Mask Assembly Projections Stabilize Unit Masks
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Solution Overview
Problem
The existing mask assembly for flat panel displays, particularly in LCD and OLED manufacturing, experiences wave formation due to contraction in the width direction of unit masks, leading to deposition inferiority, as the thin metal plates cannot withstand pulling forces and welding-induced stress, affecting the quality of thin film deposition.
Innovation Solution
A mask assembly design that includes a mask frame with frame openings and unit masks extending in one direction, featuring projections at both ends to stabilize the unit masks in a second direction, using extension units with guide rails and movement members to mitigate wave formation and maintain stability during deposition.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If unit masks are extended in the length direction by welding to the mask frame, then the mask assembly can be assembled and used for deposition, but wave formation occurs in the width direction due to contraction, degrading deposition quality
Solution Approach 1:
The mask assembly is divided into multiple unit masks that are separately manufactured and then assembled onto the mask frame. Each unit mask can be independently produced, allowing for modular assembly while maintaining overall mask functionality and deposition quality.
Solution Approach 2:
A mask frame serves as an intermediary structure that supports and positions multiple unit masks. The mask frame absorbs and distributes the stress from welding and contraction, preventing wave formation on the unit masks themselves while enabling easy assembly.
2Manufacturing precision
If unit masks are made as thin metal plates to achieve precise patterns, then deposition precision is improved, but the thin masks cannot withstand pulling forces from clamps, causing wave formation at end portions
Solution Approach 1:
The mask system separates the thin, precise unit masks from the thick, strong mask frame. The unit masks maintain their thin profile for precision while the mask frame provides the necessary structural strength to withstand clamping forces without deforming.
Solution Approach 2:
Different parts of the mask system have different thicknesses and properties: unit masks are thin for precision patterning, while the mask frame is thick for structural strength. This local differentiation allows each component to optimize its function without compromising the other.
3Strength
If welding is used to fix unit masks to the mask frame, then strong fixation is achieved, but welding-induced pulling force creates waves around welding points, affecting deposition quality
Solution Approach 1:
The mask system uses multiple separate unit masks rather than one large mask, distributing the welding points across multiple smaller components. This segmentation reduces the cumulative welding-induced stress and prevents large-scale wave formation that would affect deposition quality.
Data Source
AI summary
A mask assembly includes a mask frame having frame openings formed thereon, and a plurality of unit masks fixed to the mask frame. The respective unit masks extend in a first direction, and at least one of the plurality of unit masks includes at least one of a one sided projection projecting to one side thereof and another sided projection projecting to another side thereof, at both end portions of the unit mask, in a second direction that crosses the first direction.