Replaceable Unit Mask Structure for Open Mask Repair
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Solution Overview
Problem
Existing mask assemblies for large-area display devices face challenges in repairing defective unit masks without damaging the open mask, leading to reduced deposition yield and reliability.
Innovation Solution
A mask assembly design with an open mask and unit masks featuring deposition portions, welding portions, and residual structures, allowing for easy separation and repair by cutting boundaries between these components using laser techniques, enabling multiple replacements and improving deposition reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If the unit mask is separated from the open mask for repair, then the defective unit can be replaced, but the open mask may be damaged in the process
Solution Approach 1:
The mask assembly is divided into a reusable open mask and replaceable unit masks. The unit mask includes a deposition portion with deposition openings and welding portions protruding from it, allowing the unit mask to be separated and replaced independently while preserving the open mask structure.
Solution Approach 2:
Welding portions are pre-formed on the unit mask before assembly, and residual structures are pre-positioned on the open mask. This preliminary preparation enables quick replacement of defective unit masks by simply detaching them from their mounting positions without complex disassembly procedures that could damage the open mask.
2Productivity
If multiple unit masks are arranged on the open mask, then deposition coverage is improved, but the complexity of repair increases
Solution Approach 1:
Multiple unit masks are arranged on the open mask, each as an independent replaceable module with its own deposition portion and welding portions. This segmentation allows individual unit masks to be replaced without affecting others, simplifying repair operations despite having multiple units for comprehensive deposition coverage.
Solution Approach 2:
Defective unit masks can be discarded and replaced with new or refurbished units. The residual structures remain on the open mask to receive new unit masks, enabling rapid replacement and recovery of deposition capability without complex repair procedures.
3Ease of manufacture
If the welding portion is designed to protrude from the deposition portion, then attachment to the open mask is facilitated, but the risk of damage during separation increases
Solution Approach 1:
Welding portions are pre-formed protruding structures on the unit mask, and residual structures are pre-positioned on the open mask. This preliminary configuration creates dedicated attachment interfaces that guide proper alignment and reduce the risk of damage during both assembly and separation operations.
Solution Approach 2:
The welding portions act as intermediary structures between the unit mask and open mask. These protruding welding portions with residual structures provide a buffer zone that facilitates controlled separation, reducing direct stress on the deposition portion and minimizing damage risk during unit mask removal for repair.
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 deposition yield and reliability of the mask assembly, allowing for multiple replacements and improving the manufacturing yield of display panels.
Implementation Method 1
welding portions, and welding protrusions respectively disposed on the welding portions
Data Source
AI summary
A mask assembly includes an open mask provided with an opening and disposed on a frame, a unit mask disposed on the open mask, the unit mask including a deposition portion and welding portion, deposition openings are defined on the deposition portion to overlap the opening in a plan view, and the welding portions each protrude from the deposition portion in a protrusion direction away from the deposition portion, welding protrusions respectively disposed on the welding portions, and at least one residual structure including a residual welding portion separated from the unit mask and a residual welding protrusion disposed on the residual welding portion. The at least one residual structure is disposed between the welding portions.