Mask Frame Assembly Slot Design for Deposition Precision
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Solution Overview
Problem
The challenge in manufacturing high-resolution organic light emitting display devices is the inaccurate calculation of extension force during the extension-welding process of the mask frame assembly due to frictional forces, leading to deformation and shadow effects that affect deposition precision.
Innovation Solution
A mask frame assembly is designed with a slot on the first and second frames that are not in contact with the stage, allowing precise control of extension forces and minimizing friction, combined with a method of manufacturing that includes applying extension forces to the mask and frames to compensate for restoring forces, thereby reducing deformation and enhancing adhesion between the mask and substrate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the mask frame assembly is designed with frames contacting the stage for stability, then the stability is improved, but frictional forces are generated that cause inaccurate calculation of extension force
Solution Approach 1:
The mask frame assembly is divided into multiple frames (first frame, second frame, third frame, fourth frame) with different contact configurations. The first and second frames have slots that prevent contact with the stage, while the third and fourth frames contact the stage for stability. This segmentation allows different parts of the assembly to serve different functions - some for stability, others for friction-free extension force application.
Solution Approach 2:
Different regions of the mask frame assembly have different contact properties with the stage. Specifically, the first and second frames have slots at locations where they would contact the stage, creating friction-free zones, while the third and fourth frames maintain contact for stability. This local differentiation of contact quality resolves the contradiction between needing stability and avoiding frictional interference.
2Manufacturing precision
If extension force is applied to compensate for restoring force, then deformation is reduced, but frictional force from stage contact makes the required extension force inaccurate
Solution Approach 1:
The harmful frictional contact between the mask frame and stage is removed by introducing slots in the first and second frames. This extraction of the frictional interaction allows the extension force to be applied accurately without being distorted by friction, enabling precise compensation for the restoring force and achieving accurate deposition patterns.
Solution Approach 2:
The slot structure acts as an intermediary mechanism that allows the frame to maintain its position and stability while preventing direct frictional contact with the stage. This intermediary structure enables accurate force application by mediating between the need for stability and the need to eliminate frictional interference.
3Strength
If the mask is extended and welded to the frame, then adhesion between mask and substrate is enhanced, but the restoring force causes shape changes in the mask and frame
Solution Approach 1:
An extension force is applied to the mask frame assembly before the welding process to pre-compensate for the restoring force that will act after welding. This preliminary anti-action counterbalances the expected shape-changing force, ensuring that the mask and frame maintain their correct shapes during and after welding while still achieving strong adhesion.
Solution Approach 2:
The extension force is applied in advance of the welding operation to prepare the mask frame assembly in the correct configuration. This preliminary action ensures that when welding occurs, the components are in the optimal state for both adhesion and shape maintenance, preventing deformation that would otherwise occur due to restoring forces.
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 precision of the deposition process by minimizing deformation and shadow effects, resulting in a more accurate and precise deposition pattern on the substrate.
Implementation Method 1
a mask including a plurality of masks having an elongated stick-like shape or formed as one consolidated mask and welded to a mask frame
Implementation Method 2
After the mask and the frame have been welded, a restoring force may be applied to the mask corresponding to an extension force having been applied to the mask, and thus, shapes of the mask and the mask frame may be changed due to the restoring force
Implementation Method 3
the extension force to be applied to the frame to compensate for the restoring force applied to the mask may not be accurately calculated due to a frictional force generated between the stage and the frame during the extension-welding process of the mask
Data Source
AI summary
A mask frame assembly manufactured via an extension-welding process on a stage, the mask frame assembly includes: a mask frame disposed on a stage, the mask frame including a first frame and a second frame having a first length, and a third frame and a fourth frame having a second length, the second length less than the first length. The mask frame assembly also includes a mask having respective ends welded and combined onto the first frame and the second frame. The first frame and the second frame include a slot disposed toward the stage, and at least portions of the first frame and the second frame corresponding to the slot are not in contact with the stage. The third frame and the fourth frame and the stage are in contact with the stage.