US20150158664A1 - Carrier tray - Google Patents
Carrier tray Download PDFInfo
- Publication number
- US20150158664A1 US20150158664A1 US14/622,607 US201514622607A US2015158664A1 US 20150158664 A1 US20150158664 A1 US 20150158664A1 US 201514622607 A US201514622607 A US 201514622607A US 2015158664 A1 US2015158664 A1 US 2015158664A1
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- US
- United States
- Prior art keywords
- sidewall
- top plate
- carrier tray
- plastic film
- lateral surface
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
- B65D85/30—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure
- B65D85/42—Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure for ampoules; for lamp bulbs; for electronic valves or tubes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/10—Forming by pressure difference, e.g. vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
- B29C51/34—Moulds for undercut articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
- B65D1/34—Trays or like shallow containers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
- B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
- B65D81/025—Containers made of sheet-like material and having a shape to accommodate contents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/006—Using vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/08—Deep drawing or matched-mould forming, i.e. using mechanical means only
- B29C51/082—Deep drawing or matched-mould forming, i.e. using mechanical means only by shaping between complementary mould parts
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
- B29C51/36—Moulds specially adapted for vacuum forming, Manufacture thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D2585/00—Containers, packaging elements or packages specially adapted for particular articles or materials
- B65D2585/68—Containers, packaging elements or packages specially adapted for particular articles or materials for machines, engines, or vehicles in assembled or dismantled form
- B65D2585/6802—Containers, packaging elements or packages specially adapted for particular articles or materials for machines, engines, or vehicles in assembled or dismantled form specific machines, engines or vehicles
- B65D2585/6835—Containers, packaging elements or packages specially adapted for particular articles or materials for machines, engines, or vehicles in assembled or dismantled form specific machines, engines or vehicles audio-visual devices
Definitions
- the present disclosure relates to a container for storing and transporting an object, and more particularly, to a carrier tray for storing and transporting an electronic component.
- a carrier tray is utilized for the storage and transportation of a finished product or a semi-finished product of a liquid crystal display (LCD) panel in conventional technology.
- these carrier trays all have a stacked structure for being overlapped with each other.
- a sidewall of an upper carrier tray is mounted on a top plate of a lower carrier tray to form a containing room together.
- the containing room is used for containing the finished product or the semi-finished product of the LCD panel and protecting the finished product or the semi-finished product from damage during storage or transportation.
- thermoplastic plastic film is provided to be deformed into a carrier tray by hot pressing.
- the included angle between the sidewall and the top plate would be restricted, which leads to a poor whole structural strength of the carrier trays overlapped with each other. If the whole structural strength of the conventional carrier trays overlapped with each other is poor, the problem that the upper carrier bumps into the panel on the lower carrier tray may be occurred during the storage or transportation of the panel.
- An embodiment discloses a carrier tray comprising a top plate and a first sidewall.
- the top plate comprises a first side edge and a containing room.
- the first sidewall is connected to the top plate and is extended from the first side edge.
- the containing room and the first sidewall are disposed on the same side of the top plate.
- the first sidewall and the top plate form a first included angle of between 73 and 78 degrees therebetween.
- FIGS. 1 and 2 are a portion of process cross-sectional views of manufacturing a carrier tray
- FIG. 3 is a flow chart of a method for manufacturing a carrier tray according to an embodiment
- FIGS. 4 to 10 are cross-sectional schematic views of manufacturing a carrier tray corresponding to each step in FIG. 3 ;
- FIGS. 11A , 12 and 13 are cross-sectional schematic views of a step of removing a first mold in a method for manufacturing a carrier tray according to another embodiment
- FIG. 11B is a perspective schematic view of a portion of a first mold in FIG. 11A ;
- FIG. 14 is a perspective schematic view of a carrier tray manufactured by a method in FIG. 3 ;
- FIG. 15 is a cross-sectional schematic view along a cross-sectional line 15 - 15 in FIG. 14 ;
- FIG. 16 is a perspective schematic view of a carrier tray according to another embodiment
- FIG. 17 is a cross-sectional schematic view of a carrier tray along a cross-sectional line 17 - 17 in FIG. 16 ;
- FIG. 18 is a cross-sectional schematic view of stacked carrier trays of FIG. 15 ;
- FIG. 19 is a cross-sectional schematic view of stacked carrier trays of FIG. 17 .
- FIGS. 1 and 2 are a portion of process cross-sectional views of manufacturing a carrier tray.
- the first mold 30 comprises a top surface 31 and a first lateral surface 32 .
- the top surface 31 comprises a recession 33 and a first edge 34 .
- the first lateral surface 32 is connected to the top surface 31 and extends from the first edge 34 .
- the first lateral surface 32 and the top surface 31 forms a first included angle ⁇ 1 therebetween.
- the first included angle ⁇ 1 is between 73 to 78 degrees.
- the carrier tray 10 comprises a top plate 100 whose shape corresponds to that of the top surface 31 and a first sidewall 200 whose shape corresponds to that of the first lateral surface 32 .
