Abstract:
A packing assembly for display modules is disclosed. In one embodiment, the packing assembly includes a plurality of packing modules stacked on one another and configured to receive a plurality of display modules, each packing module comprising a seating unit where the display module is seated and a first rim unit that surrounds at least a portion of each of the display modules and a plurality of protection members covering the circuit unit to prevent the panel from being damaged by a collision between a circuit unit of a display module and a panel of another display module. According to one embodiment, transportation costs are reduced by loading and transporting more display modules in a given packing assembly.

Description:
CROSS-REFERENCE TO RELATED PATENT APPLICATION  
       [0001]     This application claims the benefit of Korean Patent Application No. 10-2005-0081753, filed on Sep. 2, 2005, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. This application also relates to U.S. patent application (Attorney Docket Number: SDIYPL.113AUS) entitled “PACKING MODULE AND PACKING ASSEMBLY COMPRISING THE SAME,” concurrently filed as this application, which is incorporated by reference.  
       BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     The present invention relates to a packing assembly for a display module.  
         [0004]     2. Description of the Related Technology  
         [0005]     Recently, display devices that use a liquid crystal display panel or a plasma display panel have received attention due to their excellent characteristics, such as high image quality, super slim shape, light weight, and a wide viewing angle with a large screen size.  
         [0006]     Hereinafter, a display module denotes a combination of a display panel, a chassis base that supports the display panel, and driving units, or a final product in which a case is added to the combination of the display panel, the chassis base, and the driving units. The display module further denotes a combination of only the circuit units and the chassis base without including the display panel.  
         [0007]      FIG. 1  is a schematic perspective view of a conventional packing assembly for the transportation of plasma display modules.  
         [0008]     Referring to  FIG. 1 , a plurality of plasma display modules  10  are transported in a box shaped container  90  in a upright position. However, when the plasma display modules  10  are vertically positioned, the weight of the plasma display modules  10  is concentrated along sides of the plasma display modules  10 . Therefore, the plasma display modules  10  can be easily damaged by vibrations or external impact and can be bent due to self-weight. To solve this problem, an additional buffer material is disposed 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 .  
       SUMMARY OF CERTAIN INVENTIVE ASPECTS  
       [0009]     One aspect of the present invention provides a display module packing assembly that reduces transportation costs by increasing a loading rate of the plasma display modules for transporting a plurality of plasma display modules. Another aspect of the present invention also provides a display module packing assembly that can safely transport plasma display modules without damaging them.  
         [0010]     Another aspect of the present invention provides a packing assembly comprising: a plurality of display modules, each comprising a panel, a chassis disposed on a rear of the panel to support the panel, and a circuit unit mounted on the chassis, a plurality of packing modules in which the display modules are stacked one another, each packing module comprising a seating unit where the display module is seated and a first rim unit that surrounds at least a portion of each of the display modules and a plurality of protection members each covering the circuit unit of each display module to prevent the panel from being damaged by a collision between a circuit unit of a display module and a panel of another display module.  
         [0011]     Each of the display modules may comprise a plurality of circuit units and the protection member may cover the highest circuit unit from the chassis among the circuit units.  
         [0012]     Each of the display modules may comprise a plurality of circuit units and the protection member may cover the nearest circuit unit from a central portion of the chassis among the circuit units.  
         [0013]     In one embodiment, the protection member is formed of expanded polypropylene (EPP), expanded polyethylene (EPE), or expanded polyurethane (EPU).  
         [0014]     Another aspect of the invention provides a packing assembly for display modules, comprising: a plurality of stacked packing modules configured to receive a plurality of display modules, wherein each packing module comprises a seating unit configured to receive a respective display module, wherein the seating unit includes a protrusion extending toward an adjacent display module, and wherein the protrusion contacts at least a portion of the adjacent display module so as to minimize movement of the adjacent display module.  
         [0015]     Still another aspect of the invention provides a method of using a packing assembly for display modules, comprising: i) providing a plurality of stacked packing modules, each packing module comprising a seating unit where a respective display module is seated and a rim unit that surrounds at least a portion of each of the display modules, ii) placing a plurality of display modules in a respective seating unit and iii) covering a circuit unit of each display module. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]     Embodiments of the present invention will be described with reference to the attached drawings.  
         [0017]      FIG. 1  is a schematic perspective view of a conventional packing assembly for the transportation of plasma display modules.  
         [0018]      FIG. 2  is a cross-sectional view of a packing assembly according to an embodiment of the present invention.  
