Title: Manufacturing method of support frame of display panel support frame of display panel and display device
Abstract: A method is provided for manufacturing a support frame of a rectangular display panel within a short working time. The method includes a process of taking out L-shaped component members each having convex portions and concave portions arranged alternately at an end portion in a manner that each of the convex portions and concave portions is bilaterally symmetrical, while a shear droop and a burr are formed on an end portion and process of fitting and coupling end portions of L-shaped component members by placing the convex portions and the concave portions in such a manner that the shear droop of each of the convex portions faces the burr of each of the concave portions and the burr of each of the convex portions faces the shear droop of each of the concave portions and that that the convex portions and the concave portions are pushed towards each other and by pressing the convex portions and the concave portions using a pair of metal molds.
Patent Number: 6,993,820 Issued on 02/07/2006 to Fujishiro, et al.
| Inventors:
|
Fujishiro; Fumihiko (Tokyo, JP);
Fukuyoshi; Hirokazu (Tokyo, JP)
|
| Assignee:
|
NEC LCD Technologies, Ltd (JP)
|
| Appl. No.:
|
860154 |
| Filed:
|
June 4, 2004 |
Foreign Application Priority Data
| Mar 26, 2001[JP] | 2001-088848 |
| Current U.S. Class: |
29/458; 29/428 |
| Current Intern'l Class: |
B23P 25/00 (20060101); B23P 11/00 (20060101) |
| Field of Search: |
29/458,428,453,521
439/775
445/23
|
References Cited [Referenced By]
| Foreign Patent Documents |
| 96394 | Dec., 1983 | EP.
| |
| 4-73714 | Mar., 1992 | JP.
| |
| 8-112630 | May., 1996 | JP.
| |
| 2000-39850 | Feb., 2000 | JP.
| |
| 2000105387 | Apr., 2000 | JP.
| |
| 2000/-314872 | Nov., 2000 | JP.
| |
Other References
Korean Office Action dated Feb. 7, 2004 (English translation of relevant portion).
|
Primary Examiner: Hong; John C.
Attorney, Agent or Firm: Dickstein, Shapiro, Morin & Oshinsky, LLP.
Parent Case Text
CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional of U.S. patent application Ser. No. 10/105,337, filed Mar.
26, 2002, now U.S. Pat. No. 6,858,978 in the name of Fumihiko FUJISHIRO and Hirokazu
FUKUYOSHI, entitled MANUFACTURING METHOD OF SUPPORT FRAME OF DISPLAY PANEL, SUPPORT
FRAME OF DISPLAY PANEL AND DISPLAY DEVICE.
Claims
What is claimed is:
1. A method for manufacturing a support frame of a rectangular display panel
having an approximately rectangular-shaped configuration and being used to support
a portion surrounding said rectangular display panel, said method comprising:
a first process of taking out a plurality of component members each having convex
portions and concave portions arranged alternately at an end portion of each of
said plurality of said component members in a manner that each of said convex portions
and said concave portions is bilaterally symmetrical and making up said support
frame by being assembled in combination, while a shear droop and a burr are formed
at each end portion of each of said plurality of said component members, from a
plate material; and
a second process of fitting and coupling end portions of said plurality of said
component members by placing said convex portions making up an end portion of each
of said plurality of said component members to be assembled in combination and
said concave portions making up said end portion of each of said plurality of said
component members to be assembled in combination in such a manner that said shear
droop of each of said convex portions faces said burr of each of said concave portions
and said burr of each of said convex portions faces said shear droop of each of
said concave portions and, while a force is applied so that said convex portions
and said concave portions are pushed towards each other, by pressing both said
convex portions and said concave portions in upward and downward directions using
a pair of metal molds on which projected portions are formed on a surface of one
or both of said metal molds in a position being apart by a specified distance from
said each end portion of two of said component members to be assembled out of said
plurality of said component members or from said end portion of one of said plurality
of component members.
2. The method for manufacturing the support frame of the display panel according
to claim 1, wherein either of two component members to be fitted and coupled to
each other out of said plurality of said component members is made of a metal having
a different conductivity or made of a resin.
3. The method for manufacturing the support frame of the display panel according
to claim 2, wherein said component member made of said resin is so configured that
conductive paint is painted or sprayed or the metal having high conductivity is
deposited or plated only on an upper face of said component member.
4. The method for manufacturing the support frame of the display panel according
to claim 2, wherein, in said second process, said component member made of said
resin, out of said plurality of said component members, is fixed and is not moved;
and wherein said projected portion is not formed on a surface corresponding to
said component member made of said resin, of said metal mold and making up said
pair of said metal molds.
5. The method for manufacturing the support frame of the rectangular display
panel according to claim 4, wherein said component member made of said resin is
so configured that conductive paint is painted or sprayed or a metal having high
conductivity is deposited or plated only on an upper face of said component member.
6. The method for manufacturing the support frame of the rectangular display
panel according to claim 1, wherein said projected portion is formed in a position
approximately being symmetric with respect to a point of said pair of metal molds.
7. The method for manufacturing the support frame of the rectangular display
panel according to claim 5, wherein said projected portion, when each of said plurality
of said component members to be assembled in combination is made of a same metal
or a different metal, is formed in a position approximately being symmetric with
respect to a point of said pair of metal molds.
