Abstract:
Packaging for a display module which is easy to install due to a simple structure, and protects the front, sides and back of the display module securely. The packaging includes a protective plate attached to the back of the panel module. The panel module includes a display panel, a chassis member and one or more circuit boards. The protective plate protects the back and sides of the panel module. The packaging also includes spacers placed between the protective plate and the chassis of the panel module and compensate for the clearance between the protective plate and the chassis of the panel module.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This application claims priority to and the benefit of Korean Patent Application No. 10-2003-0062750 filed on Sep. 8, 2003 in the Korean Intellectual Property Office, the entire content of which is incorporated herein by reference. 
   BACKGROUND OF THE INVENTION 
   (a) Field of the Invention 
   The present invention relates to packaging for display units, and in particular, to a lightweight and thin plasma display apparatus with a large screen, and to packaging for packing the plasma display unit including a plasma display module. 
   (b) Description of the Related Art 
   In general, plasma display units are light emitting devices which include two glass substrates sandwiched together and sealed to each other, and which display an image using a gas discharge between the glass substrates. Plasma display units have many applications, such as a television, a monitor and an advertising display used outdoors, and these apparatus has received much attention as a direct-view image display with a large screen for the High Definition Television (HDTV) era due to its favorable features such as its fast response, its easy enlargement of the screen, and its simple manufacturing process resulting from the lack of a need for an active element in each cell. 
   Plasma display units are usually classified into alternating current (AC) types and direct current (DC) types with respect to driving power, and surface discharge types and face discharge types with respect to gas discharge. At present, AC and surface discharge type plasma display apparatus are dominant because of their higher resolution, larger screen size and simpler manufacturing. 
   A plasma display unit includes a plasma display panel (hereinafter referred to as “PDP”) having a pair of transparent glass substrates facing each other to form discharge spaces; and having groups of electrodes placed thereon. A chassis member supports the PDP. A driving circuit board is attached to the chassis member for sending signals to the PDP. Such a plasma display unit may also be housed in a main case. 
   In contrast to other display devices, it is necessary to consider a way to transport the panel module which has large glass substrates as the main components. 
   Recently, sizes of PDP&#39;s has increased and manufacturing these large PDP&#39;s requires a large-scale facility. Thus, PDP manufacturers produce the panel module only while plasma display unit manufacturers compile plasma display units by adding other circuit blocks purchased from PDP manufacturers to the panel module, and assembling them into the main case. 
   During the transport of PDP&#39;s from the PDP manufacturer to the plasma display unit manufacturer, it is important that measures be taken to avoid damage by shock during the transport. 
   Japanese Laid Open Patent Publication Nos. 2002-302156, 2002-302187 and 2002-302193 disclose packaging structures for transporting a panel module including installing a module support plate made of corrugated cardboard to the back of the PDP module, the cardboard being larger than the outer dimensions of the panel module and covering the panel module. The module support plate is installed by using supporting means having a grooved floor and an outer edge fitted to the size of the PDP. Additionally, a frontal protective cover made of resin is used, the cover being approximately the same size or larger than the frontal frame of the plasma display module. The frontal protective cover contains an antistatic substance to protect the flexible printed circuit (FPC). 
   The aforementioned prior art uses a variety of means to protect the front, sides and back of the module, which is expensive, and requires much time to install because of its complicated structure. 
   SUMMARY OF THE INVENTION 
   In accordance with the present invention, packaging for a plasma display module is provided wherein the packaging is easy to install due to its simple structure. The packaging is designed to protect the front, sides and back of the plasma display module. 
   Further in accordance with the present invention, packaging for a plasma display module is provided that is adaptable to modules of various sizes. 
   In an exemplary embodiment of the present invention, packaging for a plasma display module includes a PDP, a chassis member, and a protective plate encompassing and protecting the back and the sides of the PDP module having a circuit board. 
   The protective plate may have bolting holes and may be fixed to bosses of the chassis member by bolts or other attachment means. 
   Also, the protective plate may have sidewalls formed along its periphery extending toward the PDP. The edges of the sidewalls may protrude a predetermined length over the front of the panel. When attached to the panel module, the inner surface of the sidewalls of the protective plate may be spaced from the panel by a predetermined gap. 
   In one exemplary embodiment, a plurality of reinforcing ribs may be formed on the back of the protective plate. Moreover, jigging holes to move the protective plate and/or attaching planes for vacuum pads may be formed on some places on the front of the protective plate. 
   The protective plate may be made of a plastic material and may also contain an antistatic substance. 
   Another exemplary embodiment of the present invention may also include spacers that are positioned between the protective plate and the chassis member of the panel module to adjust clearance. In a further embodiment the spacer may be attachable to and releasable from the protective plate without a special connecting means such as a screw. Therefore, a releasable hook may be formed on one side of the spacer, and an inserting hole for the hook may be formed on the protective plate. 
   In addition, the packaging for the plasma display module may include an antistatic plastic sheet placed at the back of the protective plate or one that covers the whole panel module, including protective plate. 
   Additionally, in order for the packaging to hold the panel module with the protective plate attached thereto, other exemplary embodiments of the present invention provide for individual packaging for a single panel module and bundle packaging for a plurality of panel modules. 
   For individual packaging, an exemplary embodiment of the present invention includes first and second shock absorbing means with a slot in each means, each shock absorbing means formed substantially identically in shape to a corner of the protective plate to be fitted therein, a first box that the first shock absorbing means may be placed; and a second box encompassing at least an external edge of the first box. 
   In another exemplary embodiment, the boxes are larger in width than the shock absorbing means. The first and second shock absorbing means may have supporting ribs formed on the sides thereof to contact the inner surface of the boxes and to create a space between the shock absorbing means and the boxes for anti-shaking properties. 
   For bundle packaging the structure may include a first box, first shock absorbing means which may be placed in the first box and may have a plurality of slots positioned apart from each other with a predetermined space on each of the first shock absorbing means and formed substantially identically in shape to an end of the protective plate to be fitted therein, second shock absorbing means which are substantially identical in shape to the first shock absorbing means to fit an end of the protective plate into the slot, a second box which may encompass the second shock absorbing means and a side cover encompassing the plurality of protective plates and being located between and contacting a first box external edge and a second box external edge. 
   The shock absorbing means may be made from expanded polypropylene (EPP) which is foamed polypropylene with grains formed by physical foaming instead of chemical foaming. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a perspective view of a packaging for a PDP according to an exemplary embodiment of the present invention. 
       FIG. 2  is a perspective view of the back of packaging for a PDP according to an exemplary embodiment of the present invention. 
       FIG. 3  is a perspective view of a spacer used for a packing equipment according to the exemplary embodiment of the present invention. 
       FIG. 4  is a plan view showing dimensions of packaging and a plasma display module according to an exemplary embodiment of the present invention. 
       FIG. 5  is a schematic diagram of a side cross-section of packaging and a plasma display module according to an exemplary embodiment of the present invention. 
       FIG. 6  is a perspective view of a plastic sheet covering a plasma display module according to an exemplary embodiment of the present invention. 
       FIGS. 7   a  and  7   b  are perspective views of individual plasma display modules according to an exemplary embodiment of the present invention. 
       FIGS. 8   a  and  8   b  are perspective views of bundle packaging for a plurality of plasma display modules according to an exemplary embodiment of the present invention. 
       FIG. 9  is an enlarged partial perspective view, of the packaging shown in  FIG. 8 . 
   

