REINFORCED TRAY STACK CONTAINER

Abstract

Various box embodiments are disclosed. In one aspect, a box is provided that includes a container. The container has a bottom panel, a front panel, a first side panel, a second side panel, a back panel, a first reinforcement structure adjacent the back panel and the first side panel and a second reinforcement structure adjacent the back panel and the second side panel. The first and second reinforcement structures reinforce the back panel against compressive forces. A lid is coupled to the container.

Description

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates generally to containers, such as boxes, and more particularly to containers for transporting semiconductor devices.

2. Description of the Related Art

Semiconductor devices, such as packaged or unpackaged semiconductor chips, frequently require transport from one location to another. Some of these trips are necessary to send the devices to one or more vendors who perform fabrication processes associated with the chips. Others may simply be deliveries to end users or customers. Frequently these semiconductor devices are first placed in a tray of one sort another. The tray is then stacked with others to form a stack of trays. The stack of trays is then strapped together with plastic straps and placed inside of a cardboard box for shipment. The semiconductor devices are sensitive to a variety of conditions associated with the shipping process. For instance, the semiconductor devices are sensitive to compressive forces, shock forces, electrostatic discharge, and sometimes humidity.

One conventional technique to protect conventional tray stacks involves placing the tray stack inside of a bubble bag, which is a plastic bag consisting of bubble wrap. The bubble bag is then surrounded with a layer of bubble sheet on all sides. The stack enclosed in both the bubble bag and bubble sheet is then placed into a conventional cardboard box. This so-called Q-Pack® box has a back panel that is not reinforced against compressive forces. In addition, the Q-Pack® box requires a carbon coating on almost all interior surfaces in order to provide Faraday shielding. Finally, the volume of the box has to be sufficiently large to accommodate the volume of the tray stack plus bubble bag plus the often irregularly shaped bubble sheets.

A conventional variant of the Q-Pack® suitable for so-called “dry packing” where the semiconductor devices are sensitive to humidity involves the placement of the stack and bubble bag combination inside of a hermetically sealed bag that is in turn placed inside of the bubble sheet and then ultimately the box as described above.

Another conventional variant utilizes a box without front or back panel reinforcement. Separate Faraday shield sheets are sandwiched above and below the stack.

The present invention is directed to overcoming or reducing the effects of one or more of the foregoing disadvantages.

SUMMARY OF THE INVENTION

In accordance with one aspect of the present invention, a box is provided that includes a container. The container has a bottom panel, a front panel, a first side panel, a second side panel, a back panel, a first reinforcement structure adjacent the back panel and the first side panel and a second reinforcement structure adjacent the back panel and the second side panel. The first and second reinforcement structures reinforce the back panel against compressive forces. A lid is coupled to the container.

In accordance with another aspect of the present invention, a box blank is provided that includes plural components foldable into a container. The components include a bottom panel, a front panel, a back panel, a first side panel, a first reinforcement structure coupled to the first side panel, a second side panel and a second reinforcement structure coupled to the second side panel, the first and second reinforcement structures are operable to reinforce the back panel against compressive forces when the container is assembled.

In accordance with another aspect of the present invention, a method of manufacturing is provided that includes fabricating a box blank that has plural components foldable into a container. The components include a bottom panel, a front panel, a back panel, a first side panel, a first reinforcement structure coupled to the first side panel, a second side panel and a second reinforcement structure coupled to the second side panel. The first and second reinforcement structures are operable to reinforce the back panel against compressive forces when the container is assembled.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other advantages of the invention will become apparent upon reading the following detailed description and upon reference to the drawings in which:

FIG. 1 is an overhead view of an exemplary box blank;

FIG. 2 is a pictorial view of a small portion of the box blank of FIG. 1 depicting some exemplary folding operations;

FIG. 3 is a pictorial view like FIG. 2 but depicting some additional exemplary folding operations;

FIG. 4 is an overhead view of the exemplary box blank in an assembled configuration;

FIG. 5 is an overhead view of a small portion of the box depicted in FIG. 4 and showing an exemplary wall construction;

FIG. 6 is an overhead view like FIG. 5 but depicting an alternate exemplary multi-ply wall construction;

FIG. 7 is a pictorial view of a portion of the box depicted in FIG. 4 but viewed from inside of a container portion thereof;