- the top plate 100 comprises a first side edge 110 and a containing room 120 whose shape corresponds to that of the recession 33 .
- the first sidewall 200 is connected to the top plate 100 and extends from the first side edge 110 .
- the containing room 120 and the first sidewall 200 are disposed on the same side of the top plate 100 .
- the first sidewall 200 and the top plate 100 have the same first included angle ⁇ 1 therebetween.
- the top plate 100 is disposed on the top surface 31
- the first sidewall 200 is disposed on the first lateral surface 32 .
- the carrier tray 10 still has plastic deformation properties, remove the first mold 30 from the plastic film 20 . Because the top plate 100 and the first sidewall 200 have the first included angle ⁇ 1 therebetween, the first sidewall 200 obstructs a removal passage of the first mold 30 . Therefore, during the removal process of the first mold 30 , a portion of the plastic film 20 (i.e. the first sidewall 200 ) is pushed by the first lateral surface 32 and is moved from an initial position to a final position (along a direction indicated by an arrow a) such that an unexpected deformation of the carrier tray 10 is generated.
- a portion of the plastic film 20 i.e. the first sidewall 200
- FIG. 3 is a flow chart of a method for manufacturing a carrier tray according to an embodiment.
- FIGS. 4 to 10 are cross-sectional schematic views of manufacturing a carrier tray corresponding to each step in FIG. 3 .
- FIG. 14 is a perspective schematic view of a carrier tray manufactured by a method in FIG. 3 .
- FIG. 15 is a cross-sectional schematic view along a cross-sectional line 15 - 15 in FIG. 14 .
- a plastic film 20 having thermoplastic properties is heated to be softened, and the plastic film 20 is disposed on a first mold 30 .
- the first mold 30 comprises a top surface 31 and a first lateral surface 32 .
- the top surface 31 comprises a recession 33 and a first edge 34 .
- the first lateral surface 32 is connected to the top surface 31 and is extended from the first edge 34 .
- a first included angle ⁇ 1 is formed between the first lateral surface 32 and the top surface 31 .
- the first included angle ⁇ 1 is between 73 to 78 degrees.
- the first included angle ⁇ 1 may be greater than or less than 78 degrees.
- the top surface 31 , the first lateral surface 32 and the recession 33 comprise multiple vents connected to an air suction pump, respectively.
- the carrier tray 10 comprises a top plate 100 and a first sidewall 200 .
- the top plate 100 comprises a first side edge 110 and a containing room 120 .
- the first sidewall 200 is connected to the top plate 100 and extends from the first side edge 110 .
- the containing room 120 and the first sidewall 200 are disposed on the same side of the top plate 100 .
- the first sidewall 200 and the top plate 100 also have the same first included angle ⁇ 1 therebetween.
- the top plate 100 is disposed on the top surface 31
- the first sidewall 200 is disposed on the first lateral surface 32 .
- the carrier tray 10 further comprises a base 300 connected to the first sidewall 200 such that the first sidewall 200 is disposed between the base 300 and the top plate 100 .
- a restorer 50 is disposed on an outer side of the first mold 30 such that the plastic film 20 is disposed between the first lateral surface 32 and the restorer 50 .
- the restorer 50 has the capability of restoring the first sidewall 200 of the plastic film 20 to an original position.
- the restorer 50 is a flexible ring-shaped structure surrounding the first mold 30 and the plastic film 20 .
- the ring-shaped structure includes a first inner surface 51 , and the first inner surface 51 faces the first lateral surface 32 .
- a second mold 60 also may be utilized to make the plastic film 20 in the recession 33 being sandwiched between the first mold 30 and the second mold 60 such that the shape of the containing room 120 of the carrier tray 10 is enabled to accurately correspond to the shape of the recession 33 .
- the sequence of disposing the restorer 50 and disposing the second mold 60 is not limited to the embodiment. The two steps are only needed to be implemented before the step of removing the first mold 30 from the plastic film 20 .
- the first mold 30 is removed from the plastic film 20 . Because the first included angle ⁇ 1 (about 73 to 78 degrees) is formed between the top plate 100 and the first sidewall 200 , the first sidewall 200 obstructs a removal passage of the first mold 30 . Therefore, during the removal process of the first mold 30 , a portion of the plastic film 20 (i.e. the first sidewall 200 ) is pushed by the first lateral surface 32 such that the restorer 50 is moved from an initial position to a final position (along a direction indicated by an arrow b).
- the restorer 50 has flexibility
- the restorer 50 stores a flexible restoring force.
- the restorer 50 starts to release the flexible restoring force to move the plastic film 20 from the final position to the initial position (along a direction indicated by an arrow c). In this way, before the carrier tray 10 is solidified, the first sidewall 200 is returned to the initial position, thereby avoiding defects.
- the second mold 60 and the restorer 50 are separated from the plastic film 20 respectively. After that, the plastic film 20 is cooled to obtain the above-mentioned carrier tray 10 .
