Mask Assembly Sub-Mask Segmentation for Display Manufacturing
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Solution Overview
Problem
Existing mask assemblies for manufacturing display apparatuses often result in pattern holes being defined in incorrect positions due to mask transformation, leading to pixels not being disposed in a fine pattern and resulting in unclear images.
Innovation Solution
A mask assembly comprising a mask frame with an opening area, a mask sheet that shields part of the opening area, and a plurality of sub-masks arranged between a clamping portion and a connection stick, where the connection stick supports the sub-masks and maintains their precise positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mask sheet is used to define pattern holes, then material deposition can be controlled, but the mask sheet transforms during the process causing pattern holes to be defined in incorrect positions
Solution Approach 1:
The mask sheet is divided into multiple independent sub-masks that are arranged in a matrix. Each sub-mask is supported by connection sticks at its corners, allowing independent positioning and stability. This segmentation prevents the entire mask sheet from transforming as a single unit, thereby maintaining pattern hole position accuracy during the deposition process.
Solution Approach 2:
Connection sticks are introduced as intermediary elements between the sub-masks and the mask frame. These connection sticks serve as mediators that hold the sub-masks in fixed positions and prevent direct contact between the mask sheet and the mask frame, eliminating the transformation issue while maintaining precise pattern hole positioning.
2Manufacturing precision
If the mask sheet is fixed to the mask frame, then the mask sheet is stable, but the pattern holes cannot be precisely positioned due to mask transformation
Solution Approach 1:
Instead of fixing a single large mask sheet to the mask frame, the mask is segmented into multiple sub-masks that are independently positioned using connection sticks. This segmentation allows precise positioning of each sub-mask without the complexity of fixing a large, prone-to-transforming sheet, thereby achieving accurate pattern hole positioning with a manageable structure.
Solution Approach 2:
Connection sticks act as intermediaries between the sub-masks and the mask frame, providing a simple yet effective mechanism for precise positioning. This intermediary approach avoids the need for complex fixing mechanisms while ensuring accurate pattern hole positioning, thus resolving the contradiction between positioning precision and structural complexity.
3Manufacturing precision
If sub-masks are arranged closely to define fine patterns, then image clarity improves, but mask transformation causes positioning errors
Solution Approach 1:
The mask is divided into multiple sub-masks with connection sticks at their corners. This segmentation allows sub-masks to be arranged closely for fine patterns while each sub-mask maintains its position independently through connection sticks, preventing transformation-induced positioning errors and ensuring both pattern fineness and position accuracy.
Solution Approach 2:
Connection sticks serve as reliable intermediaries that anchor each sub-mask in its precise position, enabling close arrangement of sub-masks for fine patterns without sacrificing position accuracy. The connection sticks prevent transformation, ensuring that the fine patterns remain accurately positioned throughout the deposition process.
Data Source
AI summary
A mask assembly includes a mask frame including an opening area, and a mask sheet disposed to shield at least a portion of the opening area and disposed on the mask frame. The mask sheet includes a clamping portion fixed to the mask frame, a connection stick disposed to be spaced apart from the clamping portion, and a plurality of sub-masks arranged between the clamping portion and the connection stick and defining a pattern hole, and the connection stick is disposed between sub-masks adjacent to each other among the plurality of sub-masks to support each of the sub-masks, and end portions of the sub-masks disposed on the connection stick are spaced apart from each other.