Mask Assembly with Detachable Blocking Plate for High-Resolution Deposition
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Solution Overview
Problem
The existing mask assembly for organic light-emitting display devices becomes cumbersome and costly as the size of the mask increases, requiring division into multiple pieces and frequent replacement due to sagging issues and pattern defects, complicating the deposition process for high-resolution displays.
Innovation Solution
A mask assembly with a detachable blocking plate and magnetic members that allows precise control over deposition material application, enabling high-resolution patterns on large substrates without the need for a separate shadow mask, simplifying the manufacturing process and reducing costs by eliminating the need for frequent mask replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mask size is increased to achieve high-resolution deposition on large substrates, then the deposition precision is improved, but the mask becomes cumbersome and requires division into multiple pieces, increasing device complexity
Solution Approach 1:
The mask assembly is divided into a mask substrate and a separate blocking plate that can be independently positioned. The blocking plate is further segmented into multiple blocking portions that can be selectively moved to cover different pixel regions. This segmentation allows the mask to maintain high precision for large substrate deposition while avoiding the complexity of creating one monolithic large mask by enabling modular configuration.
Solution Approach 2:
The blocking plate is designed to be movable relative to the mask substrate through magnetic actuators. This dynamic configuration allows the blocking plate to be repositioned to different locations on the substrate, enabling a single mask assembly to serve multiple deposition patterns and resolutions. The dynamic nature eliminates the need for multiple fixed masks, reducing device complexity while maintaining deposition precision.
2Manufacturing precision
If the mask size is increased for high-resolution deposition, then the deposition precision is improved, but the mask requires frequent replacement due to sagging and pattern defects, reducing productivity
Solution Approach 1:
The movable blocking plate design allows a single mask assembly to be reused for multiple deposition cycles by repositioning the blocking plate to different configurations. This eliminates the sagging and pattern defect issues that plague large fixed masks, as the blocking plate can be easily replaced or repositioned without affecting the mask substrate. Consequently, productivity is improved through reduced mask replacement frequency while maintaining high deposition precision.
Solution Approach 2:
The blocking plate is designed as a consumable or easily replaceable component that can be discarded or recovered independently from the mask substrate. When the blocking plate shows signs of wear or contamination, it can be replaced without replacing the entire mask assembly, thereby maintaining productivity and deposition precision over extended manufacturing periods.
3Manufacturing precision
If a separate shadow mask is used for deposition control, then the deposition precision is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The blocking plate is integrated with the mask substrate to form a unified mask assembly. The blocking plate is detachably mounted on the mask substrate, combining the functions of pattern definition and deposition control in a single integrated structure. This merging eliminates the need for a separate shadow mask, reducing device complexity and manufacturing cost while maintaining deposition precision through the coordinated action of the mask substrate and blocking plate.
Solution Approach 2:
The mask assembly with the movable blocking plate serves multiple functions: it defines deposition patterns, controls material distribution, and can be reconfigured for different pixel regions. This multi-functionality replaces the need for separate shadow masks and multiple fixed masks, simplifying the overall device structure while maintaining high deposition precision across various deposition scenarios.
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
Enables high-resolution deposition on large substrates with improved manufacturing efficiency and reduced costs by allowing precise control over the deposition process, maintaining pattern accuracy and consistency without the need for frequent mask replacements.
Implementation Method 1
a first magnetic member configured to pull the blocking plate from the hole to the second pixel, and a second magnetic member configured to pull the blocking plate from the second pixel to the hole
Data Source
AI summary
Provided is a mask assembly, an apparatus, and a method of manufacturing a display apparatus using such mask assembly and apparatus. The mask assembly deposits a deposition material on a first pixel among a plurality of pixels disposed on a device substrate and including the first pixel and a second pixel includes a mask substrate, a molding layer stacked on the mask substrate and including a hole corresponding to a position of the second pixel, a blocking plate detachably mounted in the hole and configured to block the second pixel from the deposition material by covering the second pixel when the blocking plate is detached from the hole.