FIG. 8 is a portion of FIG. 7 shown at greater magnification;

FIG. 9 is a pictorial view like FIG. 7 but depicting an alternate exemplary corner reinforcement structure;

FIG. 10 is an overhead view of an exemplary assembled box and depicting the placement of an exemplary semiconductor device storage tray stack therein;

FIG. 11 is a pictorial view of an exemplary semiconductor device tray stack exploded from an exemplary box insert;

FIG. 12 is a pictorial view of a conventional assembled box;

FIG. 13 is a pictorial view of another conventional assembled box; and

FIG. 14 is a pictorial view of another conventional assembled box.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

A box blank may be folded into a box suitable to hold multiple semiconductor device transport trays. When assembled, the box blank includes a container with a front panel and a back panel. The box blank includes reinforcement structures for the front and back panels. The reinforcement structures eliminated the need for a bulky bubble sheet wrap. The box can be made smaller than a conventional design and the bubble sheet is unnecessary. Additional details will now be described.

In the drawings described below, reference numerals are generally repeated where identical elements appear in more than one figure. Turning now to the drawings, and in particular to FIG. 1, therein is depicted a plan view of an exemplary embodiment of a box blank 10. The box blank 10 is advantageously fabricated from a sheet of cardboard the details of which will be described below. The box blank 10 may be cut from the cardboard sheet by punching or other cutting techniques. The box blank 10 may consist of a plurality of intercooperating components that may be folded and rotated in a variety of ways in order to assemble a completed box as described in more detail below.

The box blank 10 may consist of various sub-components, including a container 15 and a lid 20. The container 15 may included a left-hand reinforcement structure 25 and a right-hand reinforcement structure 30. The lid 20 may consist of a top panel 35 and a front tuck flap 40. The front tuck flap 40 is foldable relative to the top panel 35 at a fold line 45. The fold line 45 and any of the other fold lines described herein may be formed in a variety of ways, such as by mechanical deformation by a mechanical press with an appropriate footprint to initiate a plastic deformation. The top panel 35 may include a left top panel wing 50 and a right top panel wing 55. The left top panel wing 50 is foldable relative to the top panel 35 at a fold line 60 and the right top panel wing 55 is foldable relative to the top panel 35 at a fold line 65. The front tuck flap 40 may include a left front tuck flap wing 67 and a right front tuck flap wing 70. The left front tuck flap wing 67 is foldable relative to the front tuck flap 40 at a fold line 75 and the right front tuck flap wing 70 is foldable relative to the front tuck flap 40 at a fold line 80. The combination of the front tuck flap 40 and the front tuck flap wings 67 and 70 may be foldable relative to the top panel 35 at the fold line 45. Note that the top panel wings 50 and 55 have generally rounded external profiles to facilitate the easy insertion thereof into the enclosure 15 when the enclosure 15 is assembled and the lid 20 is closed. The front tuck flap wings 67 and 70 similarly have tapered external profiles to facilitate their insertion into gaps between various walls of the container 15 and the reinforcement structures 25 and 30 to be described in more detail below. The lid 20 is coupled to the container 15. This may be accomplished by fabricating the lid 20 as part of the blank 10. Optionally, the lid 20 may be fabricated separately and thereafter attached to the container 15 by adhesives, tapes or other well-known fastening techniques.

The container 15 may consist of a bottom panel 90, a back panel 95, a front panel 100, a left side panel 105 and a right side panel 110. The back panel 95 includes a left side flap 115 that is foldable at a fold line 120 and a right side flap 125 that is foldable at a fold line 130. The back panel 95 is foldable relative to the bottom panel 90 at a fold line 135. The top panel 35 of the lid 20 is foldable relative to the back panel 95 at a fold line 140. The front panel 100 is foldable relative to the bottom panel 90 at a fold line 143 and includes a left flap 145 that is foldable at a fold line 150 and a right flap 155 that is foldable at a fold line 160.

