Method and apparatus for tensioning a shadow mask for thin film deposition

1. A shadow mask tensioning method comprising:

(a) positioning a shadow mask frame and an anchor frame in spaced relation defining a gap therebetween;

(b) positioning a shadow mask on the shadow mask frame and the anchor frame with a portion of the shadow mask extending across the gap;

(c) affixing an edge of the shadow mask to the anchor frame;

(d) following steps (a)-(c), tensioning the shadow mask by urging the portion of the shadow mask into the gap; and

(e) following step (d), affixing the shadow mask to the shadow mask frame, wherein step (d) includes adjusting the tension at numerous, spaced locations of the portion of the shadow mask.

2. The method of claim 1 , wherein step (c) includes affixing multiple edges of the shadow mask to the anchor frame.

3. The method of claim 1 , wherein step (c) includes clamping the edge of the shadow mask between the anchor frame and an anchor bar.

4. The method of claim 1 , further including:

(f) following step (e), separating the shadow mask affixed to the shadow mask frame from the anchor frame.

5. The method of claim 4 , wherein step (f) includes cutting the portion of the shadow mask extending across the gap.

6. The method of claim 4 , wherein:

the shadow mask includes an edge tab;

the portion of the shadow mask is the edge tab;

step (c) includes affixing the edge tab of the shadow mask to the anchor frame; and

step (f) includes separating the edge tab from the shadow mask affixed to the shadow mask frame.

7. The method of claim 1 , wherein step (d) includes:

affixing to the anchor frame a tensioning frame that supports one or more tension screws in alignment with the gap, wherein

adjusting the tension at numerous, spaced locations of the portion of the shadow mask includes adjusting (rotating) each tensioning screw in a manner to urge the portion of the shadow mask into the gap.

8. The method of claim 1 , wherein the gap and the portion of the shadow mask surround the shadow mask frame.

9. A shadow mask tensioning apparatus comprising:

means for supporting a shadow mask with an interior portion of the shadow mask in alignment with a gap;

means for anchoring one or more edges of the shadow mask; and

means for individually urging numerous, spaced locations of the interior portion of the shadow mask into the gap.

10. The apparatus of claim 9 , wherein the means for supporting includes a shadow mask frame surrounded in spaced relation by an anchor frame defining the gap.

11. The apparatus of claim 10 , wherein the gap surrounds the shadow mask frame.

12. The apparatus of claim 9 , wherein the means for anchoring includes an anchor bar and the anchor frame sandwiching an edge of the shadow mask therebetween.

13. The apparatus of claim 12 , wherein the anchor frame surrounds the shadow mask frame and defines the gap.

14. The apparatus of claim 9 , wherein the means for individually urging includes a tensioning frame supporting tensioning screws in alignment with the interior portion of the shadow mask, each tensioning screw operative for individually urging a single location of the interior portion of the shadow mask into the gap in response to rotation of the tensioning screw.

15. The apparatus of claim 14 , wherein ends of the tensioning screws urge the interior portion of the shadow mask into the gap in response to rotation of the tensioning screws.

16. The apparatus of claim 14 , wherein each edge of the shadow mask includes an edge tab and the means for anchoring anchors each edge tab.