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WO2007124094A2 - Flat panel display shipper - Google Patents

Flat panel display shipper Download PDF

Info

Publication number
WO2007124094A2
WO2007124094A2 PCT/US2007/009721 US2007009721W WO2007124094A2 WO 2007124094 A2 WO2007124094 A2 WO 2007124094A2 US 2007009721 W US2007009721 W US 2007009721W WO 2007124094 A2 WO2007124094 A2 WO 2007124094A2
Authority
WO
WIPO (PCT)
Prior art keywords
enclosure
shipper
load bearing
flexure
bundle
Prior art date
Application number
PCT/US2007/009721
Other languages
French (fr)
Other versions
WO2007124094A3 (en
Inventor
Ronald Thomas, Jr.
Russel Raschke
Original Assignee
Entegris, Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Entegris, Inc. filed Critical Entegris, Inc.
Publication of WO2007124094A2 publication Critical patent/WO2007124094A2/en
Publication of WO2007124094A3 publication Critical patent/WO2007124094A3/en

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS 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
    • B65D81/00Containers, 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
    • B65D81/02Containers, 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
    • B65D81/025Containers made of sheet-like material and having a shape to accommodate contents
    • B65D81/027Containers made of sheet-like material and having a shape to accommodate contents double-walled
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B65CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65DCONTAINERS 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
    • B65D85/00Containers, packaging elements or packages, specially adapted for particular articles or materials
    • B65D85/30Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure
    • B65D85/48Containers, packaging elements or packages, specially adapted for particular articles or materials for articles particularly sensitive to damage by shock or pressure for glass sheets