8. The method for manufacturing the support frame of the rectangular display
panel according to claim 1, wherein each of said convex portions and said concave
portions has an approximately trapezoidal configuration.
9. The method for manufacturing the support frame of the rectangular display
panel according to claim 1, wherein each of said convex portions and said concave
portions has an approximately figure-8-shaped configuration.
10. The method for manufacturing the support frame of the rectangular display
panel according to claim 1, wherein said projected portion is formed in parallel
to each end face of each of said plurality of component members in a position being
apart by a specified distance from each face of each of said plurality of component
members so as to have a line-shaped configuration.
11. The method for manufacturing the support frame of the rectangular display
panel according to claim 10, wherein said projected portion is provided with a
portion having a radius on both sides of its root.
12. The method for manufacturing the support frame of the rectangular display
panel according to claim 1, wherein said projected portion is a conical hole formed
in a position approximately corresponding to a center of said convex portion.
13. The method for manufacturing the support frame of the rectangular display
panel according to claim 1, wherein said projected portion is a pyramidal hole
formed in a position approximately corresponding to a root of said convex portion.
14. The method for manufacturing the support frame of the rectangular display
panel according to claim 2, wherein, in said second process, when each of said
plurality of said component members to be assembled in combination is made of a
metal having high hardness, end portions of two component members to be assembled
out of said plurality of said component members are fitted and coupled with a fitting
and coupling member made of a metal having low hardness being interposed between
said end portions of said two component members.
15. The method for manufacturing the support frame of the rectangular display
panel according to claim 1, wherein, in said second process, after end portions
of each of said plurality of said component members are fitted and coupled while
a jig used to prevent deformation of each said end portion is being applied to
a side face of each of said plurality of component members making up an outside
of said support frame, a side portion of each of said plurality of component members
making up an inside of said support frame is cut.
16. A method for manufacturing a support frame of a rectangular display panel
having an approximately rectangular-shaped configuration and being used to support
a portion surrounding said rectangular display panel, said method comprising:
a first process of taking out a component member made of a metal out of a plurality
of component members each having convex portions and concave portions arranged
alternately at an end portion of each of said plurality of said component members
in a manner that each of said convex portions and said concave portions is bilaterally
symmetrical and making up said support frame by being assembled in combination,
while a shear droop and a burr are formed at each end portion of each of said plurality
of said component members from a plate material; and
a second process of fitting and coupling end portions of two component members
to be assembled in combination out of said plurality of said component members,
in the case where said plurality of said component members to be assembled in combination
is made of a same metal or made of a different metal, by placing said convex portions
making up said end portion of one of said plurality of said component members and
said concave portions making up said end portion of another of said plurality of
said component members in such a manner that said shear droop of each of said convex
portions faces said burr of each of said concave portions and said burr of each
of said convex portions faces said burr of each of said concave portions and, while
a force is applied so that said convex portions and said concave portions are pushed
towards each other, by pressing both said convex portions and said concave portions
in upward and downward directions using a pair of metal molds on which projected
portions are formed on a surface of one of said metal molds in a position being
apart by a specified distance from end portions of two of said component members
out of said plurality of said component members or from an end portion of one of
said plurality of said component members and, in a case where said plurality of
said component members to be assembled in combination is made up of a first component
member made of a metal and a second component member made of a resin, by placing
said convex portions making up an end portion of said first component member or
said second component member and said concave portions making up an end portion
of said second component member or said first component member in such a manner
that said shear droop of each of said convex portions and each of said concave
portions faces said burr of each of said concave portions and each of said convex
portions and, while said end portion of said first component member is pushed toward
said end portion of said second component member, by pressing said convex and concave
portions in upward and downward directions using a pair of metal molds on which
projected portions are formed on a surface of one of said metal molds in a position
being apart by a specified distance from said end portion of said first component member.
17. The method for manufacturing the support frame of the rectangular display
panel according to claim 16, wherein said component member made of said resin is
so configured that conductive paint is painted or sprayed or a metal having high
conductivity is deposited or plated only on an upper face of said component member.
18. The method for manufacturing the support frame of the rectangular display
panel according to claim 16, wherein each of said convex portions and said concave
portions has an approximately trapezoidal configuration.
19. The method for manufacturing the support frame of the rectangular display
panel according to claim 16, wherein each of said convex portions and said concave
portions has an approximately figure-8-shaped configuration.
20. The method for manufacturing the support frame of the rectangular display
panel according to claim 16, wherein said projected portion is formed in parallel
to each end face of each of said plurality of component members in a position being
apart by a specified distance from each face of each of said plurality of component
members so as to have a line-shaped configuration.
21. The method for manufacturing the support frame of the rectangular display
panel according to claim 20, wherein said projected portion is provided with a
portion having a radius on both sides of its root.
22. The method for manufacturing the support frame of the rectangular display
panel according to claim 16, wherein said projected portion is a conical hole formed
in a position approximately corresponding to a center of said convex portion.
23. The method for manufacturing the support frame of the rectangular display
panel according claim 16, wherein said projected portion is a pyramidal hole formed
in a position approximately corresponding to a root of said convex portion.
24. The method for manufacturing the support frame of the rectangular display
panel according to claim 16, wherein said projected portion, when each of said
plurality of said component members to be assembled in combination is made of a
same metal or a different metal, is formed in a position approximately being symmetric
with respect to a point of said pair of metal molds.
