Packaging container for transporting ceramic substrate

Abstract

A packaging container for transporting a ceramic substrate according to an embodiment of the present invention accommodates a plurality of ceramic substrates by closing a lid body against a container main body. In the packaging container, the container main body is provided with a rectangular bottom surface and four side surfaces, each connected to four edges of the bottom surface. At least two opposing side surfaces from among the four side surfaces are provided with inward-facing side surface protrusions having a height of 2 mm or more, the bottom surface is provided with an inward-facing bottom surface protrusion having a height of 2 mm or more, and the lid body is provided with a rectangular upper surface, the upper surface being provided with an inward-facing upper surface protrusion having a height of 2 mm or more.

Description

Packaging container for transporting ceramic substrates

[0001] FIELD OF THE INVENTION Embodiments of the present invention generally relate to packaging containers for transporting ceramic substrates.

[0002] In recent years, the demand for ceramic substrates has been increasing year by year with the development of semiconductor elements that require large currents, such as power electronics and next-generation power semiconductors. In particular, as elements generate more heat due to their miniaturization and higher performance, the thickness of ceramic substrates tends to become thinner in order to dissipate heat more efficiently.

[0003] As electrical appliances become smaller and more powerful, electronic components also become smaller, and the amount of heat generated by semiconductors increases due to their higher output. Ceramic substrates are used for electrical insulation of electronic components, but as electronic components become smaller, thinner substrates are required to improve heat dissipation properties. Many ceramic substrates have high electrical insulation and high heat dissipation properties, but they are also hard but brittle, so care must be taken when moving or transporting them. Because ceramic substrates are sintered bodies, they are prone to warping and surface irregularities, and when packed in layers, stress is applied, resulting in chipping and cracking defects.

[0004] On the other hand, in order to reduce the manufacturing cost of ceramic substrates, they are being manufactured in larger shapes. For example, a silicon nitride substrate, which has high strength, high toughness, and high heat dissipation properties among ceramic substrates, has been disclosed as a substrate measuring 220 mm × 220 mm × 0.32 mm (Patent Document 1).

[0005] Although magazine-type racks are easy to use for packaging substrates, they require a large transport volume. Furthermore, when transporting substrates using magazine-type racks, cushioning material is required between and around the ceramic substrates, and this cushioning material is difficult to reuse, which poses a problem from the perspective of resource conservation.

[0006] Regarding packaging containers for transporting ceramic substrates, there has been proposed a packaging container for transport that suppresses external impacts and impacts from adjacent ceramic substrates when storing, packaging and transporting the substrates (see Patent Document 2).

[0007] However, when a ceramic substrate storage container is transported long distances, for example overseas, in order to reuse the container, it can be costly to return the packaging container from the destination to the manufacturer. Even when the packaging container is not to be reused, the packaging container is required to have as simple packaging capacity as possible from the viewpoint of resource conservation.

[0008] Patent No. 6399252 Patent No. 7346604

[0009] In recent years, ceramic substrate components have become thinner and larger during production due to an increase in the amount of heat generated by semiconductor elements. Accordingly, packaging containers that store ceramic substrate sets (hereinafter simply referred to as "substrate sets") consisting of multiple stacked ceramic substrates are required to protect the ceramic substrates from external impacts to the packaging container during transportation and from impacts from adjacent ceramic substrates, and to prevent damage to the ceramic substrates due to impacts.

[0010] The present embodiment solves such problems by providing a packaging container for transporting ceramic substrates that allows for simple packaging of a substrate set while suppressing impacts from the surroundings, including the outside of the opening side of the container body, and impacts from adjacent ceramic substrates, when transporting the packaging container containing the substrate set.

[0011] A packaging container for transporting ceramic substrates according to an embodiment stores multiple ceramic substrates by closing a lid on a container body. In this packaging container, the container body has a rectangular bottom and four side surfaces connected to four edges of the bottom. At least two opposing side surfaces of the four side surfaces have inward-facing side surface protrusions with a height of 2 mm or more, and the bottom surface has inward-facing bottom surface protrusions with a height of 2 mm or more. The lid has a rectangular top surface, and the top surface has inward-facing top surface protrusions with a height of 2 mm or more.

[0012] More preferably, the packaging container for transporting ceramic substrates according to the embodiment is configured to store the substrate set so that the outer surfaces of the two ceramic substrates at both ends of the substrate set face two opposing side surfaces of the four side surfaces. Each of the two side surfaces has two or more rows of side surface convex portions extending continuously in the depth direction as side surface convex portions, and the bottom surface has two or more rows of side surface convex portions extending continuously from one side of the two side surfaces to the other as bottom surface convex portions. This example will be described later using Figures 1 to 3 of the first embodiment of the present invention.

[0013] Alternatively, a packaging container for transporting ceramic substrates according to an embodiment has a configuration in which the substrate set is stored so that the outer side of the ceramic substrate at one end of the substrate set faces the bottom. Each of the four side surfaces has two or more rows of bottom surface protrusions extending continuously in the depth direction as side surface protrusions. This example will be described later with reference to FIGS. 5 to 11 of a second embodiment of the present invention.

[0014] Alternatively, a packaging container for transporting ceramic substrates according to an embodiment has a configuration in which the substrate set is stored so that the outer surface of one end of the ceramic substrate faces the bottom surface. The bottom surface is provided with a bottom protrusion having an area ratio of 25% or more to the entire bottom surface. This example will be described later with reference to FIG. 12 of a second embodiment of the present invention.

[0015] When a substrate set is transported, if a force is applied vertically to the surface of the substrate set inside the packing container, defects such as cracks are likely to occur in the stored ceramic substrates. Also, if a force is applied horizontally to the surface of the substrate set inside the packing container, defects such as chips are likely to occur on the edges of the ceramic substrates.

[0016] Furthermore, if there are gaps between adjacent ceramic substrates in a substrate set inside a packaging container, or between the outer surfaces of the ceramic substrates at both ends of the substrate set inside the packaging container and the side surfaces of the packaging container, the adjacent ceramic substrates will collide with each other due to vibrations during transportation of the packaging container, causing defects such as cracks and chips in the ceramic substrates. However, because ceramic substrates vary in warp and thickness, it is difficult to set a storage quantity and store only the ceramic substrates in a packaging container without any gaps without using cushioning material.

