Composite Mask Assembly for Large, Lightweight Patterning
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Solution Overview
Problem
Existing mask technologies are limited by weight and size, which affects 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 and a lattice structure for enhanced stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a mask is made larger to increase production yield, then the production efficiency improves, but the weight increases
Solution Approach 1:
The mask assembly uses a composite structure combining a metal frame (high strength) with a polymer mask body (low weight). This allows the mask to be made larger for increased production yield while the polymer material keeps the overall weight low, resolving the contradiction between size and weight.
Solution Approach 2:
The mask body is constructed as a thin polymer film with patterns formed therein. This thin-film structure provides the necessary masking function while minimizing weight, enabling larger mask sizes without proportionally increasing weight, thus improving production yield efficiency.
2Productivity
If a mask is made larger to increase production yield, then the production efficiency improves, but the structural stability deteriorates
Solution Approach 1:
The metal frame provides high structural strength and stability, while the polymer mask body provides the masking function. This composite structure enables larger mask sizes for increased production yield while the metal frame maintains structural stability throughout the larger assembly.
Solution Approach 2:
The mask assembly is divided into distinct components: a metal frame structure and a polymer mask body. This segmentation allows the frame to provide structural stability while the mask body provides the functional patterning, enabling larger sizes without compromising stability.
3Weight of stationary object
If different materials are used for the mask body to reduce weight, then the weight decreases, but the manufacturing complexity increases
Solution Approach 1:
The patent uses a polymer material for the mask body which is lighter than metal. The manufacturing process involves forming patterns in the polymer layer and bonding it to a metal frame. While this composite approach reduces weight, it does increase manufacturing complexity compared to using a single material, as it requires multiple manufacturing steps including pattern formation and bonding operations.
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 mask assembly achieves a large size and low weight, improving production yield and efficiency in forming light emitting patterns on display panels.
Implementation Method 1
a welding portion disposed on the second sub-mask and in the concave portion
Implementation Method 2
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.)
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.