Definitions

  • the disclosed invention relates generally to shipping containers for fragile panels and substrates. More specifically, the invention relates to an apparatus and method for shipping bundles of fragile panels while protecting them from mechanical damage.
  • FPD Flat panel display
  • Yoshida shipper comprises an expanded polypropylene box with grooved interior surfaces that support the cells in a vertical orientation while contacting the cells only on the perimeter and providing an air gap between each cell.
  • Implementation of the Yoshida device in the context of shipping FPD cells leads to volumetrically large shippers that are relatively expensive, and not optional from a weight and handling perspective. It is also believed that more protection against drops or side impacts during shipping is available and would be desireable.
  • a second means of shipping involves bundling the FPD cells in stacks of ten, the cells being separated by sheets of polyethylene, and packaging the bundles in expanded polyethylene boxes. While reducing the bulk of the shipping container, the weight and expense of the shippers are still believed to be excessive, and protection against drops and side impacts have room for improvement.
  • Various embodiments of the invention disclose a glass panel shipper that provides the economy of space afforded by bundling the panels, but is of lighter construction, less expensive to fabricate, and offers enhanced protection against impact loads during shipping compared to conventional shippers.
  • a split container having top and bottom portions cooperate to define a receiving region for enclosing a substrate payload such as a FPD panel or a plurality of FPDs.
  • the bundle may include spacer sheets of a suitable separating material such as polyurethane or polyethylene that separate the FPDs and thereby providing a stack or bundle with six bundle sides and an upper face and a lower face.
  • the top and bottom portions may be hollow such as by blow molded or rotationally molded (polymer) construction of each.
  • the shipper may have retractable panelar portions that directly or indirectly engage a substantial portion of the sides of the payload, typically the upper and lower faces of the stack, thereby distributing static and dynamic loads over large regions of the bundle.
  • the contacting regions may be rimmed or otherwise suspended with integral flexures configured, for example, as a bellows portion or a pleated portion that flexes and provides the deflection of the panelar portions when the container is closed with a full stack received therein.
  • the flexures effectively limit and control the compressive loading on the bundles of FPDs during the closure and containment of providing substantially the same loading on bundles of different thicknesses.
  • the flexures also provide enhanced shock absorbtion in the event of an impulse load.
  • hollow sidewalls protect the bundle from side impact, and may be fitted with cushions such as compliant foam bumpers for added protection of the panel edges.
  • Certain embodiments include interlacing or interlocking structures at the juncture of the top and bottom portions providing securement of said top and bottom portions. Said interlacing between the top and bottom portions can be oriented either circumferentially or radially. Further securement and latching of the top and bottom portions may be provided by a securement mechanism such as one or more circumferential bands or straps that may be tightened in a loop around the top and bottom portions.
  • a securement mechanism such as one or more circumferential bands or straps that may be tightened in a loop around the top and bottom portions.
  • the exterior of the container in certain embodiments may be formed to accommodate such bands or straps. Other conventional latching mechanisms can also be utilized.
  • the receiving region will be generally a rectangular box shape and may have expanded corner recesses to avoid any engagement between the container and the vertical corners of the stack.
  • an enclosure configured as a flat panel shipper for transport of a bundle of flat panel displays.
  • the enclosure having a first enclosure portion and a second enclosure portion, said first enclosure portion cooperating with said second enclosure portion form an enclosure for containing said bundle of flat panel displays, said bundle of flat panel displays having a plurality of faces, each of said first and said second enclosure portions including an inner shell portion integral with an outer shell portion such that said enclosure provides hollow walls opposite each of said plurality of faces of said bundle of flat panel displays.
  • the enclosure may have a deflectable panelar member having a perimeter portion and defining a load bearing axis substantially normal to said deflectable panelar member, said deflectable panelar member being at least partially supported by at least one flexure operatively coupled to said perimeter portion, said at least one flexure enabling entirety of said deflectable panelar member to deflect along said load bearing axis when a force is applied to or withdrawn from said deflectable panelar member.
  • the flexure may be an S-shaped flexure, a U-shaped flexure, a bellows flexure and a pleated flexure.
  • the first enclosure portion and said second enclosure portion may be substantially identical and may cooperate to restrict translation or rotation of said first enclosure relative to said second enclosure portion in a direction orthogonal to said load bearing axis by way of interlacing structure at the juncture region of the first and second enclosure portions.
  • the first or said second enclosure portions may include at least one pillar extending from either of said inner shell portion or said outer shell portion into said hollow-walled structure to maintain at least a minimum separation between said inner shell portion and said outer shell portion where said at least one pillar are located, said at least one pillar including at least one flexure that enables said panelar load bearing member to deflect along said load bearing axis when a force is applied to or withdrawn from said load bearing member.
  • the flexure may be disposed between said pillar and either of said inner shell portion or said outer shell portion from which said pillar extends.
  • One or more cushions may be disposed between at least one of said plurality of faces of said bundle of flat panel displays and said hollow walls of said enclosure.
  • the bundle of flat panel displays includes spacer sheets disposed between adjacent flat panel displays of said bundle of flat panel displays.
  • the outer shell portion of at least one of said first enclosure portion and said second enclosure portion may channel recesses.
  • the enclosure has a bottom enclosure portion including an inner shell portion integral with an outer shell portion, said inner shell portion and said outer shell portion defining a hollow interior therebetween, said inner shell portion including a load bearing member having a perimeter portion, said load bearing member being at least partially suspended from a distinct and continuous flexure extending from said perimeter portion, said distinct and continuous flexure enabling entirety of said load bearing member to be displaced toward said outer shell portion when a force is applied to said load bearing member; and a top enclosure portion including an inner shell portion integral with an outer shell portion, said inner shell portion and said outer shell portion defining a hollow interior therebetween, said top enclosure portion cooperating with said bottom enclosure portion and forming a enclosure, said enclosure having a plurality of exterior faces and presenting hollow walls adjacent all of said plurality of faces.
  • the load bearing member may include at least one pillar having a distal end that extends into said hollow interior of said bottom enclosure portion.
  • At least one pillar may contact said outer shell portion and may include at least one flexure that flexes when said at least one pillar is loaded with an axial force.
  • the bottom enclosure portion and the top enclosure portion may be substantially identical and cooperate to restrict lateral translation of said bottom enclosure portion relative to said top enclosure portion.
  • the panel shipper inner shell portion may include a continuous ridge structure 5 having an inner wall, with at least one flexure being integral with said inner wall and said inner wall and said load bearing member defining a receptacle.
  • the inner shell portion may include a bridging member between said at least one flexure and said inner wall, where said bridging member defines a recess.
  • the inner shell portion may include structure defining corner recesses extending 10 outward from said receptacle portion.
  • a plurality of elongate recesses may be formed on said outer shell portion to accommodate straps for holding said bottom enclosure portion and said top enclosure portion together.
  • first enclosure portion and a second enclosure portion that 15 cooperate to form a enclosure about a payload; and means for isolating said payload from impact loads as described herein.
  • the invention includes a method of making a flat panel shipper, comprising in one embodiment the steps of:
  • a shipper for transport of at least one flat panel said shipper including a 20 hollow-walled structure having an inner shell portion and an outer shell portion, said inner shell portion including a load bearing member for contact with said at least one flat panel, said load bearing member being at least partially suspended by at least one flexure;
  • Additional steps may include one or more of the following: the step of designing a shipper included designing at least one pillar operatively coupled with said load bearing member and extending into said hollow-walled structure;
  • the step of providing a mold to produce a first portion of said shipper includes providing said mold to produce said first portion to include said at least one pillar;
  • the step of molding a first portion of a shipper includes producing said first portion with said at least one pillar;
  • the step of designing said shipper includes designing said at least one flexure to deliver a predetermined load distribution to said at least one flat panel;
  • the step of molding a first portion of a shipper includes a process selected from the group consisting of blow molding and rotational molding;
  • a method of using a shipper for shipping a plurality of fragile flat panels comprises one or more of the following steps:
  • a shipper including a first enclosure portion and a second enclosure portion, each of said first and second enclosure portions including a hollow-walled structure having an inner shell portion and an outer shell portion, wherein said inner shell portion of said first enclosure portion defines a receptacle portion including a load bearing member for contacting said plurality of fragile flat panels, said load bearing member being at least partially supported by at least one flexure;
  • securing said first enclosure to said second enclosure includes exerting a clamping force between said first enclosure portion and said second enclosure portion with at least one strap.
  • the invention includes a flat panel shipper in combination with a bundle of panel displays, comprising:
  • the enclosure may include a first portion and a second portion, said first and second portions being substantially identical, said first portion and said second portion cooperating to restrict lateral translation of said first portion relative to said second portion.
  • An advantage of the various embodiments of the present invention is that the manufacturing cost of the shipper is inexpensive relative to state of the art shippers.
  • a further advantage of particular embodiments of the invention is that the container may be configured for insertion or removal of the payload by both manual and automated means.
