Deposition Mask Assembly Welding Support Member
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Solution Overview
Problem
The existing deposition mask assembly for flat panel displays experiences pattern distortion during the welding process of divided pattern masks to a support fixture, which affects the quality of the pattern mask and the deposition process.
Innovation Solution
An apparatus is designed with a support member that includes a rod and a motor to minimize the gap between the pattern mask and the support fixture, using a welding head and a vision unit for precise alignment and auto-focus to prevent distortion, ensuring the pattern mask remains undistorted during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the support fixture is fixed to both ends of the opening of the frame mask, then the pattern mask is secured during welding, but distortion of the pattern occurs in the pattern mask
Solution Approach 1:
A support member is introduced as an intermediary component between the support fixture and the pattern mask. The support member includes a support pin that contacts the support fixture and a support surface that contacts the pattern mask, thereby mediating the connection and preventing direct distortion transmission to the pattern mask while maintaining stability during welding.
Solution Approach 2:
The support member extends in a direction perpendicular to the plane of the pattern mask, providing support from a different dimension. This vertical support structure prevents lateral distortion of the pattern mask during welding by constraining movement in the plane of the mask while allowing the support fixture to remain fixed to the frame mask.
2Stability of the object's composition
If the support fixture is installed to cross the opening of the frame mask, then the pattern mask can be secured, but the pattern mask may move during welding
Solution Approach 1:
The support member acts as a mediator between the support fixture and the pattern mask, distributing the welding forces and preventing direct transmission of distortion to the pattern mask. This intermediary structure maintains position stability while preserving welding quality.
Solution Approach 2:
The support member is installed before welding to pre-position and stabilize the pattern mask. This preliminary support action ensures that the pattern mask is held in the correct position during welding, preventing movement and maintaining manufacturing precision.
3Strength
If welding is performed to weld the pattern mask to the support fixture, then the pattern mask is secured, but distortion occurs in the pattern mask
Solution Approach 1:
The support member serves as a mediator that decouples the welding process from the pattern mask. The support fixture is welded to the frame mask, and the support member transmits this connection to the pattern mask without causing distortion, thereby achieving connection strength while maintaining manufacturing precision.
Solution Approach 2:
The support member provides localized support at specific contact points with the pattern mask, concentrating the support function at strategic locations. This localized approach prevents distortion at the welding areas while maintaining overall connection strength through the support fixture.
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 apparatus effectively minimizes pattern distortion to within an ultra-small condition (1 micrometer), reducing defects and maintaining the integrity of the pattern mask during the deposition process.
Implementation Method 1
a pattern mask welded to the support fixture to have a pattern allowing a deposition material to be transmitted therethrough
Implementation Method 2
a support member supporting the support fixture in an opposite side of the welding head with the pattern mask interposed therebetween
Implementation Method 3
a vision unit installed in an opposite side of the support member to sense supporting of the support member by a laser auto-focus
Data Source
AI summary
Provided is an apparatus for manufacturing a deposition mask assembly for a flat panel display, which prevents a pattern from being distorted in a pattern mask when divided pattern masks are welded to a support fixture. An apparatus for manufacturing a deposition mask assembly for a flat panel display of the present description, which includes a frame mask forming an opening, a support fixture installed in the frame mask, and a pattern mask welded to the support fixture to have a pattern allowing a deposition material to be transmitted therethrough, includes: a welding head disposed in a side of the pattern mask; and a support member supporting the support fixture in an opposite side of the welding head with the pattern mask interposed therebetween.