JP2024008404A - Buffer material and buffer material structure - Google Patents

Abstract

To provide a buffer material and a buffer material structure that have a simple configuration and are easily assembled.SOLUTION: A buffer material 200 is formed by assembling four buffer members 201 containing cellulose fibers FB and having a plate shape, in which the cellulose fibers FB are oriented along a main surface f1 of the buffer member 201, a first buffer member 201a and a third buffer member 201c among the four buffer members 201 are spaced apart from each other and have the respective main surfaces f1 disposed along each other, and a second buffer member 201b and a fourth buffer member 201d are spaced apart from each other and have the respective main surfaces f1 disposed along each other, a rectangular frame shape is shown when viewed in a plan view from a direction along a Z axis, and an article is stored in a region surrounded by the four buffer members 201 in the plan view.SELECTED DRAWING: Figure 7

Description

The present invention relates to a cushioning material and a cushioning material structure.

BACKGROUND ART Cushioning materials for storing items such as fragile items have been known in the past. For example, Patent Document 1 discloses a packaging box including a box-shaped main body and a reinforcing member. Further, Patent Document 2 discloses five types of cushioning materials for holding a liquid crystal television.

JP2009-280269A Japanese Patent Application Publication No. 2013-170001

However, the packaging box described in Patent Document 1 has a problem in that assembly, such as bending and fixing the reinforcing member, requires labor. Furthermore, the cushioning material described in Patent Document 2 has a problem in that the number of parts tends to increase. In other words, there has been a need for a cushioning material that has a simple configuration and is easy to assemble.

The buffer material is assembled from four plate-shaped buffer members containing cellulose fibers, the cellulose fibers are oriented along the main surface of the buffer members, and two of the four buffer members are assembled together. The members are spaced apart from each other and their main surfaces are arranged along each other, the other two buffer members are spaced apart from each other and their main surfaces are arranged along each other, and the four buffer members are spaced apart from each other and their main surfaces are arranged along each other. When viewed in plan from a direction perpendicular to all normal directions of the four main surfaces of the member, the member has a rectangular frame shape, and articles are stored in an area surrounded by the four buffer members in plan view. be done.

The buffer material structure is assembled from four plate-shaped buffer members containing cellulose fibers, the cellulose fibers are oriented along the main surface of the buffer members, and two of the four buffer members are The buffer members are spaced apart from each other and their main surfaces are arranged along each other, and the other two buffer members are spaced apart from each other and their main surfaces are arranged along each other, and the four buffer members are spaced apart from each other and their main surfaces are arranged along each other. When viewed in plan from a direction perpendicular to all the normal directions of the four main surfaces of the buffer member, it has a frame shape, and in the plan view, articles are stored in an area surrounded by the four buffer members. Ru.

FIG. 2 is a perspective view showing the configuration of a sheet applied to the buffer member according to the first embodiment. FIG. 2 is a schematic diagram showing the configuration of a test piece used in a compression test as an example. FIG. 2 is a schematic diagram showing the configuration of a test piece used in a compression test as a comparative example. FIG. 2 is a schematic diagram showing the configuration of a test piece used in a compression test as a comparative example. Graph showing the compressibility-stress curve of each test piece. FIG. 3 is a diagram showing the external appearance of a buffer member. FIG. 3 is a perspective view showing the appearance of a cushioning material. FIG. 3 is a perspective view showing how the cushioning material is used. FIG. 1 is a schematic diagram showing the configuration of a sheet manufacturing device. FIG. 7 is a diagram showing the appearance of a buffer member according to a second embodiment. FIG. 3 is a perspective view showing the appearance of a cushioning material. FIG. 7 is a diagram showing the appearance of a buffer member according to a third embodiment. FIG. 3 is a diagram showing the external appearance of a buffer member. FIG. 3 is a perspective view showing the appearance of a cushioning material.

In the embodiments described below, a buffer member made of recycled paper or the like, a buffer material and a buffer structure formed from the buffer member will be exemplified and explained with reference to the drawings. In each of the following figures, X, Y, and Z axes, which are mutually orthogonal coordinate axes, or any one of them are used as necessary, and the direction pointed by the arrow is defined as the + direction, and the direction opposite to the + direction is defined as the - direction.

Note that the X, Y, and Z directions in FIG. 9 do not necessarily match the X, Y, and Z directions in figures other than FIG. 9. Further, for convenience of illustration, the size of each member is made different from the actual size.

