Adjustable Tray for Multi-Size LCD Substrates
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Solution Overview
Problem
Current methods for transporting and storing liquid crystal display (LCD) panels are inefficient, requiring multiple boxes of different sizes, which increases transportation costs, reduces space utility, and complicates material management, as well as making it difficult for operators to quickly retrieve panels due to buffer openings.
Innovation Solution
A tray designed to concurrently load substrates of different sizes, featuring a base with grooves, lateral supporters, and corner bumps with buffer openings, compatible with a package box of a single maximum size, allowing for efficient loading and storage of variously sized substrates within a single box.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If multiple boxes of different sizes are used to load substrates of different sizes, then the substrates can be properly accommodated, but the molding cost increases and working space utility is reduced
Solution Approach 1:
The patent applies universality by designing a single box type with an adjustable tray that can accommodate substrates of different sizes. The tray's movable partition wall can be repositioned to divide the box interior into different compartments, allowing one box design to serve multiple substrate size requirements, thereby eliminating the need for multiple specialized box types.
Solution Approach 2:
The patent applies dynamics by incorporating a movable partition wall in the tray that can be adjusted to different positions. This dynamic element allows the tray to adapt its internal configuration based on the substrate size being loaded, transforming a static box design into a flexible system that can change its effective compartments as needed.
2Adaptability or versatility
If multiple boxes of different sizes are used, then substrates can be loaded appropriately, but material management becomes complicated
Solution Approach 1:
The patent applies universality by creating a single box design that can handle various substrate quantities through the adjustable tray. This standardizes the box type across all operations, simplifying material management procedures and reducing the complexity of tracking and handling different box sizes in the production environment.
3Reliability
If buffer openings are provided on the corners of boxes for protection, then transport losses from collision are avoided, but operators cannot quickly take LCD panels out of the boxes
Solution Approach 1:
The patent applies segmentation by separating the protection function from the access function. The corner bumps provide protective segmentation at the box corners, while the tray design incorporates removable side walls and an adjustable partition wall that can be quickly repositioned or removed to enable rapid substrate retrieval without compromising the protective corner features.
4Adaptability or versatility
If differently sized boxes are placed in a large iron case, then substrates can be transported, but available space is wasted and carrying amount is reduced
Solution Approach 1:
The patent applies universality by standardizing all substrate containers to a single box type with an adjustable tray. This standardization allows the iron case to be optimized for a uniform configuration, maximizing space utilization and increasing the carrying capacity compared to mixing different box sizes in the same container.
Data Source
AI summary
A tray for loading substrates includes a base, an outer frame, plural lateral supporters and plural corner bumps. The base has an upper surface with one or more grooves. The outer frame is located around four edges of the upper surface to thereby form a first space, and has two oppositely arranged first cavities. The lateral supporters are arranged on the base at four edges defining the first space against the outer frame, have second cavities arranged on internal surfaces of the lateral supporters and corresponding to the grooves. The corner bumps are arranged at corners of the outer frame, and are adjacent to the lateral supporters, the base and the outer frame. The corner bumps each have buffer openings to prevent a loaded substrate from damage by collision with the corner bumps. A package box is also disclosed, which can save cost and space in carrying the trays.