Mask Assembly Unit Mask Welding Separation for Display Deposition
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Solution Overview
Problem
Current mask assemblies for light emitting display devices face challenges in achieving precise deposition of light emitting layers due to shadow areas caused by insufficient adhesion between the base substrate and the unit masks, leading to reduced deposition precision and display quality.
Innovation Solution
The proposed mask assembly includes an open mask with alternately arranged first and second open openings, each corresponding to unit masks with specific deposition and welding portions, and tensioning mechanisms to ensure adequate separation between welding protrusions and deposition openings, enhancing adhesion and precision during the deposition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the unit masks are placed close to the deposition openings to maximize coverage, then the deposition area is increased, but the adhesion between the base substrate and unit masks deteriorates due to shadow areas
Solution Approach 1:
The mask assembly is divided into multiple unit masks (first unit masks and second unit masks) that are alternately arranged on the open mask. Each unit mask is independently positioned and welded, allowing optimized separation distances from deposition openings while maintaining overall coverage. This segmentation enables each unit mask to be placed at an optimal distance of at least 7.5mm from deposition openings to ensure adhesion, while collectively covering the required deposition area.
2Manufacturing precision
If the welding portions are positioned close to deposition openings to minimize shadow areas, then the deposition precision is improved, but the adhesion between unit masks and base substrate deteriorates
Solution Approach 1:
Different portions of the unit masks are designed with different functions and positions. The deposition openings are positioned at specific locations to define the deposition area, while the welding portions are extended at least 7.5mm from the deposition openings to ensure strong adhesion to the base substrate. This local differentiation allows each region to optimize its function: deposition openings for precise material deposition and welding portions for secure attachment, thereby achieving both high deposition precision and strong adhesion simultaneously.
3Area of stationary object
If the unit masks are arranged to cover the entire substrate, then the deposition coverage is maximized, but the separation between welding protrusions and deposition openings is reduced
Solution Approach 1:
The mask assembly is divided into multiple unit masks (first unit masks and second unit masks) that are alternately arranged on the open mask. Each unit mask is independently positioned and welded, allowing optimized separation distances from deposition openings while maintaining overall coverage. This segmentation enables each unit mask to be placed at an optimal distance of at least 7.5mm from deposition openings to ensure adhesion, while collectively covering the required deposition area.
Solution Approach 2:
The unit masks are arranged in an alternating pattern across multiple dimensions (both first and second directions), creating a grid-like structure that maximizes coverage while maintaining consistent separation distances. This two-dimensional arrangement allows the welding portions to be positioned at least 7.5mm from deposition openings in all directions, ensuring proper adhesion while covering the entire substrate area through the coordinated positioning of multiple unit masks.
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 design improves the adhesion between the base substrate and the unit masks, reduces shadow areas, and enhances the precision of deposition patterns, resulting in improved display quality by maintaining a minimum separation distance of at least 7.5 mm between welding protrusions and deposition openings.
Implementation Method 1
a first welding portion extending from the first deposition portion to the first direction and coupled with the open mask, and a second welding portion extending from the first deposition portion to a direction opposite to the first direction and coupled with the open mask
Data Source
AI summary
A mask assembly includes an open mask including first and second open openings defined therethrough and alternately arranged in a first direction, first unit masks respectively corresponding to the first open openings, and second unit masks respectively corresponding to the second open openings. Each of the first unit masks includes a first deposition portion through which first deposition openings are defined and first and second welding portions extending from the first deposition portion to the first direction and a direction opposite to the first direction, respectively. Each of the second unit masks includes a second deposition portion through which second deposition openings are defined and third and fourth welding portions extending from the second deposition portion to a second direction and a direction opposite to the second direction.