Restraining dense packaging system for LCD glass sheets

Abstract

A reusable dense packaging system used to transport large size display substrates, is provided made up of three main components; a pallet frame, a cover, and restraining means. The restraining means securely hold the glass sheets within the cover and on the pallet frame. Restraining means includes one or more retaining bars moving towards and away from the front of the glass sheets and a mechanical system. The mechanical system may include the use of a pressing panel, a belt apparatus, a scissor-like mechanism, positioning devices, or a retaining bar pulling system, each capable of moving towards and away from the front of the glass sheets. Each embodiment allows for packaging from 1 to N glass sheets with flexibility and stability and with manual or automatic operation.

Description

BACKGROUND OF THE INVENTION [0001] 1. FIELD OF THE INVENTION [0002] The present invention relates generally to packaging, and particularly to packaging for large size display substrates, such as a stack of glass sheets. [0003] 2. TECHNICAL BACKGROUND [0004] In recent years, glass substrates for Liquid Crystal Display (LCD) panels have increased in size, along with enlargement of Liquid Crystal Display panel sizes. [0005] Conventional non-contact packaging, such as PP-case and L-supporter, has dominated the market as the delivery model for smaller size glass substrates, such as Gen 4, 730 mm×920 mm, or smaller. Recognizing limitations in packing density, their requirements for significant storage space, and the difficulty to extend their application to ever-increasing sizes, these conventional non-contact or spacer type packages have effectively reached a practical limitation for glass sizes greater than or equal to Generation 5. [0006] Pursuant to the trend for larger and larger sub...

AI Technical Summary

Benefits of technology

[0020] One aspect of the present invention includes a container for packaging and transporting one or more glass sheets where the container includes a frame having a pallet with a base, a cover secured to the pallet such that said one or more g

Problems solved by technology

Recognizing limitations in packing density, their requirements for significant storage space, and the difficulty to extend their application to ever-increasing sizes, these conventional non-contact or spacer type packages have effectively reached a practical limitation for glass sizes greater than or equal to Generation 5.

When containers of these types are used, however, the size of glass sheets to be transported is limited.

Further, these containers, though adequate enough in delivery, is poor in mechanical strength.

In addition, the glass sheets are undesirably susceptible to contamination during transportation, since the crates or boxes are also poor in weatherability, often requiring over-pack (e.g. a box within a box).

Further, there is a problem in that a cleaning process for removing adherents, such as a residual adhesive remaining on the glass sheet after removing the adhesive protective films and contaminants which are attached on the glass sheets in the course of the transportation, typically takes a long time.

It should be noted that even some non-adhesive materials, such as polyethylene or polymeric films, if used, may leave some residual organic materials which must also be washed off with a detergent or other like wash; however, these non-adhesive residuals are typically not as difficult to clean off or as time consuming as residuals left behind by adhesives.

However, these and other existing prior art solutions still have several limitations.

Firstly, there is limited protection of container contents from weather during transportation.

Additionally, the disposing of these consumable items becomes an environmental and cost issue as well.

Secondly, there is marginal mechanical strength of the container due to side-wall construction of corrugated plastic materials.

Where tilting is not required (for instance as in typical PP or L type prior art containers), loading glass sheets is complex due to precision of placement in slots.

Additionally, prior art PP or L type containers typically only hold about 20 sheets of glass requiring frequent change-out of containers.

Further, the construction of mild steel with painted surfaces foun

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