EP4269275A1

EP4269275A1 - Packing material, packed body, module assembly, and module packing method

Info

Publication number: EP4269275A1
Application number: EP21915232.9A
Authority: EP
Inventors: Yoko TOKUNAGA; Aguru YAMAMOTO
Original assignee: Asahi Kasei Medical Co Ltd
Current assignee: Asahi Kasei Medical Co Ltd
Priority date: 2020-12-28
Filing date: 2021-12-24
Publication date: 2023-11-01
Also published as: JP7474357B2; WO2022145372A1; CN116419894A; JPWO2022145372A1; EP4269275A4

Abstract

The purpose of the invention is to provide a packing material capable of suppressing breakage of a header part of a module and breakage of a packaging bag packaging the module. There is provided a packing material 1 for packing modules M each having a cylindrical body part M1 and header parts M2 attached to both longitudinal ends of the body part M1 into a box B. The packing material 1 includes body part support surfaces 10 which at least partially support lower surfaces M11 of the body parts M1 of the modules M in a recumbent state, body part support walls 20 which support both side surfaces M12 of the body part M1 of each module M so as to sandwich both side surfaces M12, and top surface support walls 30 which support top surfaces M22 of both header parts M2 of the modules M. The packing material 1 is configured so that when the modules M are supported by the body part support surfaces 10, the body part support walls 20, and the top surface support walls 30, the packing material 1 is prevented from coming into contact with side surfaces M21 of the header parts M2 of the modules.

Description

Technical Field

The present invention relates to a packing material, a packed body, a module assembly, and a method of packing a module.

Background Art

Heretofore, when performing a blood purification method such as hemodialysis therapy or plasma exchange therapy, a membrane module having a treated membrane such as a hollow fiber membrane thereinside, and an adsorption module having an adsorbent such as beads thereinside (hereinafter, these may be collectively referred to as "modules") have been used. Nowadays, there have been proposed and put into practical use various packing materials which suppress breakage of the modules due to vibrations and shocks during transportation by preventing the modules from directly contacting each other inside a box and by preventing the end of each module from directly contacting an inner wall of the box (refer to, for example, Patent Documents 1 and 2).

Citation List

Patent Documents

Patent Document 1: Japanese Patent Application Laid-Open No. Hei 9 (1997)-216658
Patent Document 2: Japanese Patent Application Laid-Open No. 2014-201346

Summary of Invention

Technical Problem

Meanwhile, the module is generally transported in a state of being packaged in a packaging bag, but a problem arises in that when the conventional packing material as described in Patent Documents 1 and 2 is used, the packaging bag becomes easily damaged due to strong contact of the module with the packing material or easy wrinkling in the packaging bag. Further, when the module has a header part having a complicated shape (for example, having a plurality of irregularities on its side surface), the strength against impact or the like during transportation tends to decrease, and the development of packing materials improved therefor has been long-awaited.
The present invention has been made in view of such circumstances, and an object of the present invention is to provide a packing material capable of suppressing breakage of a header part of a module and breakage of a packaging bag which packages the module.

