Mask Assembly Segmentation for Deposition Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The deformation of masks during the manufacturing process of display devices leads to deteriorated deposition accuracy and reliability of the light emitting layer.
Innovation Solution
A mask assembly is designed with a frame and an open mask featuring a plurality of cell openings and support portions. The open mask is attached to the frame, and deposition masks are sequentially attached to the open mask, with support portions being removed to secure spaces for improved deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If masks are attached to a frame during manufacturing, then the masks can be used for deposition, but the masks deform and deposition accuracy deteriorates
Solution Approach 1:
The mask is divided into multiple separate masks, each corresponding to a specific cell opening. Each mask can be independently attached and removed, preventing mutual interference and deformation between masks while maintaining deposition accuracy for each pixel region
Solution Approach 2:
Masks are pre-attached to the frame in a specific sequence before deposition begins. The first mask is attached, deposition is performed, then the first mask is removed and second mask is attached. This preliminary sequencing ensures each mask is in optimal position during its deposition operation, preventing deformation-induced accuracy loss
2Productivity
If multiple masks are attached to form a mask assembly, then deposition can be performed on multiple pixels, but the complexity of the manufacturing process increases
Solution Approach 1:
The mask assembly is segmented into multiple independent masks that can be separately manufactured and attached. Each mask corresponds to specific pixel regions, allowing simplified individual mask design while achieving multi-pixel deposition capability through sequential operation
Solution Approach 2:
Each mask in the assembly serves multiple functions: it acts as a deposition pattern template, a structural support element, and a removable component for sequential operation. This multi-functionality reduces the need for additional specialized components, simplifying the overall manufacturing process despite handling multiple masks
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 accuracy and reliability by preventing mask deformation and ensuring precise alignment of deposition masks with the cell openings.
Implementation Method 1
a deposition method using a mask assembly
Implementation Method 2
a plurality of support portions overlapping remaining cell openings except a first cell opening among the plurality of cell openings
Implementation Method 3
welding the stretched first deposition mask to the open mask
Data Source
AI summary
The disclosure relates to a mask assembly and a method of manufacturing the mask assembly. A mask assembly includes a frame including a frame opening, and an open mask including cell openings overlapping the frame opening. The open mask further includes support portions overlapping remaining cell openings except a first cell opening among the cell openings.