The left-hand reinforcement structure 25 may consist of a wrap around panel 175, a back panel reinforcement corner 180 and a front panel reinforcement corner 185. The entire reinforcement structure 25 is foldable relative to a narrow strip 190 at a fold line 195. The combination of the narrow strip 190 and the reinforcement structure 25 is foldable relative to the side panel 105 at a fold line 200. The wrap around panel 175 may include a tab 205 that is sized to project into an opening or slot 210 in the bottom panel 90 during assembly. The slot 210 and others disclosed herein may be slots or other types of openings. The back panel reinforcement corner 180 may consist of a flap 212 that is foldable relative to another flap 215 at a fold line 217. The flap 215 is foldable relative to the wrap around panel 175 at a fold line 220. The flap 215 may include a tab 225 that may project into a slot 230 in the bottom panel 90 when the left side panel 105 and the reinforcement structure 25 are folded during assembly. The front panel reinforcement corner 185 similarly includes a flap 235 that is foldable relative to another flap 240 at a fold line 245. The flap 240 is foldable relative to the wrap around panel 175 at a fold line 250. The flap 240 may include a tab 255 that may project into a slot 260 in the bottom panel 90 much like the tab 225 described above, albeit there in conjunction with the slot 230 and not the slot 260.

The right-hand reinforcement structure 30 is essentially a mirror image of the left-hand support structure 25. In this regard, the right-hand support structure 30 may consist of a wrap around panel 265, a back panel reinforcement corner 267 and a front panel reinforcement corner 269. The entire reinforcement structure 30 is foldable relative to a narrow strip 275 at a fold line 277. The combination of the strip 275 and the reinforcement structure 30 is foldable relative to the side panel 110 at a fold line 280. The wrap around panel 265 may include a tab 285 that is sized to project into a slot 287 in the bottom panel 90 after the right side panel 110 is rotated during assembly. The back reinforcement corner 267 includes a flap 290 foldable relative to another flap 295 at a fold line 300. The flap 295 is foldable relative to the wrap around panel 265 at a fold line 305. The flap 295 may include a tab 310 that may project into a slot 315 in the bottom panel 90 when the right side panel 110 and the reinforcement structure 30 are folded during assembly. The front panel reinforcement corner 269 includes a flap 325 foldable relative to another flap 330 at a fold line 335. The flap 330 is foldable relative to the warp around panel 265 at a fold line 340. The flap 330 may include a tab 350 projectable into a slot 355 in the bottom panel 90 that functions like the tab 310, albeit in conjunction with the slot 355 and not the slot 310.

The assembly of the box blank 10 will now be described in conjunction with FIGS. 1-4. FIG. 2 and FIG. 3 are pictorial views of the front panel 100 and a portion of the bottom panel 90 cut away from the remainder of the box blank 10. Note that the slots 260 and 355 and the fold line 143 in the bottom panel 90 are visible in FIGS. 2 and 3. FIG. 4 is an overhead view of the assembled box blank 10 with the lid 20 in an open position. The assembly of the box blank 10 involves a number of folding and rotating operations. It should be understood that any or all of the folding operations described herein may be performed by human or machine. To facilitate the description of the various rotating and folding movements of the components of the box blank 10, an x, y, z axis is illustrated in FIGS. 1-4. Since FIGS. 1 and 4 are orthographic views, the z axes in those figures project out of the page and are represented by the black dots. Rotation about the x axis in one direction is labeled direction A. Rotation about the x axis in the opposite direction is labeled direction B. Rotation about the y axis in one direction is labeled direction C and in the opposite direction, direction D. Finally, rotation about the z axis in one direction is labeled direction E and in the opposite direction, direction F. The front panel 100, left flap 145 and right flap 155 will be used to illustrate the rotation description conventions applied here. Assembly may begin by folding the left flap 145 around the y axis at the fold line 150 in direction C and folding the right flap 155 around they axis at the fold line 160 in direction D. The post-fold positions of the left flap 145 and the right flap 155 are shown in small dashed in FIG. 2. Next, and as shown in FIG. 3, the front panel 100 is folded around the x axis at the fold line 143 in direction B. The post-fold positions of the front panel 100, the left flap 145 and the right hand flap 155 are shown in small dashed in FIG. 3. Alternatively, the left flap 145 could be folded around the z axis at fold line 150 and in direction E and the right flap 155 folded around the z axis at the fold line 160 in direction F after the folding of the front panel 100 at the fold line 143 as described above to yield the arrangement shown in FIG. 3. Indeed the folding operations for the front panel 100 and the left flap 145 and the right flap 155 could be performed concurrently. The folded position of the front panel 100 and the right flap 155 is also shown in FIG. 4, although the left flap 145 is obscured in that figure. The remainder of the assembly operation will be described in conjunction with FIG. 1 and FIG. 4. It should be understood that all of the sub-components of the blank 10 shown in FIG. 1 are in the same plane, namely the x-y plane, prior to any folding operations. However, once a given fold line is moved out of the x-y plane shown in FIG. 1, such as the fold lines 150 and 160 in the positions shown in FIG. 3, subsequent folds may be around the depicted x, y or z axes or, mathematically speaking, around x, y or z axes that are not shown but parallel to the depicted x, y and z axes.