[0017] A packaging container for transporting ceramic substrates according to a first embodiment of the present invention stores the substrate set so that the outer surfaces of the two ceramic substrates at both ends of the substrate set face two opposing side surfaces of the packaging container. That is, the packaging container stores the substrate set so that the edges of each ceramic substrate contact the bottom surface, and the substrate set is stored in an upright position and then closed with a lid. In this packaging container, two or more rows of side surface protrusions, for example, two rows, are formed on the side surfaces perpendicular to the outer surfaces of the ceramic substrates at both ends of the substrate set, extending continuously inward in the depth direction.

[0018] With this configuration, the two rows of side convex portions act as cushions perpendicular to the plane of the ceramic substrates at both ends, making it possible to prevent cracking or chipping of each ceramic substrate in the stored substrate set even without using cushioning material. Because the ceramic substrates have a small amount of warping, the substrate set can be stored in a packaging container so that the ceramic substrates at both ends of the substrate set are lightly pressed by the side convex portions on the two opposing sides. After the substrate set is inserted, the warped ceramic substrates return to their original shape, allowing the substrate set to be packed into the packaging container without any gaps. After insertion, the substrate set is fixed in the packaging container by the force of the pressed substrate set attempting to return to its original shape and the repulsive force of the side convex portions that are subjected to this force.

[0019] Even if there is one side protrusion (same as for side protrusions) provided on one side, for example, in one row, it is useful if the width of the side protrusion is wide and the proportion of the area occupied by the side protrusion is 25% or more of the entire side, because the substrate set can be fixed on the surface. The larger the proportion of the area occupied by the side protrusion, the larger the fixing range, so a more preferable proportion of the area occupied by the side protrusion is 50% or more. If the proportion of the area occupied by the side protrusion is less than 25%, the substrate set will be inserted at an angle and will move around the side protrusion due to vibrations during transportation, etc., and it is possible that the ceramic substrate will be subjected to impact, so it is desirable to have two or more side protrusions, for example, two or more rows.

[0020] Furthermore, in the packaging container for transporting ceramic substrates according to the first embodiment of the present invention, two or more rows of side surface convexities, for example, two rows, are formed on the bottom surface, extending continuously from one side of the two side surfaces on which the side surface convexities are provided to the other side, facing inward. These bottom surface convexities serve as vertical cushions for the lower edge of the substrate set. In this case, the substrate set is inserted so that the side surface convexities face the outer surfaces of the two ceramic substrates at both ends. This allows the lower edge of the substrate set to be supported by two rows of bottom surface convexities.

[0021] A packaging container with one bottom protrusion, for example, one row, is useful when the width of the bottom protrusion is wide and the ratio of the bottom protrusion to the entire bottom surface is 25% or more. If there is one row of protrusions, the substrate set may be inserted at an angle and may move up and down around the narrow bottom protrusion due to vibrations during transportation, so it is desirable to have two or more bottom protrusions.

[0022] Furthermore, in the packaging container for transporting ceramic substrates according to the first embodiment of the present invention, the lid is formed with two or more rows of inward-facing lid protrusions, for example, two rows, extending continuously from one side of the two side surfaces on which the side protrusions are provided to the other. These lid protrusions serve as vertical cushions for the upper edge of the substrate set. In this case, the substrate set is inserted so that the side protrusions face the outer surfaces of the two ceramic substrates at both ends. This allows the upper edge of the substrate set to be supported by two rows of lid protrusions.

[0023] A packaging container with one lid protrusion, for example, one row, is useful when the lid protrusion is wide and the bottom protrusion occupies 25% or more of the entire lid. If there is one row of protrusions, the substrate set may be inserted at an angle and may move up and down around the narrow lid protrusion as an axis due to vibrations during transportation, so it is desirable to have two or more lid protrusions.

[0024] A packaging container for transporting ceramic substrates according to a second embodiment of the present invention stores a substrate set so that the outer surface of one end of the ceramic substrate faces the bottom. That is, the packaging container is a container in which a substrate set consisting of multiple ceramic substrates stacked flat-surfaced on top of each other is placed flat with the flat surface facing downwards and the lid is closed. In this packaging container, two or more rows of side protrusions, for example, two rows, are formed on the four side surfaces of the container, extending continuously inward in the depth direction.

[0025] With this configuration, the two rows of side protrusions act as horizontal cushions against the ceramic substrate plane, preventing cracking or chipping of each ceramic substrate in the stored substrate set. In the packaging container for transporting ceramic substrates according to this second embodiment, for example, in the case of a container with a rectangular bottom, two or more side protrusions are formed on each of the four side surfaces. Although the ceramic substrates to be packed vary in size, providing cushioning to the packaging container allows the substrate set to be inserted by its own weight. After insertion, the substrate set is held in place from the sides and below by the cushioning properties of the packaging container and the substrate set's own weight. Therefore, the substrate set is secured in the packaging container by closing it by pressing the lid from above.

[0026] Even if there is one side protrusion (same as for side protrusions) provided on one side surface, for example, in one row, this is useful when the width of the side protrusion is wide and the proportion of the area occupied by the side protrusion is 25% or more of the side surface, etc. If the proportion of the area occupied by the side protrusion is less than 25% of the entire side surface, it is possible that the substrate set will not be fixed and will move around the side protrusion as an axis, so it is desirable that there are two or more side protrusions, for example, two or more rows.

[0027] Furthermore, a packaging container with one bottom protrusion, for example, one row, is useful when the width of the bottom protrusion is wide and the proportion of the bottom protrusion occupying the bottom protrusion is 25% or more of the entire bottom surface, etc. If the proportion of the area of ​​the bottom protrusion is less than 25% of the entire bottom surface, there is a risk that the substrate set will be inserted at an angle and move in the depth direction around the bottom protrusion as an axis, so it is desirable to have two or more bottom protrusions, for example, two or more rows.

[0028] Furthermore, a packaging container with one lid protrusion, for example, one row, is useful when the lid protrusion is wide and occupies 25% or more of the entire lid. If the lid protrusion occupies less than 25% of the entire lid, the substrate set may be pressed at an angle and move in the depth direction around the lid protrusion as an axis, so it is desirable to have two or more top surface protrusions, for example, two or more rows.

[0029] It should be noted that a height of about 1 mm for the side convex portions (and the same for the bottom and top convex portions) is effective when the substrate set or packaging container is small, but in order to hold the substrate set securely, it is preferable that the side convex portions protrude by 2 mm or more.