   DETAILED DESCRIPTION 
   As shown in  FIG. 1 , in an exemplary embodiment of the present invention, a protective plate  10  is in a hull shape to accommodate the panel module  100 . As shown in  FIG. 2 , a plurality of ribs  11  are formed on the back of the protective plate  10  to add the strength thereof, and spacers  20  are attached to adjust the space between the panel module  100  and the protective plate  10 . The protective plate  10  is fixed to bosses  110  formed on the chassis of the panel module  100  by bolts  12  passing through the spacers  20 . In a further embodiment, the protective plate  10  is made from a plastic material. 
   In one exemplary embodiment, jigging holes  13  are formed on the protective plate  10  to move the protective plate  10  by a jig. Further, a center opening  14  may be made in the center of the protective plate  10  to save material and reduce the weight of the packaging. Additionally, attaching planes  15  may be formed on either side of the center opening for easy attachment of vacuum pads (now shown). In one exemplary embodiment, the attaching planes  15  may have an area of at least 90mm 2 . 
   In yet another exemplary embodiment, an antistatic substance is coated on the entire surface of the protective plate  10  to protect the panel module from static electricity. Table 1shows the effect of the antistatic coating on static electricity. 
   
     
       
             
           
             
             
             
           
         
             
               TABLE 1 
             
           
           
             
                 
             
             
               Static electricity level. 
             