With the front panel 100 in the folded position, the back panel 95 is folded about the x axis at the fold line 135 in direction A approximately 90° from the position shown in FIG. 1 to the position shown in FIG. 4. Prior to folding the back panel 95, the left flap 115 may be folded about they axis at the fold line 120 in direction C and the right flap 125 folded about they axis at the fold line 130 in direction D. Alternatively, the left flap 115 and the right flap 125 may be rotated about the z axis in directions E and F, respectively, after the back panel 95 is folded. Of course, as is the case for the front panel 100, the folding operations for the back panel 95 could be combined, and the folding operations associated with both the front panel 100 and the back panel 95 could be combined. The folded positions of the back panel 95, the left flap 115 and the right flap panel 125 are shown in FIG. 4. At this point, the left side panel 105 may be rotated about the y axis at the fold line 165 in direction C to abut against the left flap 115 and the left flap 145 and the right side panel 110 may be folded about the y axis at fold line 170 in direction D to engage the right flap 125 and the right flap 155. At this stage, the positions of the left flap 115, the right flap 125 and the right flap 155 are visible as well in FIG. 4. Note that the left flap 145 is obscured by the narrow fold portion 190 in FIG. 4. Note also that a portion of the narrow fold portion 275 is cut away to reveal a portion of the right flap 155 and the side panel 110.

At this point, a multistage folding process is performed for each of the reinforcement structures 25 and 30. Beginning first with the reinforcement structure 25, the first folding operation involves folding the combination of the wrap around panel 175 and the narrow fold portion 190 about they axis at the fold line 200 in direction C. Once that fold is made, a second folding operation is performed by folding the wrap around panel 175 relative to the narrow fold portion 190 about the y axis at the fold line 195. This has the effect of bringing the wrap around panel 175, the back panel reinforcement corner 180 and the front panel reinforcement corner 185 down toward the bottom panel 90. As this folding operation takes place, the back panel reinforcement corner 180 is simultaneously folded at the fold lines 217 and 220 about the z axis so that the back panel reinforcement 180 corner assumes the position shown in FIG. 4 with the tab 225 (shown in FIG. 1) of the flap 215 inserted into the slot 230 shown in FIG. 1 (but obscured in FIG. 4) and the flap 212 positioned near or against the back panel 95. The same operation, albeit in the opposite direction, is performed with regard to the front reinforcement corner 185 involving folds at the fold lines 245 and 250 about the z axis so that the reinforcement corner 185 assumes the position shown in FIG. 4 with the tab 255 (shown in FIG. 1) of the flap 240 is inserted into the slot 260 shown in FIG. 1 (but obscured in FIG. 4) and the flap 235 positioned near or against the front panel 100. Thus, FIG. 4 shows the final position of the back reinforcement corner 180 and how the flap 215 is approximately 45° offset from the flap 212 and the flap 240 of the front reinforcement corner 185 is approximately 45° offset rotationally from the flap 235. This leaves the narrow fold portion 190 as a cover over the flaps 115, 145 and the side panel 105.