- the first mold 30 has a second lateral surface 35 which is at an opposite side of the first lateral surface 32 .
- the top surface 31 comprises a second edge 36 .
- the first edge 34 and the second edge 36 face to each other.
- the second lateral surface 35 extends from the second edge 36 .
- a second included angle ⁇ 2 is formed between the second lateral surface 35 and the top surface 31 .
- the second included angle ⁇ 2 is between 73 to 78 degrees.
- the carrier tray 10 comprises a second sidewall 400 whose shape corresponds to that of the second lateral surface 35 .
- the second sidewall 400 extends from the second side edge 130 , and the containing room 120 and the second sidewall 400 are disposed on the same side of the top plate 100 .
- the second sidewall 400 and the top plate 100 have the same second included angle ⁇ 2 , and when the first mold 30 is removed from the plastic film 20 , the second sidewall 400 is also pushed by the second lateral surface 35 to move the restorer 50 from an initial position to a final position (along a direction indicated by an arrow b).
- the restorer 50 is also pushed back to the initial position from the final position (along a direction indicated by an arrow c).
- the amount of the sidewalls 200 , 400 connected to the top plate 100 and the position of the sidewalls 200 , 400 are not limited to the embodiments.
- FIGS. 11A to 13 and 16 to 17 are cross-sectional schematic views of a step of removing a first mold in a method for manufacturing a carrier tray according to another embodiment.
- FIG. 11B is a perspective schematic view of a portion of a first mold in FIG. 11A .
- FIG. 16 is a perspective schematic view of a carrier tray according to another embodiment.
- FIG. 17 is a cross-sectional schematic view of a carrier tray along a cross-sectional line 17 - 17 in FIG. 16 .
- the method for manufacturing in this embodiment is similar to that in FIG. 3 , so only the differences are described herein.
- the first mold 30 comprises a third lateral surface 37 and a fourth lateral surface 38 .
- the top surface 31 comprises a main body 39 and a protruding part 40 .
- the protruding part 40 extends from the main body 39 toward outside the main body 39 .
- the protruding part 40 comprises a third edge 41 and a fourth edge 42 .
- the third edge 41 and the fourth edge 42 face to each other.
- the third lateral surface 37 is connected to the top surface 31 and extends from the third edge 41 .
- the fourth lateral surface 38 is connected to the top surface 31 and extends from the fourth edge 42 .
- the third lateral surface 37 and the top surface 31 form a third included angle ⁇ 3 therebetween.
- the fourth lateral surface 38 and the top surface 31 form a fourth included angle ⁇ 4 .
- the third included angle ⁇ 3 and the fourth included angle ⁇ 4 are between 73 and 78 degrees.
- the main body 39 in this embodiment may also comprise a recession (not shown), and the structure of the recession is similar to that of the recession 33 in FIG. 4 .
- the plastic film 20 may be attached to the first mold 30 to be deformed into a carrier tray 10 .
- the carrier tray 10 comprises a third sidewall 500 and a fourth sidewall 600
- the top plate 100 comprises a primary body 140 and a sticking out part 150 .
- the shape of the third sidewall 500 corresponds to that of the third lateral surface 37 .
- the shape of the fourth sidewall 600 corresponds to that of the fourth lateral surface 38 .
- the shape of the primary body 140 corresponds to that of the main body 39 .
- the shape of the sticking out part 150 corresponds to that of the protruding part 40 .
- the primary body 140 may further comprise a containing room (not shown) corresponding to the recession.
- the sticking out part 150 comprises a third side edge 151 and a fourth side edge 152 .
- the third sidewall 500 is connected to the top plate 100 and extends from the third side edge 151 .
- the fourth sidewall 600 is connected to the top plate 100 and extends from the fourth side edge 152 .
- the containing room, the third sidewall 500 and the fourth sidewall 600 are disposed on the same side of the top plate 100 .
- the third sidewall 500 and the top plate 100 form a third included angle ⁇ 3 therebetween.
- the fourth sidewall 600 and the top plate 100 form a fourth included angle ⁇ 4 therebetween.
- the restorer 50 comprises two flexible components 52 and two restoring work pieces 53 .
- An end of each of the two flexible components 52 is disposed on two fixed surfaces 70 , respectively.
- the other end of each of the two flexible components 52 is connected to the two restoring work pieces 53 , respectively.
- One of the two restoring work pieces 53 faces the third lateral surface 37
- the other restoring work piece 53 faces the fourth lateral surface 38 .
- the third sidewall 500 and the fourth sidewall 600 are also pushed by the third lateral surface 37 and the fourth lateral surface 38 such that the two restoring work pieces 53 are moved to a final position from an initial position, respectively (along a direction indicated by an arrow d).
- the two restoring work pieces 53 also pushes the third sidewall 500 and the fourth sidewall 600 from the final position to the initial position (along a direction indicated by an arrow e).
- FIG. 18 is a cross-sectional schematic view of stacked carrier trays of FIG. 15 .