  • top and bottom portions are symmetrically complimentary, thus enabling them to be made from the same mold.
  • a further advantage of certain embodiments is that the exterior may be produced with elongate recesses that enable a low profile utilization of straps while providing an added measure of structural rigidity to the shipper.
  • FIG. 1 is a cross-sectional depiction of a flat panel shipper containing a panel bundle in an embodiment of the invention.
  • FIG. 2 is an enlarged partial sectional view of the panel bundle of FIG. 1.
  • FIG. 3 is an isolated cross-sectional view of the top portion of the flat panel shipper of FIG. 1.
  • FIG. 4 is an enlarged partial sectional view of a pillar flexure of FIG. 1.
  • FIG. 5 is an enlarged partial sectional view of a continuous perimeter flexure of FIG. 1.
  • FIG. 6 is a plan view of the top portion of the flat panel shipper of FIG. 1.
  • FIG. 7 is a plan view of the bottom portion of the flat panel shipper of FIG. 1.
  • FIG. 8 is an isolated cross-sectional view of the bottom portion of the flat panel shipper of FIG. 1.
  • FIG. 9a is a cross-sectional view of a flat panel shipper partially assembled and containing a panel bundle in an embodiment of the invention.
  • FIG. 9b is a partial cross-sectional view of the flat panel shipper of FIG. 9a fully assembled.
  • FIG. 9c is a partial, isolated view depicting the deflection of the load bearing member, perimeter flexures and pillar flexures of FIG. 9a.
  • FIG. 10 is a plan view of the bottom portion of a flat panel shipper of FIG. 9.
  • FIG. 11 is a cross-sectional view of the bottom portion of the flat panel shipper of FIG. 9.
  • FIG. 12 is a cross-sectional view of a bottom portion of a flat panel shipper in an embodiment of the invention.
  • FIG. 13 is an enlarged cross-sectional view of a pillar of the flat panel shipper of
  • FIG. 14 is an enlarged cross-sectional view of a pillar of a flat panel shipper in an embodiment of the invention.
  • FIG. 15 is a cut-away perspective view of a flat panel shipper in an embodiment of the invention.
  • FIG. 16 is a perspective view of a flat panel shipper having interchangeable top and bottom portions in an embodiment of the invention.
  • FIG. 17 is a perspective view of the interchangeable top or bottom portion of the flat panel shipper of FIG. 16.
  • FIG. 18 portrays a ridge structure of a flat panel shipper in isolation in an embodiment of the invention.
  • FIGS. 1 through 8 an embodiment of a flat panel shipper 20 with a stack of flat panels received therein according to the invention is portrayed.
  • the flat panel shipper 20 comprises two enclosure portions: a top portion 22 and a bottom portion 24 defining a receiving region or pocket therebetween.
  • the top portion and bottom portions are engaged at a juncture 24.1 and have respective juncture portions 24.2, 24.3 with interlacing structure 24.5, 24.6 that in FIG. 1 is shown radially interlaced.
  • FIGS. 16 and 17 illustrate circumferential interlacing of the juncture portions 22.1.
  • the top portion 22 may have a substantially rectangular footprint of a width 23 and a length 25, and an overall height 27.
  • the top portion 22 may also be of a blow molded or rotationally molded construction that produces a hollow-walled structure 26 formed by an outer shell portion 28 integral with an inner shell portion 29.
  • a continuous lip portion or ridge structure 30 extends around the outer perimeter 32 of the top portion 22.
  • a bridging member 33 may be formed between an inner sidewall 35 of the ridge structure 30 and a perimeter flexure 36 to define an annular recess 34.
  • the shipper and stack have an axis 39.
  • a "flexure” is a distinct portion of a structure that bridges a first and a second portion of the structure and deforms when there is relative movement between the first and second portions of the structure so as to mitigate deformation of the first and second portions and to facilitate the movement between said first and second portions.
  • the flexure may be formed integrally with the first and second portions, or be formed separately for subsequent attachment therebetween.
  • the deforming function of the flexure may be accomplished by a variety of configurations that reduce the stiffness of the flexure relative to the first and second portions.
  • the reduced stiffness may be accomplished by a geometric shape that includes one or more inflections (bends, curves or folds), or by providing the flexure with thinner walls relative to the first and second portions, or by fabricating of the flexure out of a material that is more compliant than the first and second portions, or by a combination thereof.
  • inflections bends, curves or folds
  • connect fabricating of the flexure out of a material that is more compliant than the first and second portions, or by a combination thereof.
  • the perimeter flexure 36 may be a single, continuous flexure (as depicted) or may discontinuous, thereby forming a plurality of perimeter flexure elements (not depicted).
  • the perimeter flexure may be integral to a panelar bearing platform or load bearing member 38 that provides a load bearing force 39.1 normal to the panelar bearing platform
  • a pair of cavities 40 and 42 may be formed on the load bearing member 38 to define a pair of pillars 44 and 46 that extend into the hollow-walled structure 26.
  • the pillars 44, 46 may be frustum-shaped as depicted in the FIG. 1 embodiment, or of another shape suitable for the application such as a cylinder, hemisphere, polygon or some combination thereof.
  • 40 and 42 may be ringed with a continuous pillar flexure 48.
  • the perimeter flexure 36 for the embodiment of FIG. 1 forms a generally S-shaped or U-shaped cross section 50 having a thickness 52, a lateral dimension 53, and an inflective portion 51 of axial dimension 54, as best seen in FIG. 5.
  • the FIG. 1 embodiment includes pillar flexures 48 that are also of a general S-shaped or U-shaped cross-section 56, having a thickness 58, a lateral dimension 57 and an inflective portion 55 of axial dimension 60, as best depicted in FIG. 4.
  • a plurality of channel recesses 62 may be formed on the outer shell portion 28, spanning the width 23 and extending down the sides of the ridge structure 30.
  • the bottom portion 24 may be of similar construction to the top portion 22. Specifically, the bottom portion 24 may be of the same general length 25 and width 23, may have a hollow interior 64 with an outer shell portion 65 integral with an inner shell portion 63, and may have an annular recess 66 integrally joined to a bearing platform or load bearing member 68 through a continuous perimeter flexure 70 having an S-shaped cross-section.
  • a pair of frustum-shaped pillars 72 and 74, each having a proximal end 71 and a distal end 73, may extending into the hollow interior 64 from pillar flexures 76 at the proximal ends 71 having S-shaped or U-shaped cross-sections that extend from the load bearing member 68.
  • a gap 77 may be formed between the pillars 72 and 74 and the outer shell portion 65.
  • the configuration of the various S-shaped flexures 70 and 76 may be generally the same as their respective counterpart components 36 and 48 on the top portion 22.
  • the bottom portion may include channel recesses 75 formed in the outer shell portion 65 that extend the width 23 and down two sides 78 and 80 of the bottom portion 24. The recesses 75 may be positioned to align with the annular recesses 66 when the top portion 22 is placed over bottom portion 24.
  • the bottom portion 24 of the FIG. 1 embodiment also has a continuous ridge structure 82 with an inner perimeter 83.
  • the ridge structure 82 may be recessed from the outer perimeter 84 of the bottom portion 24, thereby defining a continuous shoulder 86.
  • a receptacle portion 89 may be defined generally by the inner perimeter 83 of the ridge structure 82 and the load bearing member 68.
  • a continuous perimeter channel 90 may be formed on the outer perimeter 84 of the bottom portion 24.
  • the inner perimeter 83 may further include corner recesses 87 formed at each corner of the ridge structure 82, the corner recesses 87 extending outward from the receptacle portion 89 and may define an outer extremity of the inner perimeter 83.
  • the bottom portion of the FIG. 1 embodiment also has an overall axial length 88 that is greater than the overall axial length 27 of the top portion 22.
  • the flat panel shipper 20 is portrayed as containing a panel bundle 92 in FIG. 1.
  • the panel bundle 95 is characterized by a plurality of faces 97.
  • the panel bundle 92 as depicted comprises a plurality of flat panels 94 which may be LCD assemblies or the finished glass substrates for use in LCD assemblies.
  • the fiat panels 94 may be separated interstitially by spacer sheets 96.
  • a representative and non-limiting range of panel sizes may range from approximately 200- mm width x 280-mm length (so-called "Gen 1" display panels) to 1.0-m width by 1.2-m length (so-called "Gen 6" display panels).
  • a representative range of thicknesses for the glass substrates is 0.7- to 1.1 -mm, which would approximately double in the case of LCD assemblies.
  • the number of glass substrates or LCD assemblies in this case may range from a single panel to 20 or more panels for a thickness of the panel bundle 92 ranging from approximately 1-ram to 45-mm or more.
  • the weight of the panel bundle 92 may range from less than 1-kg to more than 150-kg (330-lbf).
  • the spacer sheets may be made of embossed polyethylene of 0.5-mm to 0.8-mm thickness. Other materials and thicknesses may be used as appropriate.
  • the receptacle portion 89 may be dimensioned so that there is a gap 98 between the edges 100 of the panel bundle 92 and the inner perimeter 83 of the ridge structure 82. In the case of a flat panel display cell shipper, an exemplary and non-limiting radial thickness of the gap 98 may average approximately 3-mm. A representative and non-limiting range for the thickness of the hollow-walled structure is 20-mm to 100-mm.
  • the top portion 22 may cooperate with the bottom portion 24 to form a enclosure 101.
  • the ridge structure 82 and shoulder 86 of the lower portion 24 mate with the annular recess 34 and ridge structure 30 of the top portion 22.
  • the enclosure 101 provides the hollow-walled structure 26 opposite each of the faces 97 of the panel bundle 92.
  • a plurality of straps 102 may be disposed in the elongate or channel recesses 62 and 75 to clamp the top portion 22 and the bottom portion 24 together.
  • An elastic band 104 may also be disposed in the perimeter channel 90 of the bottom portion 24 and routed outside the straps 102.
  • the panel bundle 92 or other payload is placed on the load bearing member 68 in the receptacle portion 89 of the bottom portion 24, causing the perimeter flexure 70 to flex downward and rotate about a junction 106 between the bottom of the annular recess 66 and the perimeter flexure 70.
  • the rotational movement about the entire perimeter of the load bearing member 68 may cause the load bearing member 68 to be displaced downward and to bow away from the panel bundle 92.
  • the pillars 72 and 74 maintains at least a minimum separation between the inner shell portion 63 and the outer shell portion 65. If the lower portion 24 did not include the pillars 72 and 74 as configured, such bowing of the load bearing member 68 may cause the panel bundle 92 to be supported only by line contact at a junction 108 between the load bearing member 68 and the perimeter flexure 70.
  • the bowing and displacement of load bearing member 68 causes the pillars 72 and 74 to traverse the gap 77 and engage with the outer shell portion 65 of the bottom portion 24.
  • the stiffness of the pillars 72 and 74 causes the platform 68 to maintain contact with the center portion of the panel bundle 92, providing a more even distribution of load and reducing the interface pressure over the lower face of the panel bundle 92.
  • the local force exerted by the pillars 72 and 74 on the panel bundle 92 is mitigated when the pillar flexures 76 are utilized because they flex when the pillars