The same operation is performed in a mirror-like fashion with regard to the reinforcement structure 30 in that a multi-fold operation is performed that begins with folding the combination of the wrap around panel 265 and the narrow fold portion 275 about they axis at the fold line 280 in direction D and then subsequently folding the wrap around panel 265 relative to the narrow portion 275 about they axis and the fold line 277 in direction D. This folding about the fold line 277 continues and simultaneously the back panel reinforcement corner 267 is folded about the z axis at both the fold lines 300 and 305 and the front panel reinforcement corner 269 is similarly folded albeit in the opposite direction about the z axis at the fold lines 335 and 340 so that the tabs 310 and 350 of the flaps 295 and 330, respectively, may insert into the slots 315 and 355 and the tab 285 of the wrap around panel 265 may insert into the slot 287 in the bottom panel 90. This final position is shown in FIG. 4 where the narrow fold portion 275 forms a cover over the right flap 125 and the right flap 155 and the side panel 110. Thus, the final positions of the back panel reinforcement corner 267 and the front panel reinforcement corner 269 are shown in FIG. 4. The flaps 295 and 330 are approximately 45° out of rotation relative to the flaps 290 and 325, respectively. The flaps 290 and 325 may be near or against the back panel 95 and the front panel 100, respectively. At this point, the container 15 is fully assembled. The flaps 212 and 290 of the back panel reinforcement corners 180 and 267 are held in the position shown in FIG. 4 largely by whatever residual stiffness exists at the fold lines 217 and 220, and 300 and 305, respectively. The flaps 212 and 290 may or may not actually bear against the back panel 95. Similarly, the flaps 235 and 325 of the front reinforcement corners 185 and 269, respectively, are held in the position shown in FIG. 4 by the residual stiffness of the fold lines 245 and 250, and the fold lines 335 and 340, respectively. The flaps 235 and 325 may or may not bear against the front panel 100.

The operation to close the lid 20 will now be described. The top panel 35 may be folded about the x axis at the fold line 140 in direction A approximately 180° from the position shown in FIGS. 1 and 4. At the same time or just before, the left top panel wing 50 is rotated around they axis at the fold line 60 in direction C and the right top panel wing 55 is rotated around they axis at the fold line 65 in direction D. The objective is enable the left top panel wing 50 and the right top panel wing 55 to swing into the container 15 when the top panel 35 is rotated. After, or even before, the top panel 35 is rotated, the front tuck flap wings 67 and 70 are folded around the y axis at fold lines 75 and 80 in directions C and D, respectively. After the top panel 35 is rotated to insert the top panel wings 50 and 55 into the container 15, the front tuck flap 40 may be folded at fold line 45 about the x axis in direction A. Note that the right flap 155 of the front panel 100 is displaced along the x axis laterally relative to the side panel 110 as shown in FIG. 4. This displacement leaves a gap 370 in which the right front tuck flap wing 70 of the front tuck flap 40 may be inserted when the front tuck flap 40 is folded relative to the top panel 35. There is a corresponding gap (not visible) to accommodate the left front tuck flap wing 67. To open the lid 20, the foregoing steps are reversed.

Note the position of the dashed box 375 in FIG. 4. The dashed box 375 circumscribes a small portion of the flap 235 and the front panel 100. That portion will be shown at greater magnification in FIG. 5 and discussed presently. As shown in FIG. 5, the flap 235 and any of the other portions of the box blank 10 depicted in FIGS. 1-4 or disclosed alternatives may be a corrugated structure that includes an inner liner 380, an outer liner 385 and plural corrugations known as a media 390 sandwiched there between. The inner liner 380, the outer liner 385 and the media 390 may be composed of well-known materials. The inner and outer liners 380 and 385 may be constructed of brown Kraft with strength of about 32 ECT in lbs/in or other materials. The media 390 may take on a variety of configurations. In an exemplary embodiment a B-flute arrangement with some peak-to-peak pitch P may be used. Virgin or recycled materials may be used. It is desirable that the back panel reinforcement corners 180 and 267 and the front panel reinforcement corners 185 and 269 be fabricated from corrugated cardboard material where the long axis of the corrugations is oriented along the z axis as shown in FIG. 4. This provides significant strength against compressive forces into the page along the z axis that might otherwise crush or damage whatever contents are inside of the container 15. Here, the flap 235 may be a single ply in that there is a single media 390 sandwiched between two layers 380 and 385. However, and as shown in FIG. 6, multiple plies may be used such as the plies 395 and 400 that include respective medias 405 and 410 which may or may not have the same flute arrangement. More than two plies may be used if desired.