1. First embodiment 1.1. Sheet The cushioning material 200 according to the first embodiment is formed by assembling the cushioning member 201 made from the sheet S. As shown in FIG. 1, the sheet S is a substantially rectangular and plate-shaped member. The sheet S has main surfaces f1 and f2 that face each other, and side surfaces f3, f4, f5, and f6. Side surfaces f3 and f4 are opposite to each other, and side surfaces f5 and f6 are opposite to each other.

Sheet S includes a plurality of cellulose fibers FB. When the sheet S is viewed through the sheet S from the normal direction of the main surfaces f1 and f2, the plurality of cellulose fibers FB are not oriented in a specific direction. On the other hand, when the sheet S is seen through from the normal direction of the side surfaces f3 and f4 and the normal direction of the side surfaces f5 and f6, the plurality of cellulose fibers FB are oriented along the main surfaces f1 and f2. . This orientation state originates from the manufacturing method of the sheet S, which will be described later.

Due to the above-mentioned orientation state, the sheet S has a low buffering performance against external forces acting from the direction substantially normal to the main surfaces f1 and f2, and external forces acting from the direction substantially normal to the side surfaces f3 and f4 or the side surfaces f5 and f6. It has high buffering performance against

Here, the cushioning performance of the sheet S will be explained by showing compression test results. FIG. 2 shows a test piece TP1 as an example used in the compression test. Test piece TP1 was produced from sheet S. In the test piece TP1, the orientation direction DS of the cellulose fibers FB is along the main surface f2 and also along the main surface f1 (not shown). In the compression test, a compression force PW, which is an external force, is applied to the test piece TP1 from the normal direction of the side surface f3.

FIG. 3 shows a test piece TP2 as a comparative example used in the compression test. Test piece TP2 was produced from sheet S. Also in the test piece TP2, the orientation direction DS of the cellulose fibers FB is along the main surface f1. In the compression test, a compressive force PW is applied to the test piece TP2 from the normal direction of the main surface f1.

FIG. 4 shows test piece TP3 as a comparative example used in the compression test. Test piece TP3 was made from expanded polystyrene. In the compression test, a compressive force PW is applied to the test piece TP3 from the normal direction of the principal surface f11.

Although not shown, test piece TP4 was also used as a comparative example of the compression test. The test piece TP4 includes a plurality of cellulose fibers FB like the test piece TP1, but the cellulose fibers FB are not oriented in a specific direction when seen through the four directions described above. That is, in the test piece TP4, a plurality of cellulose fibers FB are randomly dispersed. The test piece TP4 was produced from a sheet having a lower density than the sheet S so that the orientation direction of the cellulose fibers FB was dispersed using a sheet manufacturing apparatus for the sheet S described later.

The test pieces TP1, TP2, TP3, and TP4 are approximately cubic in shape and have similar external dimensions. The test pieces TP1 and TP2 have a density of 0.15 g/cm ³ , a cellulose fiber FB content of 70% by mass, and a binder and additive content of 30% by mass. Test piece TP4 has a density of 0.09 g/cm ³ , a cellulose fiber FB content of 67% by mass, and a binder and additive content of 33% by mass.

Each of the above test pieces was subjected to a compression test in accordance with JIS K 7181 to measure the relationship between compression ratio and stress. The results are shown in FIG. In FIG. 5, the horizontal axis shows the compressibility, and the vertical axis shows the stress (MPa). The compression ratio is a value expressed as a percentage of the distance that each test piece is compressed in the direction of action of compressive force PW by compressive force PW with respect to the thickness of each test piece in the direction of action of compressive force PW. Stress is the reaction force of each specimen against the compressive force PW.

As shown in FIG. 5, in the test pieces TP2 and TP4, the stress increases relatively significantly as the compression ratio increases. This is because the surface pressed by the compressive force PW collapses, thereby increasing the density of the inside.

On the other hand, in test pieces TP1 and TP3, the increase in stress is relatively small with respect to the increase in compressibility. This is because even if the surface pressed by the compressive force PW collapses, it is difficult for the inside to become denser. That is, the test pieces TP1 and TP3 deform when compressive force PW such as an impact is applied from the outside, but have a characteristic that stress is difficult to increase in the process of deformation.

