Replaceable Unit Mask Assembly for Open Mask Repair
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Solution Overview
Problem
Current mask assembly technologies face challenges in efficiently repairing defective units without damaging the open mask, which affects deposition yield and reliability, particularly in large-area display device manufacturing.
Innovation Solution
The mask assembly design includes an open mask with unit masks that have deposition portions and welding protrusions, allowing for selective removal and replacement of defective units while minimizing damage to the open mask, using a method that involves cutting boundaries between deposition and welding portions and tensioning the preliminary unit masks to ensure precise alignment and deposition quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of repair
If a defective unit mask is removed from the open mask, 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 frame, an open mask, and multiple unit masks that can be independently removed and replaced. This segmentation allows defective unit masks to be exchanged without damaging the open mask, as each unit mask is a separate replaceable component.
Solution Approach 2:
Welding portions and welding protrusions are formed in advance on the unit masks and open mask respectively, enabling easy attachment and detachment. This preliminary preparation of connection structures allows for straightforward replacement of defective unit masks without complex assembly/disassembly procedures that could damage the open mask.
2Reliability
If the entire mask assembly is replaced when a defect occurs, then deposition quality is maintained, but manufacturing efficiency decreases
Solution Approach 1:
The mask assembly is segmented into a reusable open mask and replaceable unit masks. When a defect occurs in a unit mask, only that specific unit mask needs to be replaced rather than the entire assembly, maintaining deposition quality while significantly improving manufacturing efficiency by preserving the functional open mask.
Solution Approach 2:
When a unit mask becomes defective, it is discarded and replaced with a new unit mask, while the open mask is recovered and reused. This selective replacement approach maintains deposition quality through consistent open mask performance while improving productivity by avoiding unnecessary replacement of the entire mask assembly.
3Manufacturing precision
If unit masks are tightly attached to the open mask, then deposition precision is maintained, but repair difficulty increases
Solution Approach 1:
Welding portions and welding protrusions are formed in advance on the unit masks and open mask to create predetermined attachment points. This preliminary preparation enables unit masks to be securely attached for precise deposition while also allowing for easy removal and replacement by simply detaching these pre-formed connection structures.
Solution Approach 2:
The welding portions and welding protrusions serve as extractable connection features that can be easily separated. This allows unit masks to be tightly attached during deposition operations for precision while enabling straightforward removal for repair by simply taking out the welding connections without damaging other components.
Data Source
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Figure 3A
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 portions, 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.