Staggered Slit Splice Tape for Component Carrier Reel Alignment
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Solution Overview
Problem
Existing methods for splicing component carrier reels are prone to alignment errors, leading to costly interruptions in manufacturing and product loss due to improper component placement, and previous solutions fail to provide a strong yet flexible joint, as well as causing static shock issues.
Innovation Solution
A splice tape with a plastic-type material coated with a pressure-sensitive adhesive, featuring a staggered slit arrangement for proper alignment and adhesion, and an optional stiffening strip to prevent movement, which also allows for inductive or visual sensing of the spliced reels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If alignment tools are incorporated on the tape itself, then alignment function is provided, but it becomes difficult to accurately align spliced reels in an efficient manner
Solution Approach 1:
The tape is divided into multiple sections with staggered slits, allowing each section to be independently positioned and aligned. This segmentation enables the alignment tools to be distributed across different tape sections rather than concentrated in one location, improving both accuracy and efficiency during the splicing process.
Solution Approach 2:
The patent introduces a separate alignment tool that works in conjunction with the tape, rather than integrating alignment functions directly into the tape structure. This intermediary approach allows for more effective alignment while maintaining tape flexibility and ease of operation.
2Strength
If a static plastic carrier is used in previous splicing tapes, then structural support is provided, but it causes static shock issues
Solution Approach 1:
The patent changes the material parameter of the carrier from static plastic to a material with different electrical properties that reduces or eliminates static shock. This parameter change maintains the structural support function while removing the harmful static electricity generation.
Solution Approach 2:
The patent converts the potential harm of static electricity into a benefit by using a material that naturally dissipates static charges, thereby protecting components from static damage while maintaining the necessary structural support for tape handling.
3Adaptability or versatility
If a single splice tape design is used for numerous sizes, shapes, and widths of component carrier reels, then versatility is improved, but it becomes difficult to accurately align different reel configurations
Solution Approach 1:
The tape is segmented into multiple sections with staggered slits that can be independently adjusted and positioned. This segmentation allows the same tape design to adapt to different reel sizes, shapes, and widths while maintaining alignment accuracy through the flexible positioning of individual tape sections.
Solution Approach 2:
The patent introduces dynamic flexibility to the tape structure through staggered slits and flexible material properties, allowing the tape to bend and conform to different reel geometries. This dynamic characteristic enables a single tape design to accommodate various reel configurations while maintaining precise alignment through the flexible adjustment capability.
4Productivity
If alignment errors occur in reel splicing, then production interruption is caused, but the cost of rework and scrap increases
Solution Approach 1:
The patent incorporates alignment tools and staggered slit arrangements that enable preliminary alignment and positioning before the actual splicing operation. This preliminary action ensures that reels are correctly aligned before bonding, preventing alignment errors that would cause production interruptions and product loss.
Solution Approach 2:
The patent includes visual indicators and alignment features that provide feedback during the splicing process, allowing operators to verify alignment accuracy in real-time. This feedback mechanism prevents misalignment before it occurs, maintaining production continuity and reducing the need for costly rework and scrap.
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 ensures accurate alignment and connection of component carrier reels, reducing errors and waste, maintaining a strong yet flexible joint, and eliminating static shock issues, thus preventing costly interruptions and ensuring seamless feeding through machinery.
Implementation Method 1
The splice tape comprises a plastic-type material coated on one side with a pressure-sensitive adhesive composition
Data Source
Figure 1A~1B
Figure 2A~2B
Figure 3
AI summary
A splicing tape for accurately aligning and joining spliced component carrier reels is disclosed. The flexible splice tape allows the components to remain aligned and picked from a component carrier reel without interruption at the union of a first and second reel. The splice tape with an optional stiffening strip provides a flexible, yet strong connection to prevent back and forth, axial and lateral movement between spliced reels. The detection of the disclosed splice tape facilitates elimination of incorrect and mismatched components during splicing. The splice tape comprises a plastic-type material coated on one side with a pressure-sensitive adhesive composition. A protective paper covers the adhesive composition. The splice tape and protective paper are divided into sections using a staggered slit arrangement. The staggered slit arrangement aids in proper alignment and adhesion of the splice tape to component carrier reels.