Sub-Mask Assembly With Connecting Sticks for Precise Alignment
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Solution Overview
Problem
The existing mask assembly technologies for display panel manufacturing face challenges in improving manufacturing efficiency and reliability due to limitations in the design and alignment of sub-masks and connecting mechanisms, which affect the precision and consistency of emission patterns in organic light emitting diodes.
Innovation Solution
A mask assembly comprising a plurality of sub-masks arranged in a specific direction with connecting sticks and welding parts, where each sub-mask includes a central cell region with holes and a welding part, and alignment marks for precise alignment, connected through welding agents to enhance structural integrity and alignment accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple sub-masks are arranged and connected to improve manufacturing efficiency, then productivity increases, but alignment precision and structural reliability deteriorate
Solution Approach 1:
The mask assembly is divided into multiple sub-masks (first sub-mask, second sub-mask, third sub-mask, fourth sub-mask) arranged in a specific sequence. Each sub-mask is connected to adjacent ones through connecting sticks, allowing the system to handle large-area deposition while maintaining manageable alignment of individual segments. This segmentation enables parallel processing and improved productivity without sacrificing overall alignment precision.
Solution Approach 2:
Connecting sticks serve as intermediary elements between adjacent sub-masks. Each connecting stick includes welding parts that facilitate precise alignment and reliable connection through welding agents. These intermediaries transfer and maintain alignment accuracy across multiple sub-masks, solving the problem of cumulative alignment errors that would otherwise occur in multi-component assemblies.
2Strength
If connecting sticks are used to join sub-masks, then structural integrity improves, but device complexity increases
Solution Approach 1:
The connecting stick integrates multiple functions into a single component: it provides mechanical support between sub-masks, includes welding parts for precise alignment, and facilitates connection through welding agents. By merging alignment features, connection mechanisms, and structural support into one integrated element, the design achieves high structural integrity without proportionally increasing overall assembly complexity.
Solution Approach 2:
The connecting stick structure is designed to be universally applicable between different sub-masks. The same connecting stick design with welding parts can join any adjacent pair of sub-masks in the sequence, reducing the need for custom-designed connection elements and simplifying the overall assembly process while maintaining strong structural bonds.
3Reliability
If welding parts and welding agents are used to connect sub-masks, then connection reliability improves, but manufacturing complexity increases
Solution Approach 1:
Welding parts are pre-formed as integral components of the connecting sticks before final assembly. The welding parts are positioned and configured in advance to ensure precise alignment with the sub-masks. This preliminary preparation of connection elements ensures reliable welding outcomes while simplifying the actual assembly process, as the critical alignment work has already been done during connecting stick fabrication.
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 proposed solution improves manufacturing efficiency and reliability by ensuring precise alignment and connection of sub-masks, resulting in improved surface uniformity and defect reduction during the deposition process, thereby enhancing the quality of display devices.
Implementation Method 1
The connecting stick and the welding part are connected with each other through a plurality of welding agents
Data Source
AI summary
A mask assembly includes: a mask and a mask frame, which supports the mask. The mask includes: a plurality of sub-masks, which are arranged in a first direction and each include a short side that extends in the first direction and a long side that extends in a second direction crossing the first direction; and a connecting stick, which overlaps the long side in a plan view and connects two sub-masks adjacent to each other among the plurality of sub-masks. Each of the plurality of sub-masks includes: a central part including a cell region defining a plurality of holes therein; and a welding part disposed along the long side. The connecting stick and the welding part are connected with each other through a plurality of welding agents.