Mask Assembly Support Frame Protrusions for Vertical Deposition
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Solution Overview
Problem
Existing mask assemblies for display devices face challenges in maintaining precision and preventing deformation during vertical deposition processes, which can lead to inaccuracies in forming patterns on substrates.
Innovation Solution
A mask assembly design featuring a support frame with protruding portions on both inner and outer sides, which are tapered and intersecting, helps to distribute stress and prevent deformation, ensuring precise alignment and pattern formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional mask assembly is used in vertical deposition, then the deposition process can be completed, but the mask assembly deforms under its own weight causing poor alignment precision
Solution Approach 1:
The mask assembly is divided into multiple independent frames (first frame, second frame, third frame, fourth frame) arranged in a 2x2 grid pattern. Each frame independently supports a portion of the mask sheet, distributing the overall weight and reducing deformation. The segmentation allows each frame to be structurally optimized for minimal deflection while maintaining overall alignment precision.
Solution Approach 2:
The support frame includes asymmetric structural features: protruding portions extending in first and second directions with different configurations, and recess portions positioned asymmetrically relative to the mask sheet. This asymmetric design optimizes the structural rigidity distribution to counteract gravitational deformation in the vertical deposition orientation, with thicker or more extensive framing in regions experiencing greater stress.
2Area of stationary object
If the mask assembly is made larger for high-resolution display devices, then the display area increases, but the mask assembly becomes more prone to deformation
Solution Approach 1:
The large mask assembly is segmented into multiple smaller frames (first, second, third, fourth frames) that collectively support the entire mask sheet. Each frame acts as an independent structural unit with sufficient rigidity to maintain its local geometry, while the collective arrangement covers the large required area. This segmentation enables large-area coverage without sacrificing local precision.
Solution Approach 2:
The mask assembly transitions from a simple planar structure to a three-dimensional structured assembly with frames having specific thicknesses, protruding portions, and recess portions. This dimensional complexity adds structural rigidity in the vertical deposition direction, allowing the large-area mask to maintain its flatness and precision against gravitational forces.
3Ease of manufacture
If the mask assembly structure is simplified for ease of manufacture, then manufacturing cost decreases, but the mask assembly cannot prevent deformation during vertical deposition
Solution Approach 1:
The mask assembly uses multiple identical or similar frames (first, second, third, fourth frames) that can be manufactured using the same process and then assembled together. This modular approach maintains ease of manufacture through standardization while achieving the structural complexity needed to prevent deformation.
Solution Approach 2:
The support frame incorporates localized structural features (protruding portions and recess portions) only where needed to provide mechanical support and prevent deformation. The mask sheet itself remains relatively simple, while the framing provides the necessary structural reinforcement in specific locations without complicating the entire assembly.
Data Source
AI summary
A mask assembly according to an embodiment includes a support frame including at least four sides, a first frame disposed on the support frame and extending in a first direction, a second frame disposed on the support frame and extending in a second direction intersecting the first direction, and a mask sheet disposed on the support frame and including at least one opening. At least a side of the support frame includes a first protruding portion disposed at a first edge of the side, a second protruding portion disposed at a second edge of the side, and a recess portion disposed between the first protruding portion and the second protruding portion.