OLED Metal Mask Deformation Compensation Design
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Solution Overview
Problem
The existing methods for manufacturing metal masks for OLED display devices face challenges in accurately compensating for deformations caused by stretching and welding, leading to misalignment with the back panel of thin film transistors, which results in color mixture issues during display. Current methods require measuring and calculating compensation amounts after manufacturing, increasing process costs and inefficiency.
Innovation Solution
A design method that calculates deformation properties and compensation amounts for metal masks in two perpendicular directions based on stretching force, material properties, and design dimensions, allowing for direct consideration and compensation of deformations during the design stage, eliminating the need for pre-manufacturing sample masks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If deformation compensation is not considered during metal mask design, then the manufacturing process is simpler, but the alignment accuracy with the back panel deteriorates, causing color mixture issues
Solution Approach 1:
The patent applies preliminary action by calculating and compensating for deformation amounts during the metal mask design stage. The design method computes deformation properties based on stretching force and material properties, then incorporates compensation amounts into the mask pattern before manufacturing. This advance compensation ensures accurate alignment with the back panel after the mask undergoes stretching and welding, preventing color mixture issues without requiring complex post-manufacturing adjustments.
2Manufacturing precision
If post-manufacturing alignment corrections are used, then alignment accuracy can be improved, but the manufacturing cost and time increase
Solution Approach 1:
The patent eliminates the need for post-manufacturing alignment corrections by performing deformation compensation during the design stage. The design method calculates deformation properties based on the stretching force and material properties, then incorporates compensation amounts into the mask pattern before manufacturing. This preliminary compensation ensures that the mask maintains accurate alignment with the back panel even after stretching and welding, thereby reducing both manufacturing time and cost while maintaining high alignment accuracy.
3Manufacturing precision
If deformation properties are calculated and compensated during design, then alignment accuracy is improved, but the design process becomes more complex
Solution Approach 1:
The patent applies parameter changes by calculating deformation properties based on specific parameters such as stretching force, material properties (Young's modulus, Poisson's ratio), and mask dimensions. The design method uses these parameters to compute deformation amounts in the stretching and perpendicular directions, then incorporates compensation amounts into the mask pattern. This systematic approach to parameter-based deformation compensation improves alignment accuracy while maintaining a structured and manageable design process.
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 approach reduces process costs and improves efficiency by directly calculating compensation amounts during the design phase, ensuring accurate alignment and reducing color mixture issues by accounting for deformations in the metal mask's design, thereby enhancing the accuracy and reliability of the metal mask's alignment with the back panel.
Implementation Method 1
calculating amounts of deformations of the metal mask in two directions perpendicular to each other based on a stretching force of the metal mask in use and deformation properties of the metal mask in the two directions
Implementation Method 2
deformation properties of the metal mask in the two directions; and compensating the deformations of the metal mask in the two directions by compensation amounts for the deformations
Data Source
AI summary
A design method of a metal mask, a manufacturing method of the metal mask and a computer-readable storage medium are provided. The design method of a metal mask includes: calculating amounts of deformations of the metal mask in two directions perpendicular to each other based on a stretching force of the metal mask in use and deformation properties of the metal mask in the two directions; and compensating the deformations of the metal mask in the two directions by compensation amounts for the deformations, which are identical and opposite to the amounts of the deformations of the metal mask in the two directions, respectively.