Fine Metal Mask Assembly Layout for Evaporation Opening Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
In the manufacturing of organic light-emitting display devices, the position accuracy of evaporation openings in Fine Metal Masks (FMMs) is compromised due to uneven stress distribution during the welding process, leading to potential shifts in evaporation openings and poor color mixing in large-size masks.
Innovation Solution
A mask assembly with a frame and a mask featuring connection areas with first connection parts arranged in staggered rows and columns, ensuring uniform stress distribution and improved positional accuracy through laser-formed welding points, which are symmetrically distributed and optimized in number and distance to maintain mask integrity and accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional welding methods are used to fix the mask to the frame, then the mask can be assembled, but uneven stress distribution occurs leading to position inaccuracy of evaporation openings
Solution Approach 1:
The connection area is segmented into multiple discrete welding points arranged in specific patterns (first welding points in M rows and N columns, second welding points in K rows and L columns). This segmentation allows the stress to be distributed across multiple localized connection points rather than concentrated in a single area, achieving uniform stress distribution while maintaining manufacturing precision.
Solution Approach 2:
The patent employs asymmetric arrangement of welding points where the first welding points and second welding points are positioned at different locations with different row and column configurations. This asymmetric distribution optimizes the stress pathway and ensures uniform stress distribution across the connection area, resolving the contradiction between assembly feasibility and stress uniformity.
2Area of stationary object
If the mask size is increased to meet display device requirements, then larger display areas are achieved, but position accuracy of evaporation openings deteriorates due to stress unevenness
Solution Approach 1:
For large-size masks, the connection area is divided into multiple welding point groups with different configurations (M×N first welding points and K×L second welding points). This segmentation strategy allows the large mask area to be supported by distributed connection points, maintaining position accuracy across the entire mask surface while accommodating the increased overall size.
Solution Approach 2:
The patent extends the welding point arrangement from a single-plane configuration to a multi-dimensional layout by introducing two distinct sets of welding points (first and second welding points) with different row-column configurations. This dimensional expansion of the connection strategy enables large-area masks to maintain precision through distributed support points across multiple spatial dimensions.
3Ease of manufacture
If fewer welding points are used, then the manufacturing process is simpler, but stress distribution becomes uneven causing mask deformation
Solution Approach 1:
The welding process is segmented into two distinct stages with different welding point configurations. The first welding points (M rows, N columns) are established in an initial welding process, followed by second welding points (K rows, L columns) in a subsequent process. This segmentation enables uniform stress distribution through multiple distributed points while keeping each individual welding step relatively simple and manageable.
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 solution enhances the positional accuracy of evaporation openings, reducing wrinkles and maintaining the structural integrity of large-size masks, thereby improving the quality of organic light-emitting display devices by ensuring uniform tensile force distribution and precise alignment of evaporation openings.
Implementation Method 1
a plurality of first welding points and a plurality of second welding points are formed in the connection area by laser welding
Data Source
AI summary
Embodiments of the present disclosure provide a mask assembly and a manufacturing method thereof. The mask assembly includes: a frame; a mask provided with a mask area and connection areas positioned on opposite sides of the mask area; and a plurality of first connection parts in each connection area, wherein the plurality of first connection parts in each connection area are arranged in M rows and N columns, each row includes a plurality of first connection parts, each column includes at least one first connection part, and in the same connection area, the first connection parts of any two adjacent rows are arranged in a staggered manner, where each of M and N is an integer larger than 1, and the mask is fixed to the frame via the plurality of first connection parts.