Composite Mask Assembly for Large-Area Low-Weight Deposition
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Solution Overview
Problem
Existing mask technologies are limited in size and weight, affecting the production yield and efficiency of display panels with light emitting patterns.
Innovation Solution
A mask assembly comprising a mask frame, a mask body, a first sub-mask made of metal, and a second sub-mask made of polymer, with specific openings and a welding portion, designed to provide a large size and low weight, utilizing materials with controlled thermal expansion coefficients.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large area mask is used to increase production yield, then the mask size is increased, but the mask weight increases making it difficult to handle and position
Solution Approach 1:
The mask assembly uses a composite structure combining a rigid mask frame (metal) for structural support and positioning, with a lightweight mask body (polymer material) for the actual masking function. This composite approach allows large mask area while maintaining low weight, as the polymer material provides sufficient masking capability without the mass of a fully metal construction.
2Ease of manufacture
If a single-layer mask structure is used, then the manufacturing process is simple, but the mask cannot provide both structural stability and lightweight properties
Solution Approach 1:
The mask is divided into two functional segments: a mask frame that provides structural stability, positioning, and support, and a mask body that provides the actual masking pattern and lightweight properties. This segmentation allows each component to be optimized for its specific function - the frame for strength and the body for weight reduction - while being manufactured and assembled separately.
3Strength
If metal material is used for the entire mask, then structural strength is ensured, but the weight becomes excessive and thermal expansion affects precision
Solution Approach 1:
Different materials are applied to different parts of the mask based on local requirements: the mask frame uses metal material where structural strength, rigidity, and thermal stability are critical for positioning and support, while the mask body uses lightweight polymer material where only masking functionality is required. This local differentiation optimizes both strength and weight.
4Ease of manufacture
If the mask frame thickness is uniform throughout, then manufacturing is easier, but the welding portion requires excessive thickness affecting assembly
Solution Approach 1:
The mask frame employs variable thickness design where most of the frame maintains a first thickness for general structural support, while the welding portion specifically increases to a second thickness greater than the first. This local thickness variation ensures proper welding capability at the joint without unnecessarily increasing the thickness (and complexity) of the entire frame structure.
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 assembly achieves a large-sized mask with low weight, enhancing production yield and efficiency in display panel manufacturing by reducing material damage and improving alignment during deposition processes.
Implementation Method 1
The second sub-mask may have a thermal expansion coefficient equal to or smaller than about 2 parts per million per degree in Celsius (ppm/° C.)
Implementation Method 2
a welding portion disposed on the second sub-mask and in the concave portion
Data Source
AI summary
A mask assembly includes: a mask frame provided with a first opening defined through a center portion thereof and including an outer frame surrounding the first opening and provided with at least one concave portion defined therein; a mask body disposed to correspond to the first opening and provided with second openings defined therethrough and having an area smaller than the first opening; a first sub-mask disposed on the mask body, provided with third openings defined therethrough over an entire area thereof and having an area smaller than each of the second openings, and including a metal material; a second sub-mask disposed on the first sub-mask, provided with fourth openings defined therethrough over an entire area thereof and having an area smaller than each of the third openings in a plane, and including a polymer material; and a welding portion disposed on the second sub-mask in the concave portion.