25. The method for manufacturing the support frame of the rectangular display
panel according to claim 16, wherein, in said second process, when each of said
plurality of said component members to be assembled in combination is made of a
metal having high hardness, end portions of two component members to be assembled
out of said plurality of said component members are fitted and coupled with a fitting
and coupling member made of a metal having low hardness being interposed between
said end portions of said two component members.
26. The method for manufacturing the support frame of the rectangular display
panel according to claim 16, wherein, in said second process, after end portions
of each of said plurality of said component members are fitted and coupled while
a jig used to prevent deformation of each said end portion is being applied to
a side face of each of said plurality of component members making up an outside
of said support frame, a side portion of each of said plurality of component members
making up an inside of said support frame is cut.
27. A method for manufacturing a support frame of a rectangular display panel
having an approximately rectangular-shaped configuration and being used to support
a portion surrounding said rectangular display panel, said method comprising:
a first process of taking out a first component member made of a metal and making
up a side portion of said support frame having convex portions and concave portions
arranged alternately at its end portion in a manner that each of said convex portions
and concave portions is bilaterally symmetrical and, while a shear droop and a
burr are formed at each end portion of each of a plurality of component members,
from a plate material; and
a second process of fitting and coupling end portions of said plurality of component
members by placing said convex portions and said concave portions making up an
end portion of a second component member made of a resin making up a corner of
said support frame and having convex portions and concave portions arranged alternately
and having a positioning portion on its upper surface to be used for attaching
said rectangular display panel to a predetermined place and said concave portions
and said convex portions making up an end portion of said first component members
in a manner that each of said convex portions and said concave portions is bilaterally
symmetrical and in such a manner that said shear droop of each of said convex portions
faces said burr of each of said concave portions and said burr of each of said
convex portions faces said shear droop of each of said concave portions and, while
said end portion of said first component member is being pushed toward said end
portion of said second component member, by pressing said convex portions and said
concave portions in upward and downward directions using a pair of metal molds
on which projected portions are formed on a surface of one of said metal molds
in a position being apart by a specified distance from said end portion of said
first component member.
28. The method for manufacturing the support frame of the rectangular display
panel according to claim 27, wherein each of said convex portions and said concave
portions has an approximately trapezoidal configuration.
29. The method for manufacturing the support frame of the rectangular display
panel according to claim 27, wherein each of said convex portions and said concave
portions has an approximately figure-8-shaped configuration.
30. The method for manufacturing the support frame of the rectangular display
panel according to claim 27, wherein said projected portion is formed in parallel
to each end face of each of said plurality of component members in a position being
apart by a specified distance from each face of each of said plurality of component
members so as to have a line-shaped configuration.
31. The method for manufacturing the support frame of the rectangular display
panel according to claim 30, wherein said projected portion is provided with a
portion having a radius on both sides of its root.
32. The method for manufacturing the support frame of the rectangular display
panel according to claim 27, wherein said projected portion is a conical hole formed
in a position approximately corresponding to a center of said convex portion.
33. The method for manufacturing the support frame of the rectangular display
panel according to claim 27, wherein said projected portion is a pyramidal hole
formed in a position approximately corresponding to a root of said convex portion.
34. The method for manufacturing the support frame of the rectangular display
panel according to claim 27, wherein, in said second process, when each of said
plurality of said component members to be assembled in combination is made of a
metal having high hardness, end portions of two component members to be assembled
out of said plurality of said component members are fitted and coupled with a fitting
and coupling member made of a metal having low hardness being interposed between
said end portions of said two component members.
35. The method for manufacturing the support frame of the rectangular display
panel according to claim 27, wherein, in said second process, after end portions
of each of said plurality of said component members are fitted and coupled while
a jig used to prevent deformation of each said end portion is being applied to
a side face of each of said plurality of component members making up an outside
of said support frame, a side portion of each of said plurality of component members
making up an inside of said support frame is cut.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for manufacturing a support frame of
a display panel being used as a display device for personal computers, TV (television)
sets, or a like; and more particularly to the method of manufacturing the support
frame of the rectangular display panel which is used to support a portion surrounding
the rectangular display panel and to the support frame of the rectangular display
panel manufactured by the above method and to the display device equipped with
the above support frame.
The present application claims priority of Japanese Patent Application No. 2001-088848
filed on Mar. 26, 2001, which is hereby incorporated by reference.
2. Description of the Related Art
As a rectangular display panel, an LCD (Liquid Crystal Display) panel, a PDP
(Plasma
Display Panel), or panels made up of light emitting elements such as an EL (Electroluminescence),
an LED (Light Emitting Diode), a VFD (Vacuum Fluorescent Display), or a like are
conventionally available. In the LCD panel, a region surrounded by a scanning electrode
mounted in a row direction and by a data electrode mounted in a column direction
is used as a pixel, and by feeding a data signal produced from an image signal
to a data electrode and by feeding a scanning signal produced from a synchronous
signal to the scanning electrode, a character or an image is displayed on a display
screen. Also, in the LCD panel, a data electrode driving circuit adapted to generate
the above data signal and a scanning electrode driving circuit adapted to generate
the above scanning signal, together with control circuits used to control these
circuits, gray-scale power source, or a like, are formed integrally as an LCD module.