Some additional details of the container 15 depicted in FIG. 2 may be understood by referring now to FIG. 7. FIG. 7 is a pictorial view of a portion of the right front panel reinforcement corner 269 viewed from inside the container 15. FIG. 7 shows the front panel reinforcement corner 269 in position with the flap 325 positioned against or near the front panel 100 and the flap 330 positioned over the slot 355 in the bottom panel 90. A portion of the wrap around panel 265 and the narrow fold portion 275 are visible as well. A portion of FIG. 7 circumscribed by the dashed circle 415 will be shown at greater magnification in FIG. 8. Attention is now turned to FIG. 8. Note that a small portion of the flap 330 is depicted with the tab 350 thereof inserted into the slot 355 in the bottom panel 90. Note also that a small portion of the wrap around panel 265 and the flap 325 along with the fold lines 335 and 340 are visible. The tab 350 and the slot 355 provide a mechanical joint to hold the front panel reinforcement corner 269 in position. The same is true for the other reinforcement corners 180, 185 and 267 shown in FIGS. 1 and 4.

An alternate exemplary embodiment of a front panel reinforcement corner 269′ may be understood by referring now to FIG. 9, which is a pictorial view like FIG. 7. Here, the alternate reinforcement corner 269′ may include a 90° bend or elbow 420 between the flap 325 and the wrap around panel 265 in lieu of the dual fold arrangement shown in FIG. 7. There is no corresponding tab and slot mechanical joint as in the embodiment depicted in FIG. 7 however. The elbow 420 may be something other than true 90°. This single fold elbow 420 may be used with any of the disclosed corners at any location.

The assembled box blank 10 may be used to house a variety of articles, such as one or more trays that may hold integrated circuits, semiconductor chips, etc. at various stages of manufacture. Attention is now turned to FIG. 10, which is an overhead view of the assembled box blank 10 with the lid 20 open to reveal the container 15. Here, plural product trays, the top most of which is numbered 430, may be assembled in a stack that includes one, two, three or more such trays that each may hold plural semiconductor chip devices, two of which are shown as dashed boxes and labeled 435 and 440, respectively. The assembled stack of trays is collectively labeled 445 and may be secured together using one or more plastic or metal straps 450. To provide both mechanical shock and electrostatic discharge protection, the tray stack 445 may be placed inside of a bubble sheet 455 or other spongy bag or wrap and then the combination of the tray stack 445 and the bubble sheet 455 may be enclosed in an electrostatic discharge resistant bag 460. That combination may then be placed in the container 15 and seated on the bottom panel 90 and then the top panel 35 and the front tuck panel 40 of the lid 20 rotated and manipulated as described above in order to close the box blank 10.

If desired, and as depicted pictorially in FIG. 11, the stack 445 may be strapped by one or more straps 450 and then enclosed in the bubble sheet 455 and the ESD resistant bag 460 and that combination then placed on a box insert 465. The box insert 465 is designed to provide a mechanical shock resistant partial cage that surrounds the tray stack 445. Accordingly, the box insert 465 includes a base panel 470, a back panel 475, a front panel 480, a left panel 485 and a right panel 495 with all of these directions being arbitrary designations. The back panel 475 may be foldable about the x axis at fold positions 500 and 505. In this regard, when the tray stack 445 is placed on the base or bottom panel 470, the back panel 475 may be first folded around the x axis out of the page at the fold position 500 and thereafter folded again at the fold line 505 so that a portion of the back panel actually folds down and seats on top of the tray stack 445. The same operations will be performed with regard to both the side panels 485 and 495 and the front panel 480 that is involving folding operations at the fold lines 510, 515, 520, 525, 530 and 535 in order to form a partial protective cage around the tray stack 445. When those folding operations are completed, the combination of the box insert 465 and partially enclosed tray stack 445 may be placed in the container 15 as shown in FIG. 10. Note that some or all of the panels 470, 475, etc. of the insert 465 may be corrugated and single or multi-ply as desired depending upon the amount of shock absorption that is anticipated to be required in order to protect the stack 445.

It may be useful at this point to contrast briefly a couple of conventional box designs that may have been used to hold semiconductor devices. In this regard, attention is now turned to FIG. 12, which is a pictorial view of a conventional box 600 known as a Q-Pack® and used by the Assignee of the present application. The box 600 includes a container 605 and a clam style lid 610 that is shown in the open position. The container 605 includes a front panel 615 and a back panel 620 that are single wall and do not have additional wall reinforcement as is the case with the disclosed exemplary embodiments. The interior surfaces of the container 605 are coated with a carbon coating that provides Faraday shielding. In addition, the box 600 calls for the use of a bubble sheet in addition to a bubble bag. These requirements make the box 600 typically larger than the disclosed embodiments and more expensive from a materials standpoint. The disclosed exemplary embodiments may be around 20 to 30% smaller in volume than the box 600.

