) and a coating part (low laser absorption rate). The coating part is formed on the upper surface of the base part to create a multi-material system that combines the advantageous properties of each material for different functional requirements.
Solution Approach 2:
Different parts of the mask have different material compositions and laser absorption characteristics. The base part uses a material with high laser absorption rate for structural integrity, while the coating part uses a material with low laser absorption rate for laser protection, creating local quality variations optimized for specific functions.
2Reliability
If a thick coating part is used to protect the base part from laser damage, then the base part is better protected, but the mask thickness increases and manufacturing complexity increases
Solution Approach 1:
The thickness of the coating part is optimized to be between 1 μm and 10 μm. This parameter range provides sufficient laser protection for the base part while maintaining manageable mask thickness and manufacturing complexity. The specific thickness value is selected based on balancing protection effectiveness with manufacturing feasibility.
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
The solution enhances the reliability and accuracy of the mask manufacturing process by protecting the base part from laser damage and reducing processing costs through the strategic use of materials with different laser absorption rates, ensuring consistent quality in large-area display panel production.
Implementation Method 1
An absorption rate of the coating part for a laser may be lower than an absorption rate of the base part for the laser
Data Source
AI summary
Provided is a mask including a mask frame including a base part in which cell openings are defined, and a coating part surrounding edges of the cell openings, covering at least a portion of an upper surface of the base part, and including a materials that is different from that of the base part, and unit masks on the mask frame, respectively corresponding to the cell openings, including a material that is different from that of the coating part, and in which openings are defined.