This revealed that the test piece TP1 of the example had better buffering performance than the test pieces TP2 and TP4 of the comparative example. Furthermore, it was found that the test piece TP1 had a cushioning performance comparable to that of the test piece TP3 made of expanded polystyrene, which is widely recognized as a shock absorbing member. From the above, it was shown that the sheet S shown in FIG. 1 has excellent buffering performance against external forces acting from directions intersecting the side surfaces f3, f4, f5, and f6.

1.2. Buffer member A buffer member 201 made from sheet S will be described. The buffer material 200 includes four buffer members 201. As shown in FIG. 6, the buffer member 201 is approximately rectangular and plate-shaped. Here, in FIG. 6, the buffer member 201 on the left is viewed from the side in the direction normal to the main surface f1, and the buffer member 201 on the right is viewed from the side in the direction normal to the side surface f5. Indicates the condition. In the buffer member 201, the main surfaces f1 and f2 coincide with the same surface of the sheet S. Further, side surfaces f3, f4, f5 of the buffer member 201 and a side surface f6 (not shown) are surfaces that coincide with or are parallel to the same surface of the sheet S.

Although not shown, the buffer member 201 includes a plurality of cellulose fibers FB similarly to the sheet S. The plurality of cellulose fibers FB are oriented along the main surfaces f1 and f2 of the buffer member 201. The cushioning material 200 is formed by assembling four cushioning members 201.

The four buffer members 201 have the same shape. Specifically, each buffer member 201 includes a first notch 211a on the first side E1, and a second notch 211b on the second side E2 opposing along the first side E1.

The first notch 211a and the second notch 211b are approximately rectangular notches. The first notch portion 211a and the second notch portion 211b are arranged diagonally in the buffer member 201 when viewed from the side in the direction normal to the main surface f1. That is, the buffer member 201 has a rectangular shape with the upper left and lower right diagonal portions cut out into rectangular shapes. The long side of the rectangle is along the Z axis.

In the first notch portion 211a and the second notch portion 211b, the width corresponding to the short side of the rectangle, that is, the width A perpendicular to the first side E1 or the second side E2 is equal to or less than the thickness B of the buffer member 201. It is. Further, in the direction along the Z axis, which is the direction along the first side E1 and the second side E2, the sum of the depth L1 of the first notch 211a and the depth L2 of the second notch 211b is: The length of the buffer member 201 in the direction along the Z axis is equal to or less than K. Here, the depth L1 corresponds to the length of the long side of the rectangle of the first notch 211a, and the depth L2 corresponds to the length of the long side of the rectangle of the second notch 211b. Equivalent to.

This makes it difficult for the assembled cushioning material 200 to come apart, making it easier to maintain its shape. Assembly of the cushioning material 200 will be described later.

In addition, in the buffer member 201, the arrangement, shape, etc. of the first notch portion 211a and the second notch portion 211b are not limited to the above configuration. Further, the thickness B, length K, length of the side adjacent to the first side E1 and the second side E2, etc. of the buffer member 201 may be changed as appropriate depending on the size and shape of the article stored in the buffer member 200. Ru. Although not particularly limited, the thickness B is, for example, about 10 mm.

1.3. Cushioning Material As shown in FIG. 7, the cushioning material 200 is formed by assembling four cushioning members 201, a first buffering member 201a, a second buffering member 201b, a third buffering member 201c, and a fourth buffering member 201d. It has the cushioning material structure described below. As described above, the first buffer member 201a, the second buffer member 201b, the third buffer member 201c, and the fourth buffer member 201d have the same shape.

Among the four buffer members 201, two buffer members 201, the first buffer member 201a and the third buffer member 201c, are arranged apart from each other in the direction along the Y-axis. The main surfaces f1 and f2 of each of the first buffer member 201a and the third buffer member 201c are along the XZ plane and mutually.

Among the four buffer members 201, the other two buffer members 201, the second buffer member 201b and the fourth buffer member 201d, are arranged apart from each other in the direction along the X-axis. The main surfaces f1 and f2 of each of the second buffer member 201b and the fourth buffer member 201d are along the YZ plane and mutually.

In the buffer material 200, the first buffer member 201a, the second buffer member 201b, the third buffer member 201c, and the fourth buffer member 201d are assembled as follows. The first buffer member 201a and the second buffer member 201b are such that the second notch 211b of the first buffer member 201a and the first notch 211a of the second buffer member 201b fit into each other, and the main surfaces of each f1 are orthogonal.

