Mask Design for Irregular Screens Using Rib Cutouts
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Solution Overview
Problem
During the manufacturing of irregular screens, the support mask with an irregular opening area is prone to uneven deformation when stretched and welded to the frame, leading to reduced evaporation precision and color mixture issues in the display device.
Innovation Solution
A mask design method that includes modeling a mask layout, performing stretching simulation to identify reference openings, and providing cutouts in the second rib to compensate for tensile deformation, thereby reducing uneven deformation and improving evaporation accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a support mask with irregular opening area is used for manufacturing irregular screens, then the display area can be shaped according to design requirements, but the mask is prone to uneven deformation when stretched and welded to the frame
Solution Approach 1:
The mask structure is segmented into multiple ribs (first ribs and second ribs) that form a grid-like framework. This segmentation provides structural support to different regions of the mask independently, allowing the irregular opening areas to maintain their shape while reducing overall deformation during stretching and welding operations.
Solution Approach 2:
The mask design implements local quality by creating different structural characteristics in different regions. The first ribs connect adjacent openings while the second ribs are positioned at edges of the pattern area with specific structural features. This localized structural differentiation allows each region to compensate for its own deformation tendencies, thereby maintaining overall manufacturing precision.
2Strength
If the mask is stretched and welded to the frame, then the mask can be securely mounted, but uneven deformation occurs leading to offset of openings from design positions
Solution Approach 1:
The mask design incorporates preliminary compensation features in the form of strategically positioned ribs that anticipate and counteract deformation forces before welding occurs. The first and second ribs are pre-configured to create internal stress distribution that offsets the uneven deformation that would otherwise occur during stretching and welding, thereby maintaining opening position accuracy.
3Shape
If the opening area is made irregular to match the display screen, then the display can achieve the desired asymmetric shape, but color mixture issues occur due to reduced evaporation precision
Solution Approach 1:
The irregular opening area is segmented into multiple smaller opening regions separated by first and second ribs. This segmentation allows each opening to maintain precise dimensional control while collectively forming the desired asymmetric display area shape, thereby preventing color mixture issues that would result from poor evaporation precision.
Solution Approach 2:
The mask structure implements local quality by providing enhanced structural support through second ribs at the edges of the pattern area and first ribs between adjacent openings. This localized reinforcement ensures that each region of the irregular opening maintains its precise shape and position, enabling reliable evaporation precision even with asymmetric display area requirements.
Data Source
AI summary
The present disclosure relates to a mask, a mask device and a mask design method. The mask includes: a pattern area, wherein the pattern area includes a plurality of openings, among which adjacent openings are spaced apart by a first rib, and at least one of the plurality of openings has a non-straight side, two first straight sides intersecting with the non-straight side, and a second straight side opposite to the non-straight side and intersecting with the first straight sides; and a second rib located at an edge of the pattern area, wherein the second rib is provided with a cutout for compensating for stretch deformation of the non-straight side, extending lines of the two first straight sides extending toward the second rib along a first direction intersect with the second rib to obtain a first area, and the cutout is located at least within the first area.