Mask Assembly with Segmented Sheets for Display Deposition

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Solution Overview

Problem

The challenge in manufacturing display devices is to achieve a precise image display, which requires accurate arrangement of the organic emission layer corresponding to the pixel electrode, while existing technologies face difficulties in maintaining the precision of the intermediate layer pattern during the manufacturing process.

Innovation Solution

A mask assembly with a frame body and dividers that divides the frame into openings, where mask sheets with pattern openings are arranged and tensioned to ensure precise deposition of the organic emission layer, allowing for the formation of a precise pattern on the display substrate.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a mask assembly is used to form the organic emission layer, then the precision of the intermediate layer pattern is improved, but the device complexity increases

Engineering Contradiction:

Improveprecision of intermediate layer patternVSAvoidcomplexity of mask assembly

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The mask assembly is divided into multiple independent components: a mask frame with dividers creating multiple openings, and separate mask sheets that can be independently positioned and removed. This segmentation allows for precise control of the organic emission layer deposition in different regions while maintaining manufacturing precision.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The mask sheets are designed to be removable from the mask frame after deposition. This extraction principle allows the mask sheets to be taken out after serving their purpose of defining the pattern, simplifying the overall process and reducing the complexity of handling permanent complex structures.

Inventive Principle:

Principle #2Taking out (Extraction)

2Productivity

If multiple mask sheets are arranged on the mask frame, then the productivity of forming the organic emission layer is improved, but the device complexity increases

Engineering Contradiction:

Improveefficiency of forming organic emission layerVSAvoidcomplexity of mask assembly structure

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Multiple mask sheets are combined on a single mask frame structure, allowing simultaneous or sequential deposition operations. This merging of multiple functional elements into one integrated assembly improves productivity by enabling efficient formation of the organic emission layer across multiple regions without requiring separate operations for each region.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The mask frame structure serves multiple functions: it holds multiple mask sheets, provides structural support, defines the overall pattern geometry through dividers, and enables systematic deposition control. This multi-functionality reduces the need for additional separate components, thereby improving productivity without proportionally increasing complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If the mask sheets are arranged apart from each other, then the ease of manufacture is improved, but the manufacturing precision may be compromised

Engineering Contradiction:

Improveease of arranging mask sheetsVSAvoidalignment precision of mask sheets

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

The mask frame acts as an intermediary structure that holds and positions the mask sheets. This intermediate framework provides reference surfaces and mechanical constraints that facilitate easy arrangement and positioning of individual mask sheets while maintaining precise alignment through the structured support system.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The mask sheets are positioned apart from each other with specific spacing, allowing local access and manipulation of each sheet while maintaining overall pattern precision. This local quality approach enables easier manufacturing and assembly of individual components without compromising the global alignment precision of the complete pattern.

Inventive Principle:

Principle #3Local quality

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 solution enables the formation of a high-resolution display device by ensuring accurate alignment and deposition of the organic emission layer, enhancing the sharpness and quality of the image displayed.

Implementation Method 1

a deposition source arranged inside the chamber to face the mask assembly and supply a deposition material to the display substrate

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Data Source

PatentUS11629397B2Mask assembly, apparatus, and method of manufacturing display device

Publication Date: 2023.04.18 SAMSUNG DISPLAY CO LTD

AI summary

A mask assembly, an apparatus for manufacturing a display device, and a method of manufacturing a display device are provided. A mask assembly includes: a mask frame including a frame body portion and dividers, the frame body portion being arranged at an outside of the mask frame, and the dividers dividing an inside of the frame body portion into a plurality of openings, each of the dividers being connected in a first direction and a second direction; and a plurality of mask sheets arranged on a top surface of the mask frame, coupled to the mask frame, and including at least one pattern opening, mask sheets of the plurality of mask sheets being apart from each other in the first direction.