Solution to Problem

In order to achieve the object, a packing material according to the present invention is for packing each of modules each having a cylindrical body part and header parts attached to both ends in a longitudinal direction of the body part into a box. The packing material includes body part support surfaces each at least partially supporting a lower surface of the body part of the module in a recumbent state, body part support walls supporting both side surfaces of the body part of the module in the recumbent state so as to sandwich both side surfaces, and top surface support walls supporting top surfaces of both of the header parts of the module in the recumbent state, and is configured so that when each of the modules is supported by the body part support surfaces, the body part support walls, and the top surface support walls, the packing material is prevented from coming into contact with side surfaces of the header parts.
When such a configuration is adopted, the lower surface of the body part of the module in the recumbent state can be supported at least partially by the body part support surface, and both side surfaces of the body part of the module can be supported so as to be sandwiched by the body part support walls. Therefore, it is possible to prevent the module from moving in the left-right direction (direction perpendicular to the longitudinal direction of the module). Further, since the top surfaces of both header parts of the module in the lying state can be supported by the top surface support walls, it is possible to suppress the module from moving in the longitudinal direction. In addition, when the module is supported by the body part support surfaces, the body part support walls, and the top support walls, the packing material is configured so as not to come into contact with the side surfaces of the header parts of the module. Therefore, it is possible to prevent the side surfaces themselves of the header parts of the module from being damaged or the packaging bag covering the side surfaces of the header parts from being damaged.
The packaging material according to the present invention can be provided with leg portions each provided so as to protrude downward from the body part support surface. In such a case, the leg portions can be arranged below the body part of the module.
When such a configuration is adopted, the packing material can be installed in a stabilized state by suppressing deformation (distortion) thereof upon installing the packing material inside the box or on the shelf since each of the leg portions exists which is provided so as to protrude below the body part support surface and be arranged below the body part of the module.
In the packaging material according to the present invention, the leg portion can be arranged at a substantially central portion in a width direction of the module supported by the body part support surface.
When such a configuration is adopted, the weight of the module can be supported directly below it (approximately the central portion in the width direction) since the leg portion is arranged at the substantially central portion in the width direction of the module supported by the body part support surface. Therefore, it is possible to suppress deformation (distortion) of the packaging material.
In the packing material according to the present invention, a plurality of the leg portions can be provided along a longitudinal direction of the module supported by the body part support surface. In such a case, the plurality of leg portions can be arranged substantially symmetrically centering on a substantially central portion in the longitudinal direction of the module.
When such a configuration is adopted, the plurality of leg portions are provided along the longitudinal direction of the module supported by the body part support surface, and these multiple leg portions are arranged substantially symmetrically centering on the substantially central portion in the longitudinal direction of the module. Therefore, the weight of the module can be distributed and supported by the entire packing material. Accordingly, it is possible to suppress deformation (distortion) of the packing material without the force being biased to a part of the packing material.
In the packing material according to the present invention, a plurality of the body part support surfaces can be provided separately so as to support a plurality of locations along the longitudinal direction of the lower surface of the body part of the module. In such a case, the body part support wall and the leg portion are arranged between the body part support surfaces adjacent to each other and connected by a continuous surface.
When such a configuration is adopted, the lower surface of the body part of the module can be supported at a plurality of locations along the longitudinal direction by the body part support surfaces provided in plural separately. Further, since the body part support walls and the leg portions arranged between the adjacent body part support surfaces are connected by the continuous surface, the rigidity and strength of the packing material can be enhanced.
In the packing material according to the present invention, the body part support surface, the body part support wall, the top surface support wall, and the leg portion can be integrally molded.
When such a configuration is adopted, each configuration of the packing material (body part support surface, body part support wall, top support wall and leg portion) is integrally molded, so that it is easier to manufacture it as compared to connecting separate parts. Further, since each configuration of the packing material is integrated, it is easy to carry, and it becomes easy to perform packing work and dismantling work.
In the packing material according to the present invention, when a second packing material is loaded on the module supported by a first packing material, the leg portions of the second packing material can be arranged so as to at least partially support an upper surface of the body part of the module.
When such a configuration is adopted, the lower surface of the body part of the module can be supported by the body part support surface of the first packing material, while the upper surface of the body part of the module can be supported by the leg portions of the second packing material. Therefore, the module can be sandwiched from above and below. Therefore, it is possible to prevent the module from moving in the vertical direction.
In the packing material according to the present invention, when the second packing material is loaded on the module supported by the first packing material, and the leg portions of the second packing material at least partially support the upper surface of the body part of the module, the second packing material can be configured so as to be prevented from coming into contact with the side surface of each header part of the module.
