Split Mask Assembly for Large-Area Deposition
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Solution Overview
Problem
Existing mask frame assemblies face challenges in accommodating large-surface deposition patterns for organic light-emitting display devices without increasing etching errors, as traditional split masks become too wide and prone to errors when exceeding a certain size.
Innovation Solution
A mask frame assembly comprising a frame with multiple split masks, where each split mask is formed by coupling partial masks with uniform pattern pitches and bonded using UV-curing or thermosetting adhesives, allowing for the creation of large-surface deposition patterns without increasing etching errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If the split mask width is increased to accommodate larger deposition patterns, then the deposition area coverage is improved, but the etching precision deteriorates
Solution Approach 1:
The patent divides a large deposition pattern into multiple unit patterns, each covered by a separate split mask. Instead of using one large mask that would cause etching errors, multiple smaller masks are arranged to collectively cover the entire deposition area, maintaining etching precision while achieving large-area coverage.
2Area of stationary object
If multiple partial masks are coupled to form a large split mask, then the deposition pattern coverage is improved, but the mask assembly complexity increases
Solution Approach 1:
The mask system is segmented into multiple independent partial masks that can be manufactured separately and then coupled together. This segmentation allows for simplified manufacturing of each individual mask while achieving large-area coverage through assembly, balancing complexity and coverage requirements.
Solution Approach 2:
Multiple partial masks are merged or coupled together to form a complete mask assembly that covers the entire deposition pattern. The coupling mechanism integrates separate simple components into a functional whole, achieving large coverage without the complexity of manufacturing a single large mask.
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
Enables the easy manufacturing of split masks for large-surface screens with reduced etching errors by forming split masks from multiple partial masks with uniform pattern pitches, effectively accommodating larger deposition patterns without increasing etching errors.
Implementation Method 1
The adhesive may be a UV-curing adhesive. The UV-curing adhesive may be coated on upper and lower surfaces of the bonding portion and cured.
Implementation Method 2
The adhesive may be a thermosetting adhesive. The thermosetting adhesive may be coated on sides of the bonding portion and cured.
Data Source
AI summary
A mask frame assembly using a plurality of stick-shaped split masks. The mask frame assembly includes a plurality of split masks, each of which includes a deposition pattern corresponding to a unit screen. Each of the split masks is formed of a plurality of partial masks to form the deposition pattern corresponding to a unit screen. Accordingly, the split masks accommodating a pattern corresponding to a large screen may be easily manufactured without an increase in the amount of etching errors.