Mask Stick Edge Width Layout for Precise Emissive Layer Deposition
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Solution Overview
Problem
Existing mask assemblies for manufacturing high-resolution display devices face challenges in precisely depositing emissive layers due to limitations in design, leading to inefficiencies in forming light emitting elements.
Innovation Solution
A mask assembly with a mask frame and mask sticks featuring specific edge and branch widths, and a gap between sticks equal to the width of openings, allowing for precise alignment and deposition of emissive layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the mask stick uses conventional design without specific edge portion width control, then the manufacturing process is simpler, but the precision of emissive layer deposition deteriorates
Solution Approach 1:
The mask stick applies local quality by creating an edge portion with specific width (90-110% of branch width) at its ends, while the rest of the mask stick maintains different dimensional characteristics. This localized dimensional control at the edge portions enables precise alignment with the substrate opening, thereby improving emissive layer deposition precision without requiring the entire mask stick structure to be complex.
Solution Approach 2:
The invention applies parameter changes by specifying a precise width range (90% to 110% of the first branch width) for the edge portion in the first direction. This parameter control ensures that the edge portion aligns properly with the substrate opening during deposition, achieving high precision emissive layer formation while maintaining a relatively simple overall mask stick structure.
2Manufacturing precision
If the gap between mask sticks is not equal to the opening width, then the alignment process is more flexible, but the resolution of display device deteriorates
Solution Approach 1:
The mask stick design creates an asymmetric relationship between the edge portion width and the gap to openings. By making the edge portion width (90-110% of branch width) specifically related to the opening width, the design achieves precise alignment during deposition while maintaining manufacturing feasibility. The asymmetric dimensional relationship ensures that the edge portion properly bridges the gap between adjacent mask sticks and aligns with substrate openings.
Solution Approach 2:
The mask stick structure is designed in advance with the edge portion width predetermined at 90-110% of the first branch width. This preliminary dimensional setup ensures that when the mask assembly is used for deposition, the edge portions automatically align with the substrate openings without requiring additional adjustment or complex alignment procedures during manufacturing.
3Manufacturing precision
If the mask stick extends equally in both directions, then the structural symmetry is maintained, but the deposition coverage and resolution are insufficient
Solution Approach 1:
The mask stick deliberately breaks symmetry by extending longer in the second direction (crossing the first direction) than in the first direction. This asymmetric geometry allows the edge portions at the ends of the mask stick to extend further in the second direction, enabling better alignment with substrate openings and improved emissive layer deposition precision across the display device while maintaining a simple overall geometric form.
Data Source
AI summary
A deposition device includes: a mask frame in which a frame opening is defined; and a mask stick disposed on the mask frame and extending longer in a second direction than extending in a first direction crossing the second direction. A plurality of openings arranged in the first direction and the second direction are defined in the mask stick. The mask stick includes: first branch portions between openings adjacent to each other in the first direction and a first edge portion between a first side of opposite sides of the mask stick opposite each other in the first direction and openings adjacent to the first side. In the first direction, a first width of the first edge portion is set in a range of 90% of a first branch width of each of the first branch portions to 110% of the first branch width.