Welded Mask Assembly for Display Patterning
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Solution Overview
Problem
Current mask manufacturing methods for display devices are inefficient, particularly in forming large-size masks for patterning light emission patterns, which limits the manufacturing efficiency of display elements like organic light emitting diodes.
Innovation Solution
A mask assembly comprising two interconnected masks with specific geometric features such as long and short sides, welded portions, perforated holes, alignment marks, and metallic thin films, which are aligned and welded to create a large-area mask for improved efficiency in patterning and deposition processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a single large-size mask is used for patterning, then the manufacturing efficiency of display elements is improved, but the mask becomes difficult to manufacture and align with high precision
Solution Approach 1:
The patent divides a single large mask into multiple smaller masks (first mask and second mask) that are connected through welded portions. Each mask can be manufactured and handled separately with high precision, while the combined structure achieves the functionality of a large mask for simultaneous deposition on multiple display devices.
Solution Approach 2:
The patent introduces alignment marks and welded portions that extend in specific directions (first direction and second direction) to enable precise alignment and connection between masks. The alignment marks provide reference points in the planar arrangement, while the welded portions create three-dimensional connections that maintain precision during assembly.
2Area of stationary object
If multiple masks are connected to form a large-area mask, then the coverage area for simultaneous deposition is increased, but the structural complexity and difficulty of welding increase
Solution Approach 1:
The patent merges multiple masks (first mask and second mask) by connecting their welded portions through welding processes. The masks are arranged in a planar configuration with alignment marks that overlap, creating a unified large-area mask structure that can simultaneously pattern multiple display devices while maintaining manageable individual mask components.
3Manufacturing precision
If alignment marks and welded portions are added to connect masks, then the alignment precision is improved, but the manufacturing steps and process complexity increase
Solution Approach 1:
The patent incorporates alignment marks on the masks during the mask manufacturing process itself, before the welding step. These alignment marks are pre-formed reference features that guide the subsequent welding and alignment operations, ensuring high precision without requiring complex real-time alignment procedures during assembly.
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 solution enhances manufacturing efficiency by allowing for the simultaneous deposition on multiple display devices, reduces defect rates, and improves alignment precision, resulting in a more efficient and reliable production process for display devices.
Implementation Method 1
a first welded portion, that are sequentially arranged in the first direction... a second welded portion, that are sequentially arranged in the first direction... The first welded portion is in contact with the second welded portion
Data Source
AI summary
A mask includes a first mask that includes a first long side that extends in a first direction and a first short side that extends in a second direction that crosses the first direction and that includes a first edge portion, a first center portion, and a first welded portion, that are sequentially arranged in the first direction. The mask further includes a second mask that includes a second long side that extends in the first direction and a second short side that extends in the second direction and that includes a second welded portion, a second center portion, and a second edge portion, that are sequentially arranged in the first direction. The first welded portion is in contact with the second welded portion.