GB2513849A

GB2513849A - A Protective Packet For An Electronics Panel

Info

Publication number: GB2513849A
Application number: GB201308062A
Authority: GB
Inventors: Wojciech Slazak
Original assignee: Harvard Engineering PLC
Current assignee: Harvard Engineering PLC
Priority date: 2013-05-03
Filing date: 2013-05-03
Publication date: 2014-11-12
Also published as: GB201308062D0

Abstract

A protective packet for an electronics panel (301) (e.g. a circuit board), the protective packet comprising a container (101). The container comprises a pocket (201) arranged to contain at least a portion of the electronics panel. The container further comprises at least oneopening (111), (113) arranged to allow access through the container to a portion of the electronics panel contained in the pocket and facing into the pocket. The container is arranged to secure the electronics panel within the pocket, preferably using a fugitive glue or deformable portions arrange to snap-fit over the electronics panel, such that it can be released from the pocket. During installation fixing holes in the panel may be accessed via openings in the panel (113) allowing bolts or screws to be inserted. Selected components mounted on the panel may be accessed through openings in the panel (111) to allow configuration during installation. The panel may be made of static-dissipating material.

Description

A PROTECTIVE PACKET FOR AN ELECTRONICS PANEL

[0001] The present invention relates to a protective packet for an electronics panel. In particular, but not exclusively, the electronics panel may comprise a printed circuit board (PCB) upon which light emitting diodes (LEDs) are mounted.

BACKGROUND

[0002] In recent years, LED panels have become increasingly popular as an alternative to traditional light sources. This popularity arises from the high efficiency of LED5 compared to pievious lighting methods, offering higher levels of luminous efficiency along with a typically smaller form factor. Howevei, currently the cost of high powei LEDs is relatively high and the devices are often fragile. As such, costly damage can often occur during the manufacturing, handling, transportation or installation processes of LED panels.

This damage can result from simple, physical souices such as neglect while handling, oi, should the LEDs be susceptible, from sources such as the discharge of static electricity.

[0003] There are currently a wide valiety of ways to piotect LED panels during various stages of their manufacture and installation. For example, anti-static or conductive trays (shallow containers into which a panel may fit) may be used to contain a panel, allowing it to be moved without contact with the panel itself while also providing protection against static discharge. Another method is to use anti-static or conductive bubble bags to contain a panel, which provide similar benefits to those given above. Similarly, anti-static foam may be used to surround a panel. Said bags or foam are often manufactured from polyethylene terephthalate (PET) which protect fiom static by virtue of being slightly conductive, thereby forming a Faraday cage around the protected panel. During the transportation phase, cardboard, plastic or another suitable material may be used to form packaging to encompass one or many tiays or other containeis to provide some fuithei degiee of protection. For any necessary handling of the panels, anti-static foot or wiist straps can be worn by the handlers to reduce the risk of damage resulting from static discharge. While all of these methods reduce the risk of damage to LED panels, they all require removal of the panel from the packaging prior to installation, leaving it susceptible to static dischaige and physical damage.

[0004] It is theiefore an object of ceitain embodiments of the present invention to provide a foim of packaging foi LED panels, or various other types of electronics panels, which allow for a panel to be installed without the need to remove the packaging until the panel is suitably secure and installed.

BRIEF SUMMARY OF THE DISCLOSURE

[0005] According to a first aspect of the present invention there is provided a protective packet for an electronics panel, the protective packet comprising: a container comprising a pocket arranged to contain at least a portion of an electronics panel; wherein the container further comprises at least one opening arranged to allow access through the container to a portion of an electronics panel contained in the pocket and facing into the pocket; and wherein the container is arranged to secure an electronics panel within the pocket such that it can be released from the pocket.

[0006] An advantage of the first aspect of the invention is that because the at least one opening allows access to the electronics panel, the electronics panel can be left secured within the protective packet during the installation process. That is, in certain embodiments the packet covers delicate components such that they face into a pocket, with a more robust reverse surface of the panel facing outwards from the pocket. The panel may be offered up to a mounting surface and secured in position through the openings before the packet is removed.

