Mask Sheet Alignment and Welding for Precise Deposition Patterns
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing mask assembly manufacturing processes face challenges in accurately aligning and connecting multiple mask sheets during the deposition of organic materials on substrates, leading to potential misalignment and deformation of deposition patterns.
Innovation Solution
A mask assembly manufacturing apparatus is introduced, featuring a clamp unit with first and second clamps in different directions, a sensor to sense the second edge of the mask sheet, and a controller to align and adjust the clamps based on sensed information, along with a welder to connect adjacent mask sheets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple mask sheets are manually aligned and connected during deposition, then the manufacturing process can proceed, but misalignment and deformation of deposition patterns occur
Solution Approach 1:
The mask assembly is divided into multiple separate mask sheets that are connected through edges. Each mask sheet can be independently manufactured and positioned, then joined together to form a complete mask assembly covering the substrate. This segmentation allows for precise alignment of individual sheets while maintaining the overall functionality of the mask system.
Solution Approach 2:
An edge connection structure serves as an intermediary element between adjacent mask sheets. This connection structure facilitates precise alignment and secure joining of mask sheets during the deposition process, eliminating misalignment issues while maintaining the modular nature of the mask assembly.
2Manufacturing precision
If mask sheets are connected without precise alignment control, then the manufacturing process is simpler, but deposition pattern accuracy deteriorates
Solution Approach 1:
Mask sheets are pre-aligned and connected before the actual deposition process begins. The edge connection structures are prepared in advance to ensure precise positioning, so that when deposition starts, the mask assembly is already in the correct configuration. This preliminary preparation ensures deposition pattern accuracy without complicating the deposition operation itself.
Solution Approach 2:
Traditional mechanical alignment methods are replaced with a sensor-based detection system. Sensors detect the positions of mask sheets and provide feedback for precise alignment, eliminating the need for complex mechanical adjustment mechanisms while ensuring high deposition pattern accuracy.
3Manufacturing precision
If manual alignment methods are used for mask sheets, then the equipment is simpler, but alignment precision and deformation control worsen
Solution Approach 1:
A sensor-based feedback system is implemented to detect the positions and orientations of mask sheets during assembly. The sensors provide real-time information about alignment status, and this feedback is used to adjust and correct positioning errors. This ensures high alignment precision and deformation control while using a relatively simple sensor-based approach rather than complex mechanical control systems.
Data Source
AI summary
Provided is a mask assembly manufacturing apparatus including a mask stage for seating thereon a mask frame defining an opening, a clamp unit at one side of the mask stage, and comprising first clamps arranged in a first direction and configured to clamp a first edge of a first mask sheet, and to position a second edge of the first mask sheet, which is opposite to the first edge, over the opening, a sensor configured to sense the second edge of the first mask sheet, and a controller configured to align the first mask sheet by adjusting the first clamps based on information regarding the second edge from the sensor.