Substrate Storage Container Varying Wall Thickness
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Solution Overview
Problem
The existing substrate storage containers experience warpage and deformation due to uneven resin material arrival times during injection molding, leading to variations in skin layer thickness and residual stress distribution.
Innovation Solution
The container main body is designed with walls of varying thickness, gradually reducing from the rear wall to the opening frame, with specific thickness ranges and configurations to improve dimensional stability and reduce residual stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the walls are formed with constant thickness, then the manufacturing process is simple, but the resin material arrival time differs between gate vicinity and opening frame, causing skin layer thickness variation and residual stress
Solution Approach 1:
The patent applies local quality by varying the wall thickness according to position - the walls have greater thickness at the gate side and gradually reduce toward the opening frame side. This non-uniform thickness distribution compensates for the different resin arrival times at various positions, ensuring uniform skin layer thickness and reducing residual stress while maintaining manufacturing feasibility through injection molding.
2Manufacturing precision
If the wall thickness is increased toward the rear wall to compensate for earlier resin arrival, then the skin layer thickness becomes more uniform, but the overall container weight increases
Solution Approach 1:
The patent implements local quality by creating a position-dependent thickness profile where the walls are thicker at the gate side and gradually thinner toward the opening frame. This localized thickness variation achieves uniform skin layer thickness without uniformly increasing the entire container weight, thus resolving the contradiction between dimensional precision and weight.
3Manufacturing precision
If the wall thickness varies non-uniformly, then the resin arrival time is compensated, but the molding process becomes more complex
Solution Approach 1:
The patent applies parameter changes by modifying the wall thickness parameter as a function of position along the wall. This continuous or stepped variation in thickness parameter compensates for resin arrival time differences without requiring complex multi-step molding processes, achieving uniform skin layer formation through a single injection molding operation with optimized geometry.
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 design enhances the dimensional stability and accuracy of the container, reduces warpage, and improves productivity by ensuring uniform cooling and reduced pressure differences during molding.
Implementation Method 1
the container main body is formed by injection molding
Implementation Method 2
differences in the distribution of residual stress after cooling of a molded article is completed
Data Source
AI summary
The present disclosure provides a substrate storage container equipped with a container main body that has an opening portion formed by an opening frame at a front surface and is capable of storing a plurality of substrates and a lid that closes the opening portion. The container main body is of a box-like shape having the opening frame, a rear wall, a right wall, a left wall, a top wall, and a bottom wall. Each of the walls has a thickness which is thinner at a side toward the opening frame at the front surface than at a side toward the rear wall.