         [0019]      FIG. 3  is a perspective view of one of a plurality of plasma display modules depicted in  FIG. 2  according to an embodiment of the present invention.  
         [0020]      FIG. 4  is a perspective view of a packing module depicted in  FIG. 2  according to an embodiment of the present invention;  
         [0021]      FIG. 5  is a cross-sectional view taken along a line V-V of  FIG. 4  according to an embodiment of the present invention.  
         [0022]      FIG. 6  is a perspective view of a stacked structure of a plurality of the packing modules of  FIG. 4  according to an embodiment of the present invention.  
         [0023]      FIG. 7  is an enlarged perspective view of a connection member depicted in  FIG. 6  according to an embodiment of the present invention.  
         [0024]      FIG. 8  is a cross-sectional view of a first modified version of a protection member depicted in  FIG. 2  according to an embodiment of the present invention.  
         [0025]      FIG. 9  is a cross-sectional view of a second modified version of the protection member depicted in  FIG. 2  according to another embodiment of the present invention.  
         [0026]      FIG. 10  is a cross-sectional view of a third modified version of the protection member depicted in  FIG. 2  according to another embodiment of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0027]     Hereinafter, embodiments of the present invention will be described in detail with reference to the attached drawings. Like reference numerals refer to like elements throughout the drawings.  
         [0028]      FIG. 2  is a cross-sectional view of a packing assembly  200  according to an embodiment of the present invention.  
         [0029]     In one embodiment, as shown in  FIG. 2 , the packing assembly  200  includes a plurality of display modules  300 , a plurality of packing modules  100  and  400 , a cover  270 , and a plurality of protection members  190 . In another embodiment, the packing assembly  200  may exclude the plurality of display modules  300 .  
         [0030]     The display modules  300  can be various display modules such as plasma display modules, liquid crystal modules, etc. A plasma display module is illustrated in  FIG. 2  as an example of the display module  300 . For convenience of understanding, a perspective view of the display module of  FIG. 2  is illustrated in  FIG. 3 .  
         [0031]     Referring to  FIGS. 2 and 3 , each plasma display module  300  includes a plasma display panel  310 , a chassis  320 , and a plurality of circuit units  380 .  
         [0032]     The plasma display panel  310  displays an image using a gas discharge, and includes a front panel  311  and a rear panel  312 . The chassis  320  is disposed on a rear of the plasma display panel  310  to support the plasma display panel  310 .  
         [0033]     In one embodiment, a thermal conductive sheet  340  is interposed between the plasma display panel  310  and the chassis  320  to mainly dissipate heat generated from the plasma display panel  310 . In one embodiment, the plasma display panel  310  and the chassis  320  are coupled to each other using a double-sided tape  330 .  
         [0034]     The circuit units  380  are disposed on a rear of the chassis  320 , and the circuit units  380  include circuits for driving the plasma display panel  310 . The circuit units  380  are separated by a predetermined distance from the rear surface of the chassis  320 , and are coupled to the chassis  320  using, a coupling member, for example, a screw (not shown) and bosses  350  inserted into the chassis  320 . In one embodiment, the circuit units  380  include an X driving unit  381  and a Y driving unit  382  for driving sustain electrodes of the plasma display panel  310 , an address driving unit  383  for driving address electrodes, and a switching mode power supply (SMPS)  384  as a power supply device for driving three driving units  381 - 383 . In one embodiment, the SMPS  384  is located adjacent to a central portion of the chassis  320  and has a height H relatively higher than the other circuit units  380 .  
         [0035]     The circuit units  380  transmit electrical signals to the plasma display panel  310  through signal transmitting elements, such as a flexible printed cable (FPC), a tape carrier package (TCP), a chip-on-film (COF), etc. In one embodiment, the signal transmitting elements disposed on a rear lower portion of the chassis  320  are TCPs  370 , and the signal transmitting elements disposed on left and right sides of the chassis  320  are FPCs  375 . The TCPs  370  can be replaced by COFs.  
         [0036]     Upper and lower edge portions of the chassis  320  are bent, and a lower bent edge portion  320   a  supports the TCPs  370 . An end of each of the TCPs  370  is connected to the address driving unit  383 . The TCPs  370  are extended to surround the lower edge portion of the chassis  320  and are connected to address electrodes of the plasma display panel  310 .  