[0007] The at least one opening may comprise at least one hole through the container.

[0008] The container may further comprise at least one tab, the at least one tab comprising a segment of the container at least partially covering a hole, and which is arranged to be detached or retracted to allow access through the hole.

[0009] The container may further comprise a base section and a peripheral wall, at least part of which tapers outwards from the base section such that the container may be stacked upon a second container when the pocket does not contain at least a portion of an electronics panel.

[0010] The container may further comprise at least one stepped portion such that when the pocket does contain at least a portion of an electronics panel the container may be stacked upon a second container with the at least one stepped portion resting upon the second container.

[0011] The container may comprise deformable portions arranged to snap-fit over an electronics panel to secure the electronics panel within the pocket such that it can be released from the pocket.

[0012] The protective packet may further comprise an adhesive layer arranged to secure the electronics panel within the pocket such that it can be released from the pocket. The adhesive layer may be a fugitive glue.

[0013] The container may be formed from a static-dissipating material. Additionally or alternatively the container may be formed from a transparent material. Additionally or alternatively the container may be formed from a plastic.

[0014] According to a second aspect of the present invention there is provided a method for installing an electronics panel, the method comprising: placing an electronics in a protective packet, the protective packet comprising a container comprising a pocket which contains at least a portion of the electronics panel, the container securing the electronics panel within the pocket such that it can be released from the pocket; arranging the protective packet on a surface to which the electronics panel is to be installed; securing the electronics panel to the surface through at least one opening in the container allowing access through the container to a portion of the electronics panel contained in the pocket and facing into the pocket; and removing the protective packet from the electronics panel.

[0015] The pocket may cover at least one component protruding from or otherwise located on the electronics panel.

[0016] The at least one opening may comprise a hole through the container and wherein securing the electronics panel to the surface comprises inserting a screw or bolt through the hole and through a fixing hole within the electronics panel into the surface.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Embodiments of the invention are further described hereinafter with reference to the accompanying drawings, in which: Figure 1 is a perspective view of the underside of a protective packet embodying the invention; Figure 2 is a perspective view of the pocket-side of the protective packet of Figure 1; Figure 3 is the same view as Figure 2 wherein an example electronics panel is located in the pocket; Figures 4a and 4b show first and second perspective views respectively of the underside of the protective packet of Figure 1 when an electronics panel is located in the pocket and showing a tab attached to the protective packet and then removed from the protective packet to leave a gap; Figures 5a and 5b show first and second perspective views respectively of a stack of the protective packets, firstly where the protective packets are empty and secondly where they each contain an electronics panel; Figure 6 is a partial cross sectional view of the protective packet demonstrating the interaction between the packet, an example electronics panel and an adhesive used to secure the electronics panel in the protective packet; and Figure 7 is a perspective view of packaging for housing a stack of protective packets such as seen in the second view of Figure 5.

DETAILED DESCRIPTION

[0018] As noted above, the present invention relates generally to a protective packet for an electronics panel. One exemplary protective packet will now be described, which is arranged to protect an LED panel formed upon a PCB during transportation and installation.

[0019] Inthefollowing description, the "thickness" of a PCB refers to a dimension of the PCB which is in a direction substantially normal to a main surface of the PCB, with "main surface" being understood as the surface of the printed circuit board upon which components are printed or positioned. The other dimensions of the PCB, the "length" and "width", refer to the substantially perpendicular dimensions which define the area of the PCB.

[0020] Referring now to Figures 1, 2 and 3: Figure 1 shows a perspective view of the underside of a protective packet, while Figures 2 and 3 show similar views for the topside of the protective packet. The protective packet comprises a container 101, comprising a base section 103 and a wall 105 which extends around the periphery of the base section 103. The container 101 further comprises holes 113, tabs 111, grooves 109, stepped portions 107, lettering 118 and a pocket 201. The container 101 may be vacuum formed and composed of a conducting (or otherwise static dissipating) material. The material of the container 101 may further be chosen so as to ensure that the container 101 is suitably strong while the thickness of the material separating the topside and underside of the container 101 is minimised with respect to the thickness of an electronics panel 301 intended for the protective packet; this minimising having the purpose of reducing the overall form factor of the container 101. Also, in certain embodiments it may be desirable for the material of the container 101 to be selected such that it is transparent, that is, light may pass through the material in order to allow for visual testing of any LEDs (or other applicable components).