As shown in FIG. 29, in an LCD module
1, a front of a portion surrounding
the LCD module
1 is supported by an approximately rectangular-shaped front
frame
2 and a rear of the portion surrounding the LCD module
1 is
supported by an approximately rectangular-shaped center frame
3.
In the LCD module
1 shown in FIG. 29, the control circuits, gray-scale
power source, or a like are mounted on a printed board
4, while the data
electrode driving circuit made up of semiconductor circuits (ICs) is mounted on
a film carrier tape electrically connecting the printed board
4 and an LCD
panel
5 by each of a plurality of corresponding data electrodes and is packaged
as TCPs (Tape Carrier Packages)
61 to
68. The
printed board
4 is attached to an upper frame
3a of the
center frame
3. Moreover, positioning members
7 (another positioning
member
7 in a lower right portion is not shown) shown in FIG. 29 is used
to correctly attach the LCD module
1 in a specified position of the center
frame
3. In the positioning member
7 made of a resin, as shown in
FIG. 30, two rectangular parallel-piped bodies
9 are formed integrally on
an upper face of an approximately L-shaped substrate
8 in such a manner
that axial lines of the two rectangular parallel-piped bodies
9 intersect
each other at right angles and, in the vicinity of the two rectangular parallel-piped
bodies
9, one circular hole
10 is formed. The positioning member
7 is fixed at the center frame
3 in a method as described below.
That is, first, each of the two rectangular parallel-piped bodies
9 of the
positioning member
7 is inserted, from a rear side of the center frame
3,
into a larger size inserting hole
11 than each of upper areas of the two
rectangular parallel-piped bodies
9 each being formed in four corners of
the center frame
3. Then, a thread (not shown) is fitted, with some tolerance
being allowed, into the circular hole
10 from a rear side of the L-shaped
substrate
8 and is inserted fitly into a thread hole
12 formed in
the vicinity of the inserting hole
11 of the center frame
3 to fix
the positioning member
7 to the center frame
3.
The front frame
2 and the center frame
3 are conventionally manufactured
by following methods. Hereinafter, the front frame
2 and center frame
3
are collectively called a "support frame". That is, after a pair of L-shaped component
members is assembled in combination so that a rectangular structure is formed and
both end edges of the pair of the L-shaped component members are melted and bonded
to each other to form a rectangular frame plate member, the frame plate member
is bent in a manner that the rectangular frame plate has an approximately L-shaped
cross section, and the bent frame plate is used as the support frame. A manufacturing
method of this type is disclosed in Japanese Patent Application Laid-open Nos.
Hei 4-73714 and 2000-39850. Hereinafter, technology disclosed in these Patent Applications
is called a "first conventional example".
Moreover, in a Japanese Patent Application Laid-open No. 2000-314872, another
technology is disclosed. That is, in the example, as shown in FIG. 31, a rectangular-shaped
center frame
13 is assembled so as to have an approximately rectangular-shaped
configuration which is made up of two approximately L-shaped component members
13a and
13b and end portions of each of the
L-shaped component members
13a and
13b are
placed at corners of the rectangular-shaped center frame
13 being diagonally
opposite to each other. Moreover, as shown in FIGS. 32A and 32B, a fitting/coupling
section
14 made up of plane pierce-shaped convex portions
14a
and plane pierce-shaped concave portions
14b is provided
at a place where the L-shaped component member
13a is to be coupled
to the L-shaped component member
13b and another fitting/coupling
section
15 with plane pierce-shaped convex portions
15a and
plane pierce-shaped concave portions
15b is provided at a place
where the L-shaped component member
13a is also to be coupled
to the L-shaped component member
13b. In the L-shaped component
members
13a and
13b, portions being extruded
from a side line of each of the L-shaped component members
13a and
13b or being partitioned by dotted lines in side portions of
each of the L-shaped component members
13a and
13b
are bending margins
13c to be used when the L-shaped component
members
13a and
13b are bent so as to be approximately
L-shaped in cross sections.
A constricted portion
14c is formed in each of the plane pierce-shaped
convex portions
14a and a constricted portion
15c
is formed in each of the plane pierce-shaped convex portions
15a
and the constricted portion
14c is formed in each of the
plane pierce-shaped concave portions
14b and the constricted
portion
15c in each of the plane pierce-shaped concave portions
15b. Therefore, this causes the plane pierce-shaped convex portions
14a and the plane pierce-shaped concave portions
15a
to be tightly fitted each other, thus preventing them from being separated
from each other in a horizontal direction. In the plane pierce-shaped convex portions
14a and
15a are formed boss portions
14d
and
15d respectively in a half-punched state by a press
working method.
Next, a method for manufacturing the center frame
13 is explained. First,
the fitting/coupling sections
14 and
15 in each of the L-shaped component
members
13a and
13b are positioned to be fitted
from upward and downward directions to cause the plane pierced-shaped convex portions
14a and
15a to be mechanically fitted into
the plane pierced-shaped concave portions
14b and
15b.
Next, when the fitting/coupling sections
14 and
15 are crimped from
upward and downward directions by using a pressing machine, each of the boss portions
14d and
15d is plastic-deformed and expanded,
which causes the plane pierce-shaped convex portions
14a and
15a and the plane pierce-shaped concave portions
14b
and
15b to be fitted more tightly and to be integrated.
