Mask Assembly with Crossed Supports for Display Deposition
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Solution Overview
Problem
The existing manufacturing methods for display devices face challenges in achieving precise and efficient deposition of materials onto substrates, particularly in maintaining the shape and alignment of deposition regions, leading to issues such as sagging and deformation of mask sheets, which affect the accuracy and efficiency of the display area formation.
Innovation Solution
The proposed solution involves a mask assembly with a specific design including first and second supports with protrusions and a mask sheet, supported by a magnetic force unit, which directs the mask assembly towards the substrate, ensuring uniform deposition and reducing sagging by defining deposition regions with precise shapes and alignments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask sheet is used for material deposition, then deposition precision can be improved, but the mask sheet sags and deforms affecting alignment accuracy
Solution Approach 1:
The mask assembly is segmented into multiple components: a rigid mask frame, multiple support structures (first supports with first protrusions and second supports with second protrusions), and the mask sheet. This segmentation allows the rigid frame and supports to maintain structural stability while the mask sheet performs its deposition function, reducing sagging and deformation.
Solution Approach 2:
The mask assembly uses a composite structure combining a rigid mask frame material with a mask sheet material. The rigid mask frame provides structural support and stability, while the mask sheet enables precise material deposition. This composite approach resolves the contradiction by combining materials with complementary properties.
2Ease of manufacture
If the mask assembly structure is simplified, then ease of manufacture is improved, but deposition region shape control is reduced
Solution Approach 1:
The mask assembly is divided into modular components: a mask frame, multiple first supports with first protrusions, multiple second supports with second protrusions, and a mask sheet. This segmentation allows each component to be manufactured separately using standard processes, then assembled together to create complex deposition region shapes that would be difficult to manufacture as a single piece.
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 enhances deposition efficiency and precision, reducing sagging by up to 51% and allowing for the creation of display areas with various shapes, including curved and polygonal forms, thereby improving the overall quality of the manufactured display devices.
Implementation Method 1
a magnetic force unit arranged at an opposite side to the source unit with respect to the mask assembly and configured to direct the mask assembly toward a display substrate
Implementation Method 2
depositing, on the display substrate, the deposition material sprayed from the source unit and having passed through the mask assembly
Data Source
AI summary
In an apparatus for manufacturing a display device having a mask assembly, the mask assembly includes: a mask frame comprising an opening; a plurality of first supports spaced apart from each other on the mask frame and each comprising a first center portion crossing the opening in a first direction and a first protrusion protruding from the first center portion in a second direction crossing the first direction; a plurality of second supports spaced apart from each other on the mask frame and each comprising a second center portion crossing the opening in a third direction crossing the first direction and a second protrusion protruding from the second center portion in a fourth direction crossing the third direction; and a mask sheet comprising a plurality of pattern holes and arranged over the mask frame to be supported by the plurality of first supports and the plurality of second supports.