Packing module and packing assembly having the same

Description

CLAIM OF PRIORITY

This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C.§119 from an application for PACKING MODULE AND PACKING ASSEMBLY COMPRISING THE SAME earlier filed in the Korean Intellectual Property Office on 2 Sep. 2005 and there duly assigned Serial No. 10-2005-0081756.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a packing module and a packing assembly having the same.

2. Description of the Related Art

Recently, display devices that use liquid crystal display panels or plasma display panels (hereinafter “display panels”) have received attention due to their excellent characteristics, such as high image quality, super slim shape, light weight, and wide viewing angle with a large screen size. The display panels also include signal transmitting members, driving circuit boards, or power supply units. Hereinafter, a display module denotes a final product in which a display panel, a chassis base that supports the display panel, and driving units are coupled. Also, the display module can be a chassis itself, or a chassis that further includes the signal transmitting members, the driving circuit boards, or the power supply units.

A packing assembly includes a plurality of plasma display modules transported in a box-shaped container in an upright position. However, when the plasma display modules are vertically positioned, the weight of the plasma display modules are concentrated along their sides. Therefore, the plasma display modules can be easily damaged by vibrations or external shock and can be bent due to their own weight. To solve this problem, an additional buffer material is placed in the container. However, since the buffer material occupies an internal space of the container, the number of plasma display modules that can be loaded in the container is reduced. Accordingly, the cost of the buffer material and the reduced number of the plasma display modules in each container increase the transportation cost of the plasma display modules. Therefore, there is a need to develop a new packing assembly that can safely pack the plasma display modules and increase a loading rate thereof.

SUMMARY OF THE INVENTION

It is therefore an object of the present invention to provide an improved packing assembly used to carry plasma display panels.

It is also an object of the present invention to provide a packing module that can reduce transportation costs by increasing a loading rate of display modules and a packing assembly having the packing module.

It is further an object of the present invention to provides a display module packing module that can safely transport display modules without damaging them and a packing assembly having the same.

According to an aspect of the present invention, there is provided a packing module comprising a seating unit adapted to seat at least one display module, a first frame unit adapted to surround at least a portion of the at least one display module, and a protection member arranged between a signal transmitting member of one of the at least one display module and the first frame unit. The seating unit can include a plurality of protrusions. The plurality of protrusions can be arranged along the seating unit. An opening can be arranged in at least one portion of the seating unit. An anti-sliding layer can be arranged on a portion of the seating unit and adapted to contact one of the at least one display module. The first frame unit can include a taper part adapted to guide one of the at least one display module on an inner surface of the first frame unit. The first frame unit can include a plurality of grabbing grooves on an inner surface thereof and adapted to accommodate one of the at least one display module. The seating unit and the first frame unit can be integrally arranged together. The seating unit and the first frame unit can be made of different materials. The first frame unit can have a greater strength than the seating unit.

The packing module can also include a second frame unit adapted to surround at least a portion of the first frame unit. The first frame unit and the second frame unit can be integrally arranged together. The first frame unit, the second frame unit, and the seating unit can be integrally arranged together. The second frame unit can have a greater strength than that of the first frame unit. The signal transmitting member can be a flexible printed cable. The signal transmitting member can be a tape carrier package. The protection member can be mounted on the first frame unit. The protection member can include a plurality of fixing plates and the first frame unit comprises a plurality of fixing protrusions. The protection member can be mounted on a chassis of one of the at least one display module. The protection member can also have further an exhaust pipe fixing hole arranged at an end of the protection member, the exhaust pipe fixing hole being adapted to accommodate insertion of an exhaust pipe of the display module. The protection member can include a first protection unit and a second protection unit coupled to the first protection unit. One of the first protection unit and the second protection unit can have at least one coupling groove and the other can have a plurality of coupling protrusions adapted to couple the at least coupling groove. The protection member can be made out of a synthetic resin.

According to another aspect of the present invention, there is provided a packing assembly that includes a plurality of display modules and a plurality of packing modules stacked on top of one another, each packing module includes a seating unit adapted to seat at least one of the plurality of display modules, a first frame unit adapted to surround at least a portion of the at least one of the plurality of display modules and a protection member arranged between a signal transmitting member of the at least one of the plurality of display modules and the first frame unit. A plurality of the seating units can be horizontally arranged in each of the plurality of packing modules. Each of the plurality of display modules can be horizontally seated in a corresponding one of the plurality of seating units. The packing assembly can also include a plurality of fixing protrusions arranged on a lower part of each of the plurality of seating units. The packing assembly can also include a plurality of connection members adapted to fix together the plurality of packing modules stacked on top of one another. Each of said plurality of connection members can include a main body in the shape of a hollow cylinder and a wing part arranged around a circumference of the main body. The packing assembly can also include a cover coupled to an upper part of an uppermost one of the plurality of packing modules. A portion each of the plurality of display modules corresponding to a non-display region thereof can contact a corresponding seating unit. Each of the packing modules can also include a second frame unit adapted to surround at least a portion of the first frame unit.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the invention and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference symbols indicate the same or similar components, wherein:

