Magnet Plate with Movable Units for OLED Mask Alignment
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Solution Overview
Problem
In OLED display manufacturing, replacing the magnet plate for each new mask pattern is necessary, leading to inefficiencies in productivity and increased costs due to the need for individual magnet plate manufacturing and vacuum chamber reconfiguration.
Innovation Solution
A position controllable magnet plate with movable magnet units and a moving device, including worm gears and rack gears, allows for uniform magnetic field formation without replacing the magnet plate, enabling the same magnet plate to be used for different mask patterns by adjusting its position and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the magnet plate is replaced for each new mask pattern, then the magnetic field can be optimized for each specific pattern, but the productivity decreases and production time increases due to frequent replacement operations
Solution Approach 1:
The magnet plate is designed with movable magnet units that can be dynamically repositioned along the substrate width direction. This dynamic adjustment capability allows the magnetic field to be optimized for different mask patterns without replacing the entire magnet plate, thereby maintaining manufacturing precision while improving productivity
Solution Approach 2:
The magnet plate is divided into multiple independently movable magnet units (first, second, third, and fourth magnet units). Each magnet unit can be adjusted separately to create different magnetic field distributions, enabling pattern-specific optimization without requiring full plate replacement
2Manufacturing precision
If the magnet plate is replaced for each mask pattern, then the deposition quality can be optimized, but the production cost increases due to manufacturing multiple magnet plates
Solution Approach 1:
The magnet plate is designed as a universal platform that can accommodate multiple mask patterns through the repositioning of magnet units. This multi-functionality allows a single magnet plate to replace what would traditionally require multiple specialized magnet plates, reducing both quantity and cost
3Manufacturing precision
If the magnet plate is replaced frequently, then the magnetic field distribution can be optimized for each pattern, but the vacuum environment stability deteriorates due to repeated chamber reconfiguration
Solution Approach 1:
The magnet units can be repositioned within the vacuum chamber without breaking the vacuum seal. This dynamic adjustment capability allows magnetic field optimization while maintaining vacuum environment stability, as the chamber remains sealed throughout the adjustment process
4Device complexity
If a fixed magnet plate design is used, then the structure is simple, but the adaptability to different mask patterns is limited
Solution Approach 1:
The magnet plate incorporates movable magnet units that can be repositioned along guide rails, transforming a static structure into a dynamic one. This adds adaptability for different patterns while maintaining relatively simple mechanics through the use of guide rails and movable mounting structures
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
This solution eliminates the need for frequent magnet plate replacement, reduces production time and costs, and maintains a stable vacuum environment by allowing the same magnet plate to be used across various mask patterns, thereby improving productivity and reducing deposition costs.
Implementation Method 1
the magnet plate pulls the mask by a magnetic force, and as a result, the mask adheres to the substrate
Implementation Method 2
a magnetic field is uniformly formed only in the pulled mask, and thus, it suppresses the deformation of slits within the mask
Data Source
AI summary
A magnet plate for manufacturing a display device is disclosed. In one aspect, the plate includes at least two magnet units formed in a first direction, each magnet unit including first and second linear motion (LM) guides. The plate also includes a support plate attached to the LM guides. The magnet unit also includes a magnet supporter comprising an upper portion including a magnet coupling part, a lower portion including a plurality of cam followers, and at least two first transfer plate coupling protrusions formed at a predetermined interval. The magnet unit further includes a magnet guide plate placed beneath the magnet supporter and including a guide cam hole into which the cam follower is inserted. The guide cam hole is oblique with respect to the first direction and has a predetermined width such that the cam follower moves within the guide cam hole.