- FIG. 19 is a cross-sectional schematic view of stacked carrier trays of FIG. 17 .
- each included angle formed between the top plate 100 and the sidewalls 200 , 400 , 500 , 600 may be between 73 to 78 degrees, respectively.
- each of the included angles of the carrier tray 10 manufactured according to the embodiments is less than the included angles of a conventional carrier tray, the proportion of the contact area (the lap between the two carrier trays) between each of the sidewalls 200 , 400 , 500 , 600 of the upper carrier tray 10 and the top plate 100 of the lower carrier tray 10 is increased, thereby advancing the whole structural strength of the carrier trays 10 overlapped with each other.
- the method for manufacturing the carrier tray according to the embodiments is that before the first mold is removed, the restorer is disposed and leaned against the outer sidewall of the plastic film in advance, so when the first mold is removed, the restorer may provide an adverse flexible restoring force to push the plastic film to the original initial position. Therefore, the carrier tray manufactured by the method has the included angles formed by the top plate and each of the sidewalls therebetween and are between 73 to 78 degrees.
- the acute angles of between 73 to 78 degrees formed between the top plate and each of the sidewall is utilized to increase the distance between the sidewall of the upper carrier tray and the side edge of the top plate of the lower carrier tray, thereby, increasing the whole structural strength of the carrier tray overlapped with each other.
Abstract
A carrier tray includes a top plate and a first sidewall. The top plate includes a first side edge and a containing room. The first sidewall is connected to the top plate and is extended from the first side edge. The containing room and the first sidewall are disposed on the same side of the top plate. The first sidewall and the top plate form a first included angle of between 73 and 78 degrees therebetween.
Description
- This application is a divisional patent application U.S. application Ser. No. 13/594,427 filed on Aug. 24, 2012, for “CARRIER TRAY AND METHOD FOR MANUFACTURING THEREOF.” This application is also claims priority under 35 U.S.C. §119(a) on Patent Application No(s). 101119837 filed in Taiwan, R.O.C. on Jun. 1, 2012. Each of applications is incorporated herein by reference in its entirety.
- 1. Technical Field
- The present disclosure relates to a container for storing and transporting an object, and more particularly, to a carrier tray for storing and transporting an electronic component.
- 2. Related Art
- Generally speaking, a carrier tray is utilized for the storage and transportation of a finished product or a semi-finished product of a liquid crystal display (LCD) panel in conventional technology. Moreover, in order to save the needed space for storing and transporting the finished product or the semi-finished product, these carrier trays all have a stacked structure for being overlapped with each other. In detail, when these carrier trays are overlapped with each other, a sidewall of an upper carrier tray is mounted on a top plate of a lower carrier tray to form a containing room together. The containing room is used for containing the finished product or the semi-finished product of the LCD panel and protecting the finished product or the semi-finished product from damage during storage or transportation.
- In general, a thermoplastic plastic film is provided to be deformed into a carrier tray by hot pressing. However, during manufacturing of the carrier tray, because of the problem of a mold removal, the included angle between the sidewall and the top plate would be restricted, which leads to a poor whole structural strength of the carrier trays overlapped with each other. If the whole structural strength of the conventional carrier trays overlapped with each other is poor, the problem that the upper carrier bumps into the panel on the lower carrier tray may be occurred during the storage or transportation of the panel.
- Based on the above-mentioned problem, how to improve a method for manufacturing the carrier tray to advance the whole structural strength of the carrier trays overlapped with each other is important.
- An embodiment discloses a carrier tray comprising a top plate and a first sidewall.
- The top plate comprises a first side edge and a containing room. The first sidewall is connected to the top plate and is extended from the first side edge. The containing room and the first sidewall are disposed on the same side of the top plate. The first sidewall and the top plate form a first included angle of between 73 and 78 degrees therebetween.
- The present disclosure will become more fully understood from the detailed description given herein below for illustration only, and thus are not limitative of the present disclosure, and wherein:
-
FIGS. 1 and 2 are a portion of process cross-sectional views of manufacturing a carrier tray; -
FIG. 3 is a flow chart of a method for manufacturing a carrier tray according to an embodiment; -
FIGS. 4 to 10 are cross-sectional schematic views of manufacturing a carrier tray corresponding to each step inFIG. 3 ; -
FIGS. 11A , 12 and 13 are cross-sectional schematic views of a step of removing a first mold in a method for manufacturing a carrier tray according to another embodiment; -
FIG. 11B is a perspective schematic view of a portion of a first mold inFIG. 11A ; -
FIG. 14 is a perspective schematic view of a carrier tray manufactured by a method inFIG. 3 ; -
FIG. 15 is a cross-sectional schematic view along a cross-sectional line 15-15 inFIG. 14 ; -
FIG. 16 is a perspective schematic view of a carrier tray according to another embodiment; -
FIG. 17 is a cross-sectional schematic view of a carrier tray along a cross-sectional line 17-17 inFIG. 16 ; -
FIG. 18 is a cross-sectional schematic view of stacked carrier trays ofFIG. 15 ; and -
FIG. 19 is a cross-sectional schematic view of stacked carrier trays ofFIG. 17 . - The detailed features and advantages of the disclosure are described below in great detail through the following embodiments, the content of the detailed description is sufficient for those skilled in the art to understand the technical content of the present disclosure and to implement the disclosure there accordingly. Based upon the content of the specification, the claims, and the drawings, those skilled in the art can easily understand the relevant objectives and advantages of the disclosure.
