Deposition Mask Packaging With Flexible Film Against Deformation

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Solution Overview

Problem

Deposition masks used in manufacturing high-definition organic EL display devices are prone to plastic deformation during transportation due to applied forces and temperature changes, leading to positional shifts and uneven deposition, which affects light emission efficiency.

Innovation Solution

A deposition mask package and packaging method that includes a receiving portion with a concave portion covered by a flexible film, a lid portion, and interposed sheets with controlled thermal expansion coefficients to prevent deformation, using materials like PET film and iron alloys with specific nickel content.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the deposition mask is packaged with rigid receiving portion and lid portion, then the mask is protected from external damage, but the mask undergoes plastic deformation due to applied force

Engineering Contradiction:

Improveprotection from external damageVSAvoidplastic deformation

Core Design Contradiction:

StrengthVSShape

Solution Approach 1:

The receiving portion and lid portion are made of flexible plastic board instead of rigid materials. This flexibility allows the packaging to conform to the deposition mask without applying excessive force, thereby preventing plastic deformation while still providing protection from external damage during transportation.

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

A cushioning member is inserted between the deposition mask and the plastic board of the receiving portion and lid portion. This cushioning member absorbs and distributes applied forces, preventing direct transmission of force to the deposition mask and thus avoiding plastic deformation before damage can occur.

Inventive Principle:

Principle #11Beforehand cushioning (Prior cushioning)

2Device complexity

If the deposition mask is transported without packaging, then the mask structure remains simple, but the mask is susceptible to impact and temperature changes causing deformation

Engineering Contradiction:

Improvepackaging structureVSAvoidresistance to impact and temperature changes

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The packaging structure uses composite materials including plastic board for the receiving portion and lid portion, and a cushioning member made of different material properties. This composite structure provides both protection against impact and resistance to temperature changes while maintaining reasonable simplicity.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The cushioning member acts as an intermediary between the deposition mask and the external environment. It mediates the effects of impact and temperature changes, absorbing shocks and providing thermal insulation, thereby protecting the deposition mask without requiring a complex packaging structure.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Stability of the object's composition

If interposed sheets with different thermal expansion coefficients are used, then the mask is protected from deformation, but the packaging complexity increases

Engineering Contradiction:

Improvethermal expansion controlVSAvoidpackaging structure

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The patent specifies that the interposed sheets should have a thermal expansion coefficient within a particular range (5×10^-6 to 15×10^-6 /°C.). By controlling this physical parameter, the packaging protects the deposition mask from thermal deformation without requiring complex multi-layer structures, thus maintaining simplicity while achieving stability.

Inventive Principle:

Principle #35Parameter changes

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

Prevents plastic deformation and maintains deposition mask integrity during transportation, ensuring precise deposition and improved light emission efficiency of organic EL display devices.

Implementation Method 1

a concave portion (69) provided in the first opposing surface (68) and covered with a first flexible film (70)

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

interposed sheets with controlled thermal expansion coefficients to prevent deformation

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentUS12508797B2Deposition mask package and deposition mask packaging method

Publication Date: 2025.12.30 DAI NIPPON PRINTING CO LTD

AI summary

A deposition mask package according to the present embodiment includes a receiving portion, a lid portion that faces the receiving portion, a deposition mask that is arranged between the receiving portion and the lid portion and has an effective region in which a plurality of through-holes is formed. The receiving portion has a first opposing surface facing the lid portion and a concave portion provided on the first opposing surface. The concave portion is covered by a first flexible film. The effective region of the deposition mask is arranged on the concave portion with the first flexible film interposed therebetween.