Electroforming and Laser Mask Assembly Manufacturing

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Solution Overview

Problem

Conventional mask assembly manufacturing methods result in openings that differ from design values, leading to increased manufacturing time and reduced display resolution due to inaccuracies in forming patterns, which affects the quality of high-resolution displays.

Innovation Solution

The method involves forming a base material using an electroforming process and reprocessing the openings with a laser to achieve precise patterns, ensuring accurate alignment and deposition of materials in display manufacturing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a conventional rolling and opening formation method is used, then the manufacturing process is simple, but the opening size deviates from design values and manufacturing time increases

Engineering Contradiction:

Improvemanufacturing process simplicityVSAvoidopening size accuracy

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The electroforming process is performed in advance to create a base material with pre-formed openings that closely match the design specifications. This preliminary formation allows subsequent laser reprocessing to focus only on fine-tuning the opening dimensions and shapes, thereby achieving high precision while maintaining process efficiency

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The conventional mechanical rolling and opening formation method is replaced with an electroforming process followed by laser reprocessing. This substitution transitions from purely mechanical deformation to an electrochemical deposition process combined with precise laser processing, enabling much tighter control over opening dimensions and shapes

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of manufacture

If conventional opening formation methods are used, then the process is straightforward, but display resolution is reduced due to pattern inaccuracies

Engineering Contradiction:

Improveprocess straightforwardnessVSAvoidpattern accuracy

Core Design Contradiction:

Ease of manufactureVSMeasurement precision

Solution Approach 1:

The straightforward but imprecise mechanical opening formation is replaced with electroforming followed by laser reprocessing. The electrochemical deposition provides uniform material buildup with atomic-level precision, while laser processing delivers sub-micron accuracy in defining the final opening patterns, thereby achieving the pattern accuracy required for high-resolution displays

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The process transitions from mechanical force-based formation to electrochemical parameter control (current density, deposition time, electrolyte composition) followed by laser parameters (power, speed, focal position). These controllable parameters enable precise adjustment of opening dimensions and shapes to match design specifications exactly

Inventive Principle:

Principle #35Parameter changes

3Manufacturing precision

If electroforming and laser reprocessing are used, then manufacturing precision is improved, but process complexity increases

Engineering Contradiction:

Improveopening formation accuracyVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The manufacturing process is divided into two distinct segments: electroforming for base material creation and initial opening formation, followed by laser reprocessing for precision refinement. This segmentation allows each process to be optimized independently and performed by specialized equipment, reducing overall system complexity while achieving high precision results

Inventive Principle:

Principle #1Segmentation

4Device complexity

If conventional methods are used, then equipment requirements are simple, but manufacturing time increases due to rework

Engineering Contradiction:

Improveequipment simplicityVSAvoidmanufacturing efficiency

Core Design Contradiction:

Device complexityVSProductivity

Solution Approach 1:

The electroforming process performs the bulk of opening formation work in advance with high accuracy, eliminating the need for time-consuming mechanical rework and adjustments. The preliminary precision achieved through electrochemical deposition allows the subsequent laser step to be performed quickly as a final refinement, dramatically improving manufacturing efficiency

Inventive Principle:

Principle #10Preliminary action

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 approach reduces manufacturing time and costs while enhancing the precision of the mask assembly, enabling the production of displays with higher resolution and improved quality by ensuring accurate pattern formation and material deposition.

Implementation Method 1

forming, via an electroforming process, a base material including at least one opening on an electrode plate

Methodology Applied

Scientific EffectElectroforming: Electrodeposition

Implementation Method 2

reprocessing the at least one opening using a laser to form at least one reprocessed opening

Methodology Applied

Scientific EffectLaser processing: Laser

Data Source

PatentUS9972810B2Method of manufacturing mask assembly using electroforming and laser processes and method of manufacturing display apparatus using mask assembly

Publication Date: 2018.05.15 SAMSUNG DISPLAY CO LTD

AI summary

A method of manufacturing a mask assembly includes forming, via an electroforming process, a base material including at least one opening on an electrode plate; and reprocessing the at least one opening using a laser to form at least one reprocessed opening.