Then, by bending the bending margins
13c of each side using the pressing
machine, the rectangular-shaped center frame
13 having approximately the
same shape as the rectangular-shaped center frame
3 shown in FIG. 29 is
manufactured. Hereinafter, this technology is called a "second conventional example".
However, the first conventional example has a disadvantage in that, since
the melting and bonding processes are included in the method of manufacturing the
support frame for the display panel provided in the first conventional example,
generally, long working hours are required. Another problem is that, when a laser
deposition method is used for the melting and bonding processes, in particular,
additional special equipment has to be prepared.
On the other hand, the method for manufacturing the support frame for the display
panel provided in the second conventional example also has a disadvantage in that,
since the formation of the constricted portions
14c and
15c
is necessary, if hardness of the employed component member is very high,
it is difficult to form such the constricted portions
14c and
15c precisely. Thus, the constricted portions
14c and
15c cause low strength of the support frame itself. As a result,
if the constricted portions
14c and
15c have
not been precisely formed, when the plane pierce-shaped convex portions
14a
and
15a and the plane pierce-shaped concave portions
14b
and
15b are mechanically fitted, there is a danger that
the fitting/coupling sections
14 and
15 would not be fitted completely.
Moreover, depending on conditions applied when the plane pierce-shaped convex portions
14a and
15a and the plane pierce-shaped concave
portions
14b and
15b are mechanically fitted,
a case may occur in which both the plane pierce-shaped convex portions
14a
and
15a and plane pierce-shaped concave portions
14b
and
15b or either of the plane pierce-shaped convex portions
14a and
15a or plane pierce-shaped concave
portions
14b and
15b are broken in the constricted
portions
14c and
15c. This means that, in the
second conventional example, types of component members or manufacturing conditions
that can be applied are limited and, if types of the component members are erroneously
selected or the manufacturing conditions are erroneously set, defectives continuously
occur and a yield is decreased, as a result. Furthermore, in the case of the second
conventional example, after the plane pierce-shaped convex portions
14a
and
15a and the plane pierce-shaped concave portions
14b
and
15b are mechanically fitted, process of crimping the
fitting/coupling sections
14 and
15 from upward and downward directions
using the pressing machine is needed, which causes low productivity in manufacturing
the support frame.
Furthermore, in an upper portion of the above LCD module
1, as
shown in FIG. 29, a plurality of ICs making up the data electrode driving circuit
is mounted on a film carrier tape which is packaged in a form of the TCPs
61
to
68. Since the plurality of ICs generates data signals to be
fed to the data electrode in the LCD panel
5, high frequency noises of about
several kH
z to 1 GH
z occur and, therefore, unless an electromagnetic
shielding unit is provided, the noises cause an EMI (Electro Magnetic Interference)
to other electronic devices. To solve this problem, it can be thought that, as
a material for the front frame
2, iron or aluminum having high conductivity
is used to have it serve also as an electromagnetic shielding unit. However, iron
has a high specific gravity and high hardness and, therefore, when it is used for
a large screen, a weight of a display device becomes high and iron is difficult
to be processed. Aluminum has also a disadvantage because it is expensive. As a
material for the front frame
2, conventionally, stainless steel is used
which has low conductivity but small specific gravity and low hardness and, in
a portion above the data electrode driving circuit, a copper foil having high conductivity
is pasted up. Therefore, a process of pasting up the copper foil is additionally
required which causes an increase in component counts and in the number of processes.
As shown in FIG. 33, in a lower portion of an upper frame section
2a
of the front frame
2 are mounted the printed board
4, TCPs
61
to
68, or a like, while the upper frame section
2a
of the front frame
2 is used as a terminal being of a ground level.
Therefore, in the conventional support frame, in order to prevent the printed board
4, TCPs
61 to
68, or a like from being
in contact with the upper frame section
2a of the front frame
2,
an insulator
16 such as silicon rubber or a like is pasted up on a lower
face of the upper frame section
2a of the front frame
2 to
ensure insulation between the upper frame
2a of the front frame
2
and the TCPs
61 to
68. As a result, a process
of pasting up the insulator
16 is additionally required which causes an
increase in component counts and in the number of processes.
Moreover, in the conventional support frame, in order to attach the LCD
module
1 exactly to a specified position in the center frame
3, the
positioning member
7 is used. Therefore, a process of mounting the positioning
member
7 is additionally required which also causes an increase in component
counts and in the number of processes. Such the inconvenience as in the LCD also
occurs more or less in the display panel such as PDP or panels made up of light
emitting elements such as the EL, LED, VFD or a like in an approximately same manner.
SUMMARY OF THE INVENTION
In view of the above, it is a first object of the present invention to provide
a method for manufacturing a support frame of a display panel which is capable
of fabricating the support frame of the display panel having high strength within
short working time, without use of additional special equipment, without limitations
imposed by types of component members and/or manufacturing conditions and at a
high level of productivity and to provide the support frame and the display panel
using the support frame. It is a second object of the present invention to provide
the method for manufacturing the support frame of the display panel which is capable
of preventing EMI, insulating circuits, or positioning the display panel in small
component counts and in small numbers of processes and to provide the support frame
and the display panel using the support frame.
