Mask Frame Assembly Thermal Expansion Control
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Solution Overview
Problem
Existing mask frame assemblies used in display apparatus manufacturing often experience deformation, such as sagging, during the deposition process, which affects the quality of the pattern formed by the mask.
Innovation Solution
A mask frame assembly is designed with reinforcing members having a higher coefficient of thermal expansion than the mask, coupled to the frame and mask, allowing for controlled thermal expansion to prevent sagging by applying a tensile force and constraining the member to expand outwardly, thereby maintaining the mask's horizontal position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask frame assembly is used during deposition process, then material can be deposited in predetermined positions on substrate, but mask deformation such as sagging occurs during deposition
Solution Approach 1:
The patent changes the thermal expansion parameter by selecting materials with different coefficients of thermal expansion. The reinforcing member has a higher coefficient of thermal expansion than the mask, allowing it to expand more during heating and generate tensile force that counteracts mask sagging, thus maintaining mask shape stability while enabling precise pattern formation
Solution Approach 2:
The patent utilizes thermal expansion effects by heating the mask frame assembly during deposition. The reinforcing member expands more than the mask due to its higher coefficient of thermal expansion, creating tensile force that prevents mask sagging. This thermal expansion mechanism is used to actively maintain mask shape stability during the deposition process
2Manufacturing precision
If mask is constrained to prevent sagging, then pattern quality improves, but thermal expansion of mask is restricted
Solution Approach 1:
The reinforcing member acts as an intermediary between the mask and the heating process. It absorbs the thermal expansion differences by expanding more than the mask and converting this expansion into useful tensile force that prevents sagging. This intermediary mechanism allows the mask to be thermally constrained without direct mechanical constraint, maintaining pattern resolution while managing thermal effects
Solution Approach 2:
The patent changes the thermal expansion parameter by selecting materials with different coefficients of thermal expansion. The reinforcing member's higher coefficient allows it to expand more during heating, generating the necessary tensile force to prevent mask sagging while accommodating the thermal process requirements
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
The solution effectively reduces or prevents mask sagging, improving the adhesion between the mask and substrate and enhancing the resolution of the pattern formed, even in high-temperature deposition processes.
Implementation Method 1
a first member disposed between the first end of the mask and the frame, the first member including a material having a coefficient of thermal expansion greater than that of the mask
Data Source
AI summary
A mask frame assembly including a frame having an opening, a mask having a first end and a second end supported on the frame, and a first member disposed between the first end of the mask and the frame, the first member including a material having a coefficient of thermal expansion greater than that of the mask. A method of manufacturing a display apparatus using the mask frame assembly also is disclosed.