  • the clamping action of the straps 102 may cause the top portion 22 to react in a similar fashion to the static loading of the bottom portion 24.
  • the clamping force can push the load bearing member 38 against the panel bundle 92, causing the load bearing member 38 to displace and bow, thereby creating contact between the pillars 40, 42 and the outer shell portion 28 and restoring contact between the load bearing member 38 and the central portion of the upper face of the panel bundle 92.
  • a more uniform contact pressure is thereby exerted on the panel bundle 92.
  • the straps 102 can exert a pressure on the upper and lower faces of the panel bundle 92 to inhibit movement of the panel bundle 92 within the flat panel shipper 20 during shipping and handling.
  • the perimeter flexure 70 may be stretched and contracted in the lateral direction.
  • This in combination with the hollowness of the ridge structure 82, provides shock absorption that protects the panel bundle 92 from impacts on the sides of the flat panel shipper 20.
  • the deflections and rotations of the various flexures 36, 48, 70 and 76 and attendant reaction forces exerted on the panel bundle 92 by the load bearing members 38 and 68 is a function of many parameters, including the flexure thicknesses 52, 58, the axial dimensions 54, 60, and the lateral dimensions 53, 59.
  • the weight of the panel bundle 92 and the dimensions of the load bearing members 38, 68 may also be factors. These parameters can be optimized or "tuned" during design of the flat panel shipper to deliver a predetermined distribution of loads over the panel bundle 92. After the shipper is molded further tuning may be provided by subsequent operations such as material removal to thin portions of flexures.
  • Alternative cross-sections for the various flexures 36, 48, 70 and 76 may also be implemented.
  • additional inflective members may be added to the cross- sections 50 or 56 to form a bellows-like flexure.
  • the inflective members may be substantially arcuate, or may have a more abrupt inflection such as with a pleated structure.
  • Embodiments of the invention may be designed not only for optimum or desired distribution of a given static load, but also for distribution of additional dynamic or impact loads encountered during the shipping process (e.g. dropping the unit).
  • the pillar flexures 48, 76 may take may be located elsewhere on the pillar structure (not depicted).
  • the flexure 76 may be proximate the distal end 73 of the pillar 72 or 74 to produce the same functionality.
  • other flexure arrangements may be incorporated between the proximal end 71 and distal end 73 of the pillar 72 or 74 to provide the same functionality.
  • Such flexures may be provided as an alternative to, or in addition to, the pillar flexures 48, 76.
  • the corner recesses 87 enable the corners of the panel bundle 92 to remain untouched during shipping. Historically, damaged panel bundles typically incur damages at the corners. Hence, certain embodiments of the invention provide the corner recesses 87 to isolate the corners of the panel bundle 92 during shipment. Side loads on the panel bundle 92 is thus restricted to the mid sections of the edges 100.
  • the corner recesses 87 also enable manual removal of the panel bundle 92 as well as individual flat panels 94 because they accommodate tools or human fingers used to grip the corner regions of the panel bundle 92 or individual flat panels 94.
  • the corner recesses 87 also provide strain relief to the structure of the bottom portion 24, thereby increasing the life of the flat panel shipper.
  • FIG. 1 also accommodates automated unloading and handling of the flat panels 94.
  • Many automatic handlers utilize a vacuum or suction device that lifts the flat panels 94 individually off the panel bundle 92.
  • the flat panel shipper 20 is conducive to such automatic handling because once the top portion 22 is removed there is nothing structural inhibiting the panels 94 from being lifted away from the panel bundle 92.
  • the spacer sheets 96 may be utilized to dissipate static charges, such as by use of an electrical dissipative grade of polyurethane.
  • FIGS. 9a, 10 and 11 an alternative embodiment of the flat panel shipper 20 is illustrated wherein the inset ridge structure of the bottom portion 24 is effectively eliminated and a cushion 110 is disposed in the annular recess 66 of the bottom portion around the edges 100 of the panel bundle 92.
  • the lateral location of the perimeter flexure 70 may be located further outward, closer to the edges 100 of the panel bundle 92, than in the configuration of FIG. 1.
  • the upper portion 22 is not modified from the previous embodiment.
  • the cushion 110 cooperates with the top portion 22 to register within the annular recess 34 of the top portion 22.
  • the cushion 110 may be of any suitable compliant material or construction, such as an open or closed cell foam rubber or polyurethane, an inflatable cushion, or other cushion materials or configurations available to the artisan.
  • the cushion 110 may be continuous, or in segments 111 that provide voids 112 at the corners as shown in FIG. 10.
  • the segments 111 may be removably held in place by an interference fit between the edges 100 of the panel bundle 92 and the inner perimeter 83 of the ridge structure 82, or captured in place by insets 113 on the interior of the corners without resorting to an interference fit against the edges 100 of the panel bundle 92.
  • the segments may be attached to the bottom of the annular recess 66 for permanent installation, for example with an adhesive, or for temporary installation, such as by VELCRO.
  • FIG. 9a provides additional protection against impact.
  • the cushion 110 provides additional shock absorption for the edges 100 of the panel bundle 92.
  • the voids 112 function in the same manner as the corner recesses 87 of the FIG. 1 configuration, enabling manual removal of flat panels 94 while leaving the segments 111 in place.
  • removal of the segments 111 enables access to the edges of the flat panels 94 for manual removal, or providing unfettered removal from the panel bundle 92 by automation, such as by a vacuum or suction.
  • the clamping force 103 may be exerted by cinching the straps 102 about the flat panel shipper 20 to draw the top portion 22 into contact with the bottom portion 24 and form the enclosure 101.
  • Other mechanisms such as clasps, pinched flanges or external wrappings may be utilized apply the clamping force 103 and draw the top and bottom portions 22 and 24 together.
  • a seal such as a gasket, o-ring or elastomeric material may be disposed interstitially between the top portion 22 and the bottom portion 24 at the line of contact to provide a barrier against particulates and moisture.
  • the panel bundle 92 may be wrapped with a material (not depicted) such as a shrink wrap, and or the flat panel shipper 20 may be wrapped on the exterior to prevent contaminates from entering the enclosure 101.
  • a portion of the clamping force 103 exerted by the straps 102 is translated to the load bearing members 38 and 68 of the flat panel shipper 20 and acts in a direction substantially parallel to the enclosure-stack axis 39.
  • the clamping force 103 may cause the pillars (e.g. 42 and 72) to close the gaps 77 and contact the outer shell portions 28 and
  • FIG. 9a shows the gap 77 as still being present between the pillar 72 and the outer shell portion 65 of the bottom portion 24. Other embodiments may deflect enough under the load of the panel bundle 92 to close the gap 77.
  • the flexing action of the perimeter flexure 70 and one of the pillar flexures 76 of the load bearing member 68 of the bottom portion 24 is depicted in isolation in FIG. 9c.
  • a total displacement ⁇ is depicted, with the loaded position shown in phantom.
  • the deflection ⁇ of the load bearing member 68 of the lower portion 24 may be caused in part by the weight of the flat panel bundle 92 and in part by the force exerted by the straps 102.
  • the presence of the flexures 70 and 76 enables translation of the load bearing member 68 along the load bearing axis 39 with less deformation of the panelar portions of the load bearing member 68 than would be present in the absence of the flexures 70 or 76. The same effect may be observed for the load bearing member 38 of the top portion 22.
  • FIGS. 12 through 14 an embodiment of the bottom portion 24 is portrayed wherein the gap 77 is breached by a dimple structure 114 formed on the outer shell portion 65.
  • the region of the pillar 72 is illustrated in FIG. 13 in an example as- molded state. The same region is depicted in FIG. 14 after the dimple structure 114 has been formed.
  • An equivalent operation may be performed on the top unit 22 to provide similar functionality.
  • the dimple structure 114 may provide immediate loading of the pillars 72, 74 upon placement of a static load on the load bearing member 68 of the bottom portion 24.
  • the perimeter flexure 70 does not have to deflect axially to engage the pillars 72, 74, and thus the load bearing member 68 does not experience the initial bowing that the above disclosed embodiments before the pillars 72, 74 engage to correct the deformation. Accordingly, the contact area of the load bearing member 68 may be increased.
  • FIG. 15 another embodiment of the flat panel shipper 20 is depicted, incorporating both the dimple structures 114 and the cushion 110 aspects of the invention. Also in this embodiment, the top portion 22 and the bottom portion 24 are of substantially identical configuration.
  • the elastic band 104 may be located only on the bottom portion as depicted.
  • the straps 102 hold the flat panel shipper 20 together. In FIG. 15 the straps
  • the top and bottom portions 22 and 24 of the FIG. 15 embodiment may be identical, and thus may be manufactured using the same molding. Replacement portions 22, 24 are easier to stock.
  • the lateral position of the top portion 22 relative to the bottom portion 24 may be maintained by the clamping force exerted by the straps 102, and by the shear resistance of the cushion 110.
  • Another advantage is that the cushions 110 may be located interstitially between the faces 97 of the panel bundle 92 and the hollow-walled structure opposite the faces 97 to provide additional absorption of impact loads.
  • FIGS. 16 and 17 an embodiment of a flat panel shipper 20 is portrayed having identical and complimentary enclosure portions 115. Like previous embodiments, the corner recesses 78 and the annular recess 34 aspects are retained.
  • the embodiment further includes raised comers 116 and 118 on opposed diagonal comers of the continuous ridge structure 30, complimented by recessed comers 120 and 122 on the remaining diagonal corners. The raised corners 116, 118 mate with the recessed corners 120, 122.
  • FIG. 16 includes the advantage of identically constructed enclosure portions 115, again enabling fabrication from the same molding and easier stocking of replacement units.
  • the interlocking of the raised corners 116, 118 with the recessed corners 120, 122 counters any translational shear forces that the flat panel shipper 20 may encounter.
  • FIG. 18 another embodiment of a ridge structure 125 is shown in isolation including side midspah portions 124, end midspan portions 126 and corner portions 128.
  • the side midspan portions are further divided into a raised portion 130 and a recessed portion 132 relative to a top surface 134 of the corner portions 128.
  • One of the end midspan portions 126 may be in a recessed configuration 136, the other end midspan portion having a raised configuration 132.
  • the ridge structure 125 is symmetrical such that identical units compliment each other and interlock.
  • the ridge structure 125 upon implementation into the enclosure portions 115 or the top and bottom portions 22 and 24, retains all the advantages of the FIG. 17 embodiment. In addition, interlocking ridge structures 125 also resist any rotational shear forces exerted on the assembly.

