Magnetic Support Bar Alignment for Flat Mask Assembly
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Solution Overview
Problem
Existing mask assembly manufacturing processes face challenges in achieving high precision and reliability during the deposition of patterned functional layers in display panels, necessitating improved manufacturing methods and apparatuses.
Innovation Solution
A mask assembly manufacturing apparatus and method utilizing a magnetic unit to align a support bar over a frame, ensuring the support bar remains flat without bending, by employing magnetic units with opposite polarities to stabilize the support bar, and a fixing unit to secure it in place.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manufacturing methods are used for mask assembly, then manufacturing simplicity is maintained, but manufacturing precision and reliability deteriorate
Solution Approach 1:
The patent replaces conventional mechanical alignment methods with a magnetic field-based alignment system. Magnetic units generate magnetic fields that interact with the support bar to achieve precise alignment without direct mechanical contact, thereby improving alignment precision while avoiding complex mechanical adjustment mechanisms
Solution Approach 2:
The patent introduces magnetic units as an intermediary between the alignment unit and the support bar. These magnetic units mediate the alignment process by creating magnetic forces that guide and position the support bar accurately, eliminating the need for complex mechanical clamping or positioning systems
2Reliability
If conventional fixing methods are used for support bar, then apparatus simplicity is maintained, but reliability of mask assembly deteriorates
Solution Approach 1:
The patent replaces mechanical fixing methods with magnetic field-based fixing. The magnetic units generate magnetic forces that hold the support bar in position without physical contact, improving reliability by eliminating mechanical wear and positioning errors while avoiding complex mechanical fastening systems
Solution Approach 2:
The patent utilizes changes in magnetic field parameters (strength, direction, distribution) to achieve reliable fixing of the support bar. By adjusting magnetic field parameters rather than mechanical parameters, the system achieves more stable and reliable positioning without adding mechanical complexity
3Manufacturing precision
If support bar is not properly aligned, then manufacturing process simplicity is maintained, but deposition quality of patterned functional layers deteriorates
Solution Approach 1:
The patent replaces mechanical alignment systems with a magnetic field-based alignment unit. The magnetic units create controlled magnetic fields that guide the support bar into precise alignment, ensuring high deposition quality while avoiding complex mechanical measurement and adjustment systems
Solution Approach 2:
The patent enables the support bar to align itself through interaction with the magnetic field. The magnetic forces automatically guide the support bar into the correct position without requiring external mechanical intervention or complex positioning mechanisms, thereby achieving high precision with simpler apparatus
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 and method enhance the reliability and precision of mask assembly manufacturing, enabling improved deposition quality of patterned functional layers in display panels.
Implementation Method 1
the alignment unit includes a plurality of magnetic units
Implementation Method 2
the magnetic units include a plurality of first magnetic units disposed above the support bar and a plurality of second magnetic units disposed above the support bar, spaced apart from the first magnetic units in a second direction perpendicular to the first direction, and having a polarity opposite to a polarity of the first magnetic units
Data Source
AI summary
A mask assembly manufacturing apparatus for manufacturing a mask assembly, including a frame through which an opening is defined and a support bar disposed above the frame, includes a stage on which the frame is placed, an alignment unit disposed above the stage and including magnetic units, and a fixing unit disposed between the stage and the alignment unit and including a first sub-fixing unit which fixes one end of the support bar and a second sub-fixing unit which fixes another end of the support bar and spaced apart from the first sub-fixing unit in a first direction. The magnetic units includes first magnetic units disposed above the support bar and second magnetic units disposed above the support bar, spaced apart from the first magnetic units in a second direction perpendicular to the first direction, and having a polarity opposite to a polarity of the first magnetic units.