           
        
         
             
                 
                 
               Surface electric potential 
             
             
                 
                 
               when rubbed arbitrarily 
             
             
               Surface treatment 
               Surface resistance 
               with packing material 
             
             
                 
             
             
               No treatment 
               Greater than 10 12   
               200-5000 V 
             
             
                 
               Ω/□ 
                 
             
             
               With antistatic 
               Less than 10 11  Ω/□ 
               Less than 100 V 
             
             
               coating 
                 
             
             
                 
             
           
        
       
     
   
   Table 1shows evident differences in static electricity levels between packaging with antistatic treatment and no treatment. 
   
     
       
             
           
             
             
             
           
         
             
               TABLE 2 
             
           
           
             
                 
             
             
               Sensitivity of electronic devices to static electricity. 
             
           
        
         
             
                 
               Static electricity 
               Static electricity 
             
             
               Device 
               at breakdown (Volts) 
               at breakdown (Energy) 
             
             
                 
             
             
               MOSFET 
               100~200  
               0.5~2.0 
             
             
               EPROM 
               100 
               0.5 
             
             
               JPET 
               140~7000 
               0.98~2.45 
             
             
               OP-AMP 
               190~2500 
               1.62~31.5 
             
             
               CMOS 
               250~3000 
               3.13~450  
             
             
               BIPOLAR 
               300~7000 
                4.5~2.45 
             
             
               TRANSISTOR 
                 
             
             
                 
             
           
        
       
     