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Abstract

A shipper having enclosure portions that cooperate to enclose a payload such as a panel or panel bundle. The enclosure portions may be blow molded or rotationally molded for a hollow-walled construction. The shipper may contact a majority of the upper or lower faces of the payload, thereby distributing static and dynamic loads over a large area. Flexures operatively coupled with the contact area may provide compliance when the container is closed and shock absorption in the event of an impulse load. The hollow sidewalls may also protect the payload from side impact. The shipper may also accommodate compliant bumpers for added protection of the payload edges. Certain embodiments include identical and complimentary interlocking structures that enable the enclosure portions to be formed from a common mold. The exterior of the container may accommodate bands or straps that hold the enclosure portions together and exert a clamping pressure on the payload to limit shifting.

Description

FLAT PANEL DISPLAY SHIPPER
RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application No. 60/794,002, filed April 22, 2006, which is hereby incorporated by reference in its entirety.
FIELD OF THE INVENTION
The disclosed invention relates generally to shipping containers for fragile panels and substrates. More specifically, the invention relates to an apparatus and method for shipping bundles of fragile panels while protecting them from mechanical damage.
BACKGROUND OF THE INVENTION
Flat panel display (FPD) cells are often produced in one facility and transported to another, often between countries, for conversion to modules and then integration into TV's or monitors.
One apparatus for shipping the FPD cells between facilities is disclosed in U.S. Patent 5,588,531 to Yoshida, et al. (Yoshida). The Yoshida shipper comprises an expanded polypropylene box with grooved interior surfaces that support the cells in a vertical orientation while contacting the cells only on the perimeter and providing an air gap between each cell. Implementation of the Yoshida device in the context of shipping FPD cells leads to volumetrically large shippers that are relatively expensive, and not optional from a weight and handling perspective. It is also believed that more protection against drops or side impacts during shipping is available and would be desireable.
A second means of shipping involves bundling the FPD cells in stacks of ten, the cells being separated by sheets of polyethylene, and packaging the bundles in expanded polyethylene boxes. While reducing the bulk of the shipping container, the weight and expense of the shippers are still believed to be excessive, and protection against drops and side impacts have room for improvement. SUMMARY OF THE INVENTION
Various embodiments of the invention disclose a glass panel shipper that provides the economy of space afforded by bundling the panels, but is of lighter construction, less expensive to fabricate, and offers enhanced protection against impact loads during shipping compared to conventional shippers.
In certain embodiments, a split container having top and bottom portions cooperate to define a receiving region for enclosing a substrate payload such as a FPD panel or a plurality of FPDs. In the case of shipping a bundle of FPDs, the bundle may include spacer sheets of a suitable separating material such as polyurethane or polyethylene that separate the FPDs and thereby providing a stack or bundle with six bundle sides and an upper face and a lower face.
The top and bottom portions may be hollow such as by blow molded or rotationally molded (polymer) construction of each. The shipper may have retractable panelar portions that directly or indirectly engage a substantial portion of the sides of the payload, typically the upper and lower faces of the stack, thereby distributing static and dynamic loads over large regions of the bundle. The contacting regions may be rimmed or otherwise suspended with integral flexures configured, for example, as a bellows portion or a pleated portion that flexes and provides the deflection of the panelar portions when the container is closed with a full stack received therein.
The flexures effectively limit and control the compressive loading on the bundles of FPDs during the closure and containment of providing substantially the same loading on bundles of different thicknesses. The flexures also provide enhanced shock absorbtion in the event of an impulse load. In certain embodiments, hollow sidewalls protect the bundle from side impact, and may be fitted with cushions such as compliant foam bumpers for added protection of the panel edges.
Certain embodiments include interlacing or interlocking structures at the juncture of the top and bottom portions providing securement of said top and bottom portions. Said interlacing between the top and bottom portions can be oriented either circumferentially or radially. Further securement and latching of the top and bottom portions may be provided by a securement mechanism such as one or more circumferential bands or straps that may be tightened in a loop around the top and bottom portions. The exterior of the container in certain embodiments may be formed to accommodate such bands or straps. Other conventional latching mechanisms can also be utilized.
The receiving region will be generally a rectangular box shape and may have expanded corner recesses to avoid any engagement between the container and the vertical corners of the stack.
Disclosed herein is an enclosure configured as a flat panel shipper for transport of a bundle of flat panel displays. The enclosure having a first enclosure portion and a second enclosure portion, said first enclosure portion cooperating with said second enclosure portion form an enclosure for containing said bundle of flat panel displays, said bundle of flat panel displays having a plurality of faces, each of said first and said second enclosure portions including an inner shell portion integral with an outer shell portion such that said enclosure provides hollow walls opposite each of said plurality of faces of said bundle of flat panel displays.
Moreover, the enclosure may have a deflectable panelar member having a perimeter portion and defining a load bearing axis substantially normal to said deflectable panelar member, said deflectable panelar member being at least partially supported by at least one flexure operatively coupled to said perimeter portion, said at least one flexure enabling entirety of said deflectable panelar member to deflect along said load bearing axis when a force is applied to or withdrawn from said deflectable panelar member. The flexure may be an S-shaped flexure, a U-shaped flexure, a bellows flexure and a pleated flexure.
The first enclosure portion and said second enclosure portion may be substantially identical and may cooperate to restrict translation or rotation of said first enclosure relative to said second enclosure portion in a direction orthogonal to said load bearing axis by way of interlacing structure at the juncture region of the first and second enclosure portions.
The first or said second enclosure portions may include at least one pillar extending from either of said inner shell portion or said outer shell portion into said hollow-walled structure to maintain at least a minimum separation between said inner shell portion and said outer shell portion where said at least one pillar are located, said at least one pillar including at least one flexure that enables said panelar load bearing member to deflect along said load bearing axis when a force is applied to or withdrawn from said load bearing member.
The flexure may be disposed between said pillar and either of said inner shell portion or said outer shell portion from which said pillar extends.
One or more cushions may be disposed between at least one of said plurality of faces of said bundle of flat panel displays and said hollow walls of said enclosure.
The bundle of flat panel displays includes spacer sheets disposed between adjacent flat panel displays of said bundle of flat panel displays.
The outer shell portion of at least one of said first enclosure portion and said second enclosure portion may channel recesses.
In an embodiment the enclosure has a bottom enclosure portion including an inner shell portion integral with an outer shell portion, said inner shell portion and said outer shell portion defining a hollow interior therebetween, said inner shell portion including a load bearing member having a perimeter portion, said load bearing member being at least partially suspended from a distinct and continuous flexure extending from said perimeter portion, said distinct and continuous flexure enabling entirety of said load bearing member to be displaced toward said outer shell portion when a force is applied to said load bearing member; and a top enclosure portion including an inner shell portion integral with an outer shell portion, said inner shell portion and said outer shell portion defining a hollow interior therebetween, said top enclosure portion cooperating with said bottom enclosure portion and forming a enclosure, said enclosure having a plurality of exterior faces and presenting hollow walls adjacent all of said plurality of faces.
In said embodiment, the load bearing member may include at least one pillar having a distal end that extends into said hollow interior of said bottom enclosure portion.
At least one pillar may contact said outer shell portion and may include at least one flexure that flexes when said at least one pillar is loaded with an axial force. The bottom enclosure portion and the top enclosure portion may be substantially identical and cooperate to restrict lateral translation of said bottom enclosure portion relative to said top enclosure portion.
The panel shipper inner shell portion may include a continuous ridge structure 5 having an inner wall, with at least one flexure being integral with said inner wall and said inner wall and said load bearing member defining a receptacle.
The inner shell portion may include a bridging member between said at least one flexure and said inner wall, where said bridging member defines a recess.
The inner shell portion may include structure defining corner recesses extending 10 outward from said receptacle portion.
A plurality of elongate recesses may be formed on said outer shell portion to accommodate straps for holding said bottom enclosure portion and said top enclosure portion together.
In an embodiment a first enclosure portion and a second enclosure portion that 15 cooperate to form a enclosure about a payload; and means for isolating said payload from impact loads as described herein.
The invention includes a method of making a flat panel shipper, comprising in one embodiment the steps of:
designing a shipper for transport of at least one flat panel, said shipper including a 20 hollow-walled structure having an inner shell portion and an outer shell portion, said inner shell portion including a load bearing member for contact with said at least one flat panel, said load bearing member being at least partially suspended by at least one flexure;
providing a mold for production of a first portion of said shipper, said first portion including said at least one flexure; and, molding said first portion of said shipper to 25. produce said hollow-walled structure for isolation of said payload from impact loads, said first portion of said shipper having said at least one flexure.
Additional steps may include one or more of the following: the step of designing a shipper included designing at least one pillar operatively coupled with said load bearing member and extending into said hollow-walled structure;
the step of providing a mold to produce a first portion of said shipper includes providing said mold to produce said first portion to include said at least one pillar;
the step of molding a first portion of a shipper includes producing said first portion with said at least one pillar;
the step of forming at least one dimple structure on said outer shell portion, each of said at least one dimple structure contacting a corresponding at least one pillar;
the step of designing said shipper includes designing said at least one flexure to deliver a predetermined load distribution to said at least one flat panel;
the step of molding a first portion of a shipper includes a process selected from the group consisting of blow molding and rotational molding; and
the step of molding a second portion of said shipper with said mold, said second portion cooperating with said first portion to form an enclosure.
In a further embodiment of the invention a method of using a shipper for shipping a plurality of fragile flat panels, comprises one or more of the following steps:
selecting a shipper including a first enclosure portion and a second enclosure portion, each of said first and second enclosure portions including a hollow-walled structure having an inner shell portion and an outer shell portion, wherein said inner shell portion of said first enclosure portion defines a receptacle portion including a load bearing member for contacting said plurality of fragile flat panels, said load bearing member being at least partially supported by at least one flexure;
disposing said plurality of fragile flat panels within said receptacle portion of said first enclosure portion;
coupling said second enclosure portion with said first enclosure portion to form an enclosure about said plurality of fragile flat panels; securing said first enclosure portion to said second enclosure portion;
disposing at least one cushion member within said receptacle portion of said first enclosure portion for partially isolating said plurality of fragile flat panels from said first enclosure portion;
securing said first enclosure to said second enclosure includes exerting a clamping force between said first enclosure portion and said second enclosure portion with at least one strap.
In a further embodiment, the invention includes a flat panel shipper in combination with a bundle of panel displays, comprising:
