Client Background

The client is a manufacturer of flat display panels and touch screen assemblies serving the consumer electronics and automotive industries. Their products range from small instrument cluster displays to larger infotainment panels, all requiring strict ESD protection throughout production and shipping.

With production volumes growing and an expanding customer base across multiple regions, the client needed a packaging solution that could keep pace with their logistics demands while maintaining zero-defect delivery standards.

Challenge

The client had been using conventional corrugated plastic boxes with separate lids and loose foam inserts. Several problems emerged:

• ESD incidents during handling caused occasional but costly panel failures at incoming inspection on the customer side.

• Separate lids slowed down packing operations and were sometimes mismatched or lost.

• Loose foam inserts shifted during transport, allowing panels to move and sustain edge damage.

• Protruding stacking tabs on the old boxes wasted space and occasionally snagged on conveyor systems.

• Boxes degraded after only a few reuse cycles, driving up per-trip packaging cost.

The client needed a single packaging solution that simultaneously delivered: conductive ESD shielding, precision shock absorption, secure locking, efficient stacking, and long reuse life.

Solution

Yufa Polymer engineered a purpose-built conductive corrugated plastic case incorporating multiple materials and hardware components into one integrated design.

Side profile: metal edge banding, ergonomic handle, and the flush exterior that enables clean stacking.

Materials and Construction

• Box body and lid: Conductive PP corrugated board with surface resistance of 10³ to 10⁶ Ω, ensuring consistent ESD protection.

• Edge reinforcement: Aluminum profiles along all four sides of both the lid and body, fastened with rivets for permanent structural support.

• Corner protection: Anti-static molded corner protectors at all four corners, maintaining both physical protection and electrical continuity.

• Hinge system: Metal hinges connecting the lid to the body, allowing the lid to open fully and close with precise alignment every time.

• Closure and handling: Metal toggle locks for secure latching; ergonomic side handles for safe two-handed transport.

• Interior cushioning: Custom-cut anti-static EPE foam, bonded directly to all interior surfaces of both the lid and the body, with precision cutouts shaped to the exact panel dimensions.