JP2007073871A - Tray used for in-process shipping of substrate for thin indicating devices and shipping method of substrate for thin indicating devices using this - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a shipping method of substrate for display device which attains laborsaving/efficiency-increasing of shipping and packaging work by saving packing labor hours in integrated shipping and packing of a plurality of substrates for large display device of 26 inches or more, therewith decreasing the cost by attaining the saving of packing materials. <P>SOLUTION: The substrate for a thin display device is laid at a level, therewith using a tray for shipping between processes in a status that this laid substrate for indicating device is floated from the tray bottom, the substrate is sandwiched by a tray shoulder, and a tray lid by installing the tray lid in the top opening of the tray. Using a container with palette, a prescribed number of the trays is laminated and thrown in so as to make the shipping trays to be laid horizontally. Then, the container is inverted to 90° so as to make the trays thrown in the container to be laid longitudinally. The opening of the inverted container is closed, and the laminated body of the trays are shipped in aggregate or stored via the container. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a tray used for transporting various display device substrates such as thin liquid crystal display device panels used in televisions and PC monitors during an assembly process, and a method for shipping a thin display device substrate using the same. .

  Liquid crystal display devices used in liquid crystal televisions and PC monitors display images by applying voltage to the liquid crystal sealed between two opposing glass substrates to change the orientation of the liquid crystal molecules and change the light transmittance. It has come to be.

  In order to manufacture such a liquid crystal display device, the glass substrate is transported to a liquid crystal display device manufacturing factory. In recent years, glass substrates for display devices have become thinner and larger. For example, a glass substrate having a thickness of 0.7 mm or less is used as a substrate for a display device, and a glass substrate carried into a manufacturing factory is enlarged, and a rectangular glass substrate having a side of 1.3 m or more is used. Sometimes it is brought into the factory. Such a glass substrate may be carried into a liquid crystal display device manufacturing factory to manufacture a liquid crystal display panel used for, for example, a large liquid crystal TV of 26 inches or more or a monitor for a large PC.

  In a production line of a conventional liquid crystal display panel manufacturing factory, a backlight, which is one of the components, is installed on the liquid crystal panel, and various peripheral members such as a light guide plate, a reflective sheet, a prism sheet, and a polarizing plate are assembled. . Thereafter, the product is shipped from the manufacturing plant to the final assembly plant in order to be completed as a final product such as a TV or PC monitor.

  In a production line, when an operation is completed in a certain process and an intermediate product (work-in-process product) is conveyed to the next process, a tray (sometimes referred to as a process tray) for conveying the product is used. In particular, a substrate for a thin display device used for a 26-inch large-sized liquid crystal television or the like requires special attention in handling. Usually, the substrate is placed on a tray in a horizontal state between each process. Move. Since the transport tray needs to be escaped so that components and terminals on the back surface of the substrate do not contact the bottom of the tray, individual trays are used for each assembly process. Then, when transporting between assembly processes, the substrate is transported while regulating its position so that it does not move back and forth and from side to side, and in the next process, it is taken out from the tray and assembly work of peripheral members is performed.

<Problem 1>
Conventionally, as a process tray that moves between such assembling processes, individual flat (flat) trays adapted to work in process stored in each process have been used. However, many types of trays to be used for each process must be prepared, which is disadvantageous in terms of tray management and economy (see Patent Document 1).

<Problem 2>
The thin display device substrate is shipped and transported to a final assembly plant after inspection so as to be completed into a final product such as a television or a PC monitor. When transporting, a large display device substrate of 26 inches or more is protected from vibration, shock, etc. during movement, and the substrate is not damaged and no foreign matter adheres to prevent the substrate from being scratched or adhered. Careful handling is required so as not to adhere, and it is necessary to cover and protect each substrate with a packing cushioning material one by one. If electrical damage or moisture-proof packaging is required, put it in an antistatic bag for deaeration packaging. Furthermore, it is necessary to ship a plurality of thin display device substrates packed and packaged together in a transport box or the like.
However, such a package for transportation is heavy with 8 to 10 kg even on a single substrate, and if the number increases, it becomes difficult for one worker or a small number of people to work. There is a problem in that it requires personnel, and it is not possible to save materials for buffer packaging materials such as corrugated cardboard materials, resulting in high packaging costs (see Patent Document 2 below).