[0021] The pocket 201 shown in Figure 2 defines a portion of the container 101 upon the topside of the container 101 which is recessed to receive an electronics panel 301, and is shaped accordingly. In some embodiments the pocket 201 may be intended to encompass the entire main surface of an electronics panel 301; while in other embodiments it may only cover some predefined portion of an electronics panel 301. Similarly, in some embodiments the pocket 201 is recessed into the container 101 deep enough to ensure that no portion of an electronics panel 301 extends above the edges of the pocket 201.

Alternatively in other embodiments the electronics panel 301 may extend above the edges of the pocket 201. Preferably, if the panel extends above the edges of the pocket 201, the overlap between the electronics panel 301 and the pocket 201 is enough to prevent misalignment/rotation. It may further be intended that an electronics panel 301 is placed into the pocket 201 in a face-down orientation, that is, the main surface of an electronics panel 301 is placed facing into the pocket 201 while the reverse surface of the electronics panel 301 faces away from the container 101. The base section 103 of the container 101, specifically the portion on the reverse-side of the pocket 201 comprises grooves located such that any protrusions from the main surface of an electronics panel 301 are accommodated when the electronics panel 301 is located in the pocket 201. In some embodiments the container 101 is arranged such that the main surface of the electronics panel 301 lies substantially flush against the corresponding surface of the pocket 201. In another embodiment the container 101 is arranged such that there is interposed a securing element (for example, portions of fugitive glue 601) between the main surface of the electronics panel 301 and the corresponding surface of the pocket 201. This ensures that in certain embodiments no portion of the electronics panel 301 protrudes from the pocket, as seen in Figure 3. It will be appreciated that the overall dimensions of the container 101, and particularly the pocket 201, will be selected for a particular application and a particular electronics panel 301 to accommodate the whole or a selected part of the panel 301. The container 101 is arranged such that the panel 301 is placed into the pocket in the topside of the container 101 as shown in Figure 3. The reverse side of the panel 301 may be substantially flush with the topside of the container, or may be recessed within the container 101 (due to the depth of the pocket 201)to afford a degree of protection to the reverse side of the panel 101. In certain embodiments the reverse side of the panel 301 may be covered by a film, or other layer of material, which closes off the pocket 201 and is intended to be removed before installation. The underside of the container 101, as shown in Figure 1, displays instructions and symbols for the installer, which may be formed by mouldings in the base section lO3of the container 101. The instructions and symbols may optionally be formed in the wall of the pocket 201 facing the panel.

[0022] The container 101 is further arranged to secure an electronics panel 301 to the container 101, specifically the pocket 201 in certain embodiments. Said securing is also arranged to allow for an electronics panel 301 to be released from the container 101 after it has been secured. In some embodiments, such as that shown in the cross sectional view of Figure 6. the securing is accomplished by the use of fugitive glue 601 which is directly applied to the container 101 or electronics panel (301) in locations that will contact some suitable part of an electronics panel 301, fixing the electronics panel 301 in place until such a time as it is desired that the container 101 is removed. Owing to the nature of fugitive glue 601, the electronics panel 301 can be removed easily and in a manner which will not harm the panel 301. In some embodiments the fugitive glue 601 may be located on a surface of the pocket 201 so as to contact with the main surface of an electronics panel 301. It will be appreciated that the particular locations of the container 101 where the glue 601 is applied, and the proportion of the surface of the container 101 covered in the glue, will depend upon the properties of the electronics panel 301, for instance, its size, shape and weight.