According to a first aspect of the present invention, there is provided
a method for manufacturing a support frame of a rectangular display panel having
an approximately rectangular-shaped configuration and being used to support a portion
surrounding the rectangular display panel, the method including:
a first process of taking out a plurality of component members each having convex
portions and concave portions arranged alternately at an end portion of each of
the plurality of the component members in a manner that each of the convex portions
and the concave portions is bilaterally symmetrical and making up the support frame
by being assembled in combination, while a shear droop and a burr are formed at
each end portion of each of the plurality of the component members, from a plate
material; and
a second process of fitting and coupling end portions of the plurality of the
component
members by placing the convex portions making up the end portion of each of the
plurality of the component members to be assembled in combination and the concave
portions making up an end portion of each of the plurality of the component members
to be assembled in combination in such a manner that the shear droop of each of
the convex portions faces the burr of each of the concave portions and the burr
of each of the convex portions faces the shear droop of each of the concave portions
and, while a force (pressure) is applied so that the convex portions and the concave
portions are pushed towards each other, by pressing both the convex portions and
the concave portions in upward and downward directions using a pair of metal molds
on which projected portions are formed on a surface of one or both of the metal
molds in a position being apart by a specified distance from the each end portion
of two of the component members to be assembled out of the plurality of the component
members or from the end portion of one of the plurality of component members.
In the foregoing, a preferable mode is one wherein either of two component members
to be fitted and coupled to each other out of the plurality of the component members
is made of a metal having a different conductivity or made of a resin.
Also, a preferable mode is one wherein the component member made of the resin
is so configured that conductive paint is painted or sprayed or the metal having
high conductivity is deposited or plated only on an upper face of the component member.
Also, a preferable mode is one wherein, in the second process, the component
member made of the resin, out of the plurality of the component members, is fixed
and is not moved; and wherein the projected portion is not formed on a surface
corresponding to the component member made of the resin, of the metal mold and
making up the pair of the metal molds.
According to a second aspect of the present invention, there is provided
a method for manufacturing a support frame of a rectangular display panel having
an approximately rectangular-shaped configuration and being used to support a portion
surrounding the rectangular display panel, the method including:
a first process of taking out a component member made of a metal out of a plurality
of the component members each having convex portions and concave portions arranged
alternately at an end portion of each of the plurality of the component members
in a manner that each of the convex portions and the concave portions is bilaterally
symmetrical and making up the support frame by being assembled in combination,
while a shear droop and a burr are formed at each end portion of each of the plurality
of the component members from a plate material; and
a second process of fitting and coupling end portions of two component members
to be assembled in combination out of the plurality of the component members, in
the case where the plurality of the component members to be assembled in combination
is made of a same metal or made of a different metal, by placing the convex portions
making up the end portion of one of the plurality of the component members and
the concave portions making up the end portion of another of the plurality of the
component members in such a manner that the shear droop of each of the convex portions
faces the burr of each of the concave portions and the burr of each of the convex
portions faces the shear droop of each of the concave portions and, while a force
is applied so that the convex portions and the concave portions are pushed towards
each other, by pressing both the convex portions and the concave portions in upward
and downward directions using a pair of metal molds on which projected portions
are formed on a surface of one of the metal molds in a position being apart by
a specified distance from end portions of two of the component members out of the
plurality of the component members or from an end portion of one of the plurality
of the component members and, in the case where the plurality of the component
members to be assembled in combination is made up of a first component member made
of a metal and a second component member made of a resin, by placing the convex
portions making up an end portion of the first component member or the second component
member and the concave portions making up an end portion of the second component
member or the first component member in such a manner that the shear droop of each
of the convex portions faces the burr of each of the concave portions and the burr
of each of the convex portions faces the shear droop of each of the concave portions
and, while the end portion of the first component member is pushed toward the end
portion of the second component member, by pressing the convex and concave portions
in upward and downward directions using a pair of metal molds on which projected
portions are formed on a surface of one of the metal molds in a position being
apart by a specified distance from the end portion of the first component member.
In the foregoing, a preferable mode is one wherein the component member made
of
the resin is so configured that conductive paint is painted or sprayed or the metal
having high conductivity is deposited or plated only on an upper face of the component member.
According to a third aspect of the present invention, there is provided
a method for manufacturing a support frame of a rectangular display panel having
an approximately rectangular-shaped configuration and being used to support a portion
surrounding the rectangular display panel, the method including:
a first process of taking out a first component member made of a metal and making
up a side portion of the support frame having convex portions and concave portions
arranged alternately at its end portion in a manner that each of the convex portions
and the concave portions is bilaterally symmetrical and, while a shear droop and
a burr are formed at each end portion of each of a plurality of component members,
from a plate material; and
a second process of fitting and coupling end portions of the plurality of component
members by placing the convex portions and the concave portions making up an end
portion of a second component member made of a resin making up a corner of the
support frame and having the convex portions and the concave portions arranged
alternately and having a positioning portion on its upper surface to be used for
attaching the rectangular display panel to a predetermined place and the concave
portions and the convex portions making up an end portion of the first component
members in a manner that each of the convex portions and the concave portions is
bilaterally symmetrical and in such a manner that the shear droop of each of the
convex portions faces the burr of each of the concave portions and the burr of
each of the convex portions faces the shear droop of each of the concave portions
and, while the end portion of the first component member is being pushed toward
the end portion of the second component member, by pressing the convex portions
and the concave portions in upward and downward directions using a pair of metal
molds on which projected portions are formed on a surface of one of the metal molds
in a position being apart by a specified distance from the end portion of the first
component member.
