Mask Frame Assembly Asymmetric Welding Deflection Correction
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Solution Overview
Problem
The long-side support bar in mask frame assemblies used for thin film deposition is prone to deformation during the assembling process, especially when forming asymmetric unit cell patterns, which affects the accuracy of pattern deposition.
Innovation Solution
The method involves welding the fixing ends of the long-side support bar asymmetrically with respect to its longitudinal central axis, calculating the number of asymmetric welds based on the degree of bending deflection using the formula y=25.009 ln(x)+2.5187, and repeatedly forming welds to correct the deflection, while generating a defect signal when the correction limit is exceeded.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the long-side support bar is formed with an asymmetric shape to define the asymmetric unit cell pattern, then the pattern deposition accuracy is improved, but the support bar becomes more prone to deformation during the assembling process
Solution Approach 1:
The patent applies asymmetry by forming welds asymmetrically with respect to the longitudinal central axis of the fixing ends of the long-side support bar. This asymmetric welding configuration creates a counterbalancing effect that compensates for the inherent deformation tendency caused by the asymmetric shape of the support bar, thereby maintaining both the asymmetric pattern accuracy and the structural stability during assembly
Solution Approach 2:
The patent implements preliminary anti-action by pre-calculating the number of asymmetric welds needed to correct the bending deflection before assembly. The welding process is designed to apply a counteracting force in advance that offsets the expected deformation, preventing the support bar from bending during the assembling process while maintaining the required asymmetric pattern geometry
2Ease of manufacture
If symmetric welds are formed on the long-side support bar, then the assembly process is simplified, but the bending deflection of the support bar cannot be corrected
Solution Approach 1:
The patent deliberately introduces asymmetry in the welding configuration to correct the bending deflection of the long-side support bar. By forming welds asymmetrically positioned relative to the longitudinal central axis, the method creates a moment that counteracts the bending force, thereby improving support bar straightness while maintaining reasonable assembly complexity through automated welding processes
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 effectively corrects the bending deflection of the long-side support bar, ensuring precise pattern deposition and maintaining deposition quality by reducing the degree of bending deflection to within acceptable limits.
Implementation Method 1
welding fixing ends of a long-side support bar on a frame
Data Source
AI summary
A method of manufacturing a mask frame assembly includes: welding fixing ends of a long-side support bar on a frame; and fixing a mask having a pattern area to be divided by the long-side support bar, on the frame, wherein the welding of the fixing ends of the long-side support bar on the frame includes forming welds asymmetrically with respect to a longitudinal central axis of the fixing ends.