an enclosure containing said bundle of panel displays having a plurality of faces, said enclosure providing a hollow wall opposite each of said plurality of faces of said bundle of panel displays, said enclosure including at least one load bearing member in contact with said bundle of panel displays;
a plurality of flexures operatively coupled with said load bearing member, said plurality of flexures deflecting when contacting said bundle of panel displays; and
a plurality of pillars operatively coupled with said load bearing member, said pillars restricting the deformation of said load bearing member.
Additionally, the enclosure may include a first portion and a second portion, said first and second portions being substantially identical, said first portion and said second portion cooperating to restrict lateral translation of said first portion relative to said second portion.
An advantage of the various embodiments of the present invention is that the manufacturing cost of the shipper is inexpensive relative to state of the art shippers.
Another advantage of certain embodiments is a reduced weight compared with other shippers known in the art, which may reduce the cost of return shipment for reuse. Still another advantage of particular embodiments of the invention is that a shipper can be designed or "tuned" so that a predetermined compressive or clamping force is exerted on the payload within the blow molded or rotationally molded box.
A further advantage of particular embodiments of the invention is that the container may be configured for insertion or removal of the payload by both manual and automated means.
Another advantage of certain embodiments of the invention is that the top and bottom portions are symmetrically complimentary, thus enabling them to be made from the same mold.
A further advantage of certain embodiments is that the exterior may be produced with elongate recesses that enable a low profile utilization of straps while providing an added measure of structural rigidity to the shipper.
Further advantages of the exemplary embodiments of the invention may become apparent to those skilled in the art upon review of the figures and descriptions of the present invention herein.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross-sectional depiction of a flat panel shipper containing a panel bundle in an embodiment of the invention.
FIG. 2 is an enlarged partial sectional view of the panel bundle of FIG. 1.
FIG. 3 is an isolated cross-sectional view of the top portion of the flat panel shipper of FIG. 1.
FIG. 4 is an enlarged partial sectional view of a pillar flexure of FIG. 1.
FIG. 5 is an enlarged partial sectional view of a continuous perimeter flexure of FIG. 1.
FIG. 6 is a plan view of the top portion of the flat panel shipper of FIG. 1. FIG. 7 is a plan view of the bottom portion of the flat panel shipper of FIG. 1.
FIG. 8 is an isolated cross-sectional view of the bottom portion of the flat panel shipper of FIG. 1.
FIG. 9a is a cross-sectional view of a flat panel shipper partially assembled and containing a panel bundle in an embodiment of the invention.
FIG. 9b is a partial cross-sectional view of the flat panel shipper of FIG. 9a fully assembled.
FIG. 9c is a partial, isolated view depicting the deflection of the load bearing member, perimeter flexures and pillar flexures of FIG. 9a.
FIG. 10 is a plan view of the bottom portion of a flat panel shipper of FIG. 9.
FIG. 11 is a cross-sectional view of the bottom portion of the flat panel shipper of FIG. 9.
FIG. 12 is a cross-sectional view of a bottom portion of a flat panel shipper in an embodiment of the invention.
FIG. 13 is an enlarged cross-sectional view of a pillar of the flat panel shipper of
FIG. 12.
FIG. 14 is an enlarged cross-sectional view of a pillar of a flat panel shipper in an embodiment of the invention.
FIG. 15 is a cut-away perspective view of a flat panel shipper in an embodiment of the invention.
FIG. 16 is a perspective view of a flat panel shipper having interchangeable top and bottom portions in an embodiment of the invention.
FIG. 17 is a perspective view of the interchangeable top or bottom portion of the flat panel shipper of FIG. 16. FIG. 18 portrays a ridge structure of a flat panel shipper in isolation in an embodiment of the invention.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Referring to FIGS. 1 through 8, an embodiment of a flat panel shipper 20 with a stack of flat panels received therein according to the invention is portrayed. The flat panel shipper 20 comprises two enclosure portions: a top portion 22 and a bottom portion 24 defining a receiving region or pocket therebetween. The top portion and bottom portions are engaged at a juncture 24.1 and have respective juncture portions 24.2, 24.3 with interlacing structure 24.5, 24.6 that in FIG. 1 is shown radially interlaced. FIGS. 16 and 17 illustrate circumferential interlacing of the juncture portions 22.1. The top portion 22 may have a substantially rectangular footprint of a width 23 and a length 25, and an overall height 27. The top portion 22 may also be of a blow molded or rotationally molded construction that produces a hollow-walled structure 26 formed by an outer shell portion 28 integral with an inner shell portion 29. In this embodiment, a continuous lip portion or ridge structure 30 extends around the outer perimeter 32 of the top portion 22. A bridging member 33 may be formed between an inner sidewall 35 of the ridge structure 30 and a perimeter flexure 36 to define an annular recess 34. The shipper and stack have an axis 39.
For purposes of this patent application, a "flexure" is a distinct portion of a structure that bridges a first and a second portion of the structure and deforms when there is relative movement between the first and second portions of the structure so as to mitigate deformation of the first and second portions and to facilitate the movement between said first and second portions. The flexure may be formed integrally with the first and second portions, or be formed separately for subsequent attachment therebetween. The deforming function of the flexure may be accomplished by a variety of configurations that reduce the stiffness of the flexure relative to the first and second portions. The reduced stiffness may be accomplished by a geometric shape that includes one or more inflections (bends, curves or folds), or by providing the flexure with thinner walls relative to the first and second portions, or by fabricating of the flexure out of a material that is more compliant than the first and second portions, or by a combination thereof. When used herein, "contact," "engage," "connect" does not require direct element to element contact, there may be intermediate components, portions or materials. "Bundle" when used herein does not require a fastening of the stack.
The perimeter flexure 36 may be a single, continuous flexure (as depicted) or may discontinuous, thereby forming a plurality of perimeter flexure elements (not depicted). The perimeter flexure may be integral to a panelar bearing platform or load bearing member 38 that provides a load bearing force 39.1 normal to the panelar bearing platform
38 and parallel to the axis 39. A pair of cavities 40 and 42 may be formed on the load bearing member 38 to define a pair of pillars 44 and 46 that extend into the hollow-walled structure 26. The pillars 44, 46 may be frustum-shaped as depicted in the FIG. 1 embodiment, or of another shape suitable for the application such as a cylinder, hemisphere, polygon or some combination thereof. The openings of each of the cavities
40 and 42 may be ringed with a continuous pillar flexure 48.
The perimeter flexure 36 for the embodiment of FIG. 1 forms a generally S-shaped or U-shaped cross section 50 having a thickness 52, a lateral dimension 53, and an inflective portion 51 of axial dimension 54, as best seen in FIG. 5. Likewise, the FIG. 1 embodiment includes pillar flexures 48 that are also of a general S-shaped or U-shaped cross-section 56, having a thickness 58, a lateral dimension 57 and an inflective portion 55 of axial dimension 60, as best depicted in FIG. 4.
A plurality of channel recesses 62 may be formed on the outer shell portion 28, spanning the width 23 and extending down the sides of the ridge structure 30.
The bottom portion 24 may be of similar construction to the top portion 22. Specifically, the bottom portion 24 may be of the same general length 25 and width 23, may have a hollow interior 64 with an outer shell portion 65 integral with an inner shell portion 63, and may have an annular recess 66 integrally joined to a bearing platform or load bearing member 68 through a continuous perimeter flexure 70 having an S-shaped cross-section. A pair of frustum-shaped pillars 72 and 74, each having a proximal end 71 and a distal end 73, may extending into the hollow interior 64 from pillar flexures 76 at the proximal ends 71 having S-shaped or U-shaped cross-sections that extend from the load bearing member 68. A gap 77 may be formed between the pillars 72 and 74 and the outer shell portion 65. The configuration of the various S-shaped flexures 70 and 76 may be generally the same as their respective counterpart components 36 and 48 on the top portion 22. Also, the bottom portion may include channel recesses 75 formed in the outer shell portion 65 that extend the width 23 and down two sides 78 and 80 of the bottom portion 24. The recesses 75 may be positioned to align with the annular recesses 66 when the top portion 22 is placed over bottom portion 24.
The bottom portion 24 of the FIG. 1 embodiment also has a continuous ridge structure 82 with an inner perimeter 83. The ridge structure 82 may be recessed from the outer perimeter 84 of the bottom portion 24, thereby defining a continuous shoulder 86. A receptacle portion 89 may be defined generally by the inner perimeter 83 of the ridge structure 82 and the load bearing member 68. A continuous perimeter channel 90 may be formed on the outer perimeter 84 of the bottom portion 24. The inner perimeter 83 may further include corner recesses 87 formed at each corner of the ridge structure 82, the corner recesses 87 extending outward from the receptacle portion 89 and may define an outer extremity of the inner perimeter 83. The bottom portion of the FIG. 1 embodiment also has an overall axial length 88 that is greater than the overall axial length 27 of the top portion 22.
The flat panel shipper 20 is portrayed as containing a panel bundle 92 in FIG. 1. The panel bundle 95 is characterized by a plurality of faces 97. The panel bundle 92 as depicted comprises a plurality of flat panels 94 which may be LCD assemblies or the finished glass substrates for use in LCD assemblies. The fiat panels 94 may be separated interstitially by spacer sheets 96. In the case of a flat panel display (FPD) cell shipper, a representative and non-limiting range of panel sizes may range from approximately 200- mm width x 280-mm length (so-called "Gen 1" display panels) to 1.0-m width by 1.2-m length (so-called "Gen 6" display panels). A representative range of thicknesses for the glass substrates is 0.7- to 1.1 -mm, which would approximately double in the case of LCD assemblies. The number of glass substrates or LCD assemblies in this case may range from a single panel to 20 or more panels for a thickness of the panel bundle 92 ranging from approximately 1-ram to 45-mm or more. The weight of the panel bundle 92 may range from less than 1-kg to more than 150-kg (330-lbf).
The spacer sheets may be made of embossed polyethylene of 0.5-mm to 0.8-mm thickness. Other materials and thicknesses may be used as appropriate. The receptacle portion 89 may be dimensioned so that there is a gap 98 between the edges 100 of the panel bundle 92 and the inner perimeter 83 of the ridge structure 82. In the case of a flat panel display cell shipper, an exemplary and non-limiting radial thickness of the gap 98 may average approximately 3-mm. A representative and non-limiting range for the thickness of the hollow-walled structure is 20-mm to 100-mm.
The top portion 22 may cooperate with the bottom portion 24 to form a enclosure 101. In this embodiment, the ridge structure 82 and shoulder 86 of the lower portion 24 mate with the annular recess 34 and ridge structure 30 of the top portion 22. The enclosure 101 provides the hollow-walled structure 26 opposite each of the faces 97 of the panel bundle 92.
A plurality of straps 102 may be disposed in the elongate or channel recesses 62 and 75 to clamp the top portion 22 and the bottom portion 24 together. An elastic band 104 may also be disposed in the perimeter channel 90 of the bottom portion 24 and routed outside the straps 102.
In operation, the panel bundle 92 or other payload is placed on the load bearing member 68 in the receptacle portion 89 of the bottom portion 24, causing the perimeter flexure 70 to flex downward and rotate about a junction 106 between the bottom of the annular recess 66 and the perimeter flexure 70. The rotational movement about the entire perimeter of the load bearing member 68 may cause the load bearing member 68 to be displaced downward and to bow away from the panel bundle 92.
In the embodiment of FIG. 1, the pillars 72 and 74 maintains at least a minimum separation between the inner shell portion 63 and the outer shell portion 65. If the lower portion 24 did not include the pillars 72 and 74 as configured, such bowing of the load bearing member 68 may cause the panel bundle 92 to be supported only by line contact at a junction 108 between the load bearing member 68 and the perimeter flexure 70.
However, in the embodiment of FIG. 1, the bowing and displacement of load bearing member 68 causes the pillars 72 and 74 to traverse the gap 77 and engage with the outer shell portion 65 of the bottom portion 24. The stiffness of the pillars 72 and 74 causes the platform 68 to maintain contact with the center portion of the panel bundle 92, providing a more even distribution of load and reducing the interface pressure over the lower face of the panel bundle 92. The local force exerted by the pillars 72 and 74 on the panel bundle 92 is mitigated when the pillar flexures 76 are utilized because they flex when the pillars