   
   As seen in the Table 2, static electricity influences the quality of the product in the case of a product not having antistatic treatment. 
   As shown in  FIG. 3 , the spacer  20  placed between the protective plate  10  and the panel module  100  has a hook  21  on one end, which can be releasably attached to an inserting hole  17  ( FIG. 1 ) on the protective plate  10 . A through hole  22  for a bolt  12  may be formed at a position on the spacer  20  corresponding to a bolting hole  18  in the protective plate  10 . 
     FIG. 4  and  FIG. 5  show sidewalls  16  formed on the periphery of the protective plate  10 , wherein the sidewalls surround the sides of the panel module  100  for protection. In one exemplary embodiment, the sidewall  16  protrudes over the panel module  100  to a predetermined length h above the surface of the panel module. This allows a space between the sidewalls  16  of the protective plate  10  and the panel module  100 . 
   The clearance allows the protective plate to absorb shocks imposed on it from outside and reduces or prevents the shock from being transferred to the panel module  100 . In one exemplary embodiment, the clearance is set at least at 5mm. 
   The clearance in the horizontal and the vertical directions may be identical or they may be different. For example, as shown in  FIG. 4 , the clearance y in the horizontal direction is larger than the clearance x in the vertical direction because vibrations or droppage cause the displacement of the horizontal sidewall  16  supporting the whole weight of the panel module  100  to be greater than displacement of the vertical sidewall. Additionally, this allows for the horizontal dimension of the protective plate  10  to be minimized for the storage or transportation by a container. 
   Though typically panel modules  100  are about the same size, the bosses in panel modules  100  may vary in height depending on their position. Therefore, it is necessary to make spacers  20  with various heights. Thus, approximately sized spacers  20  may then be selected to attach the protective plate  10  to the panel module  100  and ensure that the sidewall  16  protrudes over the front surface of the panel module  100  by a desired amount. 
   In one exemplary embodiment, the protective plate  10  is fixed to the panel module  100  by the bolts  12 . In a further embodiment, the bolt is put through the bolting hole  18  of the protective plate  10  and through the through hole  22  of the spacer  20  aligned to the boss  110  of the panel module  100 , and tightened to the boss  110 . 
   The bolt  12  may be flush headed so as not to protrude from the front surface of the protective plate  10 . Furthermore, a stepped cavity  19  may be machined into the protective plate  10  to create a recessed area (for example, a countersink) around the bolting hole  18 . 
   In order to prevent the electrostatic injury to workers, the protective plate  10 , as shown in  FIG. 6 , may be covered with a plastic sheet  30  which has been given antistatic treatment. 
     FIGS. 7   a  and  7   b  show packaging for individual panel modules, and  FIG. 7   b  particularly shows packaging for a protective plate  11  affixed to a panel module. 
   In one embodiment, the packaging may include top and bottom shock absorbing means  41 ,  42  having a slot  40  therein. The shock absorbing means  41 ,  42  may be formed identically to the corner of the protective plate  11  to be inserted thereto. The shock absorbing means may be made from, for example, EPP, or any other appropriate material. 
   The packaging may also include a bottom box  43  in which the bottom shock absorbing means  42  are placed and a top box  44  that encompasses the bottom box  43 . The bottom box  43  and the top box  44  may be made from, for example, corrugated cardboard or any other appropriate material. 
   Additionally, the top and bottom shock absorbing means  41 ,  42 , may have supporting ribs  45  formed to contact the inner surfaces of the sidewalls of the top and bottom boxes  43 ,  44 . The supporting ribs  45  provide space between the shock absorbing means  41 ,  42  and the boxes  43 ,  44 , and prevent the protective plate  10  from being shaken inside. 
   In one embodiment, the packaging of a single panel module may occur as follows. The bottom shock absorbing means  42  may be placed in the bottom box  43  with their slots  40  facing up. The protective plate  11  may then be inserted into each slot  40  of the bottom shock absorbing means  42 . Then the top shock absorbing means  41  may be put on top of the protective plate  11 . 
   In one exemplary embodiment, the slot  40  formed in the shock absorbing means  41 ,  42  may be made in a single shape and a single size. This is because the panel module  100  is placed inside the protective plate  10  which has a constant shape, and only the protective plate  11  contacts the slot  40 . Thus, each of the shock absorbing means  41 ,  42  and/or the top and bottom boxes  43 ,  44  may be a common size and shape which is applicable to various panel modules  100 . 
     FIGS. 8   a  and  8   b  show a bundle packaging structure used to pack multiple protective plates containing panel modules. The bundle packaging may include a bottom box  51  laid on a pallet  50 ; and bottom shock absorbing means  52 . The bottom shock absorbing means  52  may be placed along the edges of the bottom box  51  and may have a plurality of slots  53  spaced apart from each other and adapted to receive a protective plate  11  inserted thereto. Additionally, the bundle packing structure may include top shock absorbing means  54  which mirror the shape of the bottom shock absorbing means  52 . In one embodiment, a side cover  55  may be fitted on the outer surface of the sidewall of the bottom box  51 . The side cover  55  may extend to the top shock absorbing means  54 . Further, the bundling packaging structure may include a top box  56  which encompasses the top shock absorbing means  54  and at least part of the side cover  55 . In one exemplary embodiment, the boxes  51 ,  56  may be made from corrugated cardboard and the shock absorbing means  52 ,  54  may be made from EPP. However any other suitable materials may be used. 
   In yet a further exemplary embodiment, a step  57  may be formed on each of the peripheral surfaces of the shock absorbing means  52  and  54 , to guide the boxes  51 ,  56  for secure fitting. The height of the step  57  may be the same as the wall-thickness of the boxes  51 ,  56  which allows one surface of the step to contact to the side cover  55  and one surface to contact the appropriate box  51  or  56 . 
   In another embodiment, as shown in  FIG. 9 , a groove  58  is formed on the inner and/or the outer surfaces of the slot  53  to dampen vibrations caused outside shocks. 
   In an exemplary embodiment, the bundle packaging process using a plurality of protective plates  11  may be as follows. The bottom box  51  is placed on the pallet  50  and the bottom shock absorbing means  52  are positioned at opposite sides of the bottom box  51  with the slots  53  facing up. In one embodiment, the stepped lower surface of the bottom shock absorbing means  52  is flush with the sidewall of the bottom box  51 . 
   The flush surface provides firm contact between the side cover  55  and both the bottom box  51  and the bottom shock absorbing means  52 . 
   Next, each protective plate  11  is, inserted into each slot  53  of the bottom shock absorbing means  52 . 
   After the desired number of protective plates  11  have been inserted into the slots  53  of the bottom shock absorbing means  52 , the side cover  55  is inserted over the bottom box  51 . 
   Then, the top shock absorbing means  54  are placed on top of the protective plates  10  with the slots  53  facing downward. Finally, the top box  56  is put over the top shock absorbing means  54  and covers all of the protective plates  11 . 
   The packing process may be completed by tying the pallet  50 , the side cover  55  and the top box  56  together with bands  60  after putting protection pads  59  on the edges of the top box  56 . The protection pads  59  may aid in preventing damage to the packaging caused by the bands  60 . 
   As explained hereinabove, the protective plate according to the embodiment of the present invention protects the sides, front and back of the panel module from shocks outside and makes the secure transportation possible with the packing equipment. 
   Furthermore, the protective plate can be a common part applicable to the panel modules regardless of the shape of the panel modules. Accordingly, it is possible to save the cost by mass production of the protective plate  10  and to work efficiently. 
   Although exemplary embodiments of the present invention have been described in detail hereinabove, it should be clearly understood that many variations and/or modifications of the basic inventive concept herein taught which may appear to those skilled in the art will still fall within the spirit and scope of the present invention, as defined in the appended claims.