Laser-Cut Invar Mask Assembly for Precise Display Deposition
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Solution Overview
Problem
Current display manufacturing processes, particularly in deposition methods, face challenges in achieving ultrahigh-resolution display modules due to limitations in mask technology, such as thermal expansion issues and defects in fine metal masks used for deposition processes.
Innovation Solution
A mask assembly is developed comprising a frame, an open sheet with specific thickness and material properties, and unit masks with deposition openings, where the preliminary unit mask is welded and cut into individual cell units using laser processing to enhance precision and reduce thermal expansion, improving pixel position accuracy and reducing defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fine metal mask is used for deposition process, then display manufacturing is enabled, but thermal expansion issues and defects occur reducing manufacturing precision
Solution Approach 1:
The patent changes the material parameter of the mask from conventional fine metal mask to electroformed invar, which has lower thermal expansion coefficient. This parameter change resolves the thermal expansion issues while maintaining manufacturing precision for ultrahigh-resolution display modules
Solution Approach 2:
The patent uses composite structure combining invar material (for low thermal expansion) with electroforming process (for precise pattern formation). This composite approach leverages the advantages of both material properties and manufacturing techniques to achieve both reliability and precision
2Ease of manufacture
If preliminary unit mask is stretched and welded on preliminary mask assembly, then unit masks are formed, but process complexity increases
Solution Approach 1:
The patent performs preliminary stretching and welding of the unit mask on the preliminary mask assembly before final deposition. This preliminary action simplifies the overall manufacturing process by pre-positioning and securing the mask, reducing complexity in subsequent steps
Solution Approach 2:
The patent divides the mask into multiple preliminary unit masks that are processed separately and then assembled. This segmentation allows each unit to be manufactured and positioned independently, simplifying the overall manufacturing process while maintaining precision
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 enables the manufacturing of ultrahigh-resolution display modules with improved pixel position accuracy and reduced defects by using electroformed invar for unit masks, which have lower thermal expansion and better laser processability, addressing the limitations of existing mask technologies.
Implementation Method 1
welding a preliminary unit mask to the first portion of the open sheet after stretching the preliminary unit mask on the preliminary mask assembly
Implementation Method 2
forming a plurality of unit masks by emitting laser onto the preliminary unit mask overlapping the second portion of the open sheet in a plan view
Data Source
AI summary
A method for manufacturing a mask assembly includes disposing a preliminary mask assembly including a frame having a frame opening and an open sheet having a plurality of first openings and including a first portion and a second portion, welding a preliminary unit mask to the first portion of the open sheet after stretching the preliminary unit mask on the preliminary mask assembly, welding the preliminary unit mask to the second portion of the open sheet, forming a plurality of unit masks by emitting laser onto the preliminary unit mask overlapping the second portion of the open sheet, and forming, in the plurality of unit masks, a plurality of deposition openings overlapping the plurality of first openings by emitting laser. The first portion overlaps the frame, and the second portion extends from the first portion and is disposed between the plurality of first openings.