[00231 In another embodiment (not illustrated), the container 101 may comprise deformable portions around the rim of the pocket 201 which are arranged to snap-fit around an electronics panel 301 when the electronics panel 301 is placed into the pocket 201.

[0024] Holes 113 are also shown in Figure 1 located within the container 101. More specifically, the holes 113 are located through the pocket 201. These holes 113 are located to align with corresponding screw holes 303 within an electronics panel 301. These screw holes 303 allow the electronics panel 301 to be physically attached to other objects, such as a mounting surface, during the installation process. The purpose of the holes 113 on the container 101 is to allow for the installation of an electronics panel 301 without the need to remove the container 101 beforehand. As such they are made suitably large enough so as to allow for no part of a screw to touch or trap the container 101 as it passes through both sets of holes. In this way, portions of the main surface of an electronics panel 301 can be accessed through the container 101. Screws can then be passed through the holes 113 and the screw holes 303 on an electronics panel 301 from the underside of the container 101 when the reverse surface of the electronics panel 301 is offered up to a mounting surface. Once the electronics panel 301 is installed, the container 101 can be removed to expose the main surface of the electronics panel 301. The electronics panel 301 can therefore remain housed by the protective packet during the installation process.

[0025] Referring now to Figures 4a and 4b, these show first and second perspective views respectively of the underside of the container 101 containing an electronics panel 301 within its pocket 201. It is shown that the container 101 may further comprise a number of tabs 111, which may overlap with the pocket 201. These tabs 111 are segments of the container at least partially covering a hole, and located such that they allow suitable access to any elements or components located on an electronics panel 301 that might require wiring, connecting, soldering or some other manner of work to be performed during manufacturing or installation. In this manner, an electronics panel 301 can be fully or at least partially connected electronically (or otherwise) during installation without the need to remove the protective packet beforehand. The tabs 111 serve to temporarily close off openings within the container 101. The tabs 111 may be formed by creating a line of weakness in the container surrounding a desired opening such that during installation the installer can break open the tabs 111. The tabs 111 may then be folded back to allow access to the electronics panel 301 through the opening, as shown in Figure 4a. In some embodiments, the tabs 111 may be detachable, through pulling or some other suitable method, leaving a gap 401 in the appropriate location of the container 101, as shown in Figure 4b. In other embodiments the tabs 111 may not be fully attached to the surrounding container 101, such that they may be freely folded back. It is therefore possible to access portions of the main surface of an electronics panel 301 through the container 101.

[0026] Figures 5a and 5b show, for certain embodiments of the present invention, how the protective packet may be formed so that they may be stacked in an overlapped fashion. That is, the walls 105 of the container 101 are formed such that they taper 115 away from the base section 103, such that one container 101 can be placed on top of or below another container 101 when empty. When stacked as shown in Figure 5a, the two containers 101 fit together with an underside of one container 101 substantially flush against the topside of the other container 101. In this case, the grooves 109 of each container 101 align to allow subsequent containers 101 to fit in a flush manner to form a "nested" stack 501.

If, however, the containers 101 each contain an electronics panel 301 within their respective pockets 201 then the protective packets may still stack in an overlapped manner so long as the walls 105 of each container 101 are suitably large with respect to the depth of the grooves 109 on the undersides of each container. Furthermore, stepped portions 107 aie formed upon the container 101, as best shown in Figure 1, and are arranged such that, when subsequent containers 101 are rotated through 180°, the section of the stepped portion 107 located on the underside of a container 101 rests on a section of the top of a subsequent container 101 outside of the pocket 201. In such a manner, an electronics panel 301 in the pocket 201 is placed under no pressure by containers 101 higher up a stack 503. Furthermore, the stepped portions 107 may allow for stacked containers 503 to be more easily detached from the stack 503. In some embodiments, the stepped portions 107 are formed in the container 101 such that subsequent containers 101 in a stack 503 need to be rotated through 1800 about an axis normal to the main surface of an electronic panel 301 in order for the containers 101 to stack in an overlapped manner.