FIG. 1 is a schematic perspective view of a packing assembly for the transportation of plasma display modules;

FIG. 2 is an exploded perspective view of a packing assembly according to an embodiment of the present invention;

FIG. 3 is a cross-sectional view taken along a line III-III of FIG. 2;

FIG. 4 is a perspective view of a protection member according to an embodiment of the present invention;

FIG. 5 is an exploded perspective view of a stacked structure of packing modules of FIG. 2 according to an embodiment of the present invention;

FIG. 6 is an enlarged perspective view of a connection member depicted in FIG. 5 according to an embodiment of the present invention;

FIG. 7 is a cross-sectional view of a packing assembly according to an embodiment of the present invention;

FIG. 8 is an exploded perspective view of a modified version of the protection member according to an embodiment of the present invention; and

FIG. 9 is a front view of the modified version of the protection member according to another embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, a plurality of plasma display modules 10 are transported in a box-shaped container 90 in an upright position. However, when the plasma display modules 10 are vertically positioned, the weight of the plasma display modules 10 is concentrated along their sides. Therefore, the plasma display modules 10 can be easily damaged by vibrations or external shock and can be bent due to their own weight. To solve this problem, an additional buffer material can be placed in the container 90. However, since the buffer material occupies an internal space of the container 90, the number of plasma display modules 10 that can be loaded in the container 90 is reduced. Accordingly, the cost of the buffer material and the reduced number of the plasma display modules 10 in each container 90 increase the transportation cost of the plasma display modules 10.

Turning now to FIGS. 2 and 3, FIG. 2 is an exploded perspective view of a packing module 100 according to an embodiment of the present invention, and FIG. 3 is a cross-sectional view taken along a line III-III of FIG. 2. The packing module 100 includes a seating unit 110, a first frame unit 120, a second frame unit 130, and a protection member 140. Each of a plurality of display modules 150 is seated in each of the seating units 110, and the first frame unit 120 is formed to surround respectively the display modules 150 and the seating unit 110.

The display module 150 is a plasma display module, and includes a plasma display panel 151 consisting of a first substrate 151a and a second substrate 151b, a chassis 152 that supports the plasma display panel 151 and includes a chassis bending unit 152a on an edge thereof, a cover plate 153 mounted on the chassis bending unit 152a, a circuit board 154 that includes circuit devices and is disposed on the chassis 152, a dual adhesive tape 155 that connects the plasma display panel 151 to the chassis 152, a heat conduction sheet 156 disposed between the plasma display panel 151 and the chassis 152, and signal transmitting members 157 that electrically connect the plasma display panel 151 and the circuit board 154. The signal transmitting members 157 can be flexible printed cables (FPC) or a tape carrier package (TCP).

In the present embodiment, the display module 150 is a plasma display module, but the present invention is not limited thereto. That is, the display modules of the present invention can be other various display modules, such as a liquid crystal display module.

The display module 150 loaded into the packing module 100 according to the present embodiment has a configuration as described above, but the present invention is not limited thereto. That is, in the display module 150 loaded into the packing module 100 according to the present embodiment, only the plasma display panel 151 is loaded, but a coupled state of the plasma display panel 151 to the chassis 152, a coupled state of the plasma display panel 151, the chassis 152, and the circuit board 154, or a complete product that includes the plasma display panel 151 can be loaded onto the packing module 100. Also, only the chassis 152 or the chassis 152 to which the circuit board 154 is coupled can be loaded into the packing module 100.

The seating unit 110 according to the current embodiment of the present invention is horizontally disposed with respect to the packing module 100, but the present invention is not limited thereto. That is, the seating unit 110 can be disposed at an inclination with respect to the packing module 100. The seating unit 110 has an opening 110a at a central portion thereof, and, overall, has a closed loop shape. The opening 110a reduces the weight of the seating unit 110 and increases the loading space, thereby allowing better workability.

In the present embodiment, the packing module 100 includes two horizontally seated seating units 110, each having the same structure, and accordingly, two display modules 150 can be accommodated in one packing module 100. But the present invention is not limited thereto, as the packing module 100 can instead include one seating unit 110 or three or more seating units 110 disposed horizontally.

