Stackable Mask With Integrated Stacking Guides
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Solution Overview
Problem
Conventional mask loading methods require separate facilities for storing and conveying masks and mask cassettes, leading to high logistics investment costs and increased logistical complexity.
Innovation Solution
A stackable mask design that eliminates the need for a mask cassette, featuring a mask body with rectangular shape and stacking guides on each side edge to facilitate vertical stacking and loading without additional cassettes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If separate mask cassettes are used to hold masks, then masks can be stored and conveyed, but the number of conveyed items increases and logistics investment cost increases
Solution Approach 1:
The mask and mask cassette are merged into a single integrated unit. The stacking guide structure is directly formed as part of the mask body, eliminating the separate mask cassette. This allows masks to be stacked directly on top of each other using the stacking guides, reducing the number of conveyed items from two (mask + cassette) to one (integrated mask unit).
Solution Approach 2:
The stacking guide structure serves multiple functions: it provides structural support for the mask, enables vertical stacking of multiple masks, facilitates conveyance of the mask, and eliminates the need for separate masking cassettes. This multi-functional design reduces overall system complexity while maintaining storage and conveyance capabilities.
2Reliability
If separate mask cassettes are used, then masks can be stored and conveyed, but maintenance and management costs increase
Solution Approach 1:
By combining the mask and mask cassette functions into a single integrated mask structure with built-in stacking guides, the number of components requiring maintenance is reduced. There are no separate cassettes to maintain, manage, or replace, thereby lowering ongoing maintenance and management costs.
3Device complexity
If masks are stacked vertically using stacking guides, then the number of conveyed items is reduced, but the stacking structure must be precisely aligned
Solution Approach 1:
The stacking guide structure incorporates asymmetric features including inclined guide surfaces and positioning protrusions that naturally guide masks into correct alignment during stacking. The inclined surfaces at specific angles facilitate self-alignment, reducing the need for high-precision manual or mechanical alignment while ensuring proper vertical stacking.
Solution Approach 2:
The stacking guides are pre-formed as integral parts of the mask structure during mask manufacturing. This preliminary formation of alignment features ensures that when masks are stacked, the alignment is already built-in, reducing the precision requirements during the stacking operation itself.
Data Source
AI summary
A method of loading a plurality of stackable masks for depositing organic light emitting diodes (OLEDs) includes loading an upper stackable mask on a stacking guide of a lower stackable mask, wherein each of the stackable masks includes a mask body having a rectangle shape; and the stacking guide disposed at a central portion of each of four side edges of the mask body.