[0030] In order to engage the container body and the lid for use, it is effective that the container body and the lid are integrally connected by a bendable hinge. The hinge may be formed over the entirety of one side of the rectangular shape, or may be formed only partially on one side.

[0031] The lid on which the protrusion is provided may have a flat surface structure, or may have four side surfaces connected to the four edges of the top surface, each of which extends perpendicularly to the top surface.

[0032] Here, the four side surfaces are connected to the four edges of the bottom and top surfaces, respectively, and are configured to rise perpendicular to the bottom and top surfaces. Meanwhile, to facilitate the insertion and removal of the substrate set into the packaging container and the opening and closing of the lid, it is effective to provide the four side surfaces with a taper (open inclination) of 1° or more so that the opening widens toward the bottom and top surfaces. Furthermore, to facilitate the insertion and removal of the substrate set into and from the packaging container and the opening and closing of the container, it is preferable to provide the four side surfaces with a taper of 3° or more.

[0033] Furthermore, in order to prevent deformation of the opening of the container itself and increase the strength of the entire container, it is effective to form a flange on the frame of the opening that is approximately parallel to the bottom surface and faces outward, with a width of 1 mm or more. To further increase strength, it is preferable that the width of the flange be 3 mm or more. Here, approximately parallel includes not only parallel but also non-parallel within the manufacturing tolerance range.

[0034] Furthermore, it is effective that the frame of the opening of the container body has two or more engaging flaps on the bottom surface and on the bottom surface that have outwardly facing male and female concave and convex portions, in order to engage the container body and the lid. For example, the container body engaging flap on the container body side has a concave portion, and the lid engaging flap on the lid side has a convex portion, so that the concave and convex portions can engage when the lid is closed.

[0035] Furthermore, in order to facilitate the opening of the engaged container body and lid, it is effective that the frame of the opening of the container body has an opening flap that opens outward and is approximately parallel to the bottom and top surfaces. For example, by forming the opening flap of the container body and the opening flap of the lid so that they do not overlap in the vicinity when the lid is closed to the container body, it becomes possible to pinch the opening flap and apply force in the opening direction, making it easier to open the engaged packaging container.

[0036] In addition, the height of the inserted substrate set may be the same as or lower than the height of the packaging container when the lid is closed. If the height is lower, the substrate set is fixed by, for example, sandwiching a cushioning material between the substrate set and the lid to prevent the substrate set from shifting.

[0037] The types of ceramic substrates constituting the substrate set to be stored in the packaging container for transporting the ceramic substrates according to the embodiment include silicon nitride (Si3N4) substrates, aluminum nitride (AlN) substrates, and alumina (aluminum oxide: Al2O3) substrates, and the present invention is suitable for silicon nitride substrates, which have high strength and high toughness and tend to bend when the substrate thickness is thin.

[0038] In this specification, the term "ceramic substrate" also includes a ceramic-metal bonded substrate having a metal plate bonded to one or both sides thereof (e.g., a silicon nitride-metal bonded substrate) and a ceramic circuit substrate having a circuit formed by a metal plate. In other words, a packaging container for transporting a ceramic substrate can store not only a single ceramic substrate, but also a substrate set including a ceramic-metal bonded substrate having a metal plate bonded to one or both sides thereof and a ceramic circuit substrate having a circuit formed by a metal plate.

[0039] Packaging containers for transporting ceramic substrates must be lightweight and durable while retaining a certain degree of elasticity. It is also desirable that the packaging container be thin and easily moldable into complex shapes. Furthermore, it is desirable that the packaging container be transparent or translucent so that the interior can be seen. Examples of packaging container materials that meet these requirements include plastics such as polyethylene (PE), polypropylene (PP), polystyrene (PS), and polyethylene terephthalate (PET resin). Although not transparent, natural materials such as paper and sugarcane are excellent because they are easily recyclable and environmentally friendly, and can therefore be used as packaging containers.

[0040] FIG. 1 is a perspective view showing the appearance of a packaging container for transporting a ceramic substrate according to a first embodiment; FIG. 2 is a view showing a case where side convex portions, bottom convex portions, and top convex portions protrude in a semicircular shape in the packaging container for transporting a ceramic substrate according to the first embodiment; FIG. 3 is a cross-sectional view showing a state where a substrate set is stored in the packaging container for transporting a ceramic substrate according to the first embodiment; FIG. 4 is a cross-sectional view showing a state where a substrate set is stored in the packaging container for transporting a ceramic substrate according to the first embodiment; FIG. 5 is a perspective view showing the appearance of a packaging container for transporting a ceramic substrate according to a second embodiment; FIG. 6 is a top view showing a case where side convex portions, bottom convex portions, and bottom convex portions protrude in a semicircular shape in the packaging container for transporting a ceramic substrate according to the second embodiment; FIG. 7 is a cross-sectional view showing a state where a substrate set is stored in the packaging container for transporting a ceramic substrate according to a modified embodiment; 1 is a top view of a packaging container for transporting a ceramic substrate according to a modified embodiment, in which the bottom surface convex portion and the top surface convex portion are separated; 2 is a top view of a packaging container for transporting a ceramic substrate according to a modified embodiment, in which the bottom surface convex portions and the top surface convex portions intersect in a single row; 3 is a top view of a packaging container for transporting a ceramic substrate according to a modified embodiment, in which the packaging container has a convex portion formed along the edge of the bottom surface; 4 is a top view of a packaging container for transporting a ceramic substrate according to a modified embodiment, in which there is one bottom surface convex portion and one top surface convex portion; Embodiment

[0041] Hereinafter, an embodiment of a packaging container for transporting a ceramic substrate will be described in detail with reference to the drawings.

[0042] (First embodiment) A packaging container for transporting ceramic substrates according to a first embodiment stores a substrate set consisting of a plurality of ceramic substrates in a vertical position. The packaging container for transporting ceramic substrates according to the first embodiment will be described with reference to FIGS. 1 to 4.

[0043] FIG. 1 is a perspective view showing the appearance of a packaging container for transporting a ceramic substrate according to the first embodiment.