In the foregoing, a preferable mode is one wherein each of the convex portions
and the concave portions has an approximately trapezoidal configuration.
Also, a preferable mode is one wherein each of the convex portions and the
concave portions has an approximately figure-8-shaped configuration.
Also, a preferable mode is one wherein the projected portion is formed in parallel
to each end face of each of the plurality of component members in a position being
apart by a specified distance from each face of each of the plurality of component
members so as to have a line-shaped configuration.
Also, a preferable mode is one wherein the projected portion is provided with
a portion having a radius on both sides of its root.
Also, a preferable mode is one wherein the projected portion is a conical hole
formed in a position approximately corresponding to a center of the convex portion.
Also, a preferable mode is one wherein the projected portion is a pyramidal
hole formed in a position approximately corresponding to a root of the convex portion.
Also, a preferable mode is one wherein the projected portion is formed in a
position approximately being symmetric with respect to a point of the pair of metal molds.
Also, a preferable mode is one wherein the projected portion, when each of
the plurality of the component members to be assembled in combination is made of
a same metal or a different metal, is formed in a position approximately being
symmetric with respect to a point of the pair of metal molds.
Also, a preferable mode is one wherein, in the second process, when each of
the plurality of the component members to be assembled in combination is made of
a metal having high hardness, end portions of two component members to be assembled
out of the plurality of the component members are fitted and coupled with a fitting
and coupling member made of a metal having low hardness being interposed between
the end portions of the two component members.
Also, a preferable mode is one wherein, in the second process, after end portions
of each of the plurality of the component members are fitted and coupled while
a jig used to prevent deformation of each end portion is being applied to a side
face of each of the plurality of component members making up an outside of the
display frame, a side portion of each of the plurality of component members making
up an inside of the display frame is cut.
According to a fourth aspect of the present invention, there is provided
a support frame of a rectangular display panel having an approximately rectangular-shaped
configuration and being used to support a portion surrounding the rectangular display
panel, including:
a plurality of component members each having convex portions and concave portions
arranged alternately at an end portion of each of the plurality component members
in a manner that each of the convex portions and the concave portions is bilaterally
symmetrical and having a shear droop and a burr at an end portion of each of the
plurality of component members; and
wherein the end portions of the plurality of component members are fitted
and coupled by placing the convex portions and the concave portions in such a manner
that the shear droop of each of the convex portions and each of the concave portions
faces the burr of each of the concave portions and each of the convex portions.
In the foregoing, a preferable mode is one wherein either of two component members
to be fitted and coupled to each other out of the plurality of the component members
is made of a metal having a different conductivity or made of a resin.
Also, a preferable mode is one wherein the component member made of the resin
is so configured that conductive paint is painted or sprayed or the metal having
high conductivity is deposited or plated only on an upper face of the component member.
According to a fifth aspect of the present invention, there is provided
a support frame of a rectangular display panel having an approximately rectangular-shaped
configuration and being used to support a portion surrounding the rectangular display
panel, including:
a plurality of component members made of two or more kinds of metals each having
a different conductivity or made of a resin each having convex portions and concave
portions arranged alternately in a manner that each of the convex portions and
the concave portions is bilaterally symmetrical at an end portion of each of the
plurality of component members and each having a shear droop and a burr formed
at an end portion of each of the plurality of component members; and
wherein end portions of two component members to be assembled out of the
plurality of the component members are fitted and coupled by placing the convex
portions and the concave portions in such a manner that the shear droop of each
of the convex portions faces the burr of each of the concave portions and the burr
of each of the convex portions faces the shear droop of each of the concave portions.
In the foregoing, a preferable mode is one wherein the component member made
of
the resin is so configured that conductive paint is painted or sprayed or the metal
having high conductivity is deposited or plated only on an upper face of the component member.
According to a sixth aspect of the present invention, there is provided
a support frame of a rectangular display panel having an approximately rectangular-shaped
configuration and being used to support a portion surrounding the rectangular display
panel, including:
a first component member made of a metal making up a side portion of the support
frame and having convex portions and concave portions arranged alternately in a
manner that each of the convex portions and the concave portions is bilaterally
symmetrical at an end portion of the first component member and having a shear
droop and a burr formed at an end portion of each of the first component member;
a second component member made of a resin making up a corner of the support frame
and having convex portions and concave portions arranged alternately and having
the shear droop and the burr formed at an end portion of each of the second component
member and having a positioning portion on its upper surface to be used for attaching
the rectangular display panel to a predetermined place; and
wherein end portions of the first and second component members are fitted
and coupled by placing the convex portions and the concave portions in such a manner
that the shear droop of each of the convex portions faces the burr of each of the
concave portions and the burr of each of the convex portions faces the shear droop
of each of the concave portions.
In the foregoing, a preferable mode is one wherein each of the convex portions
and the concave portions has an approximately trapezoidal configuration.
Also, a preferable mode is one wherein each of the convex portions and the
concave portions has an approximately figure-8-shaped configuration.
Also, a preferable mode is one wherein a pair of the component members to be
fitted and coupled is made of a metal having high hardness and end portions of
the pair of the component members made of the metal having high hardness are fitted
and coupled with a fitting and coupling member made of a metal having low hardness
being interposed between the component members made of the metal having high hardness.
