Mask-Support Assembly for OLED Pixel Deposition
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Solution Overview
Problem
Conventional OLED manufacturing processes face challenges in aligning and stabilizing large, thin masks during pixel deposition, leading to potential sagging or twisting, which can result in defects and failure of ultra-high-resolution pixel formation, especially in microdisplay applications for virtual reality devices.
Innovation Solution
A mask-support assembly is developed, featuring a conductive substrate with a mask pattern formed using Invar or Super Invar material, where the substrate is thinned and etched to create a support with edge and grid portions, and an adhesive layer is applied to ensure uniform stress distribution and alignment, preventing sagging under load during pixel formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a large-area thin mask is used for OLED pixel deposition, then the mask can cover the required substrate area, but the mask sags or twists under load during the deposition process
Solution Approach 1:
The mask support structure is segmented into a frame portion and multiple grid portions that extend from the frame toward the center. This segmentation provides distributed support across the large-area mask, preventing sagging and twisting while maintaining the required mask area for substrate coverage.
Solution Approach 2:
The support structure implements local quality by providing different support characteristics at different locations. The frame portion provides peripheral support while the grid portions provide intermediate support at specific intervals, creating non-uniform local support that optimizes mask stability across the entire large area.
2Manufacturing precision
If a thin mask film is used to achieve fine resolution, then the mask can enable ultra-high-resolution pixel formation, but the mask becomes prone to deformation under load
Solution Approach 1:
The support structure uses a composite design combining a frame portion and multiple grid portions made of conductive material. This composite structure provides the necessary mechanical strength to support thin mask films while maintaining the precision required for ultra-high-resolution pixel formation.
Solution Approach 2:
The support structure transitions from a two-dimensional planar support to a three-dimensional grid framework that extends vertically from the substrate. This dimensional change provides additional structural rigidity and load-bearing capacity to prevent mask deformation while maintaining fine resolution capabilities.
3Reliability
If the mask is welded and fixed to the frame using conventional methods, then the mask can be secured to the deposition frame, but the mask does not align properly during the fixing process
Solution Approach 1:
The mask is preliminarily fixed to the support structure before final welding to the deposition frame. This preliminary fixation step establishes proper alignment and position, ensuring that the mask maintains correct alignment throughout the subsequent welding process and final deposition operation.
Solution Approach 2:
The support structure acts as an intermediary between the mask and the deposition frame. It provides a stable intermediate platform that facilitates precise mask alignment and positioning before the final fixation to the deposition frame, resolving the alignment issues in conventional direct welding methods.
4Area of stationary object
If the mask area is increased to cover larger substrates, then the substrate coverage is improved, but the mask requires stronger support to prevent sagging
Solution Approach 1:
The support structure is segmented into a frame portion and multiple grid portions, creating a modular design that can be systematically scaled to accommodate different mask areas. This segmentation provides the necessary support for large-area masks without requiring a proportionally complex support system.
Solution Approach 2:
The support structure with its frame and grid portions serves multiple functions simultaneously: it provides mechanical support to prevent sagging, maintains mask alignment, conducts heat uniformly, and facilitates fixation to the deposition frame. This multi-functionality reduces the need for additional separate components, managing complexity while supporting large mask areas.
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 enables clear alignment and stability of the mask, ensuring uniform stress distribution and preventing deformation, thereby achieving ultra-high-resolution pixel deposition with improved pixel alignment and stability in OLED manufacturing.
Implementation Method 1
forming a mask including a mask pattern on a first surface of the conductive substrate... the mask made of an Invar or Super Invar material
Implementation Method 2
the mask made of an Invar or Super Invar material may be formed on the conductive substrate by an electroforming method
Implementation Method 3
an adhesive layer is applied to ensure uniform stress distribution and alignment, preventing sagging under load
Data Source
AI summary
The present invention relates to a mask-support assembly, a producing method thereof, and a mask-frame assembly. The producing method of a mask-support assembly according to the present invention may include the steps of: (a) preparing a conductive substrate; (b) forming a mask including a mask pattern on a first surface of the conductive substrate; (c) reducing a thickness of the conductive substrate on a second surface opposite to the first surface of the conductive substrate; and (d) forming a support including an edge portion and a grid portion by etching the conductive substrate on the second surface thereof.