Mask Frame Protrusions for Display Deposition Defect Control
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Solution Overview
Problem
The existing mask frame assemblies used in the manufacturing of display apparatuses, such as organic light-emitting display apparatuses, have a high probability of defects due to direct contact between the mask and the substrate during deposition processes, leading to inefficiencies and errors in the manufacturing process.
Innovation Solution
A mask frame assembly with a unique design featuring multiple opening portions and protrusions on the shielding portions, which are strategically positioned to reduce contact pressure and prevent excessive contact with the substrate, thereby minimizing defects. This design includes first and second protrusions on the first shielding portion and second shielding portion, respectively, with specific distances and orientations to manage the magnetic force and prevent bending or sagging of the mask frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mask directly contacts the substrate during deposition, then the deposition process can be performed, but the probability of defects increases due to excessive contact
Solution Approach 1:
The patent introduces asymmetric protrusions at specific positions on the mask frame, creating unequal distances from opening portions to the substrate. This asymmetric design allows selective contact control, reducing harmful contact at critical areas while maintaining necessary contact for structural support during deposition.
Solution Approach 2:
The protrusions are pre-positioned on the mask frame before deposition begins. These protrusions preliminarily establish the contact geometry, preventing excessive contact during the deposition process by creating predetermined contact points that distribute and control the contact pressure.
2Manufacturing precision
If the mask frame is rigid to maintain position, then deposition precision is improved, but magnetic force causes bending and sagging
Solution Approach 1:
The patent modifies the physical parameters of the mask frame by adding protrusions with specific heights and positions. These parameter changes allow the mask to better resist magnetic forces while maintaining positional precision, as the protrusions create a more favorable geometric distribution of forces during deposition.
Solution Approach 2:
The protrusions are designed to preemptively counteract the bending and sagging caused by magnetic forces. By positioning protrusions at strategic locations, the mask frame is pre-configured to resist the expected magnetic forces during deposition, preventing deformation before it occurs.
3Reliability
If the mask frame structure is simple, then manufacturing is easier, but defect reduction capability is insufficient
Solution Approach 1:
The mask frame is segmented into multiple functional regions through the addition of protrusions at specific positions. This segmentation allows different parts of the mask frame to serve different purposes: some areas provide structural support while others control contact with the substrate, thereby reducing defects without requiring complete redesign of the entire mask frame.
Solution Approach 2:
The patent applies local quality by adding protrusions only at specific critical positions on the mask frame rather than uniformly across the entire structure. This localized modification provides defect reduction capability at key areas while minimizing the overall increase in structural complexity.
Data Source
AI summary
A mask frame assembly includes: a mask including a plurality of opening portions; and a frame coupled to an edge of the mask, wherein the mask includes: first shielding portions extending in a first direction and parallel to each other; second shielding portions parallel to each other and extending in a second direction crossing the first direction, such that the plurality of opening portions are defined together with the first shielding portions; and a first protrusion on the first shielding portion, wherein, in the second direction, a distance from an opening portion on one side of the first shielding portion is different from a distance from an opening portion on another side of the first shielding portion.