Shape Memory Polymer Tray for ESDS Reconfiguration
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Solution Overview
Problem
The existing stackable trays for electrostatic discharge sensitive devices (ESDS) are highly specific and become obsolete quickly, leading to waste and increased costs due to the need for constant production of new trays, as they cannot be easily reused or reconfigured to accommodate varying ESDS configurations.
Innovation Solution
A stackable tray made from a shape memory polymer composite with integrated anti-static additives, processed through sheet extrusion and thermoforming, allowing the tray to change between permanent and temporary shapes in response to thermal stimuli, ensuring electrostatic discharge protection and enabling reusability and reprocessing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dedicated stackable trays are fabricated for each specific ESDS configuration, then the protection and accommodation of ESDS is optimized, but the manufacturing complexity and waste increase due to constant production of new trays
Solution Approach 1:
The patent applies parameter changes by utilizing the shape memory polymer's ability to change its physical state through temperature control. The tray material transitions between a deformable state (above switching temperature) and a rigid state (below switching temperature), allowing the same tray to be reconfigured for different ESDS configurations without requiring manufacturing new trays, thus reducing manufacturing complexity while maintaining protection reliability
Solution Approach 2:
The patent implements dynamics by creating a tray that can dynamically change its shape and configuration in response to temperature changes. The shape memory polymer allows the tray to transition between different forms to accommodate various ESDS configurations, replacing the static nature of traditional dedicated trays and eliminating the need for multiple specialized tray designs
2Adaptability or versatility
If shape memory polymer is used to create reconfigurable trays, then adaptability and reusability improve, but the manufacturing precision and dimensional accuracy may be compromised
Solution Approach 1:
The patent applies preliminary action by pre-programming the shape memory polymer with a permanent base shape that provides the fundamental tray structure and ESDS accommodation features. This pre-established geometric configuration ensures dimensional accuracy is maintained while allowing temporary deformations for reconfiguration, thus preserving manufacturing precision while achieving adaptability
Solution Approach 2:
The patent implements local quality by applying heat selectively to specific regions of the shape memory polymer tray to induce localized shape changes. This allows precise control over which portions of the tray are reconfigured while maintaining the dimensional accuracy and structural integrity of other critical regions, thus balancing adaptability with manufacturing precision
3Ease of manufacture
If traditional thermoplastic materials are used for stackable trays, then ease of manufacture is maintained, but the ability to recover and reuse trays is lost
Solution Approach 1:
The patent applies parameter changes by utilizing the shape memory polymer's temperature-responsive properties. The material can be heated above its switching temperature to become deformable for reconfiguration or recovery, then cooled below the switching temperature to rigidify and maintain the new shape. This parameter-based control enables tray recovery and reuse while maintaining ease of manufacture through conventional thermal processing methods
Solution Approach 2:
The patent implements phase transitions by exploiting the shape memory polymer's transition between a rigid crystalline phase (below switching temperature) and a deformable amorphous phase (above switching temperature). This phase change capability allows the tray to be easily manufactured using standard thermoplastic processing while enabling subsequent recovery and reuse through controlled heating and cooling cycles
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
This solution reduces waste, shortens lead times, optimizes storage space, and ensures dimensional accuracy and protection of ESDS by allowing the tray to be reconfigured for different ESDS configurations, thus improving logistics and reducing costs associated with frequent tray production and recycling.
Implementation Method 1
made from a shape memory polymer composite... allowing the tray to change between permanent and temporary shapes in response to thermal stimuli
Implementation Method 2
integrated anti-static additives... ensuring electrostatic discharge protection
Data Source
Figure 1
AI summary
The present application relates to a stackable tray for storage and transport of electrostatic discharge sensitive devices. The disclosed stackable tray is made of a shape memory polymer composite presenting electrostatic dissipative properties. The composite material used allows the recoverability and reusability of the tray for a new electronic product, while assuring process reproducibility in terms of dimensional accuracy and material properties maintenance. An anti-static additive compound is added to the composite to obtain a material that provides protection at the static dissipative range to electrostatic discharge sensitive devices from electrostatic discharges and fields. The present application also relates to a process that comprises the steps of mixing a shape memory polymer (1) with an anti-static additive compound (2), obtaining a permanent shape (3), obtaining a temporary shape (4) based on a mould structure (5), all by sheet extrusion (i), heating (ii), thermoforming (iii), cooling (iv), and shape recovery (v).