[0044] In FIG. 1 , reference numeral 1 indicates a state before ceramic substrates are stored vertically in a packaging container for transporting ceramic substrates according to the first embodiment. Reference numeral 2 indicates a substrate set consisting of a plurality of ceramic substrates, and reference numeral 3 indicates a packaging container for transporting ceramic substrates according to the first embodiment. Reference numeral 3a indicates a container body constituting the packaging container 3. Reference numeral 3b indicates a lid constituting the packaging container 3. The packaging container 3 stores a substrate set 2 vertically inside by closing the lid 3b on the container body 3a. Reference numeral 7 indicates a bottom surface of the container body 3a. The direction in which the plurality of ceramic substrates are stacked, i.e., one direction of the bottom surface 7 of the packaging container 3, is defined as the Y-axis direction. The direction in which the bottom surface 7 of the packaging container 3 is defined as the X-axis direction. The insertion direction of the substrate set 2 (arrow shown in FIG. 1 ), i.e., the depth direction of the packaging container 3, is defined as the Z-axis direction.

[0045] The container body 3a is composed of a rectangular (square or oblong) bottom surface (bottom surface 7 shown in Figures 1 and 2) and four side surfaces (back surface 8a, left surface 8b, front surface 8c, and right surface 8d shown in Figure 2) connected to the four edges of the bottom surface. The lid body 3b is composed of a top surface (top surface 13 shown in Figure 2). It is effective if the container body 3a and the lid body 3b are integrated with a hinge (hinge 10 shown in Figure 2) provided on one side surface. Note that Figures 1 to 4 will be described taking as an example a case where the bottom surface 7 and top surface 13 of the packaging container 3 are rectangular.

[0046] Here, the relationship between the bottom surface 7 of the packing container 3 and the four side surfaces 8a to 8d is approximately perpendicular, and the bottom surface 7 of the packing container 3 and the four side surfaces 8a to 8d are connected at right angles to each other. However, this is not a limitation. For example, the four side surfaces 8a to 8d of the packing container 3 may be tapered, or the bottom surface 7 of the packing container 3 and the four side surfaces 8a to 8d may be connected with chamfers or rounded edges. Here, "approximately perpendicular" includes not only perpendicular but also non-perpendicularity within the manufacturing tolerance range. The substrate set 2 is inserted into the container body 3a through the opening of the container body 3a in the direction of the arrow shown in FIG. 1, with the edge of each ceramic substrate facing downward.

[0047] Fig. 2 shows an example of the configuration of a packaging container 3 for transporting a ceramic substrate according to the first embodiment. Fig. 2 shows a case in which the bottom convex portion 5 and the side convex portion 6 of the container body 3a and the top convex portion 14 of the lid body 3b protrude in a semi-cylindrical shape (semi-circular in cross section).

[0048] Figure 2(a) is a view (plan view) of the packaging container 3 from above with the lid body 3b open, Figure 2(b) is a right side view of the packaging container 3 of Figure 2(a), Figure 2(c) is a IIC-IIC cross-sectional view of the packaging container 3 of Figure 2(a), Figure 2(d) is a view (front view) of the packaging container 3 from the front with the lid body 3b closed, and Figure 2(e) is an IIE-IIE cross-sectional view of the packaging container 3 with the lid body 3b closed.

[0049] Of the four side surfaces 8a to 8d of the packaging container 3, the back surface 8a and front surface 8c each have two rows of semi-cylindrical side surface protrusions 6, each of which has a semicircular shape that extends continuously in the depth direction. The bottom surface 7 of the packaging container 3 has two rows of semi-cylindrical bottom surface protrusions 5, each of which has a semi-circular shape that extends continuously from the front surface to the back surface (or from the back surface to the front surface). In addition to the back surface 8a and front surface 8c, two rows of bottom surface protrusions that extend continuously from one side to the other may also be provided on the other two opposing side surfaces of the four side surfaces 8a to 8d, namely the left surface 8b and the right surface 8d. In this case, the stored substrate set 2 can be made more stable.

[0050] Two rows of semi-cylindrical top convex portions 14 are formed on the top surface 13 of the packaging container 3. The semi-circular shapes extend continuously from the front side to the back side (or from the back side to the front side). The convex portions 5, 6, and 14 preferably have an inward height of 2 mm or more. It is also preferable that a flange 9 is formed around the entire periphery of the frame of the opening of the container body 3a.

[0051] Preferably, the container body 3a and the lid body 3b of the packaging container 3 are each formed with an engagement portion for male-female engagement. Body engagement flaps 11c and 11e are formed around the opening of the container body 3a, and recesses 12b and 12c are formed in the body engagement flaps 11c and 11e as engagement portions. Lid engagement flaps 11b and 11f are formed around the periphery of the lid body 3b, and protrusions 12a and 12d are formed in the lid engagement flaps 11b and 11f as engagement portions. When the lid body 3b of the packaging container 3 is closed, the recesses 12b and 12c on the container body 3a engage with the protrusions 12a and 12d on the lid body 3b, respectively, allowing the lid body 3b to remain closed relative to the container body 3a without having to continuously press the lid body 3b against the container body 3a from the outside.

[0052] In Fig. 2, a recess is provided on the container body 3a and a protrusion is provided on the lid body 3b, but the recess and protrusion may be provided in reverse. Furthermore, as long as there is a pair of recess and protrusion, for example, the engaging portions 12a and 12c may be recesses and the engaging portions 12b and 12d may be protrusions. In Fig. 2, two sets of engaging flaps and engaging portions (two pairs) are provided on each of the container body 3a and the lid body 3b, but the number of sets may be one each (one pair). When one pair of engaging flaps and engaging portions is provided, it is preferable that they be provided on the side opposite the side on which the hinge 10 is formed.

[0053] The cross-sectional shapes (planes perpendicular to the height direction of the convex portions) of the recesses 12b, 12c and the convex portions 12a, 12d may be circular, polygonal, or the like. The cross-sectional shapes of the recesses 12b, 12c and the convex portions 12a, 12d may not be the same. For example, if the cross-sectional shapes of the convex portions 12a, 12d are circular and the cross-sectional shapes of the recesses 12b, 12c are rectangular, the adhesion between the recesses 12b, 12c and the convex portions 12a, 12d is not too strong, and the engagement can be easily released with a moderate force.

[0054] Preferably, the frame of the opening of the container body 3a is formed with an outwardly protruding opening flap to facilitate manual opening of the lid body 3b when the recesses 12b, 12c and the protrusions 12a, 12d are engaged. A body opening flap 11d is formed on the frame of the opening of the container body 3a, and a lid opening flap 11a is formed around the periphery of the lid body 3b. By arranging all or part of the opening flaps 11d, 11a so that they do not overlap when the lid body 3b is closed to the container body 3a, an operator can apply force in the opening direction to the lid opening flap 11a while holding down the body opening flap 11d, thereby making it easier to open the lid body 3b when the recesses 12b, 12c and the protrusions 12a, 12d are engaged.