- Based upon the importance of advancing whole structural strength of carrier trays overlapped with each other, the inventor is aware that when the included angle between a top plate and a sidewall of each carrier tray is reduced, the contact area between a sidewall of an upper carrier tray and a top plate of a lower carrier tray is increased, thereby advancing the whole structural strength of the carrier trays overlapped with each other. However, the inventor finds that when the included angle between the top plate and the sidewall is designed to be greatly reduced, an unexpected deformation of the carrier trays may be occurred. The following describes the unexpected deformation problem of the carrier trays in detail. Please refer to
FIGS. 1 and 2 .FIGS. 1 and 2 are a portion of process cross-sectional views of manufacturing a carrier tray. - As shown in
FIG. 1 , during the process of manufacturing acarrier tray 10, first, heat and soften aplastic film 20 having thermoplastic properties, and attach theplastic film 20 to afirst mold 30 whose shape corresponds to that of thecarrier tray 10. Thefirst mold 30 comprises atop surface 31 and a firstlateral surface 32. Thetop surface 31 comprises arecession 33 and afirst edge 34. The firstlateral surface 32 is connected to thetop surface 31 and extends from thefirst edge 34. The firstlateral surface 32 and thetop surface 31 forms a first included angle θ1 therebetween. For example, the first included angle θ1 is between 73 to 78 degrees. - Because the softened
plastic film 20 has plastic deformation properties, a vacuum forming technology may be applied to the softenedplastic film 20, such that theplastic film 20 may be attached to thefirst mold 30 to be deformed into thecarrier tray 10. In this way, thecarrier tray 10 comprises atop plate 100 whose shape corresponds to that of thetop surface 31 and afirst sidewall 200 whose shape corresponds to that of the firstlateral surface 32. Thetop plate 100 comprises afirst side edge 110 and a containingroom 120 whose shape corresponds to that of therecession 33. Thefirst sidewall 200 is connected to thetop plate 100 and extends from thefirst side edge 110. The containingroom 120 and thefirst sidewall 200 are disposed on the same side of thetop plate 100. Thefirst sidewall 200 and thetop plate 100 have the same first included angle θ1 therebetween. Thetop plate 100 is disposed on thetop surface 31, and thefirst sidewall 200 is disposed on the firstlateral surface 32. - As shown in
FIG. 2 , after that, when the carrier tray 10 still has plastic deformation properties, remove thefirst mold 30 from theplastic film 20. Because thetop plate 100 and thefirst sidewall 200 have the first included angle θ1 therebetween, thefirst sidewall 200 obstructs a removal passage of thefirst mold 30. Therefore, during the removal process of thefirst mold 30, a portion of the plastic film 20 (i.e. the first sidewall 200) is pushed by the firstlateral surface 32 and is moved from an initial position to a final position (along a direction indicated by an arrow a) such that an unexpected deformation of thecarrier tray 10 is generated. - Based upon the above description, when the included angle between the
top plate 100 and thesidewall 200 of thecarrier tray 10 is greatly reduced, the unexpected deformation of thecarrier tray 10 is generated. As a result, the whole structural strength of thecarrier trays 10 overlapped with each other is not advanced. Therefore, the following further describes an improved method for manufacturing a carrier tray and detailed steps hereinafter. - Please refer to
FIGS. 3 to 10 and 14 to 15.FIG. 3 is a flow chart of a method for manufacturing a carrier tray according to an embodiment.FIGS. 4 to 10 are cross-sectional schematic views of manufacturing a carrier tray corresponding to each step inFIG. 3 .FIG. 14 is a perspective schematic view of a carrier tray manufactured by a method inFIG. 3 .FIG. 15 is a cross-sectional schematic view along a cross-sectional line 15-15 inFIG. 14 . - The following describes
Steps 10 to 60 in detail. As shown inFIGS. 3 to 5 , aplastic film 20 having thermoplastic properties is heated to be softened, and theplastic film 20 is disposed on afirst mold 30. Thefirst mold 30 comprises atop surface 31 and a firstlateral surface 32. Thetop surface 31 comprises arecession 33 and afirst edge 34. The firstlateral surface 32 is connected to thetop surface 31 and is extended from thefirst edge 34. A first included angle θ1 is formed between the firstlateral surface 32 and thetop surface 31. In this embodiment, the first included angle θ1 is between 73 to 78 degrees. However, in other embodiments, the first included angle θ1 may be greater than or less than 78 degrees. Moreover, for example, thetop surface 31, the firstlateral surface 32 and therecession 33 comprise multiple vents connected to an air suction pump, respectively. - Because of the plastic deformation properties of the softened
plastic film 20, when the air suction pump operates on the softenedplastic film 20, theplastic film 20 influenced by the suction of the air suction pumps is attached to thetop surface 31 and deformed, the firstlateral surface 32 and therecession 33. In this way, theplastic film 20 is plastically deformed into the shape of acarrier tray 10. Thecarrier tray 10 comprises atop plate 100 and afirst sidewall 200. Thetop plate 100 comprises afirst side edge 110 and a containingroom 120. Thefirst sidewall 200 is connected to thetop plate 100 and extends from thefirst side edge 110. The containingroom 120 and thefirst sidewall 200 are disposed on the same side of thetop plate 100. Thefirst sidewall 200 and thetop plate 100 also have the same first included angle θ1 therebetween. Thetop plate 100 is disposed on thetop surface 31, and thefirst sidewall 200 is disposed on the firstlateral surface 32. - Moreover, in other embodiments, the
