Mask Protrusions for OLED FMM Durability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Fine metal masks (FMMs) used in organic light emitting display device manufacturing face durability issues due to thickness reduction during tensioning, leading to potential damage or breakage during processes like tension welding, deposition, and cleaning, which increases manufacturing costs.
Innovation Solution
A mask design featuring a plate-shaped body with protrusions that maintain thickness even when tensioned, preventing deformation and enhancing durability by allowing the mask to resist external forces without reducing thickness, thus stabilizing the mask's shape and reliability during large-area OLED display manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a FMM is tensioned and welded on a mask frame, then the mask can be used for deposition process, but the overall thickness of the FMM is reduced leading to durability issues
Solution Approach 1:
The patent applies curvature to the mask plate by forming protrusions (convex portions) on its surface. These curved structures allow the mask to maintain its thickness during tensioning because the curved geometry distributes stress more effectively and prevents the plate from thinning uniformly across its surface, thereby resolving the contradiction between reliability and thickness reduction.
Solution Approach 2:
The patent changes the physical parameters of the mask plate by introducing protrusions with specific dimensions (height, width, spacing). These parameter modifications enable the mask to resist tension-induced thinning while maintaining structural integrity, thus improving durability without sacrificing the necessary thickness for withstanding mechanical stresses during welding and deposition processes.
2Area of stationary object
If the size of FMM is increased for large-area OLED display, then the deposition area is expanded, but the reduction in thickness and durability is exacerbated
Solution Approach 1:
The patent segments the mask plate surface into multiple protrusions distributed across the large area. This segmentation allows each local region to maintain adequate thickness and structural strength independently, while collectively covering a large deposition area. The protrusions create a pattern that prevents overall thinning even as the total mask size increases, thus maintaining durability across large-area OLED displays.
3Strength
If high tension is applied during welding process, then the mask can be securely mounted, but the mask may be damaged or broken due to reduced thickness
Solution Approach 1:
The patent incorporates protrusions on the mask plate before the welding process occurs. These pre-formed curved structures act as cushioning elements that absorb and distribute the high tension forces applied during welding, preventing stress concentration that would otherwise cause damage or breakage. The protrusions are designed in advance to withstand the mounting forces while preserving the mask's integrity.
Data Source
AI summary
A mask includes a plate-shaped body including openings, and a modified portion including at least one first curved portion protruding from the plate-shaped body in a first direction and longitudinally extending in a second direction.