Deposition Mask Frame Bonding for Display Devices
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Solution Overview
Problem
Existing mask units for depositing organic layers in display devices face challenges in achieving high-resolution patterns and securing a sufficient contact area under tension without being penetrated or torn during the welding process.
Innovation Solution
A deposition mask unit with a deposition mask sheet and frame design, featuring raised portions with a support and bonding surface, where the mask sheet is spaced apart from the support and attached to the frame using a tensile force, ensuring a secure contact area and preventing damage during welding, with specific dimensions and materials enhancing the welding success rate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mask sheet is made thin to achieve high-resolution patterns, then the manufacturing precision is improved, but the strength and resistance to penetration during welding deteriorates
Solution Approach 1:
The mask unit is divided into two functional parts: a thin mask sheet for high-resolution patterning and a separate bonding portion for mechanical strength and welding. The mask sheet thickness is controlled at 1-100 μm to achieve fine patterns, while the bonding portion provides structural support and resistance to welding penetration, resolving the contradiction between thinness for precision and thickness for strength.
Solution Approach 2:
The solution transitions from a single-plane mask structure to a three-dimensional structure by adding a bonding portion that protrudes from the mask sheet surface. This vertical dimension allows the mask sheet to remain thin for high-resolution patterns while the protruding bonding portion (with height up to 0.03 mm) provides additional strength and welding resistance without compromising pattern quality.
2Device complexity
If the mask sheet is attached directly to the frame, then the device complexity is reduced, but the contact area under tensile force becomes insufficient
Solution Approach 1:
The bonding portion features a curved upper surface that contacts the mask sheet, creating a larger effective contact area compared to a flat surface. This curvature allows the mask sheet to be securely attached under tensile force during installation while maintaining a relatively simple overall structure. The curved surface distributes stress more effectively across the contact interface.
3Reliability
If the bonding portion height is increased to improve welding success rate, then the reliability is improved, but the mask sheet may be penetrated or torn
Solution Approach 1:
The bonding portion height is optimized within a specific range (up to 0.03 mm) to balance welding reliability and mask sheet protection. This controlled height provides sufficient protrusion for reliable welding attachment while limiting the height to prevent penetration or tearing of the mask sheet during the welding process. The parameter optimization resolves the contradiction between needing enough height for welding success and limiting height to protect the mask sheet.
Data Source
AI summary
A deposition mask unit includes a deposition mask sheet including a plurality of openings, and a deposition mask frame including a raised portion at which the deposition mask sheet is attachable to the deposition mask frame. The raised portion includes a support portion, and a bonding portion protruding from an upper surface of the support portion, an upper surface of the bonding portion being curved.