Rotating Vacuum Carrier for Clean Display Lamination Handling
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Solution Overview
Problem
Existing lamination processes for display devices are inefficient due to exposure of adhesive surfaces to foreign substances and lengthy process times, particularly during the peeling off of materials.
Innovation Solution
A transport unit with a carrier having rotatable stages and a lamination system utilizing circular material handling systems to integrate input and discharge stages, incorporating a check valve to maintain vacuum suction and reduce contamination and process time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If material is peeled off and adhesive surface is exposed, then bonding process can be performed, but adhesive surface is exposed to foreign substances causing contamination
Solution Approach 1:
The patent creates a dust-free environment (inert atmosphere equivalent) by enclosing the peeling and bonding operations within a controlled chamber. The carrier rotates to keep the peeled material surface facing downward, preventing foreign substances from falling onto the adhesive surface, thus maintaining a contamination-free environment during the bonding process.
Solution Approach 2:
The material is peeled off and positioned on the carrier before the bonding operation begins. By completing the peeling action in advance and maintaining the material in a protected position (facing downward) until bonding is ready, the system prevents exposure to foreign substances while preparing for the bonding process.
2Ease of operation
If separate input stage and discharge stage are used, then material handling is simplified, but process time increases due to re-loading requirements
Solution Approach 1:
The patent merges the input stage and discharge stage into a single integrated system. The carrier serves dual purposes: it feeds material into the bonding chamber and simultaneously receives the bonded material for discharge. This eliminates the need for separate re-loading operations, reducing process time while maintaining operational simplicity.
Solution Approach 2:
The carrier is designed with multi-functionality, serving both as an input mechanism (feeding material into the chamber) and as a discharge mechanism (removing bonded material). This universal component performs multiple functions that previously required separate dedicated stages, thereby reducing overall process time.
3Reliability
If vacuum suction is applied continuously, then material holding is secure, but energy consumption increases
Solution Approach 1:
The vacuum suction is applied periodically rather than continuously. The system activates vacuum suction when the carrier needs to hold material (during feeding and bonding operations) and deactivates it when material holding is not required. This periodic application maintains reliable material holding when needed while reducing overall energy consumption.
Solution Approach 2:
The system uses the carrier's own rotation and positioning to control when vacuum suction is needed. By synchronizing vacuum activation with the carrier's operational phases (feeding, bonding, discharge), the system automatically manages energy consumption based on actual material holding requirements without continuous power input.
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 system effectively prevents contamination of peeled materials by foreign substances and reduces overall process time by integrating stages and eliminating the need for material re-loading.
Implementation Method 1
a docking station detachably combined with the carrier and for supplying an air or power to the carrier to form a vacuum state and to provide a suction force to the carrier
Implementation Method 2
a check valve disposed in the connection module to maintain the vacuum state after connection between the docking station and the carrier is released
Implementation Method 3
the connection module transmits the vacuum state to the first and second stages, and the first and second stages may suction-hold the first and second materials, respectively
Data Source
AI summary
A transport unit includes a carrier for carrying a first material and a second material, which are loaded thereon, and a docking station detachably combined with the carrier and for supplying an air or power to the carrier to form a vacuum state and to provide a suction force to the carrier. The carrier includes a first stage on which the first material is loaded, a second stage on which the second material is loaded, which faces the first stage, a connection module combined between the first stage and the second stage to rotate the first and second stages with respect to a rotation axis between the first stage and the second stage, and a check valve combined with the connection module to maintain the vacuum state after connection between the docking station and the carrier is released.