FIG. 13 is a pictorial view of another variant of the Q-Pack® box 700. This box 700 includes a container 705 and a lid 710 that is shown in the open position. Note that, like the conventional design depicted in FIG. 12, the box 700 includes a single wall front panel 715 and a single wall back panel 720 but neither the front panel 715 nor back panel 720 includes a reinforcement structures of the type disclosed in the exemplary embodiments herein. The box 700 requires the usage of top and bottom Faraday shield sheets (not shown).

FIG. 14 is a pictorial view of another conventional box 800 that has been used by Intel Corporation to hold semiconductor devices. The x, y, z axis system depicted in FIG. 11 is repeated here in FIG. 14. Unlike the disclosed embodiments, the box 800 does not include any internal reinforcements and consists of a pair of side flaps 807 and 809 that are foldable about the x axis directions A and B. The flap 807 may be folded about the x axis in direction A direction to closed position shown and the flap 809 may be folded around the x axis in direction B direction to achieve the closed position as shown. A gap 811 between the flaps 807 and 809 is typically secured with Kraft tape (not shown). There are side flaps (not visible) on the opposite side of the box 800 corresponding to the flaps 807 and 809. The box 800 also includes a top panel 813 and a corresponding panel opposite to the panel 813 that is not visible in FIG. 14. Similarly, a right side panel 815 includes an integral glue flap 817 that may be glued to the panel 811. The glue flap 815 is pivoted around the y-axis in direction D in order to engage the side panel 813. There is a left side panel (not visible) opposite to the right side panel 815. There are also several internal glue flaps that are not visible.

While the invention may be susceptible to various modifications and alternative forms, specific embodiments have been shown by way of example in the drawings and have been described in detail herein. However, it should be understood that the invention is not intended to be limited to the particular forms disclosed. Rather, the invention is to cover all modifications, equivalents and alternatives falling within the spirit and scope of the invention as defined by the following appended claims.

Claims

1. A box, comprising:

a container, the container including a bottom panel, a front panel, a first side panel, a second side panel, a back panel, a first reinforcement structure adjacent the back panel and the first side panel and a second reinforcement structure adjacent the back panel and the second side panel, the first and second reinforcement structures reinforcing the back panel against compressive forces;

the bottom panel including a first opening and a second opening;

the first reinforcement structure including a first wrap around panel foldably coupled to the first side panel, the first wrap around panel having a first flap and a second flap coupled to the first flap, the first flap including a first tab to insert in the first opening;

the second reinforcement structure including a second wrap around panel foldably coupled to the second side panel, the second wrap around panel having a third flap and a fourth flap coupled to the third flap, the third flap including a second tab to insert into the second opening;

the back panel including a fifth flap positioned in a gap between the first side panel and the first wrap around panel and a fifth flap positioned in another gap between the second side panel and the second wrap around panel; and

a lid coupled to the container.

2. The box of claim 1, comprising a third reinforcement structure adjacent the front panel and the first side panel and a fourth reinforcement structure adjacent the front panel and the second side panel, the third and fourth reinforcement structures reinforcing the front panel against compressive forces.

3. The box of claim 1, wherein the lid is foldably coupled to the back panel.

4. The box of claim 3, wherein the lid includes a front tuck flap with a first flap wing to insert into the gap between the first side panel and the first wrap around panel and a second flap wing to insert into the gap between the second side panel and the second wrap around panel.

5. The box of claim 1, wherein the first flap and the second flap comprise an elbow with the second flap positioned adjacent the back panel and the third flap and the fourth flap comprise another elbow with the fourth flap positioned adjacent the back panel.

6. (canceled)

7. The box of claim 1, wherein the bottom panel includes a third opening and a fourth opening, the first wrap around panel includes a third tab to insert into the third opening and the second wrap around panel includes a fourth tab to insert into the fourth opening.

