Mask Assembly Layout for Multi-Purpose Display Deposition
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Solution Overview
Problem
The manufacturing process for display apparatuses is complicated and time-consuming due to the need for separate manufacturing methods and apparatuses based on the specific purpose of each display apparatus, requiring multiple substrates and apparatuses.
Innovation Solution
A display apparatus manufacturing apparatus and method that utilizes a mask assembly with adjustable opening areas and deposition units to simultaneously produce display apparatuses with varying purposes, allowing for the concurrent formation of emission layers with different colors and patterns on a single substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If separate manufacturing methods and apparatuses are used for different display apparatus purposes, then manufacturing precision for specific purposes is improved, but device complexity and manufacturing time increase
Solution Approach 1:
The mask assembly is designed with multiple mask sheets having different opening areas, enabling a single apparatus to manufacture different types of display apparatuses (full-color displays and monochrome displays) using the same equipment. This multi-functional design eliminates the need for separate manufacturing apparatuses for different display purposes, thereby reducing device complexity while maintaining manufacturing precision through configurable mask configurations.
Solution Approach 2:
The mask assembly is segmented into multiple mask sheets (first mask sheet, second mask sheet, third mask sheet) with different opening areas. Each mask sheet can be selectively positioned to create different deposition patterns. This segmentation allows the same apparatus to produce different display types by simply changing which mask sheet is used, resolving the contradiction between precision and complexity.
2Manufacturing precision
If separate manufacturing apparatuses are used for different display apparatus purposes, then manufacturing precision for specific purposes is improved, but manufacturing time increases
Solution Approach 1:
Multiple manufacturing capabilities are merged into a single apparatus by incorporating multiple mask sheets with different opening areas. The first mask sheet enables full-color display manufacturing, while the second and third mask sheets enable monochrome display manufacturing. This merging allows the apparatus to switch between different display types without requiring separate equipment, significantly reducing manufacturing time while maintaining precision through proper mask selection.
Solution Approach 2:
The mask assembly introduces dynamic configurability to the manufacturing apparatus. By allowing selective positioning of different mask sheets (first, second, or third mask sheet) depending on the desired display type, the apparatus can adapt its configuration in real-time. This dynamic capability eliminates the need for separate static apparatuses for different display purposes, reducing both device complexity and manufacturing time.
3Manufacturing precision
If multiple substrates are used for different display apparatus purposes, then manufacturing precision for specific purposes is improved, but device complexity and material consumption increase
Solution Approach 1:
The mask assembly with multiple mask sheets enables a single substrate to be used for manufacturing different types of display apparatuses. By selecting appropriate mask sheets (first mask sheet for full-color, second or third mask sheet for monochrome), the same substrate can be processed for different display purposes, eliminating the need for separate substrates for different display types and reducing material consumption while maintaining manufacturing 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
Enables the efficient and simultaneous production of display apparatuses with diverse functionalities by optimizing the deposition process, reducing manufacturing time and complexity.
Implementation Method 1
a deposition source arranged to face the mask assembly to supply a deposition material to a display substrate
Data Source
AI summary
Provided is a display apparatus manufacturing apparatus and method. A mask assembly includes a mask frame having an opening area, a first mask sheet arranged to cover a first opening area of the opening area and having a first opening portion, and a second mask sheet arranged to cover a second opening area of the opening area and having a second opening portion, wherein the first opening portion is different in size than the second opening portion.