<Problem 3>
In addition, when packaging the product, it is necessary to place the thin display device substrates one by one vertically in the shipping box so that the product can be stably held in a package that is unlikely to be twisted, warped, bent, or cracked during transportation. There is.
Further, when the thin display device substrate is supplied to the final assembly line after unpacking, it is necessary to place the thin display device substrate on another process tray. However, the work required many personnel as in the case of packing, and had to be done manually, and the work efficiency was also poor.
JP 2004-306979 A Japanese Patent No. 3560933

Therefore, in order to solve the conventional problems, the present invention aims to make common process trays which are different for each process in the production line, and to reduce the types of trays, the process trays are shipped to the final assembly factory as they are. An object of the present invention is to provide a tray that can be used as a transport tray.
The present invention further eliminates the labor of packing when a plurality of large-sized display device substrates are packed and transported, saves packing materials, reduces costs, and saves labor and increases efficiency in packing and shipping work. The object is to propose a method for shipping a substrate for a display device that can be achieved.

The present invention uses the following means in order to solve the above problems.
That is, the tray according to claim 1 proposed by the present invention is configured such that the display device substrate is placed in a horizontal state and the placed display device substrate is transported between processes in a state where it is floated from the bottom of the tray. A tray,
In the center of the top surface of the tray, a step portion is provided that can support the flat placement by lifting the back of the thin substrate for large display devices of 26 inches or more from the bottom of the tray. A pocket portion is formed so that the terminal does not come into contact with the tray, and a peripheral wall that also serves as a positioning portion of the substrate is formed along the outer periphery of the tray so as to surround the pocket portion, and a tray lid is provided above the peripheral wall. In addition to providing a convex portion for positioning, a tray lid is installed at the upper surface opening of the tray, and the substrate is sandwiched and fixed between the tray step and the tray lid. .

  The invention according to claim 2 is characterized in that the tray lid is prevented from coming off from the tray by a clip in a state in which the tray lid is fitted to the upper surface opening of the tray. It is a conveyance tray of the board | substrate for thin display apparatuses.

The invention of claim 3 is a method of stacking and shipping the thin display device substrates housed in the transport tray according to claim 1,
Using a container having a bottom member, a ceiling member, a plurality of side wall members connecting the bottom member and the ceiling member, an opening for taking in and out the transport tray, and a lid member for opening and closing the opening, Stacking and feeding a predetermined number of trays so that the transport tray is placed horizontally in the container;
Reversing the container 90 degrees so that the transport tray placed in the container is in a vertically placed state;
Closing the inverted container opening;
A method for shipping an integrated package of substrates for a thin display device, comprising a step of collectively transporting or storing the stack of transport trays through the container.

  Further, in the invention of claim 4, after stacking the transport trays of the thin display device substrates in the vertical direction and before storing them in the container, the entire tray stack is previously bound by a binding means such as a shrink film or a fixed band. The method for shipping an integrated package of substrates for a thin display device according to claim 3, further comprising a step of binding.

The present invention aims at sharing process trays that are different for each process in a production line for a substrate for a thin display device, and a transport tray for shipping and transporting a tray that moves between assembly processes to a final assembly factory as it is. As a result, the tray can be easily managed.
Furthermore, according to the shipping method of the present invention, since the transport tray with a lid is used, the transport tray is stacked in a vertical direction and transported in a multi-layered state with the substrate sandwiched and fixed between the tray and the tray lid. When transporting and storing, it is not necessary to place a plurality of substrates in a transport box and protect them individually with cushioning materials or the like as in the prior art, improving space efficiency and saving buffer packaging materials.
Moreover, since the trays are not vertically packed in the transport box at the time of packing, labor saving and efficiency improvement of packing and shipping work can be achieved. According to the conventional method, it is possible to save labor and increase the efficiency of work that requires a considerable number of personnel for packing and unpacking.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is an explanatory view showing an example of a combined state of the tray main body 10 and the tray lid 11, FIG. 2A is a perspective view of the tray main body 10, and FIG. 2B is an upper surface opening of the tray main body 10. FIG. 2C is a perspective view of the clip, and FIGS. 3A to 3C are views of the AA line, the BB line, and the CC line of FIG. FIG.

  This tray, when a substrate such as a liquid crystal panel is placed in a horizontal state and transported between each process, places the work-in-process substrate on the upper surface of the tray main body 10 and transports it. The work-in-process substrate is taken out and the peripheral member is assembled. Further, when shipping and transporting the substrate, the tray lid 11 is fitted into the upper surface opening of the tray main body 10 and used.

