Mask Assembly with Differential Particle Size Welding
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Solution Overview
Problem
The existing mask assemblies for manufacturing display devices face challenges in achieving precise welding efficiency, which affects the resolution and reliability of the display devices, particularly due to differences in particle size and heat transfer between the pattern and welding portions of the mask sheet.
Innovation Solution
A mask assembly is designed with a pattern portion and a welding portion of different particle sizes, where the welding portion is thermally treated to enhance heat conductivity and prevent melting during the welding process, ensuring a secure and efficient connection between the mask sheet and the mask frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mask sheet has uniform particle size throughout, then the manufacturing process is simple, but the welding efficiency is poor and the pattern portion may melt during welding
Solution Approach 1:
The mask sheet is designed with different particle sizes in different regions: the welding portion has larger particles (first particle size) for high heat conductivity, while the pattern portion has smaller particles (second particle size) to prevent melting. This local differentiation resolves the contradiction by optimizing each region's properties for its specific function.
Solution Approach 2:
The mask sheet is segmented into distinct functional regions (welding portion and pattern portion) with different particle size characteristics. This segmentation allows independent optimization of thermal properties for welding versus pattern protection, achieving both high welding efficiency and pattern integrity.
2Temperature
If the particle size of the welding portion is increased to improve heat conductivity, then welding efficiency improves, but the pattern portion may be affected by excessive heat
Solution Approach 1:
Different particle sizes are assigned to different regions: larger particles in the welding portion for high heat conductivity, and smaller particles in the pattern portion for heat insulation. This local quality differentiation ensures the welding portion can efficiently conduct heat for welding while the pattern portion remains protected from excessive heat.
Solution Approach 2:
The welding portion with larger particles acts as a thermal mediator that can rapidly conduct heat away from the welding zone, preventing heat accumulation that would otherwise transfer to and damage the pattern portion. This intermediary function protects the pattern while enabling efficient welding.
3Reliability
If the particle size of the pattern portion is decreased to prevent melting, then pattern integrity is maintained, but the overall heat conductivity of the mask sheet decreases
Solution Approach 1:
The pattern portion uses smaller particles to maintain structural integrity and prevent melting during welding, while the welding portion uses larger particles to provide high heat conductivity. This local quality assignment allows the pattern portion to be optimized for heat resistance without compromising overall welding performance.
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 improves the welding efficiency and productivity, minimizing defects and ensuring precise deposition of materials onto the substrate, thereby enhancing the quality and reliability of the display devices.
Implementation Method 1
thermally treating a second portion of the base member to form a welding portion
Implementation Method 2
the welding portion having a particle size different from a particle size of the pattern portion
Data Source
AI summary
A mask assembly, and an apparatus including the same are provided. The mask assembly includes a mask sheet. The mask sheet includes a pattern portion having openings, and a welding portion connected to the pattern portion. The welding portion has a grain size different from a grain size of the pattern portion.