Flat Head Mask Frame Supports for Heavy Load Alignment
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Solution Overview
Problem
Conventional ball transfer units (BTUs) cause deformations and scratches on heavy mask frames due to concentrated pressure points, lacking a sufficient contact surface area for proper load alignment during electronic device manufacturing.
Innovation Solution
The introduction of flat head units with a larger contact surface area, incorporating a tapered and cylindrical design, and a centering mechanism with tension springs to support the load and enable free movement in the X-Y plane, reducing deformation and stress on the mask frames.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If ball transfer units (BTUs) are used to support mask frames, then the mask frames can be supported and moved, but the concentrated pressure points cause deformations and scratches on the mask frames
Solution Approach 1:
The support function is segmented from point-contact balls to distributed flat head contacts, dividing the pressure across multiple points on the flat head surface rather than concentrating it at single ball contact points
Solution Approach 2:
The contact interface transitions from zero-dimensional point contacts (balls) to two-dimensional surface contacts (flat heads), increasing the contact area dimension and distributing pressure across a larger surface
2Device complexity
If conventional support units with small contact area are used, then the structure is simple, but the contact surface area is insufficient for proper load alignment
Solution Approach 1:
The contact surface transitions from point-like (zero-dimensional) to planar (two-dimensional), providing sufficient contact area for proper load alignment while maintaining a relatively simple cylindrical or conical geometric form
3Object-affected harmful factors
If flat head units with larger contact surface area are used, then deformation and stress on mask frames are reduced, but the device structure becomes more complex
Solution Approach 1:
The flat head unit is segmented into modular components (case, flat head, tension springs, centering mechanism) that can be independently designed and assembled, managing complexity through functional decomposition
Solution Approach 2:
The flat head unit performs multiple functions simultaneously: load support, stress distribution, centering, and free movement enablement, reducing the need for separate components and managing overall system complexity
4Device complexity
If conventional support units are used, then the structure is simple, but the alignment accuracy is insufficient under heavy loads
Solution Approach 1:
The flat head provides a localized high-quality contact surface with optimal pressure distribution characteristics, creating a specific zone of improved stress distribution and alignment precision where it is most needed
Solution Approach 2:
The contact geometry parameters are changed from spherical to flat, altering the pressure distribution profile and enabling better alignment accuracy under heavy load conditions
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 flat head units effectively prevent deformations and markings on mask frames, enhance alignment accuracy, and extend the life cycle of the units under heavy loads, supporting loads up to 100 kg at elevated temperatures.
Implementation Method 1
Conventional ball transfer units (BTUs) cause deformations and scratches on heavy mask frames due to concentrated pressure points
Implementation Method 2
incorporating a tapered and cylindrical design, and a centering mechanism with tension springs to support the load and enable free movement in the X-Y plane
Data Source
AI summary
A mask frame support unit includes a case, a protruding body extending below the case, and a station having a flat head disposed above the case. The protruding body includes a tapered region and a cylindrical region. The tapered region includes a first end having a first diameter coupled to the case and comprising a second end having a second diameter opposite the first end. The second diameter is less than the first diameter, and the tapered region is coupled to the cylindrical region at the second end. The case houses a number of components including an upper receiving plate in contact with the station, a lower receiving plate disposed underneath the upper receiving plate, a flat head unit movement support mechanism disposed between the lower receiving plate and the body, and a centering component.