         [0037]     Also, the plasma display modules  300  may further include a heat dissipation member  360  covering the TCPs  370 . In one embodiment, the heat dissipation member  360  dissipates heat generated from electronic devices  375  in the TCPs  370  and protects the TCPs  370  from being damaged.  
         [0038]     In one embodiment, as depicted in  FIG. 2 , each plasma display module  300  is horizontally seated in each of the packing modules  100  with respect to the packing module  100 .  FIG. 4  is a perspective view of one of the packing modules  100  depicted in  FIG. 2  according to an embodiment of the present invention, and  FIG. 5  is a cross-sectional view taken along a line V-V of  FIG. 4  according to an embodiment of the present invention. Referring to  FIGS. 4 and 5 , each packing module  100  includes a seating unit  120 , a first rim unit  123 , and a second rim unit  110 . The seating unit  120  is for seating the plasma display module  300 . In one embodiment, the first rim unit  123  is connected to a side of the seating unit  120 , and is disposed to surround the plasma display module  300 . The seating unit  120  and the first rim unit  123  may be one body for ease of manufacturing purposes.  
         [0039]     In one embodiment, the second rim unit  110  surrounds the first rim unit  123 . The packing module  100  includes two horizontally disposed seating units  120  having the same structure, and can accommodate two plasma display modules  300 . The seating unit  120  is not limited thereto, that is, each packing module  100  can include one seating unit  120  or more than three horizontally disposed seating units  120 .  
         [0040]     In one embodiment, the second rim unit  110  includes a plurality of ribs  110   a . The ribs  110   a  reinforce the strength of the second rim unit  110 . Grooves  110   b  formed between the ribs  110   a  reduce the weight of the second rim unit  110 .  
         [0041]     In one embodiment, an opening  121   c  is formed in a central portion of the seating unit  120 . The opening  121   c  reduces the weight of the seating unit  120  and increases seating space  140 , thereby improving workability.  
         [0042]     In one embodiment, seating grooves  120   a  for ease of seating of the plasma display module  300  are formed in the seating unit  120 . Accordingly, the plasma display module  300  can be easily lifted or seated by hand in the seating grooves  120   a.    
         [0043]     In one embodiment, the seating unit  120  includes a plurality of non-continuous protrusions  121   a . In one embodiment, the protrusions  121   a  function as a buffer for preventing the plasma display module  300  from being damaged due to vibrations or impacts caused during seating the plasma display module  300  in the seating unit  120  or during transportation after the plasma display module  300  is seated in the seating unit  120 . The protrusions  121   a  can be formed in one body with the seating unit  120 .  
         [0044]     Also, an anti-sliding layer  180  having a predetermined thickness can be formed on the seating unit  120 . The anti-sliding layer  180  prevents sliding of the plasma display module  300 , and can be formed by coating silicon or a resin of a rubber group on the seating unit  120  and the protrusions  121   a . The anti-sliding layer  180  can also be formed on the plasma display module  300  where the plasma display module  300  directly contacts the packing modules  100  and  400 .  
         [0045]     As described above, the plasma display module  300  is horizontally seated in a seating space  140  defined by the seating unit  120  of each of the packing modules  100  and  400 . More specifically, a front face of the plasma display panel  310  is seated on the protrusions  121   a , to be more precise, on the anti-sliding layer  180 . At this time, portions of non-display regions S of the plasma display panel  310  may be seated on the anti-sliding layer  180  to avoid damage to an internal structure or a scratch of the plasma display panel  310 , which can be caused when the packing modules  100  and  400  and a display region D of the plasma display panel  310  directly contact each other. In particular, when a film filter is attached on the front face of the plasma display panel  310 , portions of the film filter corresponding to the non-display region S of the plasma display panel  310  may be seated on the anti-sliding layer  180 . When the film filter is attached mainly on the display region D of the plasma display panel  310 , the non-display region S of the plasma display panel  310  may be directly seated on the anti-sliding layer  180 .  
         [0046]     The first rim unit  123  may have a height that can accommodate the plasma display module  300  and can prevent the plasma display module  300  moving in the seating unit  120  when the packing assembly  200  is transported. In one embodiment, side surfaces  310   a  of the plasma display panel  310  directly contact side surfaces  122  of the first rim unit  123  to absorb impact caused during transportation and to prevent the plasma display module  300  moving in the seating unit  120 . In one embodiment, a plurality of non-continuous protrusions  121   b  are formed on a lower surface of the seating unit  120 . In one embodiment, the protrusions  121   b  are stacked pressing the bending unit  320   a  of the chassis  320 . Accordingly, the plasma display modules  300  are further safely fixed in the packing assembly  200  without an additional buffer material, thereby increasing the number of plasma display modules  300  that can be loaded in the packing assembly  200 . This results in the reduction of packing and transportation costs of the packing assembly  200 .  
