Tray module, tray assembly having the tray module, and method of fabricating display device using the tray assembly
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Solution Overview
Problem
Display device components often get stained during transportation due to the transfer of polymeric constituents from protective sheets to the components, requiring additional cleaning processes and increasing manufacturing time and cost.
Innovation Solution
A tray module with alternately stacked protective sheets, each comprising a foamed first polymer layer, a second polymer layer with an antistatic agent, and a paper layer, which prevents the transfer of polymeric constituents to the display device components by ensuring the glass components contact the paper layer, thereby reducing friction and static electricity discharge.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If protective sheets made of polymer materials are used during transportation, then the components are protected from physical damage, but polymeric constituents transfer to the components causing stains
Solution Approach 1:
The patent introduces a release layer as an intermediary between the polymer protective sheet and the display device component. This release layer prevents direct contact and material transfer while maintaining the protective function. The release layer acts as a mediator that allows the polymer sheet to provide mechanical protection without causing staining through constituent transfer.
Solution Approach 2:
The protective sheet is constructed as a composite material system consisting of multiple layers: a polymer base layer for structural protection and a release layer with specific surface properties to prevent staining. This composite structure combines the advantages of polymer materials (strength, cushioning) while eliminating their disadvantage (staining through material transfer).
2Manufacturing precision
If additional cleaning processes are implemented to remove stains, then the quality of components is maintained, but manufacturing time and cost increase
Solution Approach 1:
The release layer is applied in advance to prevent the staining problem before it occurs during transportation. By preemptively introducing the stain-preventive release layer, the patent eliminates the need for subsequent cleaning operations, thereby saving manufacturing time and reducing process complexity.
Solution Approach 2:
The patent converts the potential harmful effect of polymer-material contact into a beneficial outcome by using the release layer to create a controlled interface. The release layer's specific properties (low surface energy, non-staining characteristics) transform what would be a staining hazard into a protective mechanism that actively prevents contamination.
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 effectively prevents staining of display device components during transportation, simplifies the manufacturing process, and reduces the need for additional cleaning, thereby lowering costs and time.
Implementation Method 1
a first polymer layer including a first polymer resin which is foamed
Implementation Method 2
the first polymer layer including a first polymer resin which is foamed
Implementation Method 3
the second polymer layer including a second polymer resin; and a paper layer disposed on at least one of the second polymer layer
Data Source
AI summary
A tray module includes a tray in which a plurality of display device components are alternately stackable with a plurality of protective sheets. Each of a protective sheet among the plurality of protective sheets includes: a first polymer layer including a first polymer resin which is foamed, and top and bottom surfaces opposite to each other; a second polymer layer on each of the top and bottom surfaces of the first polymer layer, the second polymer layer including a second polymer resin; and a paper layer defining an outer surface of the protective sheet.