<About the tray body>
The tray body 10 is integrally formed in a rectangular parallelepiped shape with foamed resin or the like, and has a step portion 2 on which a work-in-process substrate G transported between processes is placed in a horizontal state, and a substantially rectangular bottom portion formed deeper than the step portion. 3 and the peripheral wall part 4 provided so that it may protrude above the side edge part over the perimeter of a bottom part.
The bottom 3 has a substantially rectangular shape that is slightly larger than the substrate to be accommodated in order to accommodate several types of substrates having different sizes, and particularly accommodates a 26-inch large / thin display device substrate. As an example, it is formed with a length of about 805 mm and a width of about 510 mm.
In addition, a horizontal step 2 is provided at the center of the bottom 3 so that at least the back of the work-in-process substrate G is supported in a state where it floats from the bottom of the tray and can be placed flat. Although the step part 2 of embodiment is formed in the substantially concave shape seeing from the plane, it does not restrict to this.
Around the step portion 2, a pocket portion 5 is formed so that components and terminals protruding from the substrate do not come into contact with the bottom of the tray. The pocket portion is formed to a depth of about 65 mm as an example. The step portion 2 is formed to be about 20 mm higher than the deepest portion of the pocket portion 5.

Further, a peripheral wall portion 4 is formed along the outer periphery of the tray so as to surround the pocket portion 5. The peripheral wall portion 4 also serves as a positioning portion that supports the bottom surface of the substrate during transportation.
In addition, the convex part 6 for positioning a tray cover is provided in the upper part of the surrounding wall part 4. As shown in FIG. The convex portion 6 may be provided on at least the upper surfaces of the pair of opposed peripheral wall portions 4, but it is preferable to provide the convex portion 6 so as to be substantially circular (endless) over the entire upper portion of the peripheral wall as shown.

  There is no restriction | limiting in particular about the foaming resin which comprises the tray main body 10, For example, the foaming molded article which consists of a phenol resin, an acrylic resin, a polyester resin, a polyolefin resin, a fluororesin, a urethane resin etc. can be illustrated.

<About the tray cover>
The tray lid 11 is formed of a resin molded product that can be fitted to the upper surface of the tray main body 10 to seal the opening of the main body 10, but is preferably a transparent body that allows the inside of the tray to be seen through. That is, it is a resin molded body formed in a similar shape so that it can be placed almost horizontally on the upper surface of the tray body 10 having a rectangular parallelepiped shape. As shown in FIGS. 1 to 3C, the peripheral edge of the tray lid 11 is provided with a frame portion 7 that can be fitted to the convex portion 6 provided on the peripheral wall portion 4 of the main body 10 on substantially the entire circumference. . On the inner side of the frame portion 7, projections and depressions 8, 9 projecting toward the bottom of the tray are provided so that one end of the work-in-process substrate G accommodated in the tray can be suppressed and positioned. The shift is prevented.

  The resin constituting the tray lid 11 of the present invention is not particularly limited, but specifically, a general-purpose resin that can withstand external forces during shipping and transportation, such as polyethylene. A vacuum resin molded product using polypropylene, phenol resin, acrylic resin, polyester resin, ABS, FRP, nylon or the like can be mentioned, and a transparent resin molded product is preferable.

  As shown in FIG. 3, the tray main body 10 of the present invention in which the substrate G is accommodated has a tray lid 11 placed on the upper surface opening, a convex portion 6 provided on the peripheral wall portion 4 of the main body, and a tray lid frame portion 7. And the body and the lid are integrated, and one end of the substrate G is positioned by restraining the concave and convex portions 8 and 9 of the lid. Further, for example, the clip 12 shown in FIG. 2C is used and held so that the tray lid 11 does not come off the main body 10. Incidentally, the illustrated clip 12 is a foamed resin clip having a cross-sectional saddle shape made of the same material as that of the main body 10, and includes a notch portion 4a provided on the peripheral wall of the tray and an engaging portion 7a provided on the tray lid. It is configured to be elastically sandwiched from above and below.

A plurality of (approximately 10 to 20) transport trays storing the substrates G are stacked and shipped and transported in a pallet container 20 which will be described later in a state where a plurality (approximately 10 to 20) are stacked in the vertical direction. At this time, for example, before being put into a pallet container, the entire tray stack 100 can be previously bound by a binding means such as a shrink film or a band 14 (see, for example, FIG. 4).
Since the transport tray of the present invention configured as described above sandwiches the substrate G between the tray lid 11 and the main body 10, it is possible to prevent the substrate G from being damaged due to the misalignment of the substrate G and foreign matter adhesion. Further, using a container 20 with a pallet, which will be described later, with the substrate sandwiched and fixed between the tray and the tray lid, the above transport trays are stacked in the vertical direction and shipped in a multi-layered state. Therefore, it is not necessary to individually protect the substrate with a buffer material or the like during transportation, so that space efficiency is improved and buffer packaging material can be saved.