Upon the adoption of such a configuration, when the second packing material is loaded on the module supported by the first packing material, and the leg portions of the second packing material at least partially support the upper surface of the body part of the module, the second packing material is configured so as not to come into contact with the side surface of each header part of the module, so that it is possible to prevent the packaging bag covering the side surface of the header part of the module from being sandwiched between the side surface and the second packing material and wrinkled or damaged. When a large impact is applied in the vertical direction while the module is set in the second packing material, it is possible to prevent the side surface of the header part of the module arranged in the first packing material and the side surface of the header part of the module arranged in the second packing material from coming into contact via the second packing material and receiving an impact, resulting in damage to them.
In the packing material according to the present invention, when the module has a protrusion plug protruding from the side surface of the header part, an area where the protrusion plug is accommodated can be formed between the first packing material and the second packing material.
When such a configuration is adopted, it is possible to prevent the protrusion plug from being damaged or the packaging bag around the protrusion plug from being damaged by being pressed against the packing material and subjected to an impact.
In such a packing material according to the present invention, at least a part of the body part support surface is made to be a flat surface, and the body part support wall is arranged substantially perpendicular to the flat surface.
Upon the adoption of such a configuration, since the body part support wall is arranged substantially perpendicular to the flat surface constituting at least a part of the body part support surface, it is possible to support the module as if the body part of the module is accommodated in the box having the bottom surface (flat surface of the body part support surface) and the two side surfaces (body part support walls) connected substantially perpendicular to the bottom surface.
In the packing material according to the present invention, when the top surface of the header part of the module includes a flat surface portion substantially orthogonal to the longitudinal direction of the module and a shaft portion protruding from the flat surface portion along the longitudinal direction of the module, the top surface support wall supports at least a portion of the flat surface portion of the top surface, which is below the shaft portion.
When such a configuration is adopted, at least a portion (one location) of the flat surface portion of the top surface of the header part of the module, which is below the shaft portion can be supported by the top surface support wall. Therefore, as compared with the case where portions (two locations) on the side of the shaft portion of the flat surface portion of the top surface are supported as in the conventional case, the flat surface portion of the top surface can be supported in a wider range. Further, when the header part of the module is covered with the packaging bag, the top surface of the header part can be supported in a relatively flat state (a state in which wrinkles are difficult to form) of the packaging bag, so that the packaging bag can be prevented from being damaged.
In the packing material according to the present invention, it can be provided with a module support portion having the body part support surface, the body part support wall, and the top surface support wall and supporting the single module. In such a case, a plurality of the module support portions can be provided so that a plurality of the modules are supported in a state of being arranged in parallel with each other. At this time, when the module is supported by each of the module support portions, the side surfaces of the header parts of the adjacent modules can be configured so as not to come into contact with each other.
Upon the adoption of such a configuration, when the module is supported by each of the plurality of module support portions, the side surfaces of the header parts of the adjacent modules are configured so as not to come into contact with each other, so that it is possible to prevent in advance a situation in which the packaging bag covering the side surface of the header part of the module is damaged by contact between the side surfaces of the header parts. Further, when a large impact is applied in the left-right direction when the module is set in the packing material, it is possible to prevent the side surface of the header part of the module and the side surface of the header part of the module arranged adjacently in the packing material from coming into contact with each other and receiving an impact, resulting in damage to them.
In the packing material according to the present invention, when the module is supported by each of the module support portions, it is possible to prevent a partition wall from existing between the side surfaces of the header parts of the adjacent modules.
Upon the adoption of such a configuration, when the module is supported by each of the plurality of module support portions, no partition wall exists between the side surfaces of the header parts of the adjacent modules, so that it is possible to prevent in advance a situation in which the packaging bag covering the side surface of the header part of the module is damaged by the partition wall. In addition, since the partition wall does not exist, the lateral dimension of the packing material can be shortened, and the module can be accommodated compactly.
A packed body according to the present invention includes the packing material already described, and a box accommodating the packing material. Such a packed body can include a spacer member which closes a gap formed between the upper surface of the body part of the module supported by the packing material and an inner surface of the box facing the upper surface of the body part.
When such a configuration is adopted, the gap formed between the upper surface of the body part of the module supported by the packing material and the inner surface of the box facing the upper surface can be closed by the space member, so that the module can be suppressed from moving in the vertical direction. Further, when the modules supported by the packing material are loaded in a plurality of stages, it is also possible to suppress the vertical movement of these entirety.
Further, a module assembly according to the present invention includes a module having a cylindrical body part and header parts attached to both longitudinal ends of the body part, and includes the already-described packing material.
In addition, as a module packing method according to the present invention, there is provided a method of packing modules each having a cylindrical body part and header parts attached to both longitudinal ends of the body part into a box using the already-described packing material. In the module packing method, a lower surface of the body part of the module in a recumbent state is at least partially supported by the body part support surfaces, both side surfaces of the body part of the module in the recumbent state are supported so as to sandwich both side surfaces by the body part support walls, and top surfaces of both of the header parts of the module in the recumbent state are supported by the top surface support walls of the packing material. When each of the modules is supported by the body part support surfaces, the body part support walls, and the top surface support walls of the packing material, the packing material does not come into contact with side surfaces of the header parts.

