OLED Mask Assembly Buffer Region Alignment
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Solution Overview
Problem
The existing mask assembly for OLED display manufacturing has poor alignment accuracy due to deformation of the Open MASK during welding, causing the evaporation region to change and fail in precise alignment with the substrate, leading to poorer pattern formation quality.
Innovation Solution
A mask assembly comprising a frame, a first mask with an opening region, and a second mask with an evaporation region and a buffer region, where the orthographic projection of the first mask's boundary is within the second mask's buffer region, reducing stress differences and maintaining alignment accuracy even if the first mask deforms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the Open MASK is welded to the metal frame, then the mask assembly is assembled, but the Open MASK deforms under welding force causing the evaporation region to shift and misalign with the substrate
Solution Approach 1:
The mask assembly is divided into three independent components: the metal frame, the Open MASK, and the FMM. The FMM is separately welded to the metal frame, while the Open MASK is positioned on the frame without direct welding. This segmentation isolates the FMM (which defines the evaporation region) from welding forces, preventing deformation and maintaining alignment accuracy between the evaporation region and substrate.
Solution Approach 2:
The metal frame serves as an intermediary structure that supports both the Open MASK and the FMM. By welding the FMM directly to the rigid metal frame rather than to the Open MASK, the frame acts as a stable mediator that maintains the precise position of the evaporation region independent of Open MASK deformation during assembly.
2Device complexity
If the evaporation region is defined by the opening region of the Open MASK, then the mask assembly structure is simplified, but the evaporation region changes position when the Open MASK deforms during welding
Solution Approach 1:
The functions of defining the evaporation region and blocking evaporation material are separated into different components. The FMM defines the evaporation region through its evaporation holes, while the Open MASK's opening region solely blocks evaporation material. This segmentation allows the evaporation region position to be determined by the rigidly mounted FMM rather than the deformable Open MASK, maintaining position stability without significantly increasing overall structural complexity.
Data Source
AI summary
The present disclosure provides a mask assembly and a method for manufacturing the same, and a display device. The mask assembly includes a frame, a first mask and a second mask, and the first mask and the second mask are superposed on the frame; the first mask includes an opening region, the second mask includes an evaporation region in which a first evaporation hole is provided for allowing an evaporation material to pass therethrough and a buffer region surrounding the evaporation region and configured to block off the evaporation material, and an orthographic projection of the boundary of the opening region onto the second mask is located within the buffer region.