Mask Assembly for Non-Rectangular Display Deposition
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Solution Overview
Problem
Conventional mask assemblies for display device manufacturing are limited to producing rectangular or square display areas, making it difficult to apply display devices to variously shaped products.
Innovation Solution
A mask assembly comprising a mask frame with multiple openings and thin shielding plates, where the shielding portions selectively block openings to form deposition regions of non-rectangular or non-square shapes, allowing for the creation of display areas with diverse shapes by varying the positioning and thickness of the shielding plates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional mask assemblies are used, then rectangular or square display areas can be manufactured, but it is difficult to apply display devices to variously shaped products
Solution Approach 1:
The mask assembly is divided into multiple mask sheets (first mask sheet, second mask sheet, third mask sheet) that can be independently configured. Each mask sheet contains multiple openings that can be selectively used or blocked by shielding plates, allowing flexible combination to achieve various display area shapes without requiring a completely new mask structure for each shape.
Solution Approach 2:
The mask assembly incorporates movable or adjustable shielding plates that can be positioned to block specific openings in the mask sheets. This dynamic configuration capability allows the same mask assembly to produce different display area shapes by adjusting which openings are blocked, rather than requiring fixed structures for each shape.
2Adaptability or versatility
If thin shielding plates are added to create non-rectangular shapes, then shape versatility improves, but mask assembly complexity increases
Solution Approach 1:
Thin shielding plates are introduced as intermediary elements between the mask sheets and the deposition source. These shielding plates act as adjustable blockers that can be positioned to prevent deposition material from reaching specific areas, thereby defining non-rectangular display area shapes without requiring complex modifications to the mask sheets themselves.
Solution Approach 2:
The shielding plates are strategically positioned at specific locations to block only the necessary openings, creating local modifications to the deposition pattern. This allows non-rectangular shapes to be achieved by blocking specific regional areas rather than requiring complete reconfiguration of the entire mask assembly structure.
3Adaptability or versatility
If multiple mask sheets and shielding plates are used, then non-rectangular display areas can be formed, but manufacturing precision requirements increase
Solution Approach 1:
The mask assembly segments the deposition control function across multiple mask sheets and shielding plates. Each component handles a specific portion of the shape definition, which simplifies the precision requirements for each individual component compared to requiring a single complex mask to define the entire non-rectangular shape.
Solution Approach 2:
The mask sheets and shielding plates are pre-configured with specific opening patterns and blocking positions that are designed to work together. This preliminary configuration ensures that when deposition occurs, the combined effect of multiple components produces the desired shape with appropriate precision without requiring real-time adjustment.
Data Source
AI summary
Provided are a display device, a mask assembly, and an apparatus and a method for manufacturing the display device. The mask assembly includes: a mask frame; at least two mask sheets installed on the mask frame, each of the mask sheets including a plurality of openings; and at least two thin shielding plates installed on the mask frame such that the thin shielding plates are spaced apart from each other and shield a portion of the plurality of openings of each mask sheet, wherein one of the mask sheets and the thin shielding plates includes a shielding portion between the thin shielding plates spaced apart from each other, the shielding portion selectively blocking at least portions of the openings so as to form a deposition region having a shape other than a rectangle or a square.