Advantageous Effects of Invention

According to the present invention, it is possible to provide a packing material capable of suppressing breakage of a header part of a module and breakage of a packaging bag which packages the module.

Brief Description of Drawings

Fig. 1 is a perspective view of a packing material according to an embodiment of the present invention.
Fig. 2 is a perspective view illustrating a state in which a module is supported by the packing material according to the embodiment of the present invention.
Fig. 3 is a plan view (top view) illustrating a state in which the packing material according to the embodiment of the present invention is stacked vertically in three stages.
Fig. 4 is a cross-sectional view taken along line IV-IV of Fig. 3.
Fig. 5 is a cross-sectional view taken along line V-V of Fig. 3.
Fig. 6 is a cross-sectional view taken along line VI-VI of Fig. 3.
Fig. 7 is a right side view (view seen from the direction of arrow VII of Fig. 3) illustrating the state in which the packing material according to the embodiment of the present invention is stacked vertically in three stages.
Fig. 8 is a left side view (view seen from the direction of arrow VIII of Fig. 3) illustrating the state in which the packing material according to the embodiment of the present invention is stacked vertically in three stages.
Fig. 9 is an explanatory view for describing the outline of a packed body according to an embodiment of the present invention.

Description of Embodiments

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
First, the configuration of a packing material 1 according to the embodiment of the present invention will be described with reference to Figs. 1 to 8. The packing material 1 according to the present embodiment is for packing each of membrane modules (modules) M used when carrying out blood purification methods such as hemodialysis therapy and plasma exchange therapy, virus removal of biomedicine and blood derivatives, water purification treatment, and the like in a box B (refer to Fig. 9). Incidentally, the packing material according to the present invention can be used not only for packing the membrane module M but also for packing an adsorption module having an adsorbent such as beads thereinside.
Incidentally, as illustrated in Fig. 2, the module M packed by the packing material 1 according to the present embodiment has a cylindrical body part M1, header parts M2 attached to both ends of the body part M1 in its longitudinal direction L, and protrusion plugs M3 each protruding from a side surface M21 of the header part M2. A top surface M22 of the header part M2 of the module M includes a flat surface portion M221 substantially orthogonal to the longitudinal direction L of the module M and a shaft portion M222 protruding from the flat surface portion M221 along the longitudinal direction L of the module M. A module assembly is constituted by the packing material 1 and the modules M.
As illustrated in Figs. 4 to 8, the packing material 1 is configured to be stacked in a vertical direction H. In the following description, when the two packing materials 1 stacked in the vertical direction H are distinguished from each other, the packing material 1 arranged below is referred to as a "first packing material 1A". "A" is added to the end of the code of each configuration of the first packing material 1A. On the other hand, the packing material 1 arranged above is referred to as a "second packing material 1B", and "B" is added to the end of the code of each configuration of the second packing material 1B.
As illustrated in Fig. 1 and the like, the packing material 1 includes a plurality of module support portions 2 which support a single module M. The plurality of module support portions 2 are arranged along the lateral direction (direction orthogonal to the longitudinal direction L of the module M) W so as to support the plurality of modules M in a state in which they are arranged parallel to each other. In the present embodiment, as illustrated in Fig. 2, there is illustrated an example in which the packing material 1 provided with the four module support portions 2 is adopted, but the number of the module support portions 2 is not limited to this.
When the module M is supported by each of the module support portions 2, as illustrated in Figs. 2 and 5, there is no partition wall between the side surfaces M21 of the header parts M2 of the adjacent modules M. In addition, the side surfaces M21 of the header parts M2 of the adjacent modules M do not come into contact with each other.
Each module support portion 2 of the packing material 1 includes a body part support surface 10, a body part support wall 20, a top surface support wall 30, and a leg portion 40.
The body part support surface 10 functions to at least partially support a lower surface M11 of the body part M1 of the module M in a recumbent state. As illustrated in Fig. 6 and the like, a plurality of the body part support surfaces 10 are provided separately so as to support a plurality of locations along the longitudinal direction L of the lower surface M11 of the body part M1 of the module M. One of them (a surface supporting a substantially central portion of the lower surface M11 of the body part M1 of the module M in the longitudinal direction L) is made to be a flat surface 11. When the module M is contained in a packaging bag, the module M comes into contact with the flat surface 11 at one point, so that spaces are created on the left and right sides of the module M, and folded wrinkles are less likely to enter in the packaging bag. In the present embodiment, as illustrated in Fig. 6 and the like, the three body part support surfaces 10 are provided, and one of them (the surface located substantially in the center of the longitudinal direction L) is made to be a flat surface 11, but the numbers of the body part support surfaces 10 and the flat surfaces 11 and the position of the flat surface 11 are not limited to this. The ratio of the total length of the body part support surfaces 10 in the longitudinal direction L to the distance between the top surface support walls 30 in the longitudinal direction L of the packing material 1 is preferably 30% or more.
The body part support walls 20 function to support both side surfaces M12 of the body part M1 of the module M in the recumbent state so as to sandwich both side surfaces M12. As illustrated in Fig. 1 and the like, the body part support wall 20 is arranged substantially perpendicular to the flat surface 11 of the body part support surface 10. In the present embodiment, as illustrated in Fig. 1 and the like, the two body part support walls 20 are provided separately along the longitudinal direction L so as to support two locations along the longitudinal direction L of both side surfaces M12 of the body part M1. Thus, in the present embodiment, since the body part support wall 20 is not provided at the substantially central portion in the longitudinal direction L, it is easy to place the module M on the packing material 1 in the packing work.
