Mask Assembly with Non-Opening Regions for Pixel Accuracy
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Solution Overview
Problem
Existing mask assemblies for display apparatus manufacturing face challenges in achieving precise pixel position accuracy (PPA) and deposition yield, particularly due to issues with mask deformation and misalignment during the deposition process.
Innovation Solution
The mask assembly includes a non-opening region with varying thickness and a support stick to stabilize the mask, along with welding regions and nuggets for improved adhesion, allowing for precise deposition and correction of pixel position accuracy through additional laser welding in non-opening regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fine metal mask is extended and adhered to a mask frame for independent deposition method, then deposition can be performed on the substrate, but mask deformation and misalignment occur during the deposition process reducing pixel position accuracy
Solution Approach 1:
The mask is divided into multiple independent deposition regions separated by non-opening regions. Each deposition region can be independently controlled and deposited upon, while the non-opening regions act as stabilizing structures that prevent mask deformation during the deposition process, thereby resolving the contradiction between achieving precise pixel position accuracy and maintaining mask stability.
Solution Approach 2:
The mask structure incorporates non-opening regions with specific thickness characteristics (first portion and second portion with different thicknesses) at strategic locations. These non-opening regions provide localized structural support and stability to the mask, preventing deformation during deposition while allowing the deposition regions to maintain their precision for accurate pixel positioning.
2Manufacturing precision
If the mask width is made less than the opening width to improve pixel position accuracy, then multiple masks can be mounted on the mask frame, but mask stability and adhesion are reduced
Solution Approach 1:
The mask structure segments the deposition function from the support function. The deposition regions are optimized for precision while the non-opening regions provide structural integrity. This segmentation allows the mask width to be less than the opening width for improved pixel position accuracy while the non-opening regions compensate for reduced adhesion through their stabilizing presence.
Solution Approach 2:
The mask assembly combines multiple materials with different properties: the mask body material provides deposition precision while the non-opening regions and support sticks provide structural strength and adhesion. This composite structure resolves the contradiction between having narrow mask width for precision and maintaining sufficient adhesion strength.
3Manufacturing precision
If additional laser welding is performed in non-opening regions to correct misalignment, then pixel position accuracy is improved, but manufacturing time and process complexity increase
Solution Approach 1:
The mask is designed with non-opening regions that are pre-configured to receive laser welding for misalignment correction. By incorporating these regions during the initial mask fabrication, the subsequent laser welding process becomes a straightforward correction step rather than a complex realignment operation, reducing the time and complexity of the overall manufacturing process while improving pixel position accuracy.
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
Enhances pixel position accuracy and deposition yield by stabilizing the mask and correcting misalignments, leading to improved manufacturing efficiency and quality of display apparatuses.
Implementation Method 1
a deposition source arranged in the chamber and configured to supply a deposition material into the chamber; and a mask assembly arranged to face the deposition source and configured to transmit the deposition material and deposit the deposition material on the substrate
Implementation Method 2
a support stick extending in a direction that intersects the lengthwise direction of the mask
Implementation Method 3
correcting misalignments through additional laser welding in non-opening regions
Data Source
AI summary
A mask assembly including a mask frame including an opening; and a mask arranged on the mask frame and including a deposition region and a non-opening region arranged around the deposition region, the deposition region facing the opening to transmit a deposition material. A width of the non-opening region in a lengthwise direction of the mask is about 200 μm to about 500 μm.