[0055] In FIG. 2 , the bottom surface protrusion 5 on the bottom surface 7 and the side surface protrusion 6 on the side surface are connected, but they may be formed in separate positions, i.e., unconnected positions. Furthermore, the two side surface protrusions 6 on the side surface are formed to extend in the depth direction (i.e., parallel to the Z axis) so as to cut across the side surface. However, additional protrusions may be formed in the directions parallel to the Y axis and X axis. Furthermore, the side surface protrusions 6 may be separated midway, i.e., the side surface protrusions 6 may be discontinuous rather than continuous. Alternatively, the side surface protrusions 6 may be formed vertically in a single row. Furthermore, the side surface protrusions 6 may not be continuous from the end but may be separated midway and form two rows. Furthermore, a single side surface protrusion 6 may account for 25% or more of the area of ​​the entire side surface.

[0056] Although each of the two rows of protrusions 5, 6, 14 is effective with just one row, it is preferable that there are two or more rows in order to support the substrate set 2.

[0057] The protrusions 5, 6, and 14 provided on the bottom surface 7, the two side surfaces 8a and 8c, and the top surface 13 may protrude in a rectangular parallelepiped shape (rectangular in cross section) or a triangular prism shape (triangular in cross section) instead of a semi-cylindrical shape (semi-circular in cross section). That is, the bottom surface protrusions 5, the side surface protrusions 6, and the top surface protrusions 14 of the packaging container 3 protrude in a U-shape. Note that, since shock is more easily absorbed when the cross section of the tip of the protrusions 5, 6, and 14 is smaller than the cross section of the base, the protrusions 5, 6, and 14 are preferably semi-cylindrical or triangular prism-shaped. Furthermore, the shapes of all or some of the protrusions 5, 6, and 14 may be different.

[0058] 2 do not need to extend over the entire surface, but may be formed only at locations that come into contact with some of the ceramic substrates in the substrate set 2.

[0059] It should be noted that the side convex portions 6 of the packaging container 3 that face the outer surfaces of the two ceramic substrates at both ends of the substrate set 2 do not need to be continuous in the depth direction. For example, the side convex portions 6 may be separated partway in the depth direction, so as to hold down the two ceramic substrates at several points.

[0060] FIG. 3 is a cross-sectional view showing the packing container 3 in a state in which a substrate set 2 is stored. FIG. 3(a) is a IIC-IIC cross-sectional view of the packing container 3 in FIG. 2(a), and FIG. 3(b) shows the state in which the lid 3b is closed and engaged by the engaging portion from the state in FIG. 3(a). FIG. 3(c) is a IIE-IIE cross-sectional view of the packing container 3 in FIG. 2(a). The packing container 3 has two rows of bottom convex portions 5 and top convex portions 14 that press the surface of the substrate set 2, where multiple ceramic substrates are stacked, to provide cushioning and prevent shock during transport. Two rows of side convex portions 6 formed on the side surface press the outer surfaces of the two outermost ceramic substrates of the substrate set 2 with two lines to prevent shock during transport.

[0061] Furthermore, the lid 3b can have not only the top surface 13 but also four side surfaces connected to the four edges of the top surface 13. The top surface 13 and the four side surfaces can form a cavity having an opening in the lid 3b.

[0062] FIG. 4 is a cross-sectional view showing a state in which a substrate set 2 is housed in a packaging container 3 including a lid 3b having four side surfaces 15 connected to the four edges of the top surface 13. FIG. 4(a) is a cross-sectional view of the same cross section as FIG. 3(a), and FIG. 4(b) shows a state in which the lid 3b is closed from the state shown in FIG. 3(a) and engaged by the engaging portion. FIG. 4(c) is a cross-sectional view of the same cross section as FIG. 3(c). The packaging container 3 has two rows of bottom surface protrusions 5 and top surface protrusions 14 formed on the bottom surface 7, which press the substrate set 2 in two rows to provide cushioning and prevent shock during transport. Two rows of side surface protrusions 6 formed on the side surface press the surface of the substrate set 2, where multiple ceramic substrates are stacked, with two lines to prevent shock during transport. In this case, side surface protrusions (not shown) similar to those formed on the side surfaces 8a and 8c of the container body 3a may be formed on the side surface 15 of the lid 3b.

[0063] Furthermore, in order to facilitate the insertion and removal of the substrate set 2 into the container body 3a, it is effective to provide the sides of the container body 3a and the lid 3b with a taper (open inclination) of 1° or more so that the openings widen toward the bottom surface 7 and the top surface 13. Also, in order to provide strength to the openings of the container body 3a and the lid 3b, it is effective to form a flange (not shown) with a width of 1 mm or more around the entire periphery of the frame of the opening.

[0064] Preferably, the container body 3a and the lid body 3b of the packaging container 3 shown in Figure 4 are each formed with an engaging portion for male-female engagement. Body engaging flaps 11c and 11e are formed around the opening of the container body 3a, and recesses 12b and 12c are formed in the body engaging flaps 11c and 11e as engaging portions. Lid engaging flaps 11b and 11f are formed around the periphery of the lid body 3b, and protrusions 12a and 12d are formed in the lid engaging flaps 11b and 11f as engaging portions. When the lid body 3b of the packaging container 3 is closed, the recesses 12b and 12c on the container body 3a engage with the protrusions 12a and 12d on the lid body 3b, respectively, so that the lid body 3b can remain closed relative to the container body 3a without having to continuously press the lid body 3b against the container body 3a from the outside.

[0065] Preferably, an opening flap is formed on the frame of the opening of the container body 3a shown in Fig. 4 to facilitate manual opening of the lid body 3b when the recesses 12b, 12c and the protrusions 12a, 12d are engaged. A body opening flap 11d is formed on the frame of the opening of the container body 3a, and a lid opening flap 11a is formed around the periphery of the lid body 3b. By arranging all or part of the opening flaps 11d, 11a so that they do not overlap when the lid body 3b is closed to the container body 3a, an operator can apply force in the opening direction to the lid opening flap 11a while holding down the body opening flap 11d, making it easier to open the lid body 3b when the recesses 12b, 12c and the protrusions 12a, 12d are engaged.