<About Container>
A shipping method using the container 20 with pallets will be described.
FIGS. 5A to 5F illustrate a method of accommodating and taking out the tray stack 100 of the present invention from the palletized container 20.
The illustrated container 20 with a pallet includes a bottom member 21, a plurality of side wall members 22 surrounding the front and rear four surfaces, an opening 23 for taking in and out a stacked body of trays, and a lid member 24 for closing the opening, A pallet 25 having a plurality of insertion ports is attached to the bottom.
<Tray collection / container storage / shipping process>
(1) First, a predetermined number of trays 100 are stacked horizontally by an elevator (FIG. 5A).
(2) Next, a predetermined number of trays are pushed into the container 20 with pallets placed horizontally for accommodating the trays by an extrusion device (FIG. 5B).
(3) After completing the loading, the container 20 with the pallet is inverted 90 degrees, and the stacked trays in the container are placed in an inverted state (FIGS. 5C to 5E). Subsequently, the container lid 24 is attached to complete the packaging for transportation. In this state, the tray assembly is managed and shipped to the final assembly factory (FIG. 5F).
(4) When the tray is taken out from the container in the final assembly factory, the container 20 in which the trays are vertically stacked is inverted 90 degrees, and the tray in the container 20 is placed horizontally (FIG. 5C).
(5) Next, contrary to FIG. 5C, the stacking tray 100 is slid in the horizontal direction, taken out from the container, and the tray placed in the horizontal state is carried out to the take-out line of the final factory.

  As described above, the shipping and transporting method of the present invention is a state in which the transport trays are stacked vertically in a state where the substrates are sandwiched and fixed between the tray and the tray lid using the transport tray with a lid, and stacked in multiple stages. Into the container. After completion of loading, the container is inverted 90 degrees and the trays stacked in the container are placed in a vertical position. When shipping, the substrates are placed one by one in the vertical direction as before, and individually with cushioning materials. There is no need for protection, thus improving space efficiency and work efficiency and saving buffer packaging materials. Further, the substrate can be placed in a vertical position, and can be stably positioned and shipped in a package that is unlikely to be twisted, warped, bent or cracked.

It is a partially cutaway explanatory view showing an example of a combined state of a tray body and a tray lid. (A) is a perspective view of a tray main body, (B) is a perspective view of a tray lid, (C) is a perspective view of a clip. (A to C) are cross-sectional schematic views of lines AA, BB, and CC in FIG. It is explanatory drawing of the state which bound the whole tray laminated body with the band etc. (A to F) illustrate a method of accommodating a tray stack in a transport container.

Explanation of symbols

2 Step part 3 Bottom part 4 Peripheral wall part 4a Notch part 5 Pocket part 6 Projection part 7 Frame part 7a Engagement part 8 Concavity and convexity 10 Tray body 11 Tray lid 12 Clip 14 Band 20 Container 21 with pallet Bottom member 22 Side wall member 23 Opening part 24 Lid member 25 Pallet 100 Tray stack

Claims (4)

The display device substrate is placed in a horizontal state, and the display device substrate placed is a tray that conveys between processes in a state of floating from the tray bottom,
At the center of the upper surface of the tray, there is provided a step portion that can support the flat placement by floating the back of the thin substrate for large display devices of 26 inches or more from the bottom of the tray, and a component protruding from the substrate around the step portion, A pocket portion is formed so that the terminal does not come into contact with the tray, and a peripheral wall that also serves as a positioning portion of the substrate is formed along the outer periphery of the tray so as to surround the pocket portion, and the tray lid is disposed above the peripheral wall. A thin display device characterized in that a positioning projection is provided and a tray lid is installed in an upper opening of the tray so that the substrate is sandwiched between the tray step and the tray lid. Substrate transport tray.   2. The substrate for a thin display device according to claim 1, wherein the tray lid is prevented from coming off from the tray by a clip in a state where the tray lid is fitted to the upper surface opening of the tray. tray. In the method of stacking and shipping the thin display device substrates stored in the transport tray according to claim 1,
Using a container having a bottom member, a ceiling member, a plurality of side wall members connecting the bottom member and the ceiling member, an opening for taking in and out the transport tray, and a lid member for opening and closing the opening A step of stacking and feeding a predetermined number of trays so that the transport tray is placed horizontally in the container;
Reversing the container 90 degrees so that the transport tray placed in the container is in a vertically placed state;
Closing the inverted container opening;
A method for shipping an integrated package of substrates for thin display devices, comprising a step of collectively transporting or storing the stack of transport trays through the container.   After stacking the substrate tray for the thin display device in the vertical direction and before putting it into the container, it has a step of binding the entire tray stack in advance by a binding means such as a shrink film or a fixed band. A method for shipping an integrated package of substrates for a thin display device according to claim 3.

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