Deposition Mask Tensioning via Insertion Blocks

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Solution Overview

Problem

Existing methods for manufacturing deposition masks struggle to ensure uniform tension and prevent twisting or deformation of mask strips during bonding, leading to potential shadowing and inaccuracies in organic film deposition for OLED displays.

Innovation Solution

A method involving a frame with specific supports and insertion blocks is used to bond mask strips to the frame, ensuring uniform tension and preventing twisting by matching the height and shape of the supports and blocks, allowing for precise deposition mask formation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mask strips are bonded to the frame using existing methods, then the mask can be manufactured, but the mask strips may twist or deform during bonding, leading to deposition inaccuracies

Engineering Contradiction:

Improvedeposition pattern accuracyVSAvoidmask strip shape stability

Core Design Contradiction:

Manufacturing precisionVSStability of the object's composition

Solution Approach 1:

The method applies preliminary tension to the mask strip before bonding, and uses insertion blocks to maintain this tension state during the bonding process. This preliminary action ensures the mask strip is properly stretched and positioned before it is permanently fixed to the frame, preventing subsequent twisting or deformation that would compromise deposition accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Insertion blocks are introduced as intermediary elements between the mask strip and the frame during the bonding process. These blocks maintain uniform tension and prevent direct contact that could cause localized stress concentration and deformation. After bonding, the insertion blocks are removed, having served their mediating function during the critical bonding phase.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Manufacturing precision

If tension is applied to mask strips during bonding, then uniform deposition can be achieved, but the mask strips may still deform or twist without proper control mechanisms

Engineering Contradiction:

Improveuniformity of organic film depositionVSAvoidmask strip dimensional stability

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The mask strip is tensioned in advance before bonding, and this tensioned state is maintained throughout the bonding process using insertion blocks. This preliminary action ensures uniform stretching and positioning, which is critical for achieving uniform organic film deposition while maintaining dimensional stability throughout the process.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The method controls the tension parameter applied to the mask strip during bonding, maintaining it at an optimal level that ensures uniform deposition without causing excessive stress that would lead to deformation. The insertion blocks help distribute and control this tension parameter uniformly across the mask strip width.

Inventive Principle:

Principle #35Parameter changes

3Ease of manufacture

If the mask strip is stretched and bonded without support structures, then the bonding process is simpler, but the mask strip cannot maintain uniform tension and may twist

Engineering Contradiction:

Improvebonding process simplicityVSAvoidmask strip alignment accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Insertion blocks serve as temporary intermediary support structures during the bonding process. These blocks are simple to implement and use, providing the necessary support to maintain uniform tension and prevent twisting. After bonding is complete, the blocks are removed, leaving a precisely aligned mask strip without requiring complex support structures.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This method enables accurate and uniform deposition of organic films, reducing shadowing and enhancing the quality of OLED display manufacturing by ensuring the mask strips are not twisted or deformed, thus improving the pattern accuracy of the organic emission layer.

Implementation Method 1

inserting an insertion block corresponding in shape to the fastening recess into the fastening recess, bonding opposing ends of a mask strip having an opening pattern to the contact faces while stretching the mask strip

Methodology Applied

Scientific EffectMechanical support:

Implementation Method 2

bonding opposing ends of a mask strip having an opening pattern to the contact faces while stretching the mask strip

Methodology Applied

Scientific EffectAdhesion: Adhesive

Data Source

PatentUS9376743B2Method of manufacturing mask for deposition

Publication Date: 2016.06.28 SAMSUNG DISPLAY CO LTD

AI summary

A method of manufacturing a deposition mask includes providing a frame including a pair of first supports and a pair of second supports surrounding an opening, each of the first supports including a contact face corresponding to a face of the first support and including a fastening recess at an outer edge of the first support, inserting an insertion block corresponding in shape to the fastening recess into the fastening recess, bonding opposing ends of a mask strip having an opening pattern to the contact faces while stretching the mask strip, and removing the insertion block from the fastening recess.