Mask Assembly Segmentation for Non-Traditional Display Shapes
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Solution Overview
Problem
Traditional mask assemblies struggle to accommodate non-traditional display screen shapes, such as those with rounded or chamfered areas, leading to issues with stress distribution and material evaporation.
Innovation Solution
A mask assembly comprising a metal frame with a first operation window, a metal plate with connecting posts and second operation windows, and at least one Fine Metal Mask (FMM) with openings, where the FMM is welded to the metal frame between connecting posts, allowing for flexible adaptation to various display screen shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional linear support and overlay structure plus FMM is used, then manufacturing process is simple, but it cannot accommodate non-traditional screen shapes with rounded or chamfered areas
Solution Approach 1:
The mask assembly is divided into multiple components: a metal frame providing linear support, a metal plate with connecting posts for structural segmentation, and FMM with openings for pattern definition. This segmentation allows each component to be optimized independently while adapting to non-traditional screen shapes through the flexible combination of linear and curved elements.
2Reliability
If FMM openings are arranged in traditional straight lines, then manufacturing is straightforward, but stress distribution of FMM is affected when special-shaped openings are required
Solution Approach 1:
The FMM is designed with different opening arrangements in different regions: traditional straight-line openings in rectangular areas and special-shaped openings in rounded or chamfered areas. The metal plate with connecting posts provides localized structural support to maintain stress distribution uniformity while accommodating these varying opening patterns throughout the mask assembly.
3Manufacturing precision
If opening is designed on FMM at position where material may not be evaporated, then pattern precision is improved, but traditional linear structure cannot block evaporation at chamfer
Solution Approach 1:
The metal plate acts as an intermediary component between the metal frame and FMM. Its connecting posts are positioned to block material evaporation at chamfered areas, while the FMM openings are precisely designed to control material deposition in rounded or chamfered regions. This intermediary structure enables both evaporation blocking and precise pattern formation.
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 proposed mask assembly effectively addresses the challenge of non-traditional screen shapes by ensuring proper stress distribution and material evaporation, enhancing the reliability and efficiency of the display device manufacturing process.
Implementation Method 1
the plurality of connecting posts are located in the grooves and welded to the metal frame
Implementation Method 2
the at least one FMM is provided with a plurality of openings penetrating through a thickness direction of the at least one FMM, and is welded to the metal frame
Data Source
AI summary
Provided by the present disclosure are a mask assembly and a manufacturing method thereof. In the mask assembly, a plurality of connecting posts are arranged at intervals on an outer periphery of a body of a metal plate, and a plurality of grooves matched with the connecting posts are arranged on a metal frame.