carrier tray 10 further comprises a base 300 connected to thefirst sidewall 200 such that thefirst sidewall 200 is disposed between the base 300 and thetop plate 100. - As shown in
FIG. 6 , before thefirst mold 30 is removed from theplastic film 20, arestorer 50 is disposed on an outer side of thefirst mold 30 such that theplastic film 20 is disposed between the firstlateral surface 32 and therestorer 50. Therestorer 50 has the capability of restoring thefirst sidewall 200 of theplastic film 20 to an original position. In this embodiment, therestorer 50 is a flexible ring-shaped structure surrounding thefirst mold 30 and theplastic film 20. The ring-shaped structure includes a firstinner surface 51, and the firstinner surface 51 faces the firstlateral surface 32. - Moreover, during the step of disposing the
restorer 50, asecond mold 60 also may be utilized to make theplastic film 20 in therecession 33 being sandwiched between thefirst mold 30 and thesecond mold 60 such that the shape of the containingroom 120 of thecarrier tray 10 is enabled to accurately correspond to the shape of therecession 33. However, the sequence of disposing therestorer 50 and disposing thesecond mold 60 is not limited to the embodiment. The two steps are only needed to be implemented before the step of removing thefirst mold 30 from theplastic film 20. - As shown in
FIGS. 6 and 7 , thefirst mold 30 is removed from theplastic film 20. Because the first included angle θ1 (about 73 to 78 degrees) is formed between thetop plate 100 and thefirst sidewall 200, thefirst sidewall 200 obstructs a removal passage of thefirst mold 30. Therefore, during the removal process of thefirst mold 30, a portion of the plastic film 20 (i.e. the first sidewall 200) is pushed by the firstlateral surface 32 such that therestorer 50 is moved from an initial position to a final position (along a direction indicated by an arrow b). - Afterwards, as shown in
FIGS. 7 and 8 , because therestorer 50 has flexibility, when therestorer 50 is pushed outwardly by the firstlateral surface 32 and theplastic film 20 together, therestorer 50 stores a flexible restoring force. Until the firstlateral surface 32 is completely removed from theplastic film 20, therestorer 50 starts to release the flexible restoring force to move theplastic film 20 from the final position to the initial position (along a direction indicated by an arrow c). In this way, before thecarrier tray 10 is solidified, thefirst sidewall 200 is returned to the initial position, thereby avoiding defects. - After that, as shown in
FIGS. 9 to 10 , after the step of removing thefirst mold 30 from theplastic film 20 and before the step of cooling theplastic film 20, thesecond mold 60 and therestorer 50 are separated from theplastic film 20 respectively. After that, theplastic film 20 is cooled to obtain the above-mentionedcarrier tray 10. - The above-mentioned method for manufacturing the
carrier tray 10 is described at a side of thecarrier tray 10 and that of thefirst mold 30. The following describes another side of thecarrier tray 10 and that of thefirst mold 30 together. Please refer toFIGS. 4 to 10 and 14 and 15 together. In this embodiment, thefirst mold 30 has a secondlateral surface 35 which is at an opposite side of the firstlateral surface 32. Thetop surface 31 comprises asecond edge 36. Thefirst edge 34 and thesecond edge 36 face to each other. The secondlateral surface 35 extends from thesecond edge 36. A second included angle θ2 is formed between the secondlateral surface 35 and thetop surface 31. For example, the second included angle θ2 is between 73 to 78 degrees. By completely imitating the above-mentioned method for manufacturing, thecarrier tray 10 comprises asecond sidewall 400 whose shape corresponds to that of the secondlateral surface 35. Thesecond sidewall 400 extends from thesecond side edge 130, and the containingroom 120 and thesecond sidewall 400 are disposed on the same side of thetop plate 100. Thesecond sidewall 400 and thetop plate 100 have the same second included angle θ2, and when thefirst mold 30 is removed from theplastic film 20, thesecond sidewall 400 is also pushed by the secondlateral surface 35 to move therestorer 50 from an initial position to a final position (along a direction indicated by an arrow b). In addition, until the secondlateral surface 35 is completely removed from theplastic film 20, therestorer 50 is also pushed back to the initial position from the final position (along a direction indicated by an arrow c). However, the amount of thesidewalls top plate 100 and the position of thesidewalls - The shapes of the
carrier tray 10 are not limited to the above-mentioned embodiments. In other embodiments, thecarrier trays 10 further have other kinds of stacked structures. Moreover, therestorer 50 is not limited to the ring-shaped structure according to the above-mentioned embodiments. In other embodiments, therestorer 50 further has other kinds of structure. Please refer toFIGS. 11A to 13 and 16 to 17.FIGS. 11A , 12 and 13 are cross-sectional schematic views of a step of removing a first mold in a method for manufacturing a carrier tray according to another embodiment.FIG. 11B is a perspective schematic view of a portion of a first mold inFIG. 11A .FIG. 16 is a perspective schematic view of a carrier tray according to another embodiment.FIG. 17 is a cross-sectional schematic view of a carrier tray along a cross-sectional line 17-17 inFIG. 16 . The method for manufacturing in this embodiment is similar to that inFIG. 3 , so only the differences are described herein. - In this embodiment, the