[0066] As shown in Figure 4, in the packaging container 3, the depth of the side surface of the lid body 3b is the same as or shallower than the depth of the side surface of the container body 3a. Therefore, even without providing a protrusion on the side surface of the lid body 3b, the side surface protrusion 6 of the container body 3a can provide a sufficient effect of fixing the substrate set 2 and absorbing impact. However, similar to the side surface protrusion 6 of the container body 3a, a protrusion can also be provided on the side surface of the lid body 3b. In this case, the effect of fixing the substrate set 2 and absorbing impact can be further improved.

[0067] The effective size of the packaging container 3 in the stacking direction of the multiple ceramic substrates constituting the substrate set 2 (in the case of vertical placement, the direction parallel to the Y-axis) can also be determined taking into account the warping of the ceramic substrates. From a width y0 in the direction parallel to the Y-axis when the ceramic substrates are not (or have little) warped, the ceramic substrates at both ends are pressed inward to reduce the substrate set 2 to a width y1 (y1 < y0), and the substrate set 2 is then inserted into the container body 3a. Then, the pressure on the ceramic substrates at both ends is released to reduce the substrate set 2 to a width y2 (y1 < y2 < y0), and the substrate set 2 can be stabilized by pressing the substrate set 2 against the side convex portions 6. It is also possible to set y0 = y2 without considering the warping of the ceramic substrates.

[0068] According to the packaging container 3 of the first embodiment, when transporting the packaging container 3 in which the substrate set 2 is stored upright, it is possible to simply package the substrate set 2 while suppressing impacts from the surroundings, including the outside on the opening side of the container body 3a, and impacts between the stacked ceramic substrates.

[0069] Second Embodiment A packaging container for transporting ceramic substrates according to a second embodiment stores a substrate set consisting of a plurality of ceramic substrates in a flat position. The packaging container for transporting ceramic substrates according to the second embodiment will be described with reference to FIGS. 5 to 12.

[0070] FIG. 5 is a perspective view showing the appearance of a packaging container for transporting a ceramic substrate according to the second embodiment.

[0071] In FIG. 5 , reference numeral 15 indicates a state before ceramic substrates are placed flat in a packaging container for transporting ceramic substrates according to the second embodiment. Reference numeral 2 indicates a substrate set consisting of a plurality of ceramic substrates, and reference numeral 4 indicates a packaging container for transporting ceramic substrates according to the second embodiment. Reference numeral 4a indicates a container body constituting the packaging container 4. Reference numeral 4b indicates a lid constituting the packaging container 4. The packaging container 4 stores a substrate set 2 placed flat inside by closing the lid 4b on the container body 4a. Reference numeral 7 indicates the bottom surface of the container body 4a. The direction in which the plurality of ceramic substrates are stacked and the insertion direction of the substrate set 2 (arrow shown in FIG. 5 ), i.e., the depth direction of the packaging container 4, is defined as the Z-axis direction. One direction of the bottom surface 7 of the packaging container 4 is defined as the X-axis direction. One direction of the bottom surface 7 of the packaging container 4 is defined as the Y-axis direction.

[0072] The container body 4a is composed of a rectangular (square or oblong) bottom surface 7 and four side surfaces (back surface 8a, left surface 8b, front surface 8c, and right surface 8d shown in FIG. 6) connected to the edges of the bottom surface 7. The lid body 4b is composed of a top surface (top surface 13 shown in FIG. 6). It is effective if the container body 4a and the lid body 4b are integrated with a hinge (hinge 10 shown in FIG. 6) provided on one side surface. Note that in FIGS. 5 to 12, an example will be described in which the bottom surface 7 and top surface 13 of the packaging container 4 are rectangular.

[0073] Here, the relationship between the bottom surface 7 of the packing container 4 and the four side surfaces 8a to 8d is approximately perpendicular, and the bottom surface 7 of the packing container 4 and the four side surfaces 8a to 8d are connected at right angles to each other, but this is not a limitation. For example, the four side surfaces 8a to 8d of the packing container 4 may be tapered, or the bottom surface 7 of the packing container 4 and the four side surfaces 8a to 8d may be connected with chamfers or rounded corners. The substrate set 2 is inserted into the container body 4a through the opening of the container body 4a in the direction of the arrow shown in FIG. 5, with the outer surface of one of the ceramic substrates of the substrate set 2 facing downward.

[0074] FIG. 6 shows a top view of a packaging container 4 for transporting a ceramic substrate according to a second embodiment. Two rows of semi-cylindrical side protrusions 6, each of which has a semicircular shape extending continuously in the depth direction, are formed on all side surfaces 8a to 8d of the packaging container 4. Two rows of semi-cylindrical bottom protrusions 5, each of which has a semi-circular shape extending continuously from the rear surface 8a to the front surface 8c (parallel to the X-axis), are formed on the bottom surface 7 of the packaging container 4. Two rows of semi-cylindrical top protrusions 14, each of which has a semi-circular shape extending continuously from the front surface to the rear surface (or from the rear surface to the front surface), are formed on the top surface 13 of the packaging container 4. The protrusions 5, 6, and 14 preferably have an inward height of 2 mm or more. It is preferable that a flange 9 be formed around the entire periphery of the opening of the container body 4a.

[0075] Preferably, the container body 4a and the lid 4b of the packaging container 4 are each formed with an engaging portion for male-female engagement. Body engaging flaps 11c and 11e are formed around the opening of the container body 4a, and recesses 12b and 12c are formed in the body engaging flaps 11c and 11e as engaging portions. Lid engaging flaps 11b and 11f are formed around the periphery of the lid 4b, and protrusions 12a and 12d are formed in the lid engaging flaps 11b and 11f as engaging portions. When the lid 4b of the packaging container 4 is closed, the recesses 12b and 12c on the container body 4a engage with the protrusions 12a and 12d on the lid 4b, respectively, allowing the lid 4b to remain closed relative to the container body 4a without having to continuously press the lid 4b against the container body 4a from the outside.