A plurality of protrusions 111 are discontinuously formed along the seating unit 110. The protrusions 111 allow the display modules 150 to be safely seated on the seating unit 110 and act as a buffer that prevents the display modules 150 from being damaged by vibrations or shock during transportation. The protrusions 111 can be integrally formed with the seating unit 110.

An anti-sliding layer 112 having a predetermined thickness can be formed on the seating unit 110. The anti-sliding layer 112 prevents the plasma display module 150 from sliding, and can be formed by coating silicon or resin of a rubber group on the seating unit 110. The anti-sliding layer 112 can also be formed on the plasma display module 150 where the plasma display module 150 directly contacts the seating unit 110. The anti-sliding layer 112 can be made out of silicon or rubber, but the present invention is not limited thereto. That is, the anti-sliding layer 112 can instead be made out of any material that can prevent the display module 150 from sliding, for example, a polyurethane resin or an acryl resin, etc.

Turning now to FIGS. 3 and 5, a fixing protrusion 113 is formed on a lower part of each of the seating units 110. The fixing protrusion 113 fixes the display module 150 seating in the lower packing module 100 when the packing modules 100 are stacked on top of one another.

Taper part 120a is formed on an inner surface of the first frame unit 120. The taper part 120a has a downward slope to guide the plasma display module 150 along the taper part 120a for seating the display module 150 in the seating unit 110, thereby improving work efficiency.

As illustrated in FIG. 2, the first frame unit 120 includes a plurality of grabbing grooves 120b for easily seating the display module 150 in the seating unit 110. Accordingly, the display module 150 can be easily lifted by inserting a hand in the grabbing grooves 120b.

The first frame unit 120 can be made out of the same material as the seating unit 110 and can be integrally formed with the seating unit 110. More specifically, the seating unit 110 and the first frame unit 120 can be made out of expanded polypropylene (EPP) with a density of 25 to 35 kg/m³.

The seating unit 110 and the first frame unit 120 according to the present embodiment are made out of EPP, but the present invention is not limited thereto. That is, there are no specific limitations in selecting the material for forming the seating unit 110 and the first frame unit 120, and the seating unit 110 and the first frame unit 120 can be made out of different materials from each other. For example, the first frame unit 120 can be made out of EPP and the seating unit 110 can be made out of expanded polyethylene (EPE). Also, the first frame unit 120 can have a greater strength than the seating unit 110.

In the present embodiment, the first frame unit 120 and the seating unit 110 are integrally formed with each other, but the present invention is not limited thereto. That is, the first frame unit 120 and the seating unit 110 can instead be coupled together using an adhesive after the first frame unit 120 is manufactured separately from the seating unit 110.

The second frame unit 130 formed to surround the first frame unit 120 can be made out of the same material as the first frame unit 120, but can be formed to have a greater strength by having a higher density than that of the first frame unit 120. That is, the second frame unit 130 can be made out of EPP having a density of 60 to 70 kg/m³ to have a strength greater than the first frame unit 120 and the seating unit 110. This is because the second frame unit 130 maintains an overall skeleton of the packing module 100 and prevents damage of the display module 150 from an external shock. Also, since the seating unit 110 and the first frame unit 120 directly contact or can contact the display module 150, the seating unit 110 and the first frame unit 120 can be made out of a relatively soft material.

According to the present embodiment, the first frame unit 120 and the second frame unit 130 are separately manufactured, and afterward, they are coupled together using an adhesive, but the present invention is not limited thereto. That is, the first frame unit 120 and the second frame unit 130 can be integrally formed with each other. Also, the seating unit 110, the first frame unit 120, and the second frame unit 130 can be integrally formed with each other.

A plurality of ribs 130a and coupling protrusions 130c are formed along the second frame unit 130. The ribs 130a increase the strength of the second frame unit 130. Grooves 130b are formed between the ribs 130a to reduce the weight of the second frame unit 130. Connection holes 131 that penetrate the second frame unit 130 are formed on corners of the second frame unit 130. Connection members 171 are inserted into the connection holes 131.

The protection member 140 is mounted on the first frame unit 120. To mount the protection member 140, a plurality of fixing protrusions 121 are discontinuously formed on the first frame unit 120.

The protection member 140 has a shape as depicted in FIG. 4. That is, the protection member 140 has a “” shaped cross-sectional view to protect the signal transmitting members 157.

The protection member 140 includes fixing plates 141 which are inserted into the fixing protrusions 121 of the first frame unit 120 to attach the protection member 140 to the first frame unit 120. An exhaust pipe fixing hole 142 is formed in an end of the protection member 140 so that an exhaust pipe 151c of the plasma display panel 151 can be inserted therethrough.