Further, in the present embodiment, the two body part support walls 20 along the longitudinal direction L are arranged substantially symmetrically about the substantially central portion of the longitudinal direction L. Each of the two body part support walls 20 along the longitudinal direction L is provided with a recess 21 for improving the strength. The number and shape of the body part support walls 20 are not limited to this, but in order to suppress the movement of the module M in the width direction W, the height of the body part support wall 20 (the dimension indicated by reference numeral T in Fig. 4, that is, the dimension from the lowermost portion of the body part support surface 10 to the uppermost portion of the body part support wall 20 in the vertical direction H) is preferably set to 50% or more of the diameter of the body part M1 of the module M. Incidentally, the height of the body part support wall 20 can be set to 50% or more of the distance between the adjacent body part support walls 20 regardless of the diameter of the body part M1 of the module M. The height of the body part support wall 20 is more preferably set to 55% or more of the diameter of the body part M1 of the module M (and/or the distance between adjacent body part support walls 20), and still more preferably 60% or more. Further, considering the ease of taking out the module M and the ease of manufacturing the packing material 1, the height of the body part support wall 20 is preferably set to 150% or less of the diameter of the body part M1 of the module M (and/or the distance between the adjacent body part support walls 20), more preferably 100% or less, and still more preferably 75% or less. Moreover, the total length of the body part support walls 20 along the longitudinal direction L is not particularly limited, but can be appropriately set while considering the ease of placing the module M during packing work, the formation of escape routes for air in the packaging bag when the module M is placed in the packaging bag, the strength of the body part support wall 20, etc.
The top surface support walls 30 function to support the top surfaces M22 of both header parts M2 of the module M held in the recumbent state. As illustrated in Fig. 6 and the like, the top surface support wall 30 in the present embodiment is configured to support a relatively wide portion (one location) of the flat surface portion M221 of the top surface M22 of the header part M2 of the module M, which is placed below the shaft portion M222. Therefore, the flat surface portion M221 of the top surface M22 can be supported in a wider range compared to the case of supporting relatively narrow portions (two locations) on the side of the shaft portion M222, of the flat surface portion M221 of the top surface M22. Further, when the header part M2 of the module M is covered with the packaging bag, the top surface M22 of the header part M2 can be supported in a relatively flat state (a state in which wrinkles are difficult to form), so that it is possible to prevent the breakage of the packaging bag.
In the present embodiment, when the body part M1 of the module M is supported by the body part support surface 10, the body part support wall 20, and the top surface support wall 30, the packing material 1 does not come into contact with the side surface M21 of the header part M2 of the module M (that is, a gap is formed between the side surface M21 of the header part M2 of the module M and the packing material 1) as illustrated in Figs. 5 and 6.
The leg portion 40 is provided so as to protrude downward from the body part support surface 10, and functions to support the module M via the body part support surface 10 and the like. As illustrated in Fig. 6 and the like, the leg portion 40 in the present embodiment is provided in plural (four) along the longitudinal direction of the module M supported by the body part support surface 10. These four leg portions 40 are arranged substantially symmetrically about the substantially central portion of the module M in the longitudinal direction L. Further, the leg portion 40 is arranged below the body part M1 of the module M supported by the body part support surface 10, and is arranged at a substantially central portion in the width direction (lateral direction W) of the module M.
In the present embodiment, as illustrated in Figs. 4 and 6, when the second packing material 1B is loaded on the module M supported by the first packing material 1A, each leg portion 40B of the second packing material 1B is arranged so that it at least partially supports the upper surface M13 of the body part M1 of the module M (the leg portion 40B at least partially abuts the upper surface M13 of the module M). In the present embodiment, since the four leg portions 40 are provided, they support the upper surface M13 of the module M at four points (they are in contact with the upper surface M13 of the module M at four points).
The number and shape of the leg portions 40 are not limited to this, but the length and installation area of the installation surface of each leg portion 40 along the longitudinal direction L can be set in a range which can support the weight of the module M when an impact is applied. Further, it is preferable that when two or more stages are loaded, the packaging bag can be arranged between the leg portion 40B and the leg portion 40B of the upper-stage packing material 1B when the module M is contained in the packaging bag and air exists in the packaging bag, and the length and area of the leg portion 40B are set so that the upper-stage leg portion 40B can be installed in the body part M1 without floating.
Further, in the present embodiment, as illustrated in Figs. 5 and 6, when the second packing material 1B is loaded" on the module M supported by the first packing material 1A, and the leg portions 40B of the second packing material 1B at least partially support the upper surface M13 of the body part M1 of the module M (when each leg portion 40B at least partially abuts on the upper surface M13 of the module M), the second packing material 1B does not come into contact with the side surface M21 of the header part M2 of the module M. Moreover, at this time, as illustrated in Figs. 4 and 5, an area A where the protrusion plug M3 of the module M is accommodated is formed between the first packing material 1A and the second packing material 1B. Incidentally, when the protrusion plug M3 of the module M arranged near the outer peripheral edge of the packing material 1 is made horizontal, the outer peripheral edge of the packing material 1 is preferably located outside the tip of the protrusion plug M3 of the module M. When done in this way, it is possible to prevent the breakage or the like of the protrusion plug M3 of the module M due to the protrusion plug M3 of the module M protruding outward from the outer peripheral edge of the packing material 1.
As illustrated in Fig. 3, the packing material 1 according to the present embodiment is configured left-right symmetrically in the longitudinal direction L of the module M (that is, line-symmetrically across the center line in the longitudinal direction L) in a plan view, and is configured left-right symmetrically even in the lateral direction W (that is, line-symmetrically across the center line in the width direction W). By forming the packing material 1 in such a symmetrical shape, there is an advantage that the packing work of each module M becomes easier to do, and the loading work of the packing materials 1 becomes easier to do.
Further, as illustrated in Figs. 1 to 3, a recess 50 is provided on the outer peripheral edge of the packing material 1 according to the present embodiment at a substantially central portion in the longitudinal direction L of the module M in a plan view. By providing such a recess 50 on the outer peripheral edge of the packing material 1, it becomes easier for an operator to hold the packing material 1 by hand, and it becomes easier to put the packing material 1 in and out of the box B. Along with this, there is an advantage that the packing work of the module M and the taking-out work thereof from the box B becomes easier to do.
