Fine Metal Mask Plate Stretching with Embedded Shaping Mold
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Solution Overview
Problem
During the manufacturing of fine metal masks for organic light-emitting display devices, the stretching process often results in deformation or damage to the mask region, affecting the straightness and flatness of the formed mask plate, which in turn impacts the quality of the film formed by evaporation.
Innovation Solution
A manufacturing method involving embedding a shaping mold with barrier columns into the mask sheet, fixing it with an adhesive layer, performing a stretching process, and separating the mold at a controlled temperature to form the mask plate, which prevents deformation and ensures the mask region's integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a stretching process is performed on the mask sheet to form the mask plate, then the mask plate can be formed with the required shape and size, but the mask region undergoes deformation or damage affecting straightness and flatness
Solution Approach 1:
The shaping mold is embedded in the mask region before the stretching process is performed. This preliminary action protects the mask region from deformation during stretching, maintaining straightness and flatness while still allowing the overall mask plate to be formed through the stretching process.
Solution Approach 2:
The shaping mold acts as an intermediary protective structure embedded in the mask region. It serves as a mediator that prevents direct deformation of the mask region during stretching, while still allowing the stretching process to proceed for forming the mask plate shape.
2Manufacturing precision
If the shaping mold is embedded in the mask region to prevent deformation, then the straightness and flatness are maintained, but the device complexity increases
Solution Approach 1:
The shaping mold is segmented into multiple barrier columns distributed across the mask region. This segmentation allows the mold to be embedded in a standardized, modular manner, reducing overall complexity while maintaining protection of the mask region during stretching.
Solution Approach 2:
The shaping mold can be reused across multiple mask sheet productions. By creating a standardized mold structure that can be copied and reused, the initial complexity investment is amortized over multiple productions, reducing the effective complexity per unit.
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 method effectively prevents deformation of the mask region during stretching, ensuring the straightness and flatness of the mask plate, thereby improving the accuracy and quality of the film formed by evaporation.
Implementation Method 1
fixing the mask sheet with the shaping mold; forming an adhesive layer on a side of the mask sheet away from the supporting part, to adhere the mask sheet to the plurality of barrier columns
Implementation Method 2
A material of the adhesive layer comprises a thermal separation adhesive, and the thermal separation adhesive is configured to fail after being heated to a preset temperature; heating the mask sheet fixed with the shaping mold to the preset temperature to separate the shaping mold from the mask sheet
Data Source
AI summary
Embodiments of the present disclosure provide a manufacturing method of a mask plate. The manufacturing method of the mask includes: embedding a shaping mold in a mask region of a mask sheet; fixing the mask sheet with the shaping mold; performing a stretching process on the mask sheet fixed with the shaping mold; and separating the mask sheet from the shaping mold to form the mask.