As is shown in Figure 1, this is accomplished by forming a single stepped portion 107 along a portion of an edge of the container 101 and two stepped portions 107 along an opposite edge of the container 101. The stepped portions 107 on opposing sides are not formed directly opposite each other. As such, if the container 101 shown in Figure 1 contains an electronic panel 301 and is stacked without rotating alternate containers 101, like stepped portions 107 align and rest in each other leaving the grooves 109 of the upper container 101 to rest on the outward-facing surface ot the electronics panel 301, thereby placing pressure on the grooves 109. However, by rotating alternate containers 101 by 180° the stepped portions 107 no longer align and rest on the top of a subsequent container 101, providing clearance between the grooves 109 and the outward-facing surface of an electronics panel 301 and forming a spaced apart stack as shown in Figure 5b. In other embodiments, where the stepped portions 107 do not provide a sufficient gap between the reverse surface of the electronics panel 301 and the adjacent container, the grooves 109 can be formed in such a way, that they are the same height as the stepped portions and provide additional support, by resting on the reverse surface of the subsequent electronics panel below.

[0028] Figure 7 illustrates a packaging system 701 tor packaging a stack 503 of protective packets containing electronic panels 301 for use in shipping. The stepped portions 107 are located along the edges of the container 101 outside the pocket 201, and these stepped portions 107 may be designed and located to allow for a container 101 to be gripped individually and, if stacked with other containers 101, removed from the stack in a clean manner. In some embodiments, the packaging system 701 shown in Figure 7 comprises a cardboard box designed to the dimensions of a stack of a predetermined number of containers 101. In other embodiments the packaging system 701 may be collapsible so as to save space when not in use. In other embodiments, the packaging system 701 may be constructed so as to allow access to a stack of containers 503 while ensuring that the stack is reliably contained.

[0029] An exemplary embodiment of an invention for protectively packaging electronics panels has been presented. Upon its manufacture an electronics panel may be housed within a protective packet and, as described above, it need not be removed from the protective packet until it has been installed as per its intended use. This provides the advantage of minimising the time for which an electronics panel is vulnerable due to being no longer protectively contained, and is therefore expected to reduce damage and costs.

[0030] Throughout the description and claims of this specification, the words comprise" and "contain" and variations of them mean "including but not limited to", and they are not intended to (and do not) exclude other components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

[0031] Features, integers or characteristics described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith.

