Mask Assembly Spot Welding for Thin Film Deposition
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Solution Overview
Problem
The existing methods for manufacturing mask assemblies for thin film deposition, particularly for large-sized flat panel displays, face challenges in minimizing the deterioration or warping of division masks during the welding process, leading to undesired separation between the mask and the substrate.
Innovation Solution
A method involving spot welding of division masks to a mask frame using a zigzag pattern for first and second welding points, with optional center welding, and supporting bars to reduce interference and maintain mask stability, thereby minimizing mask distortion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If spot welding is used to attach the division mask to the mask frame, then the mask assembly can be manufactured efficiently, but the division mask deteriorates or warps causing separation from the substrate
Solution Approach 1:
The welding process is segmented into multiple passes with intermediate cooling periods. The welding is divided into first welding points and second welding points, with the mask surface cooled between passes to prevent cumulative thermal distortion while maintaining manufacturing efficiency.
Solution Approach 2:
A cooling structure is integrated into the welding system that serves dual functions: it cools the mask surface during welding to prevent warping, and also provides structural support during the attachment process, addressing both precision and stability requirements.
2Strength
If multiple welding points are formed to ensure secure attachment, then the attachment strength increases, but the thermal interference causes greater mask distortion
Solution Approach 1:
The welding process uses periodic action by forming welding points in sequences with cooling intervals. Multiple welding passes are performed with the mask surface cooled between passes, allowing secure attachment through multiple welding points while preventing cumulative thermal distortion that would cause warping.
Solution Approach 2:
The welding process applies local quality by concentrating thermal energy at specific welding points rather than uniformly across the mask. Each welding point receives localized heat treatment, and the cooling structure applies localized cooling at the mask surface, ensuring attachment strength at weld points while maintaining overall mask flatness.
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 effectively reduces the change or distortion of the division mask during welding, ensuring stable attachment and maintaining the integrity of the mask assembly for efficient thin film deposition.
Implementation Method 1
spot welding opposing ends of the division mask along the first direction to the mask frame
Data Source
AI summary
A method of manufacturing a mask assembly for thin film deposition includes: positioning a division mask on a mask frame, wherein the division mask has a length in a first direction that is greater than a width in a second direction perpendicular to the first direction; and spot welding opposing ends of the division mask along the first direction to the mask frame, wherein the spot welding comprises: forming first welding points in a first zigzag pattern starting from a peripheral portion along the second direction of the division mask toward a central portion along the second direction of the division mask; and forming second welding points between the first welding points.