OLED Mask Frame Locking Fittings for Polishing-Free Rework
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Solution Overview
Problem
The existing mask frames used in large-size OLED display manufacturing are costly and have a short life due to complex rework processes and frequent polishing requirements, leading to increased product costs and reduced reliability.
Innovation Solution
A mask frame design featuring pairs of grooves on its surface and locking fittings that securely attach mask sheets without the need for welding, allowing for easy detachment and reattachment, reducing the need for polishing and extending the mask frame's service life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mask sheets are fixed on the mask frame by welding, then the mask structure is strong and reliable, but the rework process becomes complex and the mask frame life is reduced due to polishing requirements
Solution Approach 1:
The mask assembly is segmented into mask frame and mask sheets that can be independently removed and reinstalled. The locking fitting mechanism allows each mask sheet to be separately fixed and released without affecting the entire mask structure, enabling simplified rework processes.
Solution Approach 2:
The connection between mask sheets and mask frame is made dynamic rather than permanent. The locking fittings can be repeatedly engaged and disengaged, allowing the mask sheets to be dynamically adjusted, removed for cleaning, and reinstalled without damaging the mask frame.
2Strength
If mask sheets are welded to the mask frame, then the connection is strong and stable, but the mask frame thickness is reduced and service life is shortened after multiple polishing operations
Solution Approach 1:
Locking fittings serve as intermediary components between the mask sheets and mask frame. These fittings provide the necessary connection strength while being removable without polishing the mask frame, thus preserving the mask frame's thickness and extending its service life.
Solution Approach 2:
The welding process is replaced with a mechanical locking system. Instead of permanently joining mask sheets to the mask frame through welding followed by polishing, the mechanical locking fittings provide equivalent or superior connection strength without requiring material removal, thereby extending mask frame life.
3Stability of the object's composition
If welding is used to fix mask sheets on the mask frame, then the mask structure is stable, but frequent rework and polishing increase manufacturing costs
Solution Approach 1:
The locking fittings are designed to be repeatedly used across multiple mask sheets and rework cycles. Instead of consuming the mask frame through repeated welding and polishing, the locking fittings are recovered and reused, reducing manufacturing costs associated with mask frame maintenance and replacement.
Data Source
AI summary
A mask and a fabricating method thereof are provided. In the mask, a plurality of pairs of grooves corresponding to the plurality of mask sheets are disposed on a mask frame, each of the mask sheets includes a portion overlapping with a corresponding pair of grooves, and includes a plurality of pairs of locking fittings; each of the locking fittings includes an engaging portion and two connecting portions disposed on two sides thereof; the engaging portion are engaged with the corresponding grooves to clamp a portion of the mask sheet overlapping with the grooves, and the connecting portions are detachably connected with the mask frame to fix the plurality of mask sheets on the mask frame; during the rework process of the mask, only the locking fittings need to be removed to separate the mask frame and the mask sheets, so the mask frame does not need to be polished.