72, 74 experience an axial force. The clamping action of the straps 102 may cause the top portion 22 to react in a similar fashion to the static loading of the bottom portion 24. The clamping force can push the load bearing member 38 against the panel bundle 92, causing the load bearing member 38 to displace and bow, thereby creating contact between the pillars 40, 42 and the outer shell portion 28 and restoring contact between the load bearing member 38 and the central portion of the upper face of the panel bundle 92. A more uniform contact pressure is thereby exerted on the panel bundle 92. In this way, the straps 102 can exert a pressure on the upper and lower faces of the panel bundle 92 to inhibit movement of the panel bundle 92 within the flat panel shipper 20 during shipping and handling.
The perimeter flexure 70 may be stretched and contracted in the lateral direction.
This, in combination with the hollowness of the ridge structure 82, provides shock absorption that protects the panel bundle 92 from impacts on the sides of the flat panel shipper 20.
The deflections and rotations of the various flexures 36, 48, 70 and 76 and attendant reaction forces exerted on the panel bundle 92 by the load bearing members 38 and 68 is a function of many parameters, including the flexure thicknesses 52, 58, the axial dimensions 54, 60, and the lateral dimensions 53, 59. The weight of the panel bundle 92 and the dimensions of the load bearing members 38, 68 may also be factors. These parameters can be optimized or "tuned" during design of the flat panel shipper to deliver a predetermined distribution of loads over the panel bundle 92. After the shipper is molded further tuning may be provided by subsequent operations such as material removal to thin portions of flexures.
Alternative cross-sections for the various flexures 36, 48, 70 and 76 may also be implemented. For example, additional inflective members may be added to the cross- sections 50 or 56 to form a bellows-like flexure. The inflective members may be substantially arcuate, or may have a more abrupt inflection such as with a pleated structure. Embodiments of the invention may be designed not only for optimum or desired distribution of a given static load, but also for distribution of additional dynamic or impact loads encountered during the shipping process (e.g. dropping the unit).
In addition to taking on other forms, the pillar flexures 48, 76 may take may be located elsewhere on the pillar structure (not depicted). For example, the flexure 76 may be proximate the distal end 73 of the pillar 72 or 74 to produce the same functionality. Likewise, other flexure arrangements may be incorporated between the proximal end 71 and distal end 73 of the pillar 72 or 74 to provide the same functionality. Such flexures may be provided as an alternative to, or in addition to, the pillar flexures 48, 76.
The corner recesses 87 enable the corners of the panel bundle 92 to remain untouched during shipping. Historically, damaged panel bundles typically incur damages at the corners. Hence, certain embodiments of the invention provide the corner recesses 87 to isolate the corners of the panel bundle 92 during shipment. Side loads on the panel bundle 92 is thus restricted to the mid sections of the edges 100. The corner recesses 87 also enable manual removal of the panel bundle 92 as well as individual flat panels 94 because they accommodate tools or human fingers used to grip the corner regions of the panel bundle 92 or individual flat panels 94. The corner recesses 87 also provide strain relief to the structure of the bottom portion 24, thereby increasing the life of the flat panel shipper.
The embodiment of FIG. 1 also accommodates automated unloading and handling of the flat panels 94. Many automatic handlers utilize a vacuum or suction device that lifts the flat panels 94 individually off the panel bundle 92. The flat panel shipper 20 is conducive to such automatic handling because once the top portion 22 is removed there is nothing structural inhibiting the panels 94 from being lifted away from the panel bundle 92.
The spacer sheets 96 may be utilized to dissipate static charges, such as by use of an electrical dissipative grade of polyurethane.
Referring to FIGS. 9a, 10 and 11, an alternative embodiment of the flat panel shipper 20 is illustrated wherein the inset ridge structure of the bottom portion 24 is effectively eliminated and a cushion 110 is disposed in the annular recess 66 of the bottom portion around the edges 100 of the panel bundle 92. The lateral location of the perimeter flexure 70 may be located further outward, closer to the edges 100 of the panel bundle 92, than in the configuration of FIG. 1. In the embodiment depicted, the upper portion 22 is not modified from the previous embodiment. The cushion 110 cooperates with the top portion 22 to register within the annular recess 34 of the top portion 22. The cushion 110 may be of any suitable compliant material or construction, such as an open or closed cell foam rubber or polyurethane, an inflatable cushion, or other cushion materials or configurations available to the artisan.
The cushion 110 may be continuous, or in segments 111 that provide voids 112 at the corners as shown in FIG. 10. The segments 111 may be removably held in place by an interference fit between the edges 100 of the panel bundle 92 and the inner perimeter 83 of the ridge structure 82, or captured in place by insets 113 on the interior of the corners without resorting to an interference fit against the edges 100 of the panel bundle 92.
Optionally, the segments may be attached to the bottom of the annular recess 66 for permanent installation, for example with an adhesive, or for temporary installation, such as by VELCRO.
Operationally, the embodiment of FIG. 9a provides additional protection against impact. The cushion 110 provides additional shock absorption for the edges 100 of the panel bundle 92. The voids 112, when present, limit contact with the corner portions of the panel bundle 92, akin to the corner recesses 87 of the FIG. 1 configuration.
The voids 112 function in the same manner as the corner recesses 87 of the FIG. 1 configuration, enabling manual removal of flat panels 94 while leaving the segments 111 in place. For configurations where the segments 111 are removable, removal of the segments 111 enables access to the edges of the flat panels 94 for manual removal, or providing unfettered removal from the panel bundle 92 by automation, such as by a vacuum or suction.
Referring to FIGS. 9b and 9c, the operation of the flat panel shipper in response to a load or a clamping force 103 is depicted. In the FIG. 9b embodiment, the clamping force 103 may be exerted by cinching the straps 102 about the flat panel shipper 20 to draw the top portion 22 into contact with the bottom portion 24 and form the enclosure 101. Other mechanisms (not depicted) such as clasps, pinched flanges or external wrappings may be utilized apply the clamping force 103 and draw the top and bottom portions 22 and 24 together.
A seal (not depicted) such as a gasket, o-ring or elastomeric material may be disposed interstitially between the top portion 22 and the bottom portion 24 at the line of contact to provide a barrier against particulates and moisture. In addition or in the alternative, the panel bundle 92 may be wrapped with a material (not depicted) such as a shrink wrap, and or the flat panel shipper 20 may be wrapped on the exterior to prevent contaminates from entering the enclosure 101.
A portion of the clamping force 103 exerted by the straps 102 is translated to the load bearing members 38 and 68 of the flat panel shipper 20 and acts in a direction substantially parallel to the enclosure-stack axis 39. The clamping force 103 may cause the pillars (e.g. 42 and 72) to close the gaps 77 and contact the outer shell portions 28 and
65. Once this contact is made, a portion of any additional inward translation of the load bearing members 38 and 68 along the load bearing axis 39 may cause the pillar flexures 48 and 76 to flex. The depiction of FIG. 9a shows the gap 77 as still being present between the pillar 72 and the outer shell portion 65 of the bottom portion 24. Other embodiments may deflect enough under the load of the panel bundle 92 to close the gap 77.
The flexing action of the perimeter flexure 70 and one of the pillar flexures 76 of the load bearing member 68 of the bottom portion 24 is depicted in isolation in FIG. 9c. A total displacement δ is depicted, with the loaded position shown in phantom. The deflection δ of the load bearing member 68 of the lower portion 24 may be caused in part by the weight of the flat panel bundle 92 and in part by the force exerted by the straps 102. The presence of the flexures 70 and 76 enables translation of the load bearing member 68 along the load bearing axis 39 with less deformation of the panelar portions of the load bearing member 68 than would be present in the absence of the flexures 70 or 76. The same effect may be observed for the load bearing member 38 of the top portion 22.
Referring to FIGS. 12 through 14, an embodiment of the bottom portion 24 is portrayed wherein the gap 77 is breached by a dimple structure 114 formed on the outer shell portion 65. The region of the pillar 72 is illustrated in FIG. 13 in an example as- molded state. The same region is depicted in FIG. 14 after the dimple structure 114 has been formed. An equivalent operation may be performed on the top unit 22 to provide similar functionality.
The dimple structure 114 may provide immediate loading of the pillars 72, 74 upon placement of a static load on the load bearing member 68 of the bottom portion 24. The perimeter flexure 70 does not have to deflect axially to engage the pillars 72, 74, and thus the load bearing member 68 does not experience the initial bowing that the above disclosed embodiments before the pillars 72, 74 engage to correct the deformation. Accordingly, the contact area of the load bearing member 68 may be increased.
Referring to FIG. 15, another embodiment of the flat panel shipper 20 is depicted, incorporating both the dimple structures 114 and the cushion 110 aspects of the invention. Also in this embodiment, the top portion 22 and the bottom portion 24 are of substantially identical configuration. The elastic band 104 may be located only on the bottom portion as depicted. The straps 102 hold the flat panel shipper 20 together. In FIG. 15 the straps
102 are portrayed in a somewhat loosened state because the ridge portion 30 and the annular recess 34 of the top portion 22 is not seated against the shoulder 86 of the bottom portion and the cushion 110, respectively.
The top and bottom portions 22 and 24 of the FIG. 15 embodiment may be identical, and thus may be manufactured using the same molding. Replacement portions 22, 24 are easier to stock. The lateral position of the top portion 22 relative to the bottom portion 24 may be maintained by the clamping force exerted by the straps 102, and by the shear resistance of the cushion 110. Another advantage is that the cushions 110 may be located interstitially between the faces 97 of the panel bundle 92 and the hollow-walled structure opposite the faces 97 to provide additional absorption of impact loads.
Referring to FIGS. 16 and 17,. an embodiment of a flat panel shipper 20 is portrayed having identical and complimentary enclosure portions 115. Like previous embodiments, the corner recesses 78 and the annular recess 34 aspects are retained. The embodiment further includes raised comers 116 and 118 on opposed diagonal comers of the continuous ridge structure 30, complimented by recessed comers 120 and 122 on the remaining diagonal corners. The raised corners 116, 118 mate with the recessed corners 120, 122.
Functionally, the embodiment of FIG. 16 includes the advantage of identically constructed enclosure portions 115, again enabling fabrication from the same molding and easier stocking of replacement units. In addition, the interlocking of the raised corners 116, 118 with the recessed corners 120, 122 counters any translational shear forces that the flat panel shipper 20 may encounter. Referring to FIG. 18, another embodiment of a ridge structure 125 is shown in isolation including side midspah portions 124, end midspan portions 126 and corner portions 128. The side midspan portions are further divided into a raised portion 130 and a recessed portion 132 relative to a top surface 134 of the corner portions 128. One of the end midspan portions 126 may be in a recessed configuration 136, the other end midspan portion having a raised configuration 132. The ridge structure 125 is symmetrical such that identical units compliment each other and interlock.
The ridge structure 125, upon implementation into the enclosure portions 115 or the top and bottom portions 22 and 24, retains all the advantages of the FIG. 17 embodiment. In addition, interlocking ridge structures 125 also resist any rotational shear forces exerted on the assembly.
The foregoing discussion is directed to the shipment of panel bundles. It is noted that the various embodiments may be configured for the shipment of single panels, such as a quartz glass photomask.
The invention may be embodied in other specific and unmentioned forms, apparent to the skilled artisan, without departing from the spirit or essential attributes thereof, and it is therefore asserted that the foregoing embodiments are in all respects illustrative and not to be construed as limiting.
References to relative terms such as upper and lower, front and back, left and right. or the like, are intended for convenience of description and are not contemplated to limit the present invention, or its components, to any specific orientation. All dimensions depicted in the figures may vary with a potential design and the intended use of a specific embodiment of this invention without departing from the scope thereof.
Each of the additional figures and methods disclosed herein may be used separately, or in conjunction with other features and methods, to provide improved systems and methods for making and using the same. Therefore, combinations of features and methods disclosed herein may not be necessary to practice the invention in its broadest sense and are instead disclosed merely to particularly describe representative and preferred embodiments of the instant invention.