first mold 30 comprises a thirdlateral surface 37 and a fourthlateral surface 38. Thetop surface 31 comprises amain body 39 and a protrudingpart 40. The protrudingpart 40 extends from themain body 39 toward outside themain body 39. The protrudingpart 40 comprises athird edge 41 and afourth edge 42. Thethird edge 41 and thefourth edge 42 face to each other. The thirdlateral surface 37 is connected to thetop surface 31 and extends from thethird edge 41. The fourthlateral surface 38 is connected to thetop surface 31 and extends from thefourth edge 42. The thirdlateral surface 37 and thetop surface 31 form a third included angle θ3 therebetween. The fourthlateral surface 38 and thetop surface 31 form a fourth included angle θ4. In this embodiment, the third included angle θ3 and the fourth included angle θ4 are between 73 and 78 degrees. Themain body 39 in this embodiment may also comprise a recession (not shown), and the structure of the recession is similar to that of therecession 33 inFIG. 4 . - Because the softened
plastic film 20 has the plastic deformation properties, theplastic film 20 may be attached to thefirst mold 30 to be deformed into acarrier tray 10. In this way, thecarrier tray 10 comprises athird sidewall 500 and afourth sidewall 600, and thetop plate 100 comprises aprimary body 140 and a sticking outpart 150. The shape of thethird sidewall 500 corresponds to that of the thirdlateral surface 37. The shape of thefourth sidewall 600 corresponds to that of the fourthlateral surface 38. The shape of theprimary body 140 corresponds to that of themain body 39. The shape of the sticking outpart 150 corresponds to that of the protrudingpart 40. Theprimary body 140 may further comprise a containing room (not shown) corresponding to the recession. The sticking outpart 150 comprises athird side edge 151 and afourth side edge 152. Thethird sidewall 500 is connected to thetop plate 100 and extends from thethird side edge 151. Thefourth sidewall 600 is connected to thetop plate 100 and extends from thefourth side edge 152. The containing room, thethird sidewall 500 and thefourth sidewall 600 are disposed on the same side of thetop plate 100. Thethird sidewall 500 and thetop plate 100 form a third included angle θ3 therebetween. Thefourth sidewall 600 and thetop plate 100 form a fourth included angle θ4 therebetween. - Before the
first mold 30 is removed from theplastic film 20, arestorer 50 is needed to be disposed on an outer side of thefirst mold 30 in advance such that not only a portion of theplastic film 20 attached to the thirdlateral surface 37 is disposed between the thirdlateral surface 37 and therestorer 50 but also another portion of theplastic film 20 attached to the fourthlateral surface 38 is disposed between the fourthlateral surface 38 and therestorer 50. In this embodiment, therestorer 50 comprises twoflexible components 52 and two restoringwork pieces 53. An end of each of the twoflexible components 52 is disposed on two fixedsurfaces 70, respectively. The other end of each of the twoflexible components 52 is connected to the two restoringwork pieces 53, respectively. One of the two restoringwork pieces 53 faces the thirdlateral surface 37, and the other restoringwork piece 53 faces the fourthlateral surface 38. - However, when the
first mold 30 is removed from theplastic film 20, thethird sidewall 500 and thefourth sidewall 600 are also pushed by the thirdlateral surface 37 and the fourthlateral surface 38 such that the two restoringwork pieces 53 are moved to a final position from an initial position, respectively (along a direction indicated by an arrow d). After that, until the thirdlateral surface 37 and the fourthlateral surface 38 are completely removed from theplastic film 20, the two restoringwork pieces 53 also pushes thethird sidewall 500 and thefourth sidewall 600 from the final position to the initial position (along a direction indicated by an arrow e). - Please refer to
FIGS. 18 to 19 .FIG. 18 is a cross-sectional schematic view of stacked carrier trays ofFIG. 15 .FIG. 19 is a cross-sectional schematic view of stacked carrier trays ofFIG. 17 . In thecarrier tray 10 manufactured by the above-mentioned method, each included angle formed between thetop plate 100 and thesidewalls carrier tray 10 manufactured according to the embodiments is less than the included angles of a conventional carrier tray, the proportion of the contact area (the lap between the two carrier trays) between each of thesidewalls upper carrier tray 10 and thetop plate 100 of thelower carrier tray 10 is increased, thereby advancing the whole structural strength of thecarrier trays 10 overlapped with each other. - To sum up, the method for manufacturing the carrier tray according to the embodiments is that before the first mold is removed, the restorer is disposed and leaned against the outer sidewall of the plastic film in advance, so when the first mold is removed, the restorer may provide an adverse flexible restoring force to push the plastic film to the original initial position. Therefore, the carrier tray manufactured by the method has the included angles formed by the top plate and each of the sidewalls therebetween and are between 73 to 78 degrees.
