Deposition Mask Frame Assembly With Sequential X-Y Tensioning
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Solution Overview
Problem
Large deposition stick masks used in manufacturing OLED display panels experience non-uniform tensile force application, leading to wrinkles and sagging, which degrade the quality of the deposition mask frame assembly, particularly for medium or large display panels.
Innovation Solution
A method involving the use of a quadrangular frame with support and gap stick masks, where the support stick mask is tensioned in the Y-axis direction and the gap stick mask in the X-axis direction, with adhesive tensioning in the Y-axis direction, and the deposition stick mask is welded in both directions to prevent wrinkles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a large deposition stick mask is tensioned by a large number of grippers at the same time, then mass production capability is enabled, but non-uniform tensile force is applied causing wrinkles and contraction
Solution Approach 1:
The mask tensioning process is divided into two sequential stages: first tensioning in the Y-axis direction, then tensioning in the X-axis direction. This segmentation of the tensioning process allows uniform force application in each direction independently, preventing the non-uniform tension and wrinkles that occur when multiple grippers apply force simultaneously in both directions.
Solution Approach 2:
The mask is first tensioned in the Y-axis direction before being tensioned in the X-axis direction. This preliminary action in one direction establishes a stable baseline tension that prevents distortion when the second direction's tensioning is applied, ensuring uniform force distribution throughout the mask.
2Stability of the object's composition
If the deposition stick mask is tensioned uniformly in both directions simultaneously, then mask stability is improved, but wrinkles occur due to higher contraction force in intermediate regions
Solution Approach 1:
The simultaneous bidirectional tensioning is segmented into sequential unidirectional tensioning steps. By applying tension first in the Y-axis direction and then in the X-axis direction, the mask achieves stable tension distribution without the intermediate region contraction and wrinkles that occur with simultaneous bidirectional tensioning.
Solution Approach 2:
The tensioning process transitions from a static simultaneous application to a dynamic sequential application. The mask is first stabilized in one direction, then adjusted in the perpendicular direction, allowing the system to adapt and maintain uniform tension without creating localized stress concentrations that cause wrinkles.
3Manufacturing precision
If adhesive tensioning is applied in the Y-axis direction during welding, then wrinkles are prevented, but process complexity increases
Solution Approach 1:
The mechanical gripper-based tensioning system is supplemented with an adhesive tensioning mechanism applied during the welding process. This substitution replaces or augments the mechanical force application with a chemical bonding approach that maintains tension while reducing the risk of wrinkles, particularly in the Y-axis direction during the sequential tensioning 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 ensures a fine and high-quality deposition mask frame assembly by preventing wrinkles and maintaining pattern hole accuracy, reducing shadow effects, and ensuring tight contact with TFT glass during the deposition process.
Implementation Method 1
adhesively tensioned in the Y-axis direction
Implementation Method 2
welding the deposition stick mask on a mask frame by laser
Implementation Method 3
an organic material is heated in a deposition source disposed at lower part of a chamber to sublimate and deposit the organic material on the TFT glass
Data Source
AI summary
Provided is a method of manufacturing a deposition mask frame assembly, the method including placing and welding a support stick mask and a gap stick mask on a frame, and joining edges of a deposition stick mask with the frame by welding while the deposition stick mask is tensioned in a longitudinal direction of the X-axis direction and at the same time, adhesively tensioned in the Y-axis direction, thereby preventing wrinkles due to the tensioning of the deposition stick mask to manufacture a fine and high-quality deposition mask frame assembly.