OLED Mask Frame Assembly with Segmented Stick Masks
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Solution Overview
Problem
Conventional mask frames used in organic light-emitting diode (OLED) display manufacturing are prone to deformation and contamination, leading to reduced durability and precision in the deposition process.
Innovation Solution
A mask frame assembly comprising a frame, an open mask, and stick masks, where the open mask has specific openings and supporters to prevent deformation during cleaning, allowing for precise deposition patterns and improved durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a conventional mask is repeatedly cleaned and used in the deposition process, then productivity is maintained, but the mask deforms and durability deteriorates
Solution Approach 1:
The mask is divided into a frame portion and multiple stick mask portions that can be independently replaced. The stick masks are detachably coupled to the frame, allowing individual stick masks to be replaced when deformed while keeping the frame and other stick masks in use, thus maintaining continuous productivity while ensuring mask reliability.
2Productivity
If a conventional mask is repeatedly cleaned, then it can be reused for multiple depositions, but the mask becomes contaminated and precision decreases
Solution Approach 1:
The stick masks are designed to be disposable components that are replaced when contaminated or deformed, rather than repeatedly cleaned. The frame structure allows for easy replacement of stick masks, ensuring that only clean, precise masks are used for deposition while maintaining high productivity through quick更换.
3Ease of manufacture
If the mask structure is simplified for ease of manufacture, then production cost decreases, but the mask becomes more prone to deformation
Solution Approach 1:
The mask is segmented into a simple frame structure and separate stick mask portions. The frame provides structural stability and support, while the stick masks can be independently manufactured with simple structures. This segmentation allows each component to be optimized for its specific function, maintaining overall stability while keeping manufacturing simple.
4Loss of substance
If the mask is made thinner to reduce material usage, then loss of substance decreases, but the mask becomes more susceptible to deformation
Solution Approach 1:
The thin stick masks are supported by the frame structure, which provides the necessary strength and rigidity. The frame acts as a support backbone that allows the stick masks to be thin and consume less material while maintaining overall structural integrity and resistance to deformation during cleaning and deposition processes.
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 enhances the durability and precision of the deposition process, reducing the likelihood of deformation and maintaining high-resolution manufacturing of OLED displays.
Implementation Method 1
depositing an organic material on the substrate by evaporating or sublimating the organic material using a deposition source
Implementation Method 2
depositing an organic material on the substrate by evaporating or sublimating the organic material using a deposition source
Implementation Method 3
causing, at least in part, gases to be sprayed toward the stick masks after depositing the deposition material on the substrate
Data Source
AI summary
A mask frame assembly includes a frame, an open mask, and stick masks. The open mask is supported by the frame. The stick masks are disposed on the open mask and include ends coupled to the frame. The open mask includes: a first opening disposed in association with opposing ends of the open mask; and a second opening disposed between the first openings, the second opening being larger than the first opening. First deposition patterns of a first stick mask of the stick masks and second deposition patterns of a second stick mask of the stick masks overlap the second opening.