[0076] In addition, it is preferable that an opening flap be formed on the frame of the opening of the container body 4a to facilitate manual opening of the lid body 4b when the recesses 12b, 12c and the protrusions 12a, 12d are engaged. A main body opening flap 11d is formed on the frame of the opening of the container body 4a, and a lid opening flap 11a is formed around the periphery of the lid body 4b. By arranging all or part of the opening flaps 11d, 11a so that they do not overlap when the lid body 4b is closed to the container body 4a, an operator can apply force in the opening direction to the lid opening flap 11a while holding down the main body opening flap 11d, making it easier to open the lid body 4b when the recesses 12b, 12c and the protrusions 12a, 12d are engaged.

[0077] FIG. 7 is a cross-sectional view showing the packing container 4 in a state in which a substrate set 2 is stored. FIG. 7(a) is a VIIA-VIIA cross-sectional view of the packing container 4 in FIG. 6, and FIG. 7(b) shows the state in which the lid 4b is closed and engaged by the engaging portion from the state in FIG. 7(a). FIG. 7(c) is a VIIC-VIIC cross-sectional view of the packing container 4 in FIG. 6. The packing container 4 has two rows of bottom convex portions 5 and top convex portions 14 that press against the outer surfaces of the two outermost ceramic substrates of the substrate set 2, providing cushioning and preventing impact during transport. Two rows of side convex portions 6 formed on the side surface press against the surface of the substrate set 2 where multiple ceramic substrates are stacked with two lines, preventing impact during transport.

[0078] 6, the bottom protrusions 5 on the bottom surface 7 and the side protrusions 6 on the side surfaces are connected, but they may be formed in separate positions, i.e., in positions where they are not connected. Also, the two rows of bottom protrusions 5 on the bottom surface 7 are formed to extend in the direction from the back surface 8a to the front surface 8c (in the direction parallel to the X-axis), but this is not limited to this case.

[0079] Furthermore, in order to make it easier to insert and remove the substrate set 2 into and from the container body 4a, it is effective to provide the four side surfaces 8a to 8d with a taper (opening slope) of 1° or more so that the opening of the container body 4a widens toward the bottom surface 7. Also, in order to provide strength to the opening of the container body 4a, it is effective to form a flange with a width of 1 mm or more around the entire periphery of the frame of the opening.

[0080] In the flat-placed packaging container 4, the lid body 4b may be configured to have four side surfaces 15, similar to the packaging container 3 shown in FIG.

[0081] The effective size of the packaging container 4 in the stacking direction of the multiple ceramic substrates constituting the substrate set 2 (parallel to the Z axis when laid flat) can also be determined taking into account warpage of the ceramic substrates. The substrate set 2 is inserted into the container body 4a in a state of width z0 in the direction parallel to the Z axis when the ceramic substrates are not (or have little) warped. Then, by closing the lid 4b, the substrate set 2 is pressed by the convex portions 5 and 14, resulting in a state of width z2 (z2 < z0), and the substrate set 2 can be stabilized by pressing it against the convex portions 5 and 14. Note that z0 = z2 may be satisfied without considering warpage of the ceramic substrates.

[0082] According to the packaging container 4 of the second embodiment, when transporting the packaging container 4 in which the substrate set 2 is stored flat, it is possible to simply package the substrate set 2 while suppressing impacts from the surroundings, including the outside of the opening side of the container body 4a, and impacts between the stacked ceramic substrates.

[0083] (Modifications) Modifications regarding the arrangement of the bottom convex portion 5, the side convex portion 6, and the top convex portion 14 when the board set 2 is stored vertically and when the board set 2 is stored flat will be described with reference to FIGS. 8 to 12.

[0084] For example, as shown in FIG. 8, the bottom convex portion 5 and the top convex portion 14 of the packaging containers 3 and 4 may include convex portions that extend in the direction parallel to the Y axis in addition to the direction parallel to the X axis.

[0085] For example, as shown in Figure 9, the packaging containers 3 and 4 may have discontinuous bottom convex portions 5 and top convex portions 14 formed on the bottom surface 7 and top surface 13 in the direction from one side to the other side of two opposing side surfaces among the four side surfaces (in the direction parallel to the X-axis).

[0086] 10 , the packaging containers 3 and 4 may have a row of bottom protrusions 5 and a row of top protrusions 14 formed on the bottom surface 7 and the top surface 13, respectively, that extend continuously from one side of two opposing side surfaces to the other side (parallel to the X-axis) and from one side of the other two opposing side surfaces to the other side (parallel to the Y-axis). In this case, it is preferable that the two bottom protrusions 5 intersect at approximately the center of the bottom surface 7, and the two top protrusions 14 intersect at approximately the center of the top surface 13. Here, approximately the center includes not only the center but also a non-center within the manufacturing tolerance range.

[0087] Furthermore, as shown in Fig. 11 , in addition to the bottom surface protrusions 5 and top surface protrusions 14 shown in Fig. 10 , protrusions formed along the edge of the bottom surface 7 may be included as the bottom surface protrusions 5 and top surface protrusions 14. In Fig. 11 , the bottom surface protrusions 5 and top surface protrusions 14 shown in Fig. 10 are shown as bottom surface protrusions 5a and top surface protrusions 14a, and the rectangular protrusions formed along the edge of the bottom surface 7 are shown as bottom surface protrusions 5b and top surface protrusions 14b.

[0088] 12, the bottom surface protrusion 5 and the top surface protrusion 14 may be a single protrusion in which the area ratio of the bottom surface protrusion 5 and the top surface protrusion 14 is 25% or more of the entire bottom surface. Also, although the bottom surface protrusion 5 and the top surface protrusion 14 have the same shape in FIGS. 1 to 12, they may have different shapes. In the case of different shapes, for example, one of the bottom surface protrusion 5 and the top surface protrusion 14 is semi-cylindrical and the other is rectangular.

[0089] In the packing containers 3 and 4 shown in Figures 1 to 7, there are two rows of protrusions on each of the bottom surface 7, two side surfaces 8a and 8c, and the top surface 13, and although a single row is effective, it is desirable to have two or more rows in order to support the substrate set 2.

[0090] 1 to 7, the protrusions 5, 6, and 14 provided on the bottom surface 7, two side surfaces 8a and 8c, and top surface 13 of the packaging containers 3 and 4 are effective regardless of the shape of the protrusions, as long as the protrusions protrude from the surfaces. If the protrusions 5, 6, and 14 are U-shaped, they can contact the substrate set 2 over a larger area than if they were semi-cylindrical, making it possible to further stabilize the contained substrate set 2. Note that it is preferable to chamfer the corners of the U-shape when making the packaging container 3 from a material that is relatively easy to process, such as the aforementioned plastic.