Claims

CLAIMSWhat is claimed is:
1. A combination flat panel shipper for transport of a bundle of flat panel displays and the bundle of flat panel displays, comprising:
a first enclosure portion; and
a second enclosure portion,
said first enclosure portion cooperating with said second enclosure portion to form an enclosure for containing said bundle of flat panel displays, said bundle of flat panel displays having a plurality of faces,
each of said first and said second enclosure portions including an inner shell portion integral with an outer shell portion such that said enclosure provides hollow walls opposite each of said plurality of faces of said bundle of flat panel displays.
2. The combination of claim 1 wherein said inner shell portion of at least one of said first enclosure portion and said second enclosure portion includes:
a deflectable panelar member having a perimeter portion and defining a load bearing axis substantially normal to said deflectable panelar member, said deflectable panelar member being at least partially supported by at least one flexure operatively coupled to said perimeter portion, said at least one flexure enabling entirety of said deflectable panelar member to deflect along said load bearing axis when a force is applied to or withdrawn from said deflectable panelar member.
3. The combination of claim 2 wherein said at least one flexure is selected from the group consisting of an S-shaped flexure, a U-shaped flexure, a bellows flexure and a pleated flexure.
4. The combination of claim 1 wherein said first enclosure portion and said second enclosure portion are substantially identical and cooperate to restrict translation of said first enclosure relative to said second enclosure portion in a direction orthogonal to said load bearing axis.
5. The combination of claim 4 wherein said first enclosure portion and said second enclosure portion cooperate to restrict rotation of said first enclosure relative to said second enclosure portion about said load bearing axis.
6. The combination of claim 1 wherein at least one of said first and said second enclosure portions include at least one pillar extending from either of said inner shell portion or said outer shell portion into said hollow-walled structure to maintain at least a minimum separation between said inner shell portion and said outer shell portion where said at least one pillar are located, said at least one pillar including at least one flexure that enables said panelar load bearing member to deflect along said load bearing axis when a force is applied to or withdrawn from said load bearing member.
7. The combination of claim 6 wherein said flexure is disposed between said pillar and either of said inner shell portion or said outer shell portion from which said pillar extends.
8. The combination of claim 1 further comprising at least one cushion disposed between at least one of said plurality of faces of said bundle of flat panel displays and said hollow walls of said enclosure.
9. The combination of claim 1 wherein said bundle of flat panel displays includes spacer sheets disposed between adjacent flat panel displays of said bundle of flat panel displays.
10. The combination of claim 1 wherein said first and second enclosure portions are of a blow molded or a rotationally molded construction.
11. The combination of claim 1 wherein said outer shell portion of at least one of said first enclosure portion and said second enclosure portion include channel recesses.
12. A panel shipper for transporting at least one panel, comprising
a bottom enclosure portion including an inner shell portion integral with an outer shell portion, said inner shell portion and said outer shell portion defining a hollow interior therebetween, said inner shell portion including a load bearing member having a perimeter portion, said load bearing member being at least partially suspended from a distinct and continuous flexure extending from said perimeter portion, said distinct and continuous flexure enabling entirety of said load bearing member to be displaced toward said outer shell portion when a force is applied to said load bearing member; and
a top enclosure portion including an inner shell portion integral with an outer shell portion, said inner shell portion and said outer shell portion defining a hollow interior therebetween, said top enclosure portion cooperating with said bottom enclosure portion and forming a enclosure, said enclosure having a plurality of exterior faces and presenting hollow walls adjacent all of said plurality of faces.
13. The panel shipper of claim 12 wherein said load bearing member further includes at least one pillar having a distal end that extends into said hollow interior of said bottom enclosure portion.
14. The panel shipper of claim 13 wherein said at least one pillar contacts said outer shell portion and includes at least one flexure that flexes when said at least one pillar is loaded with an axial force.
15. The panel shipper of claim 12 wherein said bottom enclosure portion and said top enclosure portion are substantially identical and cooperate to restrict lateral translation of said bottom enclosure portion relative to said top enclosure portion.
16. The panel shipper of claim 12 wherein said inner shell portion includes a continuous ridge structure having an inner wall, said at least one flexure being integral with said inner wall, said inner wall and said load bearing member defining a receptacle.
17. The panel shipper of claim 16 wherein said inner shell portion includes a bridging member between said at least one flexure and said inner wall, said bridging member defining a recess.
18. The panel shipper of claim 16 wherein said inner shell portion includes structure defining comer recesses extending outward from said receptacle portion.
19. The panel shipper of claim 12 further comprising a plurality of elongate recesses formed on said outer shell portion to accommodate straps for holding said bottom enclosure portion and said top enclosure portion together.
20. The panel shipper of claim 12 wherein the top enclosure portion and bottom enclosure portion contact at respective juncture portions; and wherein said juncture portions have at least one of circumferential interlacing structure and radially interlacing structure.
21. A shipper comprising:
a first enclosure portion and a second enclosure portion that cooperate to form a enclosure about a payload; and
means for isolating said payload from impact loads.
22. A method of making a flat panel shipper, comprising:
designing a shipper for transport of at least one flat panel, said shipper including a hollow-walled structure having an inner shell portion and an outer shell portion, said inner shell portion including a load bearing member for contact with said at least one flat panel, said load bearing member being at least partially suspended by at least one flexure;
providing a mold for production of a first portion of said shipper, said first portion including said at least one flexure;
molding said first portion of said shipper to produce said hollow-walled structure for isolation of said payload from impact loads, said first portion of said shipper having said at least one flexure.
23. The method of claim 22 wherein:
the step of designing a shipper includes designing at least one pillar operatively coupled with said load bearing member and extending into said hollow-walled structure;
the step of providing a mold to produce a first portion of said shipper includes providing said mold to produce said first portion to include said at least one pillar; and
the step of molding a first portion of a shipper includes producing said first portion with said at least one pillar.
24. The method of claim 23 further comprising forming at least one dimple structure on said outer shell portion, each of said at least one dimple structure contacting a corresponding at least one pillar.
25. The method of claim 22 wherein the step of designing said shipper includes designing said at least one flexure to deliver a predetermined load distribution to said at least one flat panel.
26. The method of claim 22 wherein the step of molding a first portion of a shipper includes a process selected from the group consisting of blow molding and rotational molding.
27. The method of claim 22 further comprising:
molding a second portion of said shipper with said mold, said second portion cooperating with said first portion to form an enclosure.
28. A method of using a shipper for shipping a plurality of fragile flat panels, comprising:
selecting a shipper including a first enclosure portion and a second enclosure portion, each of said first and second enclosure portions including a hollow-walled structure having an inner shell portion and an outer shell portion, wherein said inner shell portion of said first enclosure portion defines a receptacle portion including a load bearing member for contacting said plurality of fragile flat panels, said load bearing member being at least partially supported by at least one flexure;
disposing said plurality of fragile flat panels within said receptacle portion of said first enclosure portion;
coupling said second enclosure portion with said first enclosure portion to form an enclosure about said plurality of fragile flat panels; and
securing said first enclosure portion to said second enclosure portion.
29. The method of claim 28 further comprising: disposing at least one cushion member within said receptacle portion of said first enclosure portion for partially isolating said plurality of fragile flat panels from said first enclosure portion.
30. The method of claim 27 wherein the step of securing said first enclosure to said second enclosure includes exerting a clamping force between said first enclosure portion and said second enclosure portion with at least one strap.
31. A flat panel shipper in combination with a bundle of panel displays, comprising:
an enclosure containing said bundle of panel displays having a plurality of faces, said enclosure providing a hollow wall opposite each of said plurality of faces of said bundle of panel displays, said enclosure including at least one load bearing member in contact with said bundle of panel displays;
a plurality of flexures operatively coupled with said load bearing member, said plurality of flexures deflecting when contacting said bundle of panel displays; and
a plurality of pillars operatively coupled with said load bearing member, said pillars restricting the deformation of said load bearing member. •
32. The flat panel shipper of claim 31 wherein said enclosure includes a first portion and a second portion, said first and second portions being substantially identical, said first portion and said second portion cooperating to restrict lateral translation of said first portion relative to said second portion.
33. A flat panel shipper in combination with a bundle of panel displays, comprising:
an enclosure comprising a first enclosure portion and a second enclosure portion, the first and second joinable at a juncture to define an inner pocket containing said bundle of flat panels, each of the first enclosure portion and second enclosure portion having a juncture portion for engaging the juncture portion of the other of the first enclosure portion and second enclosure portion, the respective juncture portions having interlacing structure for limiting portions having interlacing structure for limiting translational movement between the first and second enclosure portions.
34. The flat panel shipper of claim 33 wherein the interlacing structure is interlaced in a circumferential arrangement.
35. The flat panel shipper of claim 33 wherein the interlacing structure is interlaced in a radial arrangement.
PCT/US2007/009721 2006-04-22 2007-04-23 Flat panel display shipper WO2007124094A2 (en)

Applications Claiming Priority (2)

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US79400206P 2006-04-22 2006-04-22
US60/794,002 2006-04-22

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CN108792280A (en) * 2018-06-26 2018-11-13 芜湖广智天和信息技术有限公司 A kind of computer hardware mainboard packing box for transportation

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CN107934216B (en) * 2017-11-30 2024-01-23 广东美的制冷设备有限公司 Air conditioner outdoor unit with packaging structure

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TW200817249A (en) 2008-04-16

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