Multi-Layer Mask Assembly for Display Deposition Shadow Reduction
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Solution Overview
Problem
Existing mask assemblies for depositing materials in display apparatus manufacturing often suffer from reduced deposition quality due to shadow phenomena and inadequate contact with the substrate.
Innovation Solution
A mask assembly comprising a mask frame with an opening region covered by a first mask sheet, which includes multiple layers with ribs and openings, and a second mask sheet welded to the first mask sheet, enhancing contact and reducing shadows.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a simple mask structure is used, then manufacturing is easier, but deposition quality deteriorates due to shadow phenomena
Solution Approach 1:
The mask sheet is divided into multiple layers (first mask sheet with ribs and openings, second mask sheet with pattern holes) that work together to eliminate shadow phenomena while maintaining manufacturing feasibility
Solution Approach 2:
The mask structure transitions from a single-plane design to a multi-layer three-dimensional structure, where the first mask sheet provides structural support and the second mask sheet provides precise patterning, thereby improving deposition quality without excessive manufacturing complexity
2Manufacturing precision
If the mask assembly is positioned closer to the substrate, then deposition quality improves, but shadow phenomena increase
Solution Approach 1:
The mask system is segmented into two functional layers: the first mask sheet with a grid of ribs and openings that provides structural integrity and reduces shadowing, and the second mask sheet with pattern holes that enables precise material deposition
Solution Approach 2:
Different regions of the mask assembly have different properties - the first mask sheet provides mechanical support and general shadow reduction, while the second mask sheet provides localized precise patterning where material deposition is required
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 improved mask assembly enhances deposition quality by minimizing shadow effects and ensuring better contact with the display substrate, leading to more uniform and efficient material deposition.
Implementation Method 1
a second layer on a first surface of the first layer and extending around the first openings
Implementation Method 2
a first weld portion on the second layer exposed through the first through portion
Implementation Method 3
The deposition material may be ejected from (or emitted by) a deposition source and deposited on a display substrate through a mask assembly
Data Source
AI summary
A mask assembly includes: a mask frame having an opening region; and a first mask sheet covering the mask frame. The first mask sheet includes: a first layer including a plurality of first ribs extending in a first direction and a plurality of second ribs extending in a second direction crossing the first direction and having a plurality of first openings defined by the first ribs and the second ribs; a second layer on a first surface of the first layer and extending around the first openings; and a third layer on a second surface of the first layer and having a plurality of pattern holes overlapping the first openings.