Mask Sheet Tensioning and Pressing for Precise Frame Alignment
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Solution Overview
Problem
In the manufacturing of display devices, existing mask assembly technologies face challenges in reducing mask sheet deformation and improving alignment precision, leading to issues with image quality and increased processing time due to the need for high tensile forces and precise alignment of large mask sheets.
Innovation Solution
An apparatus and method for manufacturing a mask assembly that includes a tensioning part to apply forces in multiple directions, a pressing part to bend the mask sheet, and a header to fix the mask sheet to the frame using a laser beam, reducing deformation and improving alignment accuracy by using a dummy portion and rollers to apply forces and control bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If high tensile forces are applied to large mask sheets for alignment, then alignment precision is improved, but mask sheet deformation increases
Solution Approach 1:
The mask sheet is divided into a cell area (active region) and a dummy portion (non-active region). The dummy portion serves as a dedicated tensioning zone where forces can be applied without affecting the cell area, thereby preventing deformation in the active region while still achieving proper alignment through the dummy portion.
Solution Approach 2:
The dummy portion acts as an intermediary element between the tensioning part and the cell area. It absorbs the mechanical stress and deformation, serving as a buffer that protects the cell area from direct force application while enabling the necessary tensioning for alignment precision.
2Manufacturing precision
If precise alignment of mask sheets is performed, then image quality is improved, but processing time increases
Solution Approach 1:
The dummy portion is pre-configured with tensioning features that allow for rapid alignment. By having the dummy portion ready with its specific geometry and material properties, the tensioning and alignment process can be completed more quickly without compromising the precision required for pixel position accuracy.
Solution Approach 2:
The dummy portion allows for optimization of tensioning parameters (force distribution, application points) independently of the cell area. This enables faster adjustment and alignment processes while maintaining the precise pixel positioning required for high image quality, as the dummy portion can be rapidly tuned without affecting the active display area.
3Measurement precision
If mask sheets are tensioned in multiple directions, then alignment accuracy is improved, but device complexity increases
Solution Approach 1:
The dummy portion serves multiple functions simultaneously: it provides tensioning in multiple directions, acts as a deformation buffer, enables alignment, and serves as a laser fixation target. This multi-functionality reduces the need for separate mechanisms for each function, thereby simplifying the overall device complexity while maintaining high alignment accuracy through multi-directional tensioning.
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
The solution effectively reduces mask sheet deformation, improves alignment precision, and shortens the manufacturing process time by allowing for more efficient tensioning and alignment, resulting in higher-quality mask assemblies and display devices with improved pixel position accuracy.
Implementation Method 1
a header configured to irradiate a laser beam toward the mask sheet to fix the mask sheet to the mask frame
Implementation Method 2
a pressing part configured to correspond to the dummy portion and press the dummy portion in a third direction intersecting a plane in which the first direction and the second direction extend
Data Source
AI summary
An apparatus and a method for manufacturing a mask assembly and a method of manufacturing a display device are provided. The apparatus may include: a tensioning part configured to be spaced apart from a mask frame comprising at least one opening, the tensioning part configured to tension a mask sheet in at least one of a first direction and a second direction, the mask sheet comprising a cell area corresponding to the at least one opening, and a dummy portion arranged outside the cell area; a pressing part configured to correspond to the dummy portion and press the dummy portion in a third direction intersecting a plane in which the first direction and the second direction extend; and a header configured to irradiate a laser beam toward the mask sheet to fix the mask sheet to the mask frame.