Protective Tray Module Structure for Adhesive Contamination Control
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Solution Overview
Problem
Loading target parts, such as ultra-thin glass, can be damaged during transportation due to collisions within a tray, and the use of protective films can lead to contamination of the tray and the parts due to adhesive layers rubbing against the tray surfaces.
Innovation Solution
A tray module design that includes a first and second protective film with adhesive layers, a cover film covering the exposed adhesive portions, and a tray structure that accommodates the parts, preventing direct contact between the adhesive layers and the tray surfaces by using protruding edge and accommodating portions to minimize movement and contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If protective films with adhesive layers are used to prevent damage to loading target parts during transportation, then the parts are protected from collision damage, but the adhesive layers may rub against the tray surfaces and cause contamination
Solution Approach 1:
A cover film is introduced as an intermediary element between the protective film's adhesive layer and the tray surface. The cover film prevents direct contact between the adhesive layer and tray, eliminating contamination while maintaining the protective function. The cover film is selectively positioned at areas where adhesive exposure is most likely to occur during transportation.
Solution Approach 2:
The protective film system is segmented into multiple functional layers: the protective film with adhesive layer for damage prevention, and a separate cover film for contamination prevention. This segmentation allows each layer to perform its specific function independently - the protective film adheres to the loading target part while the cover film prevents adhesive contact with the tray.
2Object-affected harmful factors
If the cover film completely covers the loading target part, then contamination is prevented, but the adhesive layers cannot effectively secure the part to the tray
Solution Approach 1:
The cover film is designed with non-uniform coverage - it selectively covers only the areas where adhesive exposure would cause contamination (such as peripheral regions and corners) while leaving other areas exposed to maintain proper adhesion. This local quality approach ensures contamination prevention without compromising the securing function.
3Reliability
If the protective film is made larger to ensure full coverage of the loading target part, then protection is improved, but the exposed adhesive portions increase the risk of tray contamination
Solution Approach 1:
The cover film acts as a mediator that allows the protective film to be larger for complete coverage without increasing contamination risk. The cover film specifically caps the adhesive portions that would otherwise be exposed, enabling the protective film dimensions to be optimized for protection without the trade-off of increased contamination.
Data Source
AI summary
A tray module includes a first protective film, a second protective film, a cover film, and a tray. The first protective film includes a first adhesive layer. A loading target part is in contact with a bottom surface of the first adhesive layer. The second protective film includes a second adhesive layer. The loading target part is in contact with an upper surface of the second adhesive layer. The cover film is in contact with a portion of the second adhesive layer exposed by a distance (e.g., a predetermined or selectable distance) from an edge of the first protective film in a direction. Since the loading target part is fixed to the tray by the cover film instead of the protective films, contamination of the loading target part or the tray due to the first adhesive layer or the second adhesive layer may be prevented.