[0091] Furthermore, the convex portions 5, 6, and 14 provided on the bottom surface 7, two side surfaces 8a and 8c, and top surface 13 of the packaging containers 3 and 4 shown in Figures 1 to 7 do not need to extend over the entire surface, but only need to be formed in the areas that come into contact with the substrate set 2.

[0092] According to at least one of the embodiments described above, when transporting the packaging container 3 containing the substrate set 2, it is possible to simply package the substrate set 2 while suppressing impacts from the surroundings, including the outside on the opening side of the container bodies 3a, 4a, and impacts between the stacked ceramic substrates.

[0093] When packaging the substrate set 2 in a packaging container without a lid, the substrate set 2 is exposed on the top opening side of the packaging container, so it is desirable to cover the exposed portion (or the entire substrate set 2) with a protective material to protect the exposed portion. For example, conceivable methods include covering the exposed portion of the substrate set 2 with a protective material and bundling the protective material with a bundling material such as a rubber band, or bundling the protective material in a vacuum pack. Protecting the exposed portion in such a way requires bundling materials or the use of a dedicated vacuum device, which is time-consuming and labor-intensive. On the other hand, with the packaging containers 3 and 4, simply by closing the lid 3b on the container body 3a, the substrate set 2 can be simply packaged while suppressing impacts from the surroundings, including the outside of the opening side of the container body 3a or 4a.

[0094] Although several embodiments of the present invention have been described above, these embodiments are presented by way of example only and are not intended to limit the scope of the invention. These novel embodiments can be embodied in various other forms, and various omissions, substitutions, modifications, etc. can be made without departing from the spirit of the invention. These embodiments and their modifications are included within the scope and spirit of the invention, as well as within the scope of the invention and its equivalents as set forth in the claims. Furthermore, the above-described embodiments can be implemented in combination with each other.

Claims

1. A packaging container for transporting ceramic substrates that stores multiple ceramic substrates by closing a lid on a container body, wherein the container body has a rectangular bottom and four side surfaces connected to the four edges of the bottom, at least two opposing sides of the four side surfaces have inward-facing side surface protrusions that are 2 mm or more in height, the bottom surface has inward-facing bottom surface protrusions that are 2 mm or more in height, and the lid has a rectangular top surface that has inward-facing top surface protrusions that are 2 mm or more in height.

2. A packaging container for transporting ceramic substrates as described in claim 1, characterized in that the container is configured to store the ceramic substrate set, which is made up of multiple ceramic substrates stacked on top of each other, so that the outer sides of the two ceramic substrates at both ends of the ceramic substrate set face two opposing side surfaces out of the four side surfaces, and each of the two side surfaces has two or more rows of side surface convex portions that extend continuously in the depth direction as the side surface convex portions, and the bottom surface has two or more rows of bottom surface convex portions that extend continuously in the direction from one side to the other of the two side surfaces as the bottom surface convex portions.

3. A packaging container for transporting ceramic substrates as described in claim 1, characterized in that the container is configured to store the ceramic substrate set, which is made up of multiple ceramic substrates stacked together, so that the outer surface of the ceramic substrate at one end of the ceramic substrate set faces the bottom surface, and that each of the four side surfaces has two or more rows of side surface protrusions that extend continuously in the depth direction as the side surface protrusions.

4. A packaging container for transporting ceramic substrates as described in claim 3, characterized in that the bottom surface has two rows of bottom surface convex portions on the bottom surface, extending continuously from one side to the other of two opposing side surfaces among the four side surfaces.

5. A packaging container for transporting ceramic substrates as described in claim 3, characterized in that the bottom surface has two rows of bottom surface convex portions extending continuously from one side to the other of two opposing side surfaces among the four side surfaces, and two rows of bottom surface convex portions extending continuously from one side to the other of two other opposing side surfaces among the four side surfaces.

6. A packaging container for transporting ceramic substrates as described in claim 3, characterized in that the bottom surface has two rows of bottom surface convex portions extending intermittently from one side to the other of two opposing side surfaces among the four side surfaces.

7. A packaging container for transporting ceramic substrates as described in claim 3, characterized in that the bottom surface protrusions are provided on the bottom surface in a row extending continuously from one side to the other of two opposing side surfaces among the four side surfaces, and in that the bottom surface protrusions are provided in a row extending continuously from one side to the other of two other opposing side surfaces among the four side surfaces, and the two bottom surface protrusions intersect at approximately the center of the bottom surface.

8. A packaging container for transporting a ceramic substrate according to claim 7, wherein the two bottom surface convex portions further include a convex portion formed along the edge of the bottom surface.

9. A packaging container for transporting ceramic substrates as described in claim 1, characterized in that the ceramic substrate set, which is made up of multiple ceramic substrates stacked together, is stored so that the outer surface of the ceramic substrate at one end of the ceramic substrate set faces the bottom surface, and the bottom surface is provided with one bottom surface convex portion whose area ratio to the entire area of ​​the bottom surface is 25% or more.

10. A packaging container for transporting ceramic substrates according to any one of claims 1 to 9, characterized in that the container body and the lid are integrally connected by a bendable hinge.

11. A packaging container for transporting ceramic substrates according to any one of claims 1 to 9, characterized in that the lid further has four side surfaces connected to the four edges of the top surface, respectively.

12. A packaging container for transporting ceramic substrates according to any one of claims 1 to 9, characterized in that an outward flange is formed on the frame of the opening of the container body.

13. A packaging container for transporting ceramic substrates as described in any one of claims 1 to 9, characterized in that male and female engaging portions are provided on the contact surface formed when the lid body is closed against the container body.

14. A packaging container for transporting ceramic substrates as described in any one of claims 1 to 9, characterized in that the container body and the lid body each have an outwardly protruding opening flap, and all or part of the two opening flaps are positioned so as not to overlap when the lid body is closed against the container body.

15. A packaging container for transporting ceramic substrates as described in any one of claims 1 to 9, characterized in that the four side surfaces are tapered so that the opening of the container body widens as it approaches the bottom surface.

16. A packaging container for transporting a ceramic substrate according to any one of claims 1 to 9, characterized in that the material is plastic.

17. A packaging container for transporting ceramic substrates according to any one of claims 1 to 9, characterized in that each of the plurality of ceramic substrates is configured to contain a silicon nitride substrate or a silicon nitride metal bonded substrate.

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