The protection member 140 serves to protect flexible printed cables of the signal transmitting members 157 while the tape carrier package is protected by the cover plate 153 which is mounted to protect integrated circuit chips. However, to completely protect the signal transmitting members 157, the protection member 140 can also be used in addition to the cover plate 153.

In the present embodiment, the protection member 140 has a “” shape, but the present invention is not limited thereto. That is, the protection member 140 can be any shape as long as the protection member 140 can protect the signal transmitting members 157 of the display module 150.

In the present embodiment, the protection member 140 is mounted on the first frame unit 120, but the present invention is not limited thereto. That is, the protection member 140 can also be mounted on the chassis 152.

In the present embodiment, the protection member 140 includes the fixing plates 141 to mount the protection member 140 to the first frame unit 120, but the present invention is not limited thereto. That is, the protection member 140 can instead include simple holes to be coupled to the fixing protrusions 121 of the first frame unit 120. Also, the protection member 140 can include mounting protrusions and the first frame unit 120 can include mounting holes corresponding to the mounting protrusions of the protection member 140 for coupling, or the first frame unit 120 and the protection member 140 can be coupled using an additional adhesive element.

Also, the exhaust pipe fixing hole 142 is formed in an end of the protection member 140 so that the exhaust pipe 151c of the plasma display panel 151 can be inserted therethrough. However, there is no requirement for an exhaust pipe fixing hole 142 when the protection member 140 is mounted on a side of the display module 150 where there is no exhaust hole.

Also, the protection member 140 according to the present embodiment is made out of a synthetic resin, but the present invention is not limited thereto. That is, the protection member 140 can be made out of any metal having sufficient strength to protect the signal transmitting members 157 from shock.

Turning now to FIG. 5, FIG. 5 is an exploded perspective view of a stacked structure of the packing modules 100 of FIG. 2 according to an embodiment of the present invention. In FIG. 5, to show the stacking state of the packing modules 100, the display module 150 and the protection member 140 are excluded.

Referring to FIG. 5, the packing modules 100 are stacked on top of one another, and the packing modules 100 are fixed together using connection members 171, which will now be described in detail. As described above, the second frame unit 130 includes connection holes 131, and one connection member 171 is inserted into each connection hole 131 to join together the packing modules 100.

Turning now to FIG. 6, FIG. 6 is an enlarged perspective view of the connection member 171 depicted in FIG. 5 according to an embodiment of the present invention. Referring to FIG. 6, the connection member 171 includes a main body 173 in the shape of a hollow cylinder and a wing part 174 formed around a circumference of the main body 173. The main body 173 is fitted into the connection hole 131. An upper portion 173a of the main body 173 is inserted into the connection hole 131 of an above packing module 100, and a lower portion 173b of the main body 173 is inserted into the connection hole 131 of a below packing module 100. Therefore, the above packing module 100 and the below packing module 100 can be fixed together.

Also, the protrusions 130c are formed on an upper surface of the second frame unit 130, and concave units (not shown) are formed on a lower surface of the second frame unit 130. When the packing modules 100 are stacked, the protrusions 130c of the upper surface of the second frame unit 130 of a below packing module 100 are inserted into the concave units of the lower surface of the second frame unit 130 of an above packing module 100. Therefore, the connection between the above and below packing modules 100 is reinforced.

Turning now to FIG. 7, FIG. 7 is a cross-sectional view of a packing assembly 200 according to an embodiment of the present invention. The same reference numerals will be used for elements described in the previous embodiments. Referring to FIG. 7, the packing assembly 200 includes a plurality of display modules 150, a plurality of packing modules 100 and 400, and a cover 270.

The display modules 150 are horizontally loaded in loading spaces 160 and 460 defined by seating units 110 and 410 of each of the packing modules 100 and 400. More specifically, a front face of a plasma display panel 151 is seated on protrusions 111 of the seating unit 110, or more precisely, on an anti-sliding layer 112.

The display modules 150 according to the present embodiment are loaded horizontally with respect to the packing module 100 and are horizontally oriented during transportation, but the present invention is not limited thereto. That is, the seating unit 110 of the packing modules 100 may not be horizontally formed. In this case, the display modules 150 are not horizontally loaded with respect to the packing modules 100. Also, even if the display modules 150 are horizontally loaded in the packing modules 100, the display modules 150 can be transported on a slant due to limited space.