The body part support surface 10, the body part support wall 20, the top surface support wall 30, and the leg portion 40 of each module support portion 2 are integrally molded by a general pulp mold manufacturing method, injection molding method, or the like. Further, as illustrated in Fig. 3 and the like, the body part support wall 20 and the leg portion 40 of each module support portion 2 are arranged between the adjacent body part support surfaces 10 (the body part support surfaces 10 of each module support portion 2 adjacent along the longitudinal direction L), and are connected by a continuous surface. Connecting the body part support wall 20 and the leg portion 40 of each module support portion 2 by the continuous surface makes it possible to increase the strength of the module support portion 2 and the packing material 1. Further, in the present embodiment in which a plurality of the module support portions 2 are provided so that the plurality of modules M are supported in a state of being arranged in parallel with each other, the body part support walls 20 and the leg portions 40 are arranged alternately along the lateral direction W over the adjacent module support portions 2, and these are connected by the continuous surface. Consequently, it is possible to enhance the strength of the packing material 1 having the plurality of module support portions 2. Each module support portion 2 (packing material 1) can be made of paper such as used newspaper or corrugated cardboard, a synthetic resin such as polystyrene, polypropylene, and polyethylene terephthalate, and foamable synthetic resins such as polyurethane and polystyrene, etc. Incidentally, in the present embodiment, there is illustrated an example in which each module support portion 2 (body part support surface 10, body part support wall 20, top surface support wall 30, and leg portion 40) is integrally molded, but each module support portion may be formed by combining a plurality of parts.
Next, the configuration of a packed body 100 according to an embodiment of the present invention will be described with reference to Fig. 9.
As illustrated in Fig. 9, the packed body 100 according to the present embodiment includes packing materials 1 and a box B accommodating the packing materials 1 therein. The packaging material 1 has already been described. As the box B, for example, a substantially rectangular parallelepiped box made of corrugated cardboard or the like can be adopted. In the packed body 100, a gap G is formed between the upper surface M13 of the body part M1 of the uppermost stage module M supported by the packing material 1 and an inner surface B1 of the box B facing the upper surface M13 of the body part M1, but a spacer member S which partially closes the gap G can be provided. By providing such a space member S, it is possible to suppress the movement of the module M in the vertical direction, and it is possible to suppress the movement of the entire modules M loaded in plural stages in the vertical direction.
The shape of the spacer member S is not particularly limited, and it is sufficient if the gap G formed between the upper surface M13 of the body part M1 of the uppermost stage module M and the inner surface B1 of the box B can be at least partially closed. The material for the spacer member S is not particularly limited insofar as it can suppress the vertical movement of the module M. For example, a plurality of sheets of corrugated cardboards each having a predetermined thickness can be stacked to form a spacer member S. Further, a plate-shaped (thin rectangular parallelepiped) spacer member S having a predetermined thickness, which is made of paper or a foamable synthetic resin may be adopted. Incidentally, in addition to the spacer member S, a thin plate member (pad) having a substantially rectangular shape in a plan view, which is comprised of, for example, corrugated cardboard or the like, can also be provided between the uppermost stage module M and the inner surface (upper surface) B1 in the box B. It is also possible to integrate the thin plate member (pad) and the spacer member S.
In the packing material 1 according to the embodiment described above, the lower surface M11 of the body part M1 of the module M in the recumbent state can be supported at least partially by the body part support surface 10, and both side surfaces M12 of the body part M1 of the module M can be supported so as to be sandwiched by the body part support walls 20. Therefore, it is possible to suppress the module M from moving in the left-right direction (the width direction W perpendicular to the longitudinal direction L of the module M). Further, since the top surfaces M22 of both header parts M2 of the module M in the recumbent state can be supported by the top surface support walls 30, it is possible to suppress the module M from moving in the longitudinal direction L. In addition, when the module M is supported by the body part support surface 10, the body part support wall 20, and the top surface support wall 30, the packing material 1 is configured so as not to come into contact with the side surface M21 of the header part M2 of the module M, so that it is possible to prevent the side surface M21 itself of the header part M2 of the module M from breaking or the packaging bag covering the side surface M21 of the header part M2 from breaking.
Also, the packing material 1 according to the embodiment described above includes the leg portions 40 each provided so as to protrude downward from the body part support surface 10 and to be arranged below the body part M1 of the module M. Therefore, when the packing material 1 is installed inside the box B or on a shelf, it can be installed in a stable state while suppressing deformation (distortion) of the packing material 1. Further, the leg portions 40 can absorb an impact received from below, and the impact acting on the module M can be relaxed.
Further, in the packing material 1 according to the embodiment described above, since each leg portion 40 is arranged at the substantially central portion in the width direction (lateral direction W) of the module M supported by the body part support surface 10, the weight of the module M can be supported directly therebelow (approximately at the central portion in the width direction). Therefore, it is possible to suppress the deformation (distortion) of the packing material 1.
Yet further, in the packing material 1 according to the embodiment described above, the plurality of leg portions 40 are provided along the longitudinal direction L of the module M supported by the body part support surface 10, and these plural leg portions 40 are arranged substantially symmetrically about the substantially central portion of the module M in the longitudinal direction L. Therefore, the weight of the module M can be dispersed and supported by the entire packing material 1. Accordingly, the force is not biased to a part of the packing material 1, and the deformation (distortion) of the packing material 1 can be suppressed.