- Moreover, in the carrier tray disclosed in the embodiments, the acute angles of between 73 to 78 degrees formed between the top plate and each of the sidewall is utilized to increase the distance between the sidewall of the upper carrier tray and the side edge of the top plate of the lower carrier tray, thereby, increasing the whole structural strength of the carrier tray overlapped with each other.
- Note that the specifications relating to the above embodiments should be construed as exemplary rather than as limitative of the present invention, with many variations and modifications being readily attainable by a person of average skill in the art without departing from the spirit or scope thereof as defined by the appended claims and their legal equivalents.
Claims (4)
1. A carrier tray, comprising:
a top plate including a first side edge and a containing room; and
a first sidewall connected to the top plate and extended from the first side edge, the containing room and the first sidewall being disposed on the same side of the top plate, and the first sidewall and the top plate forming a first included angle of between 73 and 78 degrees therebetween.
2. The carrier tray according to claim 1 , further comprising a base connected to the first sidewall such that the first sidewall is disposed between the base and the top plate.
3. The carrier tray according to claim 1 , further comprising a second sidewall, the top plate comprising a second side edge facing the first side edge, wherein the second sidewall extends from the second side edge, the containing room and the second sidewall are disposed on the same side of the top plate, and the second sidewall and the top plate form a second included angle of between 73 and 78 degrees therebetween.
4. The carrier tray according to claim 1 , further comprising a third sidewall and a fourth sidewall, the top plate comprising a primary body and a sticking out part, wherein the containing room is disposed on the primary body, the sticking out part extends from the primary body toward outside the primary body, the sticking out comprises a third side edge and a fourth side edge facing to each other, the third sidewall is connected to the top plate and extends from the third side edge, the fourth sidewall is connected to the top plate and extends from the fourth side edge, the containing room, the third sidewall and the fourth sidewall are disposed on the same side of the top plate, the third sidewall and the top plate form a third included angle of between 73 and 78 degrees therebetween, and the fourth sidewall and the top plate form a fourth included angle of between 73 and 78 degrees therebetween.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US14/622,607 US20150158664A1 (en) | 2012-06-01 | 2015-02-13 | Carrier tray |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
TW101119837 | 2012-06-01 | ||
TW101119837A TWI443053B (en) | 2012-06-01 | 2012-06-01 | Carrier tray and thereof manufacture method |
US13/594,427 US8986589B2 (en) | 2012-06-01 | 2012-08-24 | Carrier tray and method for manufacturing thereof |
US14/622,607 US20150158664A1 (en) | 2012-06-01 | 2015-02-13 | Carrier tray |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US13/594,427 Division US8986589B2 (en) | 2012-06-01 | 2012-08-24 | Carrier tray and method for manufacturing thereof |
Publications (1)
Publication Number | Publication Date |
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US20150158664A1 true US20150158664A1 (en) | 2015-06-11 |
Family
ID=47051568
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Application Number | Title | Priority Date | Filing Date |
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US13/594,427 Active 2033-02-07 US8986589B2 (en) | 2012-06-01 | 2012-08-24 | Carrier tray and method for manufacturing thereof |
US14/622,607 Abandoned US20150158664A1 (en) | 2012-06-01 | 2015-02-13 | Carrier tray |
Family Applications Before (1)
Application Number | Title | Priority Date | Filing Date |
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US13/594,427 Active 2033-02-07 US8986589B2 (en) | 2012-06-01 | 2012-08-24 | Carrier tray and method for manufacturing thereof |
Country Status (3)
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US (2) | US8986589B2 (en) |
CN (1) | CN102756862B (en) |
TW (1) | TWI443053B (en) |
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Also Published As
Publication number | Publication date |
---|---|
US20130319905A1 (en) | 2013-12-05 |
TWI443053B (en) | 2014-07-01 |
TW201350404A (en) | 2013-12-16 |
US8986589B2 (en) | 2015-03-24 |
CN102756862B (en) | 2014-10-08 |
CN102756862A (en) | 2012-10-31 |
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