Mask Assembly Protrusion Reduces Contact Area
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Solution Overview
Problem
Existing display device manufacturing methods face challenges in reducing the contact area between the mask assembly and the display substrate, leading to potential damage and affecting the quality and durability of the display substrate.
Innovation Solution
A mask assembly design with a second mask layer having a 2-1st and 2-2nd mask portion, where the 2-2nd mask portion protrudes towards the display substrate, reducing the contact area and incorporating a magnetic force to align and position the mask assembly accurately during the deposition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mask assembly contacts the display substrate directly, then the mask assembly provides stable support during deposition, but the contact area causes damage to the display substrate and reduces its quality and durability
Solution Approach 1:
The mask assembly transitions from a single-plane contact structure to a multi-layer three-dimensional structure. The second mask layer extends in the vertical dimension with a protruding portion that contacts the display substrate, while the first mask layer remains elevated. This dimensional separation reduces the contact area on the display substrate surface while maintaining structural support functionality.
Solution Approach 2:
The mask assembly is divided into multiple functional layers: a first mask layer for defining deposition patterns, a second mask layer for additional pattern definition and substrate contact, and a support beam structure for mechanical stability. This segmentation allows each layer to perform its specific function while minimizing harmful contact area.
2Manufacturing precision
If the mask assembly is positioned close to the display substrate for accurate alignment, then manufacturing precision is improved, but shadowing effects increase during deposition
Solution Approach 1:
The mask assembly utilizes vertical positioning through multiple layers at different heights. The first mask layer is positioned higher to minimize shadowing during deposition, while the second mask layer extends lower to contact the substrate for precise alignment. This three-dimensional arrangement decouples the alignment function (requiring close proximity) from the deposition function (requiring minimal shadowing).
Solution Approach 2:
The support beam acts as an intermediary structure that holds the mask layers at optimized positions. It connects the elevated first mask layer to the substrate-contacting second mask layer, enabling precise alignment without requiring the entire mask assembly to be close to the substrate, thereby reducing shadowing effects.
3Device complexity
If a simple single-layer mask structure is used, then device complexity is reduced, but the contact area cannot be sufficiently minimized
Solution Approach 1:
The mask assembly is segmented into multiple layers with distinct functions. The first mask layer handles pattern definition with minimal substrate contact, while the second mask layer provides additional pattern control and deliberate substrate contact at reduced area. This segmentation enables contact area minimization without excessive complexity.
Solution Approach 2:
The solution moves from a two-dimensional planar mask to a three-dimensional multi-layer structure. By utilizing the vertical dimension, the mask assembly can reduce horizontal contact area while maintaining necessary structural support and pattern definition functions, achieving contact minimization without significant complexity increase.
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 design minimizes damage to the display substrate, improves the quality and durability of the mask assembly, and enhances the manufacturing efficiency by reducing shadowing effects during deposition.
Implementation Method 1
a magnetic force portion which is disposed in the chamber and applies magnetic force to the mask assembly
Implementation Method 2
a deposition source which is disposed in the chamber, faces the mask assembly and supplies a deposition material such that the deposition material passes through the mask assembly and is deposited on the display substrate
Data Source
AI summary
An apparatus for manufacturing a display device includes a chamber, a mask assembly disposed in the chamber and facing a display substrate, a magnetic force portion which is disposed in the chamber and applies magnetic force to the mask assembly, and a deposition source which is disposed in the chamber, faces the mask assembly and supplies a deposition material so that the deposition material passes through the mask assembly and is deposited on the display substrate, where the mask assembly includes a first mask layer in which a first mask opening is defined, and a second mask layer which is disposed on the first mask layer and in which a second mask opening overlapping the first mask opening is defined, where the second mask layer includes a 2-1st mask portion, and a 2-2nd mask portion protruding from the 2-1st mask portion toward the display substrate.