Mask Assembly Opening Sequence for Pixel Position Accuracy
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Solution Overview
Problem
Current mask assembly manufacturing methods face challenges in achieving high deposition accuracy during the display manufacturing process, as the existing methods do not effectively manage the deformation forces and stress on the mask sheet, leading to inaccuracies in pixel position alignment.
Innovation Solution
The method involves preparing a mask sheet and frame, stretching and fixing the sheet to the frame, fixing unit masks on the sheet, and forming openings by removing overlap portions using a laser, which reduces deformation forces and stress, thereby improving pixel position accuracy by controlling the order and formation of openings and grooves.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If openings are formed in the mask sheet before fixing unit masks, then manufacturing process is simpler, but deformation forces and stress cause poor pixel position accuracy
Solution Approach 1:
The patent applies preliminary action by forming grooves in the mask sheet before fixing the unit masks. These grooves are formed at predetermined positions where openings will later be created, allowing the mask sheet to be pre-prepared without causing deformation. The grooves serve as preparation steps that do not yet create full openings, thus avoiding the deformation problem while still advancing the manufacturing process.
Solution Approach 2:
The patent segments the opening formation process into two distinct stages: first forming grooves (partial removal), then later forming complete openings after unit masks are fixed. This segmentation allows the manufacturing process to progress without creating the harmful deformation that would occur if full openings were made immediately, thereby resolving the contradiction between manufacturing simplicity and position accuracy.
2Stability of the object's composition
If mask sheet is stretched and fixed to frame, then structural stability is improved, but stress and deformation forces increase affecting deposition accuracy
Solution Approach 1:
The patent applies preliminary action by forming grooves in the mask sheet before it is stretched and fixed to the frame. This preliminary groove formation creates stress relief zones that prevent excessive stress concentration during the stretching and fixing process, thereby maintaining structural stability while minimizing deformation that would affect deposition accuracy.
Solution Approach 2:
The patent applies local quality by creating grooves at specific predetermined positions in the mask sheet where unit masks will be fixed. These localized grooves provide stress relief exactly where needed, allowing the rest of the mask sheet to maintain its structural integrity and stability while preventing deformation at critical areas that would affect pixel position accuracy.
3Manufacturing precision
If openings are formed by removing overlap portions, then deposition accuracy is improved, but manufacturing time increases
Solution Approach 1:
The patent segments the opening formation into two phases: groove formation (partial removal) done before unit mask fixation, and complete opening formation done after fixation. This segmentation allows the more time-consuming precise opening formation to be performed when the mask sheet is already stable and positioned correctly, ensuring deposition accuracy while organizing the manufacturing steps efficiently.
Solution Approach 2:
The patent applies preliminary action by forming grooves at the predetermined opening positions before fixing unit masks. This preliminary groove formation prepares the mask sheet in advance, so that when complete openings are formed later, the positions are already established and the unit masks are securely in place, thereby maintaining high deposition accuracy without unnecessary delays.
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 enhances deposition accuracy by minimizing deformation forces and stress on the mask sheet, resulting in improved pixel position alignment and increased manufacturing speed, while reducing potential damage to the unit masks.
Implementation Method 1
forming an opening by removing an overlap portion, of the mask sheet, overlapping the unit mask
Data Source
AI summary
A mask assembly manufacturing method includes preparing a mask sheet and a frame, stretching and fixing the mask sheet to the frame, fixing a unit mask on the mask sheet, and forming an opening by removing an overlap portion of the mask sheet overlapping the unit mask after the fixing of the unit mask on the mask sheet.