All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

[0032] The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Claims

CLAIMS: 1. A protective packet for an electronics panel, the protective packet comprising: a container comprising a pocket arranged to contain at least a portion of an electronics panel; wherein the container further comprises at least one opening arranged to allow access through the container to a portion of an electronics panel contained in the pocket and facing into the pocket; and wherein the container is arranged to secure an electronics panel within the pocket such that it can be released from the pocket.
2. A protective packet in accordance with claim 1, wherein the at least one opening comprises at least one hole through the container.
3. A protective packet in accordance with claim 2, wherein the container further comprises at least one tab, the at least one tab comprising a segment of the container at least partially covering a hole, and which is arranged to be detached or retracted to allow access through the hole.
4. A protective packet in accordance with any one of the preceding claims, wherein the container further comprises a base section and a peripheral wall, at least part of which tapers outwards from the base section such that the container may be stacked upon a second container when the pocket does not contain at least a portion of an electronics panel.
5. A protective packet in accordance with any one of the preceding claims, wherein the container further comprises at least one stepped portion such that when the pocket does contain at least a portion of an electronics panel the container may be stacked upon a second container with the at least one stepped portion resting upon the second container.
6. A protective packet in accordance with any one of the preceding claims, wherein the container comprises deformable portions arranged to snap-fit over an electronics panel to secure the electronics panel within the pocket such that it can be released from the pocket.
7. A protective packet in accordance with any one of the preceding claims, wherein the protective packet further comprises an adhesive layer arranged to secure the electronics panel within the pocket such that it can be released from the pocket.
8. A protective packet in accordance with claim 7, wherein the adhesive layer is a fugitive glue.
9. A protective packet according to any one of the preceding claims, wherein the container is formed from a static-dissipating material.
10. A protective packet according to any one of the preceding claims, wherein the container is formed from a transparent material.
11. A protective packet in accordance with any one of the preceding claims, wherein the container is formed from a plastic.
12. A method for installing an electronics panel, the method comprising: placing an electronics in a protective packet, the protective packet comprising a container comprising a pocket which contains at least a portion of the electronics panel, the container securing the electronics panel within the pocket such that it can be released from the pocket; arranging the protective packet on a surface to which the electronics panel is to be installed; securing the electronics panel to the surface through at least one opening in the container allowing access through the container to a portion of the electronics panel contained in the pocket and facing into the pocket; and removing the protective packet from the electronics panel.
13. A method in accordance with claim 12, wherein the pocket covers at least one component protruding from or otherwise located on the electronics panel.
14. A method in accordance with claim 12 or claim 13, wherein the at least one opening comprises a hole through the container and wherein securing the electronics panel to the surface comprises inserting a screw or bolt through the hole and through a fixing hole within the electionics panel into the surface.AMENDMENTS TO THE CLAIMS HAVE BEEN FILED AS FOLLOWS: CLAIMS: 1. A protective packet for an electronics panel, the protective packet comprising: a container comprising a pocket arranged to contain at least a portion of the electronics panel; wherein the container further comprises at least one opening arranged to allow access through the container to a portion of the electronics panel contained in the pocket and facing into the pocket; wherein the container is arranged to secure the electronics panel within the pocket such that it can be released from the pocket; and wherein, to secure the electronics panel within the pocket such that it can be released from the pocket, either: the container comprises deformable portions arranged to snap-fit over the electronics panel; or the protective packet further comprises an adhesive layer.CD2. A protective packet in accordance with claim 1, wherein the at least one opening o comprises at least one hole through the container.3. A protective packet in accordance with claim 2, wherein the container further comprises at least one tab, the at least one tab comprising a segment of the container at least partially covering a hole, and which is arranged to be detached or letracted to allow access through the hole.4. A protective packet in accordance with any one of the preceding claims, wherein the container further comprises a base section and a peripheral wall, at least part of which tapers outwards from the base section such that the container may be stacked upon a second container when the pocket does not contain at least a portion of an electronics panel.5. A protective packet in accordance with any one of the preceding claims, wherein the container further comprises at least one stepped portion such that when the pocket does contain at least a portion of the electronics panel the container may be stacked upon a second container with the at least one stepped portion resting upon the second container.6. A protective packet in accordance with claim 1, wherein the adhesive layer is a fugitive glue.7. A protective packet according to any one of the preceding claims, wherein the container is formed from a static-dissipating material.8. A protective packet according to any one of the preceding claims, wherein the container is formed from a transparent material.9. A protective packet in accordance with any one of the preceding claims, wherein the container is formed from a plastic.CD10. A method for installing an electronics panel, the method comprising: O placing the electronics panel in a protective packet, the protective packet comprising a container comprising a pocket which contains at least a portion of the electronics panel, the container securing the electronics panel within the pocket such that it can be released from the pocket; arranging the protective packet on a surface to which the electronics panel is to be installed; securing the electronics panel to the surface through at least one opening in the container allowing access through the container to a portion of the electronics panel contained in the pocket and facing into the pocket; and removing the protective packet from the electronics panel; wherein, to secure the electronics panel within the pocket such that it can be released from the pocket, either: the container comprises deformable portions arranged to snap-fit over the electronics panel; or the protective packet further comprises an adhesive layer.11. A method in accordance with claim 10, wherein the pocket covers at least one component protruding from or otherwise located on the electronics panel.12. A method in accordance with claim 10 or claim 11, wherein the at least one opening comprises a hole through the container.13. A method in accordance with claim 12, wherein securing the electronics panel to the surface comprises inserting a screw or bolt through the hole and through a fixing hole within the electronics panel into the surface.CD Co