Mask Assembly Segmentation for Display Deposition Alignment
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Solution Overview
Problem
There is a need for a mask assembly with high precision in the open region to improve the deposition quality of patterned functional layers in display panels, as existing technologies struggle to achieve precise control over the shape and alignment of these layers.
Innovation Solution
A mask assembly comprising a frame with a mask sheet that includes multiple masks coupled by welding, featuring tension portions and coupling portions that are strategically designed to maintain the shape and alignment of deposition openings, ensuring precise deposition without overlapping, and a method for manufacturing this assembly that involves aligning, coupling, and tensioning these components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single large-area mask is used to cover the entire display panel, then the deposition area is sufficient, but the mask sags during deposition causing poor alignment and shape distortion
Solution Approach 1:
The mask assembly is divided into multiple separate masks (first mask and second mask) that are coupled together, rather than using a single large mask. This segmentation prevents sagging while maintaining sufficient coverage area for large display panels.
Solution Approach 2:
Multiple separate masks are coupled together using coupling portions to form an integrated mask assembly that functions as a unified structure during deposition, achieving both large area coverage and precise alignment through the combined strength of multiple components.
2Manufacturing precision
If multiple masks are coupled together to prevent sagging, then alignment precision is improved, but the device complexity increases
Solution Approach 1:
The coupling portions are strategically positioned only at specific regions where masks need to be joined, rather than uniformly across the entire mask assembly. This localized approach maintains precision while minimizing added complexity.
Solution Approach 2:
The coupling portions are pre-formed on the masks before assembly, and the masks are designed with predetermined coupling regions that simplify the assembly process and reduce the complexity of aligning and joining multiple components during manufacturing.
3Stability of the object's composition
If the mask sheet is tensioned to maintain shape, then the shape stability is improved, but the risk of deformation or damage during tensioning increases
Solution Approach 1:
The mask assembly incorporates tension portions that allow dynamic adjustment of tension levels, enabling the mask to be tensioned sufficiently for shape stability while preventing excessive tension that could cause deformation or damage.
Solution Approach 2:
The tension portions are designed with specific geometric parameters (width, length, positioning) that optimize the tension distribution across the mask assembly, maintaining shape stability while minimizing stress concentrations that could lead to deformation or damage.
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 provides improved precision and quality in the mask assembly, preventing sagging and maintaining the shape of deposition openings during the deposition process, resulting in enhanced deposition quality for display panels.
Implementation Method 1
The first coupling portions and the second coupling portions may be coupled to each other by welding
Data Source
AI summary
A mask assembly includes a frame opening, and a mask sheet. The mask sheet includes a first mask including a first body part having at least one first deposition opening, first coupling portions, each of which protrudes from at least one first side of the first body part, and a second mask including a second body part having at least one second deposition opening, second coupling portions, each of which protrudes from at least one first side of the second body part, The at least one first side of the first mask and the at least one first side of the second mask face each other. The first coupling portions overlap the second coupling portions, respectively.