8. A box blank, comprising:

plural components foldable into a container, the components including a bottom panel, a front panel, a back panel, a first side panel, a first reinforcement structure coupled to the first side panel, a second side panel and a second reinforcement structure coupled to the second side panel, the first and second reinforcement structures being operable to reinforce the back panel against compressive forces when the container is assembled;

the bottom panel including a first opening and a second opening;

the first reinforcement structure including a first wrap around panel foldably coupled to the first side panel, the first wrap around panel having a first flap and a second flap coupled to the first flap, the first flap including a first tab to insert in the first opening;

the second reinforcement structure including a second wrap around panel foldably coupled to the second side panel, the second wrap around panel having a third flap and a fourth flap coupled to the third flap, the third flap including a second tab to insert into the second opening; and

the back panel including a fifth flap positionable in a gap between the first side panel and the first wrap around panel formed when the first wrap around panel is folded relative to the first side panel and a sixth flap positionable in another gap between the second side panel and the second wrap around panel formed when the second wrap around panel is folded relative to the second side panel.

9. The box blank of claim 8, comprising a lid to cover the container.

10. The box blank of claim 8, comprising a third reinforcement structure adjacent the front panel and the first side panel and a fourth reinforcement structure adjacent the front panel and the second side panel, the third and fourth reinforcement structures being operable to reinforce the front panel against compressive forces when the container is assembled.

11. (canceled)

12. The box blank of claim 8, wherein the bottom panel includes a third opening and a fourth opening, the first wrap around panel includes a third tab to insert into the third opening and the second wrap around panel includes a fourth tab to insert into the fourth opening.

13. The box blank of claim 8, wherein the first flap and the second flap comprise an elbow with the second flap positioned adjacent the back panel and the third flap and the fourth flap comprise another elbow with the fourth flap positioned adjacent the back panel.

14. (canceled)

15. (canceled)

16. A method of manufacturing, comprising:

fabricating a box blank having plural components foldable into a container, the components including a bottom panel, a front panel, a back panel, a first side panel, a first reinforcement structure coupled to the first side panel, a second side panel and a second reinforcement structure coupled to the second side panel, the first and second reinforcement structures being operable to reinforce the back panel against compressive forces when the container is assembled.

the bottom panel including a first opening and a second opening;

the first reinforcement structure including a first wrap around panel foldably coupled to the first side panel, the first wrap around panel having a first flap and a second flap coupled to the first flap, the first flap including a first tab to insert in the first opening;

the second reinforcement structure including a second wrap around panel foldably coupled to the second side panel, the second wrap around panel having a third flap and a fourth flap coupled to the third flap, the third flap including a second tab to insert into the second opening; and

the back panel including a fifth flap positionable in a gap between the first side panel and the first wrap around panel formed when the first wrap around panel is folded relative to the first side panel and a sixth flap positionable in another gap between the second side panel and the second wrap around panel formed when the second wrap around panel is folded relative to the second side panel.

17. The method of claim 16, wherein the box blank comprises a lid.

18. The method of claim 16, wherein the box blank includes a third reinforcement structure adjacent the front panel and the first side panel and a fourth reinforcement structure adjacent the front panel and the second side panel, the third and fourth reinforcement structures being operable to reinforce the front panel against compressive forces when the container is assembled.

19. (canceled)

20. The method of claim 16, wherein the bottom panel includes a third opening and a fourth opening, the first wrap around panel includes a third tab to insert into the third opening and the second wrap around panel includes a fourth tab to insert into the fourth opening.

21. The method of claim 16, wherein the first flap and the second flap comprise an elbow with the second flap positioned adjacent the back panel and the third flap and the fourth flap comprise another elbow with the fourth flap positioned adjacent the back panel.

22. The method of claim 16, comprising assembling the box blank into a box.

23. The box blank of claim 9, wherein the lid is foldably coupled to the back panel.

24. The box blank of claim 23, wherein the lid includes a front tuck flap with a first flap wing to insert into the gap between the first side panel and the first wrap around panel and a second flap wing to insert into the gap between the second side panel and the second wrap around panel.

25. The method of claim 17, wherein the lid is foldably coupled to the back panel.

26. The method of claim 25, wherein the lid includes a front tuck flap with a first flap wing to insert into the gap between the first side panel and the first wrap around panel and a second flap wing to insert into the gap between the second side panel and the second wrap around panel.