Mask Assembly Protruding Portion Reduces Shadow Area in Display Manufacturing
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Solution Overview
Problem
The existing methods for manufacturing display apparatuses face challenges in accurately limiting the deposition range of deposition materials, leading to increased shadow areas and larger device sizes, which hinder miniaturization and space optimization for other components.
Innovation Solution
A mask assembly with a mask frame and a mask having at least one opening, featuring a protruding portion that surrounds the opening and inclines inwardly, allowing the deposition material to be precisely deposited within the display area while reducing shadow areas by ensuring the material passes through the opening to contact the display substrate effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional mask without protruding portion is used, then the mask structure is simple, but the shadow area increases and deposition material is deposited beyond the designed area
Solution Approach 1:
The mask structure transitions from a flat two-dimensional configuration to a three-dimensional structure with protruding portions that extend toward the substrate. This dimensional change enables the protruding portions to physically define the deposition boundary through their inner surfaces, preventing material deposition beyond the designed area while maintaining manufacturing precision.
Solution Approach 2:
The protruding portions act as intermediary elements between the mask body and the substrate. These protruding portions with inclined inner surfaces serve as mediators that control and limit the deposition material flow, ensuring precise deposition range control by blocking material from reaching areas beyond the designed pattern.
2Area of stationary object
If the mask body portion is placed close to the display substrate, then the shadow area is reduced, but the risk of contact and damage to the substrate increases
Solution Approach 1:
The mask structure implements local quality differentiation where only the protruding portions extend close to the substrate to define the deposition boundary, while the main mask body portion maintains a safe distance. This localized proximity ensures minimal shadow area at the critical deposition boundary without compromising substrate integrity across the entire mask area.
Solution Approach 2:
The mask is segmented into two functional parts: protruding portions that extend close to the substrate for precise boundary definition, and a mask body portion that maintains distance for substrate protection. This segmentation allows the mask to simultaneously reduce shadow area and protect the substrate from damage.
3Area of stationary object
If the inner surface of the protruding portion is made vertical, then the structure is simple, but the shadow area cannot be effectively reduced
Solution Approach 1:
The inner surface of the protruding portion is designed with an inclined angle (30-60 degrees) rather than a vertical configuration. This angular inclination creates a gradual transition that effectively blocks deposition material from reaching the substrate beyond the designed area, significantly reducing the shadow area while maintaining reasonable structural complexity.
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 solution enables precise deposition of materials within the display area, reducing shadow areas and allowing for smaller device sizes and improved space utilization, thereby enhancing the manufacturing efficiency and reducing defects in display apparatuses.
Implementation Method 1
the protruding portion protruding from the mask body portion and configured to protrude toward a display substrate and contact the display substrate
Implementation Method 2
a deposition material is configured to pass through the at least one opening to be deposited in an entire display area of a display panel
Data Source
AI summary
A mask assembly and an apparatus and method for manufacturing a display apparatus are provided. A mask assembly includes a mask frame and a mask on the mask frame and having at least one opening. The mask includes a mask body portion having the at least one opening, and a protruding portion arranged to surround the at least one opening and including an inner surface defining the at least one opening, the protruding portion protruding from the mask body portion and configured to protrude toward a display substrate and contact the display substrate. A deposition material is configured to pass through the at least one opening to be deposited in an entire display area of a display panel including a plurality of pixels.