Vapor Deposition Mask Welding to Prevent Flexure on Frames
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Solution Overview
Problem
The challenge in manufacturing vapor deposition mask devices is the generation of flexure or wavy shapes in thin vapor deposition masks when supported on frames, leading to reduced adhesion and weld strength due to the gap between the mask and the frame, especially when the mask thickness is reduced.
Innovation Solution
A method and apparatus for manufacturing vapor deposition mask devices involve clamping the extension sections of the mask to apply tension such that the weld section is in close contact with the frame's front surface, and the extension section is partially towards the back surface, using a jig or clamp to secure the mask in a way that prevents flexure, and employing laser welding for joining the mask to the frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the thickness of the vapor deposition mask is reduced to achieve high precision deposition patterns, then the manufacturing precision is improved, but the strength at the weld section deteriorates
Solution Approach 1:
The vapor deposition mask is divided into three distinct sections: a first section with through-holes for deposition, a second section (weld section) for frame attachment, and a third section (extension section) extending toward the back surface. This segmentation allows each section to be optimized independently - the first section for precision deposition with reduced thickness, while the second and third sections provide structural support and welding strength.
Solution Approach 2:
The mask structure extends in the thickness direction (third dimension) by adding the extension section that protrudes toward the back surface of the frame. This dimensional extension provides additional welding surface area and structural support without affecting the front surface deposition precision, effectively decoupling the precision requirement from the strength requirement.
2Manufacturing precision
If the thickness of the vapor deposition mask is reduced to achieve high precision deposition patterns, then the manufacturing precision is improved, but the adhesion between mask and frame deteriorates
Solution Approach 1:
The mask is segmented into a thin first section for deposition and a third extension section for adhesion. The extension section specifically engages with the frame's front and back surfaces, providing dedicated adhesion functionality separate from the deposition function, thus maintaining both precision and reliability.
Solution Approach 2:
The extension section utilizes the thickness direction to create a multi-surface engagement with the frame. By extending toward the back surface, it creates both front-surface adhesion and potential back-surface support, enhancing overall adhesion reliability without compromising the thin profile needed for precision deposition.
3Stability of the object's composition
If the vapor deposition mask is supported on the frame in a pulled state to prevent flexure, then the stability is improved, but flexure or wavy shape may be generated when thickness is reduced
Solution Approach 1:
The mask is divided into a first section for deposition and a third extension section for support. The extension section acts as a structural support element that can be anchored to the frame, providing stability and preventing flexure in the thin first section without interfering with the deposition function.
Solution Approach 2:
The extension section utilizes the thickness direction to provide structural support. By extending toward the back surface and anchoring there, it creates a support mechanism that stabilizes the thin mask section while maintaining the precision required for deposition on the front surface.
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 enhances the adhesion between the vapor deposition mask and the frame, improves the weld strength, and prevents flexure or wavy shape generation in the mask, ensuring precise deposition patterns for high-resolution display devices.
Implementation Method 1
The vapor deposition mask is fixed to the frame by welding
Implementation Method 2
employing laser welding for joining the mask to the frame
Data Source
AI summary
A method of manufacturing a vapor deposition mask device includes: a preparing step of preparing a vapor deposition mask that includes a plurality of through-holes extending from a first surface to a second surface; and a welding step of welding the vapor deposition mask to a front surface of a frame that includes the front surface and a back surface opposite to the front surface.