Mask Assembly Hole Tapering to Reduce Shadow and Deformation
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Solution Overview
Problem
The manufacturing process of mask assemblies in display devices is prone to shadow phenomena and unnecessary deformation, which affects the deposition process and the quality of the final product.
Innovation Solution
A method involving fixing a mask sheet to a mask frame and performing laser processing to create deposition holes with specific geometric configurations, including symmetrical and concave shapes, to minimize shadowing and deformation during the deposition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional mask sheets are used without specific geometric configurations, then the manufacturing process is simpler, but shadow phenomena occur during deposition
Solution Approach 1:
The patent applies asymmetry by designing the deposition holes with non-uniform cross-sections where the width varies along the thickness direction of the mask sheet. This asymmetric geometry prevents shadow phenomena during deposition by ensuring uniform material distribution, resolving the contradiction between eliminating shadow effects and maintaining structural simplicity.
Solution Approach 2:
The patent changes the geometric parameters of the deposition holes by making the width vary continuously or discontinuously along the thickness direction. This parameter modification allows the holes to eliminate shadow effects while controlling the complexity of the mask structure through precise geometric definition.
2Stability of the object's composition
If mask sheets are processed without proper geometric design, then manufacturing is easier, but unnecessary deformation occurs during manufacturing
Solution Approach 1:
The asymmetric geometry of the deposition holes, with widths that vary along the thickness direction, provides structural stability that prevents unnecessary deformation during manufacturing. This asymmetric design maintains the rigidity and shape integrity of the mask assembly while being manufacturable through controlled processing methods.
Solution Approach 2:
By carefully controlling the width parameters of the deposition holes at different positions along the thickness direction, the patent achieves optimal structural stability. The parameter variation is designed to prevent deformation during manufacturing while maintaining ease of production through defined geometric constraints.
3Manufacturing precision
If deposition holes have uniform width throughout, then manufacturing is simpler, but deposition uniformity is poor
Solution Approach 1:
The patent employs asymmetric hole geometry where the width of deposition holes varies along the thickness direction of the mask sheet. This asymmetric configuration ensures uniform deposition by compensating for distance variations from the deposition source, achieving manufacturing precision while the geometry is defined through controllable parameters rather than complex structures.
Solution Approach 2:
The patent achieves deposition uniformity by varying the width parameter of the deposition holes along the thickness direction. This parameter change is systematically controlled to ensure that material distribution is uniform across the substrate, resolving the contradiction between deposition precision and geometric complexity through defined parameter relationships.
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
Reduces shadow phenomena and unnecessary deformation, ensuring precise and uniform deposition on the display substrate, thereby improving the manufacturing process efficiency and product quality.
Implementation Method 1
laser processing, by a laser processing apparatus, the plurality of first deposition holes into a plurality of mask deposition holes penetrating the sheet frame, respectively
Data Source
AI summary
A method of manufacturing a mask assembly includes fixing a mask sheet to a mask frame, wherein the mask sheet includes a sheet frame and a plurality of first deposition holes penetrating the sheet frame, and laser processing, by a laser processing apparatus, the plurality of first deposition holes into a plurality of mask deposition holes penetrating the sheet frame, respectively, wherein each of the plurality of first deposition holes includes a 1st-1 deposition hole in a first surface of the sheet frame, and a 1st-2 deposition hole in a second surface of the sheet frame opposite to the first surface and communicating with the 1st-1 deposition hole, wherein a width of each of the plurality of mask deposition holes gradually decreases from the first surface of the sheet frame toward the second surface of the sheet frame.