Mask Assembly Support Bars Prevent Pattern Deformation
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Solution Overview
Problem
Conventional deposition methods for flat panel displays face issues with pattern deformation of mask assemblies due to substrate weight, leading to inaccurate material deposition and reduced precision.
Innovation Solution
A mask assembly with a support bar system that crosses the opening of the mask frame, providing additional structural support to prevent deformation by distributing the substrate's weight and stress across a larger area, while maintaining alignment and precision during the deposition process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional mask assembly is used during deposition, then the deposition process can be performed, but the center portion of the substrate bends toward the mask assembly due to substrate weight, causing pattern deformation and inaccurate alignment
Solution Approach 1:
The mask assembly is segmented into multiple components: a mask frame, a pattern mask, and multiple support bars. This segmentation allows the support bars to be positioned at specific locations to provide targeted structural support, preventing the mask assembly from deforming under substrate weight while maintaining deposition precision
Solution Approach 2:
Support bars are introduced as a vertical structural element extending from the mask frame to support the pattern mask. This adds a dimensional element that distributes the substrate weight across multiple support points, preventing the center portion bending issue and maintaining pattern alignment during deposition
2Ease of manufacture
If the mask assembly structure is simplified, then manufacturing is easier, but the pattern mask deforms under substrate weight during deposition
Solution Approach 1:
The mask assembly is divided into separable components (mask frame, pattern mask, support bars) that can be manufactured independently and then assembled through welding. This segmentation simplifies manufacturing while the support bars provide necessary structural reinforcement to prevent pattern deformation during deposition
Solution Approach 2:
Multiple components are merged through welding to create the complete mask assembly structure. The mask frame, pattern mask, and support bars are welded together to form an integrated structure that is both manufacturable and structurally sound for maintaining pattern alignment during deposition
Data Source
AI summary
A mask assembly includes a mask frame, the mask frame having an opening and a frame surrounding the opening, a pattern mask on the mask frame, the pattern mask including a pattern portion having at least one pattern overlapping the opening and a welding portion attached to the frame, and at least one support bar crossing the opening and attached to the pattern mask.