According to a seventh aspect of the present invention, there is provided
a display device equipped with a support frame which supports a rectangular display
panel and a portion surrounding the rectangular display panel described above.
With the above configuration, a plurality of component members each having convex
portions and concave portions arranged alternately at an end portion of each of
the plurality of component members in a manner that each of the convex portions
and the concave portions is bilaterally symmetrical, while a shear droop and a
burr are formed at each end portion of each of the plurality of component members
is taken from a plate material. Next, the convex portions making up an end portion
of one of the plurality of component members to be used for assembling and the
concave portions making up an end portion of another of the plurality of component
members to be used for assembling are placed in such a manner that the shear droop
of each of the convex portions faces the burr of each of the concave portions and
the burr of each of the convex portions faces the shear droop of each of the concave
portions and that a force is applied so that the convex portions and the concave
portions are pushed towards each other and by pressing the convex portions and
the concave portions in upward and downward directions using a pair of metal molds
on which projected portions are formed on a surface of one of the metal molds in
a position being apart by a specified distance from an end portion of two of the
component members out of the plurality of component members or from an end portion
of one of the plurality of component members. As a result, end portions of the
plurality of component members are fitted and coupled. Therefore, a support frame
of a rectangular display panel can be manufactured within short working time, without
use of special equipment, without limitations imposed by types of component members
and/or manufacturing conditions and at a high level of productivity.
With another configuration as above, a component member made of a metal out
of a plurality of the component members each having the convex portions and the
concave portions arranged alternately at an end portion of each of the plurality
of component members in a manner that each of the convex portions and the concave
portions is bilaterally symmetrical and making up the support frame by being assembled,
while a shear droop and a burr are formed at each end portion of each of the plurality
of component members is taken out from a plate material and, in the case where
the plurality of the component members to be assembled in combination is made up
of component members made of a same metal or made of a different metal, the convex
portions making up an end portion of one of the plurality of component members
and the concave portions making up an end portion of another of the plurality of
component members placed in such a manner that the shear droop of each of the convex
portions faces the burr of each of the concave portions and the burr of each of
the convex portions faces the shear droop of each of the concave portions and that
a force is applied so that the convex portions and the concave portions are pushed
towards each other and by pressing the convex and concave portions in upward and
downward directions using a pair of metal molds on which projected portions are
formed on a surface of one of the metal molds in a position being apart by a specified
distance from an end portion of two of the component members out of the plurality
of component members or from an end portion of one of the plurality of component
members and, in the case where the plurality of the component members to be assembled
in combination is made up of a first component member made of a metal and a second
component member made of a resin, the convex portions making up an end portion
of the first component member and the concave portions making up an end portion
of the second component member placed in such a manner that the shear droop of
each of the convex portions faces the burr of each of the concave portions and
the burr of each of the convex portions faces the shear droop of each of the concave
portions and that the end portion of the first component member is pushed toward
the end portion of the second component member and by pressing the convex and concave
portions in upward and downward directions using a pair of metal molds on which
projected portions are formed on a surface of one of the metal molds in a position
being apart by a specified distance from the end portion of the first component
member, thus causing end portions of the plurality of component members to be fitted
and coupled. Therefore, it is possible to take countermeasures against EMI and/or
to insulate circuits in small component counts and in small numbers of processes.
With still another configuration as above, a first component member made of
a metal and making up a side portion of the support frame having convex portions
and concave portions arranged alternately at its end portion in a manner that each
of the convex portions and the concave portions is bilaterally symmetrical, while
a shear droop and a burr are formed at each end portion of each of the plurality
of component members is taken out from a plate material. Then, the convex portions
making up an end portion of a second component member made of a resin making up
a corner of the support frame and having the convex portions and concave portions
arranged alternately and having a positioning portion on its upper surface to be
used for attaching the display panel to a predetermined place and the concave portions
making up an end portion of the first component members in a manner that each of
the convex portions and the concave portion is bilaterally symmetrical, are placed
in such a manner that the shear droop of each of the convex portions faces the
burr of each of the concave portions the burr of each of the convex portions faces
the shear droop of each of the concave portions and, while the end portion of the
first component member is pushed toward the end portion of the second component
member, by pressing the convex and concave portions in upward and downward directions
using a pair of metal molds on which projected portions are formed on a surface
of one of the metal molds in a position being apart by a specified distance from
the end portion of the first component member, thus causing end portions of a plurality
of component members to be fitted and coupled. Therefore, it is possible to perform
positioning of the display panel in small component counts and in small numbers
of processes.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other objects, advantages, and features of the present invention
will be more apparent from the following description taken in conjunction with
the accompanying drawings in which:
FIG. 1 is an exploded perspective view showing L-shaped component members making
up a front frame in a developed state according to a first embodiment of the present invention;
FIG. 2 is a partial expanded view of an A portion of one L-shaped component
member of FIG. 1 and of a B portion of another L-shaped component member of FIG. 1;
FIG. 3 is a schematic cross-sectional view explaining a process in which punching
is performed on a stainless steel plate to produce the L-shaped component member
according to the first embodiment of the present invention;
FIG. 4 is a schematic cross-sectional view explaining a shear droop and a burr
produced in a convex portion of the L-shaped component member;
FIG. 5 is an expanded top view of a fitting/coupling section according to the
first embodiment of th