         [0047]     An upper surface of the first rim unit  123  is substantially the same level as the upper surface of the second rim unit  110 . In one embodiment, a taper portion  123   a  is formed on an upper portion of the first rim unit  123 . In one embodiment, a slope is formed downwards from the taper portion  123   a  to guide the plasma display module  300  to be safely seated on the seating unit  120  along the taper portion  123   a  when the plasma display module  300  is seated on the seating unit  120 , thereby improving work efficiency.  
         [0048]     The seating unit  120 , the first rim unit  123 , and the second rim unit  110  can be formed of various materials, for example, wood board, plastic material, metals. etc.  
         [0049]     The seating unit  120  and the first rim unit  123  may be formed of the same material, and the second rim unit  110  may be formed of a different material from the seating unit  120  and the first rim unit  123 . At this time, the material for forming the second rim unit  110  may have a higher strength than the material for forming the seating unit  120  and the first rim unit  123 . This is because the second rim unit  110  maintains an overall skeleton of the packing module  100  and prevents damage of the plasma display panel  310  from external impact. Also, since the seating unit  120  and the first rim unit  123  directly contact or can contact the plasma display module  300 , the seating unit  120  and the first rim unit  123  may be formed of a relatively soft material.  
         [0050]     To make the second rim unit  110  having a different strength from the seating unit  120  and the first rim unit  123 , the second rim unit  110  may be formed to have a different density from the seating unit  120  and the first rim unit  123 . For example, the second rim unit  110  and the seating unit  120  can be formed of expanded polypropylene (EPP), expanded polyethylene (EPE), expanded polyurethane (EPI) etc. At this time, the second rim unit  110  may have a density of about 60 to about 70 kg/m 3 , and the seating unit  120  and the first rim unit  123  may have a density of about 25 to about 35 kg/m 3 .  
         [0051]      FIG. 6  is a perspective view of a stacked structure of the packing modules  100  of  FIG. 4 . In one embodiment, as illustrated in  FIG. 6 , the packing modules  100  are stacked on top of one another, and are fixed together by fixing elements  150 . In this embodiment, connection holes  152  are formed on each corner portion of the second rim unit  110  through the second rim unit  110 . In one embodiment, a connection member  151  is inserted in each connection hole  152 .  FIG. 7  is an enlarged perspective view of the connection member  151  depicted in  FIG. 6  according to an embodiment of the present invention. Referring to  FIG. 7 , the connection member  151  includes a hollow-cylinder shaped main body portion  153  and a wing portion  154  formed around a circumference of the main body portion  153 . In one embodiment, the main body portion  153  is inserted into the connection hole  152  in a fitting state. In one embodiment, an upper main body portion  153   a  defined by the wing unit portion  154  is inserted into the connection hole  152  of the upper packing module, and a lower main body portion  153   b  is inserted into the connection hole  152  of the lower packing module. Therefore, the upper packing module and the lower packing module can be fixed to each other.  
         [0052]     In one embodiment, protrusions  110   c  are formed on an upper surface of the second rim unit  110 , and concave units (not shown) are formed on a lower surface of the second rim unit  110 . In one embodiment, when the packing modules  100  are stacked, the protrusions  110   c  of the upper surface of the second rim unit  110  of a lower packing module  100  are inserted into the concave units of the lower surface of the second rim unit  110  of an upper packing module  100 . In this embodiment, the connection between the upper and lower packing modules  100  are fixed.  
         [0053]     Referring to  FIG. 1  again, the cover  270  is coupled to an uppermost portion of the packing module  100 . The cover  270  prevents the plasma display module  300  being damaged by moisture or dust infiltrated into the seating space  140 , thereby improving air-tightness of the seating space  140 . The cover  270  may be formed of substantially the same material as the second rim unit  110  of the packing module  100 .  
         [0054]     In one embodiment, the lowermost seating unit  420  of the packing module  400  does not have an opening  121   c  to avoid entering moisture or dust into the seating space  140  since the moisture or dust can damage the plasma display module  300 . However, other portions of the packing module  400  have the same structure as the packing module  100  depicted in  FIG. 4 , and thus, detailed descriptions thereof are omitted.  
