Mask Assembly with Segmented Support and Connection Portion for Pixel Deposition
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Solution Overview
Problem
As display devices become smaller and more complex, there is a significant challenge in accurately arranging pixels to form precise patterns, particularly in ensuring that deposition materials are accurately disposed at the pixels during manufacturing.
Innovation Solution
A mask assembly is developed, comprising a support with a first opening, a connection portion with a second opening, and a mask with pattern holes corresponding to the openings. This assembly is used in a method and apparatus for manufacturing display devices, allowing for precise deposition of materials onto substrates.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If display devices become smaller and more complex, then display device integration is improved, but manufacturing precision of pixel patterns deteriorates
Solution Approach 1:
The mask assembly is divided into separate components: a support structure with first openings, a connection portion with second openings, and a mask with pattern holes. This segmentation allows each component to be optimized independently for its specific function while maintaining overall precision in the pixel pattern formation.
Solution Approach 2:
The connection portion acts as an intermediary element between the support and the mask. It includes openings that align with the first openings in the support and work in conjunction with the pattern holes in the mask to precisely control material deposition at pixel locations, thereby maintaining manufacturing precision despite device miniaturization.
2Manufacturing precision
If deposition material is deposited accurately at pixels, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The mask assembly merges multiple functional elements into a single integrated structure: the support provides mechanical stability with first openings, the connection portion provides alignment with second openings, and the mask provides the precise pattern with pattern holes. This combination achieves accurate material deposition while managing structural complexity through functional integration.
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 mask assembly enables the precise arrangement of pixels in a display device, allowing for the formation of high-resolution display devices with accurate deposition of materials, thereby addressing the challenge of achieving precise patterns in smaller display devices.
Implementation Method 1
a mask assembly arranged between the substrate and the deposition source, wherein the mask assembly includes a support defining a first opening therein; a connection portion defining a second opening therein, and a mask arranged on the connection portion, and configured to shield the first opening and the second opening, and defining a plurality of pattern holes corresponding to the first opening and the second opening
Data Source
AI summary
Provided are a mask assembly, a method of manufacturing a mask assembly, and a method and apparatus for manufacturing a display device using a mask assembly. The mask assembly includes: a support defining a first opening therein; a connection portion defining a second opening therein, arranged on the support, and comprising at least one of metal, metal oxide, metal nitride, and alloy thereof, wherein the second opening corresponds to the first opening; and a mask arranged on the connection portion, configured to shield the first opening and the second opening, and defining a plurality of pattern holes corresponding to the first opening and the second opening.