Tray module, tray assembly having the tray module, and method of fabricating display device using the tray assembly

{
  "publication_number": "US11592611B2",
  "country": "US",
  "kind": "B2",
  "title": "Tray module, tray assembly having the tray module, and method of fabricating display device using the tray assembly",
  "abstract": "A tray module includes a tray in which a plurality of display device components are alternately stackable with a plurality of protective sheets. Each of a protective sheet among the plurality of protective sheets includes: a first polymer layer including a first polymer resin which is foamed, and top and bottom surfaces opposite to each other; a second polymer layer on each of the top and bottom surfaces of the first polymer layer, the second polymer layer including a second polymer resin; and a paper layer defining an outer surface of the protective sheet.",
  "claims": [
    "1. A tray module, comprising: a tray in which a plurality of display device components are alternately stackable with a plurality of protective sheets, each of the plurality of display device components having an exposed glass layer, wherein each of a protective sheet among the plurality of protective sheets includes: a first polymer layer including a first polymer resin which is foamed, and top and bottom surfaces opposite to each other; a second polymer layer on each of the top and bottom surfaces of the first polymer layer, the second polymer layer including a second polymer resin; and a paper layer disposed on at least one of the second polymer layer on each of the top and bottom surfaces of the first polymer layer, and the plurality of display device components alternately stacked with the plurality of protective sheets within the tray disposes each of the exposed glass layers forming an interface with the paper layer of a respective protective sheet among the plurality of protective sheets.",
    "2. The tray module of claim 1, wherein within the protective sheet, the paper layer includes a cellulose pulp.",
    "3. The tray module of claim 1, wherein within the protective sheet, the paper layer includes an antistatic agent.",
    "4. The tray module of claim 1, wherein a thickness of the paper layer within the protective sheet is from about 50 micrometers to about 100 micrometers.",
    "5. The tray module of claim 1, wherein the plurality of display device components includes a light guide plate or a display panel.",
    "6. The tray module of claim 1, wherein the plurality of display device components each includes a light guide plate including a glass light guide layer as the exposed glass layer and a quantum-dot layer which is on the glass light guide layer, the plurality of protective sheets includes a first protective sheet and a second protective sheet, and the plurality of display device components alternately stacked with the plurality of protective sheets within the tray disposes: the first protective sheet and the second protective sheet on opposing surfaces of the light guide plate, the glass light guide layer forming an interface with the paper layer of the first protective sheet, and the quantum-dot layer forming an interface with the second polymer layer of the second protective sheet.",
    "7. The tray module of claim 1, wherein the protective sheet further includes an adhesive layer disposed directly between the second polymer layer and the paper layer.",
    "8. The tray module of claim 1, wherein the tray includes: a bottom portion on which the plurality of display device components and the plurality of protective sheets are supportable; and a sidewall portion extending from the bottom portion.",
    "9. The tray module of claim 1, wherein the first polymer layer within the protective sheet further includes a foaming agent.",
    "10. The tray module of claim 1, wherein the second polymer layer within the protective sheet further includes an antistatic agent.",
    "11. The tray module of claim 1, wherein within the protective sheet, the second polymer layer is directly on the first polymer layer.",
    "12. The tray module of claim 1, wherein within the protective sheet, the first polymer resin is low-density polyethylene, and the second polymer resin is high-density polyethylene.",
    "13. The tray module of claim 1, wherein within the protective sheet, a thickness of the first polymer layer is from about 800 micrometers to about 1200 micrometers, and a thickness of the second polymer layer is from about 25 micrometers (μm) to about 35 micrometers.",
    "14. A tray assembly, comprising: a plurality of tray modules which are stackable on each other; and a support plate on which the plurality of tray modules are supportable, wherein each of the tray modules includes a tray in which a plurality of display device components are alternately stackable with a plurality of protective sheets, each of the plurality of display device components having an exposed glass layer, each of a protective sheet among the plurality of protective sheets includes: a first polymer layer including a first polymer resin which is foamed, and top and bottom surfaces opposite to each other, a second polymer layer on each of the top and bottom surfaces of the first polymer layer, the second polymer layer including a second polymer resin; and a paper layer disposed on at least one of the second polymer layer on each of the top and bottom surfaces of the first polymer layer, and the plurality of display device components alternately stacked with the plurality of protective sheets within the tray disposes each of the exposed glass layers forming an interface with the paper layer of a respective protective sheet among the plurality of protective sheets.",
    "15. The tray assembly of claim 14, wherein the plurality of display device components each includes a light guide plate including a glass light guide layer as the exposed glass layer or a display panel including a glass substrate as the exposed glass layer.",
    "16. The tray assembly of claim 15, wherein the light guide plate further includes a quantum-dot layer on the glass light guide layer, and the plurality of display device components alternately stacked with the plurality of protective sheets within the tray respectively disposes the glass light guide layer forming an interface with the paper layer of the respective protective sheet among the plurality of protective sheets.",
    "17. The tray assembly of claim 14, wherein the first polymer layer further includes a foaming agent, and the second polymer layer further includes an antistatic agent."
  ],
  "description_excerpt": "This application claims priority to Korean Patent Application No. 10-2019-0030753 filed on Mar. 18, 2019, and all the benefits accruing therefrom under 35 U.S.C. § 119, the entire contents of which are hereby incorporated by reference.\n\n1) Field The invention relates to a tray module, a tray assembly including the tray module, and a method of fabricating a display device using the tray assembly. More particularly, the invention relates to a tray module including a protective sheet between display device components and with which the display device components are transported, a tray assembly including the tray module, and a method of fabricating a display device using the tray assembly. 2) Description of the Related Art A display device includes a number of components such as a display panel, a protective member, an optical member, and the like. The display device may further include a touch screen, depending on usage thereof. A transmissive or transflective display device may further include a backlight unit. Such display device components are collectively integrated through a lamination process, an assembly process, and the like to provide the display device.\n\nOne or more embodiment of the invention provides a tray module which reduces or effectively prevents display device components from being stained during transportation thereof between physical locations. One or more embodiment of the invention provides a tray assembly which reduces or effectively prevents display device components from being stained during transportation thereof between physical locations.",
  "cpc": [
    "G02B 6/0093",
    "A47G 19/00",
    "B65D 85/48",
    "B65G 2201/022",
    "B65G 47/52",
    "B65G 49/064",
    "G02B 6/005",
    "G02B 6/0065",
    "G02B 6/0076",
    "G02B 6/0088",
    "G02F 1/1303",
    "H10P 72/17",
    "H10P 72/18",
    "H10P 72/1908",
    "H10P 72/1912",
    "H10P 72/1928"
  ],
  "ipc": [
    "A47G 19/00",
    "B65G 47/52",
    "F21V 8/00"
  ],
  "assignees": [
    "SAMSUNG DISPLAY CO LTD"
  ],
  "inventors": [
    "CHO JIN-WOOK",
    "KOO JA HUEM",
    "SIM BO BAE",
    "JOO SUNG JIN",
    "CHOI WONJUN"
  ],
  "filing_date": "2020-03-16",
  "publication_date": "2023-02-28",
  "grant_date": "2023-02-28",
  "priority_date": "2019-03-18",
  "application_number": "US-202016819395-A",
  "family_id": "72513985",
  "citations": [
    "KR101011257B1",
    "KR20120089233A",
    "KR20180006208A",
    "KR20180054750A",
    "US2006124574A1",
    "US2018305096A1",
    "US4584225A",
    "US6474475B1"
  ]
}