Metal Plate Particle Control for Deposition Mask Precision
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Solution Overview
Problem
The existing methods for manufacturing deposition masks face challenges in achieving accurate shape precision of through holes, particularly due to the presence of particles in the metal plates used, which can affect the dimensional accuracy and pixel density of display devices like smartphones and tablets.
Innovation Solution
A metal plate with specific conditions regarding particle distribution, such as a number of particles with equivalent circle diameters of 1 μm or more between 50 and 3000 per 1 mm³ and fewer than 50 particles with diameters of 3 μm or more per 1 mm³, is used to improve the accuracy of through holes formed in the deposition mask, ensuring precise manufacturing of high-pixel-density displays.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a metal plate is used for manufacturing a deposition mask, then the mask can be formed with through holes, but particles in the metal plate cause inaccuracy in the shape of the through holes
Solution Approach 1:
The patent applies the extraction principle by removing particles from the metal plate before manufacturing the deposition mask. The metal plate is subjected to a particle removal process that extracts harmful particles while retaining the base metal structure, thereby eliminating the source of shape inaccuracy in through holes without compromising the overall mask functionality
Solution Approach 2:
The patent applies parameter changes by modifying the particle concentration parameter in the metal plate. By controlling and reducing the particle density to specific thresholds, the material properties of the metal plate are optimized to enable precise through hole formation while maintaining structural integrity and other desirable properties of the base metal
2Ease of manufacture
If particles are present in the metal plate, then the material can be obtained easier, but the dimensional accuracy of through holes deteriorates
Solution Approach 1:
The patent applies preliminary action by performing particle removal treatment on the metal plate before the deposition mask manufacturing process begins. This preliminary step eliminates particles that would otherwise cause dimensional inaccuracies in subsequent through hole formation, ensuring high precision without requiring changes to the base metal production process
Solution Approach 2:
The patent introduces an intermediary particle removal process between metal plate production and deposition mask manufacturing. This intermediary step acts as a bridge that preserves the ease of metal plate production while eliminating harmful particles, thereby maintaining dimensional accuracy in the final product without compromising manufacturing efficiency
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 proposed method enhances the accuracy and precision of through holes in deposition masks, enabling the production of high-pixel-density displays by controlling particle distribution and size, thus improving the manufacturing process and device performance.
Implementation Method 1
a step of rolling a base metal having an iron alloy containing nickel to produce the metal plate
Data Source
AI summary
A method for manufacturing a metal plate, the metal plate including a first surface and a second surface positioned on the opposite side of the first surface, may include a step of rolling a base metal having an iron alloy containing nickel to produce the metal plate. The metal plate may include particles containing as a main component an element other than iron and nickel. In a sample including the first surface and the second surface of the metal plate, the following conditions (1) and (2) regarding the particles may be satisfied:(1) The number of the particles having an equivalent circle diameter of 1 μm or more is 50 or more and 3000 or less per 1 mm3 in the sample, and(2) The number of the particles having an equivalent circle diameter of 3 μm or more is 50 or less per 1 mm3 in the sample.