A non-display region S of the plasma display panel 151 can be seated on the anti-sliding layer 112. This is because when the packing modules 100 and 400 and a display region D of the plasma display panel 151 directly contact each other, an internal structure or of the plasma display panel 151 can be damaged or a surface of the plasma display panel 151 can be scratched.

In particular, when a film filter (not shown) is attached to the front face of the plasma display panel 151, portions of the film filter corresponding to the non-display region S of the plasma display panel 151 can be seated on the anti-sliding layer 112. When the film filter is attached mainly to the display region D of the plasma display panel 151, the non-display region S of the plasma display panel 151 can be directly seated on the anti-sliding layer 112.

A first frame unit 120 can have a height sufficient to accommodate the display module 150 and can prevent the display module 150 from moving when the packing assembly 200 is transported. Also, as described above, a protection member 140 formed on the first frame unit 120 protects the signal transmitting members 157 and effectively absorbs impact the display modules 150 receive during transportation, and prevents the display modules 150 from moving during transportation.

Also, a plurality of fixing protrusions 113 are discontinuously formed on a lower surface of the seating unit 110. The fixing protrusions 113 are stacked to press either the chassis bending unit 152a or the cover plate 153 of the display module 150 when in the packing module 100. Accordingly, the display modules 150 are further safely fixed in the packing assembly 200.

Accordingly, the display modules 150 can be disposed without an additional buffer material, thereby increasing the number of display modules 150 that can be loaded in the packing assembly 200. This results in a reduction of packing and transportation costs for the packing assembly 200.

The seating unit 410 of the lowermost packing module 400 does not have an opening 110a. This lack of an opening is to prevent moisture or dust from entering the seating space 460 since the moisture or dust can damage the display modules 150. However, other portions of the packing module 400 have the same structure as the packing module 100 depicted in FIG. 2, and thus, detailed descriptions thereof are omitted.

A cover 270 is coupled to the uppermost packing modules 100. The cover 270 prevents the display modules 150 from being damaged by moisture or dust infiltrating into the seating space 160. Cover fixing protrusions 270a that perform the same function as the fixing protrusion 113 are formed on an inner surface of the cover 270. The cover 270 can be made out of substantially the same material as a second frame unit 130 of the packing module 100.

A modified version of the protection member 140 will now be described with reference to FIGS. 8 and 9. FIG. 8 is an exploded perspective view of a modified protection member 540 and FIG. 9 is a front view of a modified protection member 540 according to another embodiment of the present invention. The protection member 540 includes a first protection unit 541 and a second protection unit 542 coupled to the first protection unit 541.

The first protection unit 541 essentially protects the signal transmitting members 157 on a circuit board 154 side of the display module 150, and the second protection unit 542 essentially protects the signal transmitting members 157 on the plasma display panel 151 side of the display module 150. The first protection unit 541 includes coupling grooves 541 b and the second protection unit 542 includes coupling protrusions 542b. The first protection unit 541 and the second protection unit 542 are coupled together by inserting the coupling protrusions 542b into the coupling grooves 541b of the first protection unit 541.

In the present embodiment, the first protection unit 541 includes the coupling grooves 541b and the second protection unit 542 includes the coupling protrusions 542b, but the present invention is not limited thereto. That is, the first protection unit 541 can include the coupling protrusions 542b and the second protection unit 542 can include the coupling grooves 541b, or the first protection unit 541 and the second protection unit 542 can be coupled using an adhesive without using the coupling protrusions 542b and the coupling grooves 541b. The first protection unit 541 can include first reinforcing ribs 541a to increase the rigidity of the first protection unit 541, and the second protection unit 542 can also include second reinforcing ribs 542a to increase the rigidity of the second protection unit 542.

When the packing modules 100 are structured using the protection member 540 as described above, the signal transmitting members 157 are disposed on an inner side of the protection member 540. At this time, the protection member 540 protects the signal transmitting members 157 by being mounted on the chassis 152 (not shown) of the display module 150 or by being inserted between the chassis 152 and the first frame unit 120.

Accordingly, the protection member 540 having the above structure can further safely protect the signal transmitting members 157 by including the first protection unit 541 that protects the signal transmitting members 157 near the circuit board 154 and the second protection unit 542 that protects the signal transmitting members 157 near the plasma display panel 151.

The packing modules and the packing assembly according to the present invention have the following advantages. First, the packing assembly has a large seating space since the display modules are loaded without buffer materials. Therefore, a larger number of display modules can be loaded than before in a similar-sized packing assembly, thereby reducing packing costs and transportation costs. Second, since the display modules are safely seated in a packing module, damage to the display modules can be prevented when the packing assembly is packed or transported.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and details can be made therein without departing from the spirit and scope of the present invention as defined by the following claims.