Conductive Tray Assembly for Static-Safe Display Component Transfer

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Solution Overview

Problem

Display device components face challenges during transfer and assembly due to static electricity generation, which can lead to damage and sticking issues during the integration of different manufactured parts from separate lines.

Innovation Solution

A tray module with conductive protection films and a conductive pattern is used to create a discharge path, allowing for the safe transfer of display device members by dissipating static electricity, and a tray assembly is designed to stack these modules with a support plate for efficient electrical connection and discharge.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If display device members are transferred using conventional trays without conductive protection, then the transfer process is simple and cost-effective, but static electricity accumulates causing damage and sticking issues during assembly

Engineering Contradiction:

Improveprotection against static electricity damageVSAvoidstructure of tray module

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The tray module is segmented into distinct functional layers: conductive protection films are applied separately to display device members, and conductive patterns are independently formed on the tray. This segmentation allows each component to be optimized for its specific function while maintaining overall system reliability against static electricity.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Conductive protection films serve as intermediary elements between the display device members and the environment, preventing direct contact that could generate static electricity. The conductive patterns on the tray act as intermediate discharge paths, safely redirecting static charges away from sensitive components without requiring complex shielding structures.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If conductive protection films and conductive patterns are applied to the tray, then static electricity is discharged effectively, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvedischarge path formationVSAvoidmanufacturing process

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The manufacturing approach changes parameters by using standard conductive materials (conductive protection films with specific resistivity ranges and conductive patterns with controlled geometry) that can be applied using conventional coating and printing techniques. This allows effective static discharge while maintaining compatibility with existing manufacturing capabilities.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The solution employs composite structures: conductive protection films combining insulating substrates with conductive layers, and conductive patterns using conductive inks or pastes on tray surfaces. These composite materials provide both the necessary electrical functionality and ease of application through standard manufacturing processes.

Inventive Principle:

Principle #40Composite materials

3Productivity

If multiple tray modules are stacked in a tray assembly, then transfer capacity and efficiency increase, but electrical connection and discharge reliability become more difficult to ensure

Engineering Contradiction:

Improvetransfer capacityVSAvoidelectrical connection between trays

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

Multiple tray modules are merged into a stacked assembly where conductive patterns on adjacent trays make electrical contact through their interfaces. This combining approach maintains individual tray functionality while creating a continuous electrical discharge path across the entire stack, enabling high-capacity transfer with reliable static electricity management.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The conductive patterns on stacked trays are designed to create equipotential connections between layers, ensuring that static charges can dissipate uniformly across all trays in the assembly. This equipotential design prevents potential differences that could cause arcing or ineffective discharge, maintaining reliability as productivity increases through stacking.

Inventive Principle:

Principle #12Equipotentiality

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 tray module effectively discharges static electricity, preventing damage and sticking during the transfer and assembly of display device components, ensuring reliable integration of display panels, backlight units, and optical members.

Implementation Method 1

at least two conductive protection films to be alternatingly stacked with the at least two members of the display device; and a conductive pattern on the tray to provide or form a discharge path with the at least two conductive protection films

Methodology Applied

Scientific EffectElectrostatic Discharge: Electrostatic Discharge

Data Source

PatentUS11810806B2Tray module, tray assembly including the same, and method for manufacturing display device using the same

Publication Date: 2023.11.07 SAMSUNG DISPLAY CO LTD

AI summary

A tray module capable of discharging static electricity to safely transfer display device members (e.g., components) includes: a tray configured to accommodate at least two members of a display device, at least two conductive protection films alternatingly stacked with the members of the display device, and a conductive pattern on the tray to provide a discharge path with the conductive protection films to ground.