         [0055]     Referring to  FIG. 2 , the protection members  190  covering each of the SMPSs  384  are depicted. The protection members  190  are disposed to protect the plasma display panel  310 . More specifically, when the plasma display modules  300  are transported while stacked in the packing module  100 , the plasma display modules  300  move up and down in the packing module  100 . Due to the movement of the plasma display modules  300 , a plasma display module  300  stacked can collide with a plasma display module  300  stacked above through the opening  121   c . The movement of the plasma display module  300  is larger at the central portion of the plasma display module  300 . In particular, even though the circuit unit  380  is not disposed on the central portion of the plasma display module  300 , the circuit unit  380 , which is the highest (H) from the chassis  320 , has a high possibility of colliding with the plasma display module  300  located above when the circuit unit  380  is moved even slightly. When the plasma display module  300  and the circuit unit  380  collide with each other, the plasma display panel  310  can be seriously damaged. If the plasma display panel  310  has a film filter on the front face thereof, the film filter can be torn. However, the protection member  190  covering the SPMS  384  can prevent a direct collision between the plasma display panel  310  and the SMPS  384 , thereby preventing damage of the plasma display panel  310 . However, according to the above embodiment, the protection member  190  covers the SMPSs  384 , but the present invention is not limited thereto. That is, the protection member  190  can cover other circuit units  380  that can damage the plasma display module  300 .  
         [0056]     The protection member  190  may be formed of various materials, such as expanded polypropylene (EPP), expanded polyethylene (EPE), expanded polyurethane (EPU), etc. However, the present invention is not limited thereto.  
         [0057]     Also, in the current embodiment, the protection member  190  is not fixed on the chassis  320  or the packing module  100 . Therefore, the packing procedure is that a plasma display module  300  is seated on a packing module  100 , and afterward, the SMPS  384  is covered by the protection member  190 , and another plasma display module  300  is stacked on another packing module  100 .  
         [0058]     However, as depicted in  FIG. 8 , a protection member  290  can be fixed on the chassis  320 .  FIG. 8  is a cross-sectional view of a first modified version of the protection member  190  depicted in  FIG. 2  according to an embodiment of the present invention. In this case, a process for disposing the protection member  290  is unnecessary, thereby increasing work efficiency. The protection member  290  is fixed to the chassis  320  using screws  298 . Also, after a boss (not shown) is inserted in the chassis  320 , the protection member  290  can be fixed by coupling the boss and the screw  298 . In particular, when the protection member  290  is formed of a conductive material, the protection member  290  shields electromagnetic waves generated from the SMPS  384 .  
         [0059]      FIG. 9  is a cross-sectional view of a second modified version of the protection member  190  depicted in  FIG. 2  according to another embodiment of the present invention. In one embodiment, as shown in  FIG. 9 , a protection member  390  includes holes  390   a  for dissipating heat. When a circuit unit such as the SMPS  384  is driven, a large amount of heat is generated. The holes  390   a  allow external air to flow smoothly, thereby promoting heat dissipation. The protection member  390  is fixed to the chassis  320  using, for example, screws  298 .  
         [0060]      FIG. 10  is a cross-sectional view of a third modified version of the protection member  190  depicted in  FIG. 2 . In one embodiment, as illustrated in  FIG. 10 , a protection member  490  includes a non-conductive main body  491  and a conductive layer  492  formed on the non-conductive main body  491 . In one embodiment, the non-conductive main body  491  is formed of a bumper material to reduce damage by an impact. The conductive layer  492  shields electromagnetic waves generated from the SMPS  384 . In one embodiment, the protection member  490  is fixed to the chassis  320  using, for example, screws  298 .  
         [0061]     The packing assembly for display modules according to embodiments of the present invention has the following advantages.  
         [0062]     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 a conventional packing assembly in a similar-sized packing assembly, thereby reducing packing costs and transportation costs.  
         [0063]     Second, since the display modules are safely seated in a packing module, damage of the display modules can be prevented when the packing assembly is packed or transported. In particular, collisions between display modules stacked on one another can be prevented by protection members, thereby allowing safe transportation of the display modules.  
         [0064]     While the above description has pointed out novel features of the invention as applied to various embodiments, the skilled person will understand that various omissions, substitutions, and changes in the form and details of the device or process illustrated may be made without departing from the scope of the invention. Therefore, the scope of the invention is defined by the appended claims rather than by the foregoing description. All variations coming within the meaning and range of equivalency of the claims are embraced within their scope.