Still further, in the packing material 1 according to the embodiment described above, the lower surface M11 of the body part M1 of the module M can be supported at a plurality of locations along the longitudinal direction by the plurality of separately provided body part support surfaces 10. In addition, since the body part support walls 20 and the leg portions 40 arranged between the adjacent body part support surfaces 10 are connected by the continuous surface, the rigidity and strength of the packing material 1 can be enhanced.
Still further, in the packing material 1 according to the embodiment described above, since each configuration (body part support surface 10, body part support wall 20, top surface support wall 30, and leg portion 40) is integrally molded, it is easier to manufacture it as compared to connecting separate parts. In addition, since each configuration of the packing material 1 is integrated, it is easy to carry, and it becomes easy to perform packing work and dismantling work.
Still further, in the packing material 1 according to the embodiment described above, the lower surface M1 of the body part M1 of the module M is supported by the body part support surface 10A of the first packing material 1A, while the upper surface M13 of the body part M1 of the module M can be supported by the leg portions 40B of the second packing material 1B, so that the module M can be sandwiched from above and below. Therefore, it is possible to prevent the module M from moving in the vertical direction.
Still further, in the packing material 1 according to the embodiment described above, when the second packing material 1B is loaded on the module M supported by the first packing material 1A, and the leg portions 40B of the second packing material 1B at least partially support the upper surface M13 of the body part M1 of the module M, the second packing material 1B is configured so as not to come into contact with the side surface M21 of the header part M2 of the module M. Therefore, it is possible to prevent the packaging bag covering the side surface M21 of the header part M2 of the module M from being sandwiched between the side surface M21 and the second packing material 1B and becoming wrinkled or damaged. In addition, when a large impact is applied in the vertical direction while the module M is set in the second packing material 1B, it is possible to prevent the side surface M21 of the header part M2 of the module M arranged in the first packing material 1A and the side surface M21 of the header part M2 of the module M arranged in the second packing material 1B from coming into contact via the second packing material 1B and receiving an impact, resulting in damage to them.
Still further, in the packing material 1 according to the embodiment described above, since the area A where the protrusion plug M3 protruding from the side surface M21 of the header part M2 of the module M is accommodated is formed between the first packing material 1A and the second packing material 1B, it is possible to prevent the protrusion plug M3 from being damaged or the packaging bag around the protrusion plug M3 from being damaged by being pressed against the packing material 1 and subjected to the impact.
Still further, in the packing material 1 according to the embodiment described above, since the body part support wall 20 is arranged substantially perpendicular to the flat surface 11 constituting at least a part of the body part support surface 10, it is possible to support the lower surface M11 and both side surfaces M12 of the body part M1 of the module M as if by accommodating the body part M1 of the module M in the box having the bottom surface (flat surface 11 of the body part support surface 10) and the two side surfaces (body part support walls 20) connected substantially perpendicular to the bottom surface.
Still further, in the packing material 1 according to the embodiment described above, a relatively wide portion (one location) of the flat surface portion M221 of the top surface M22 of the header part M2 of the module M, which is below the shaft portion M222, can be at least supported by the top surface support wall 30. Therefore, as compared with the case where a relatively narrow portion (two locations) on the side of the shaft portion M222 of the flat surface portion M221 of the top surface M22 is supported as in the conventional case, the flat surface portion M221 of the top surface M22 can be supported in a wider range. Further, when the header part M2 of the module M is covered with the packaging bag, the top surface M22 of the header part M2 can be supported in a relatively flat state (a state in which wrinkles are difficult to form) of the packaging bag, so that the packaging bag can be prevented from being damaged.
Still further, in the packing material 1 according to the embodiment described above, when the module M is supported by each of the plurality of module support portions 2, the side surfaces M21 of the header parts M2 of the adjacent modules M are configured so as not to come into contact with each other, so that it is possible to prevent in advance a situation in which the packaging bag covering the side surface M21 of the header part M2 of the module M is damaged by contact between the side surfaces M21 of the header parts M2. Further, when a large impact is applied in the left-right direction when the module M is set in the packing material 1, it is possible to prevent the side surface M21 of the header part M2 of the module M and the side surface M21 of the header part M2 of the module M arranged adjacently in the packing material 1 from coming into contact with each other and receiving an impact, resulting in damage to them.
Still further, in the packing material 1 according to the embodiment described above, when the module M is supported by each of the plurality of module support portions 2, no partition wall is provided between the side surfaces M21 of the header parts M2 of the adjacent modules M, so that it is possible to prevent in advance a situation in which the packaging bag covering the side surface M21 of the header part M21 of the module M is damaged by the partition wall. In addition, since the partition wall does not exist, the lateral dimension of the packing material 1 can be shortened, and the module M can be accommodated compactly.
Still further, in the packed body 100 according to the embodiment described above, since it is possible to close the gap G formed between the upper surface M13 of the body part M1 of the module M supported by the packing material 1 and the inner surface B1 of the box B facing the upper surface M13 by the spacer member S, it is possible to suppress the module M from moving in the vertical direction. In addition, when the modules M supported by the packing material 1 are loaded in plural stages, it is possible to suppress even the movement of the whole thereof in the vertical direction.
The present invention is not limited to the above embodiments, and those obtained by appropriately design-changing such embodiments by those skilled in the art are also included in the scope of the present invention insofar as they have the features of the present invention. That is, each element included in the embodiments and its arrangement, material, condition, shape, size, etc. are not limited to those exemplified, and can be appropriately changed. Further, the elements included in the embodiments can be combined as much as technically possible, and the combinations of these are also included in the scope of the present invention insofar as the features of the present invention are included.

Reference Signs List

1: packing material
2: module support portion
10: body part support surface
11: flat surface
20: body part support wall
30: top surface support wall
40: leg portion
50: recess
100: packed body
A: area where protrusion plug of module is accommodated
B: box
B1: inner surface of box
G: gap
L: longitudinal direction of module
M: module
M1: body part
M11: lower surface of body part
M12: side surface of body part
M13: upper surface of body part
M2: header part
M21: side surface of header part
M22: top surface of header part
M221: flat surface portion of top surface of header part
M222: shaft portion of top surface of header part
M3: protrusion plug
S: spacer member
W: width direction of module

Claims

A packing material for packing each of modules each having a cylindrical body part and header parts attached to both ends in a longitudinal direction of the body part into a box, comprising:
body part support surfaces each at least partially supporting a lower surface of the body part of the module in a recumbent state;

body part support walls supporting both side surfaces of the body part of the module in the recumbent state so as to sandwich both side surfaces; and

top surface support walls supporting top surfaces of both of the header parts of the module in the recumbent state,

wherein when each of the modules is supported by the body part support surfaces, the body part support walls, and the top surface support walls, the packing material is configured to be prevented from coming into contact with side surfaces of the header parts.
The packing material according to claim 1, including a leg portion provided so as to protrude downward from the body part support surface,
wherein the leg portion is arranged below the body part of the module.
The packing material according to claim 2, wherein the leg portion is arranged at a substantially central portion in a width direction of the module supported by the body part support surface.
The packing material according to claim 2 or 3, wherein a plurality of the leg portions are provided along a longitudinal direction of the module supported by the body part support surface, and
wherein the leg portions are arranged substantially symmetrically centering on a substantially central portion in the longitudinal direction of the module.
The packing material according to any one of claims 2 to 4, wherein a plurality of the body part support surfaces are provided separately so as to support a plurality of locations along the longitudinal direction of the lower surface of the body part of the module, and
wherein the body part support wall and the leg portion are arranged between the body part support surfaces adjacent to each other and connected by a continuous surface.
The packing material according to any one of claims 2 to 5, wherein the body part support surface, the body part support wall, the top surface support wall, and the leg portion are integrally molded.
The packing material according to any one of claims 2 to 6, wherein when a second packing material is loaded on the module supported by a first packing material, the leg portions of the second packing material are arranged so as to at least partially support an upper surface of the body part of the module.
The packing material according to claim 7, wherein when the second packing material is loaded on the module supported by the first packing material, and the leg portions of the second packing material at least partially support the upper surface of the body part of the module, the second packing material is configured so as to be prevented from coming into contact with the side surface of the header part of the module.
The packing material according to claim 7 or 8, wherein the module has a protrusion plug protruding from the side surface of the header part, and
wherein an area where the protrusion plug is accommodated is formed between the first packing material and the second packing material.
The packing material according to any one of claims 1 to 9, wherein at least a part of the body part support surface is made to be a flat surface, and
wherein the body part support wall is arranged substantially perpendicular to the flat surface.
The packing material according to any one of claims 1 to 10, wherein the top surface of the header part of the module includes a flat surface portion substantially orthogonal to the longitudinal direction of the module and a shaft portion protruding from the flat surface portion along the longitudinal direction of the module, and
wherein the top surface support wall supports at least a portion of the flat surface portion of the top surface, which is below the shaft portion.
The packing material according to any one of claims 1 to 11, including a module support portion having the body part support surface, the body part support wall, and the top surface support wall and supporting the single module,
wherein a plurality of the module support portions are provided so that a plurality of the modules are supported in a state of being arranged in parallel with each other, and

wherein when the module is supported by each of the module support portions, the side surfaces of the header parts of the adjacent modules are configured so as not to come into contact with each other.
The packing material according to claim 12, wherein when the module is supported by each of the module support portions, there is no partition wall between the side surfaces of the header parts of the adjacent modules.
A packed body including the packing material according to any one of claims 1 to 13, and a box accommodating the packing material.
The packed body according to claim 14, including a spacer member which closes a gap formed between the upper surface of the body part of the module supported by the packing material and an inner surface of the box facing the upper surface of the body part.
A module assembly, comprising:
a module having a cylindrical body part and header parts attached to both longitudinal ends of the body part; and

the packing material according to any one of claims 1 to 13.
A method of packing modules each having a cylindrical body part and header parts attached to both longitudinal ends of the body part into a box using the packing material according to any one of claims 1 to 13, comprising the steps of:
at least partially supporting a lower surface of the body part of the module in a recumbent state by the body part support surfaces;

supporting both side surfaces of the body part of the module in the recumbent state so as to sandwich both side surfaces by the body part support walls; and

supporting top surfaces of both of the header parts of the module in the recumbent state by the top surface support walls; and

when each of the modules is supported by the body part support surfaces, the body part support walls, and the top surface support walls of the packing material, preventing the packing material from coming into contact with side surfaces of the header parts.