The second buffer member 201b and the third buffer member 201c are such that the second notch 211b of the second buffer member 201b and the first notch 211a (not shown) of the third buffer member 201c fit into each other. The main surfaces f1 are orthogonal. Although not shown, the third buffer member 201c and the fourth buffer member 201d are such that the second notch 211b of the third buffer member 201c and the first notch 211a of the fourth buffer member 201d fit into each other. However, each main surface f1 is orthogonal to each other. The fourth buffer member 201d and the first buffer member 201a are such that a second notch 211b (not shown) of the fourth buffer member 201d and a first notch 211a of the first buffer member 201a fit into each other. The main surfaces f1 are orthogonal.

The cushioning material 200 has a rectangular frame shape when viewed in plan from a direction perpendicular to all normal directions of the four principal surfaces f1 of the four cushioning members 201, that is, from a direction along the Z axis. In the cushioning material 200, an article (not shown) is stored in a region 200p surrounded by the four cushioning members 201. Note that the cushioning material of the present invention is not limited to being rectangular in plan view, but may be triangular or polygonal, for example. In this case, the number of buffer members 201 is increased or decreased depending on the shape.

Items stored in the cushioning material 200 include, for example, fragile items such as ceramics, porcelain, and glassware, as well as information terminal devices such as wristwatches, laptop computers, small game consoles, smartphones, printers, and projectors, precision parts, and models. , home appliances, and fruits and vegetables.

Cushioning material 200 can be considered as a cube. Therefore, a plurality of cushioning materials 200 may be stacked and placed, or a plurality of cushioning materials 200 may be packed together, with articles stored in the area 200p.

The cushioning material 200 has a surface other than the main surfaces f1 and f2, that is, one of the above-mentioned side surfaces f5 and f6, facing the direction along the X-axis and the Y-axis. Therefore, when an external force acts on the cushioning material 200 from a direction substantially along the X-axis and the Y-axis, it is possible to receive the external force at either side f5 or f6.

In addition, the cushioning material 200 has one of the above-mentioned side surfaces f3 and f4 facing in the direction along the Z-axis. Therefore, when an external force acts on the cushioning material 200 from a direction substantially along the Z-axis, it is possible to receive the external force at either side f3 or f4. As described above, the cushioning material 200 protects the articles stored in the region 200p due to the above-mentioned cushioning performance against external forces acting from directions substantially along each of the XYZ axes.

As shown in FIG. 8, the cushioning material 200 may be removably housed in an outer box 290. Thereby, the articles stored in the area 200p of the cushioning material 200 can be prevented from being soiled. Moreover, handling and storage of the cushioning material 200 containing articles can be facilitated. For the outer box 290, materials such as cardboard, cardboard, and resin are applied.

When the cushioning material 200 is housed in the outer box 290, it is preferable that the outer dimensions of the cushioning material 200 match the inner diameter dimensions of the outer box 290. Thereby, the cushioning material 200 can be steadily stored in the outer box 290.

1.4. Sheet Manufacturing Apparatus A method for manufacturing the sheet S and the buffer member 201 will be described together with the configuration of the sheet manufacturing apparatus 1. In the following description of the sheet manufacturing apparatus 1, the end of the raw material, web, etc. in the conveyance direction is sometimes referred to as downstream, and the side that goes back in the conveyance direction is sometimes referred to as upstream. Note that the manufacturing method of the sheet S and the buffer member 201 and the sheet manufacturing apparatus 1 described below are merely examples, and the present invention is not limited thereto.
As shown in FIG. 9, the sheet manufacturing apparatus 1 includes, from upstream to downstream, a material supply section 5, a coarse crushing section 10, a defibrating section 30, a pipe 40, a supply member 42, a forming section 100, and a web conveyance section. 70, a molding section 150, and a cutting section 160. Note that in the following description regarding FIG. 9, the +Z direction is sometimes referred to as upward, and the -Z direction is sometimes referred to as downward.

The sheet manufacturing apparatus 1 includes a control section 28 that integrally controls the operation of each of the above components. The sheet manufacturing apparatus 1 manufactures a sheet S, which is a sheet-shaped molded body. The thickness of the sheet S is not particularly limited, as long as the cushioning member 201 made from the sheet S exhibits cushioning performance. The thickness of the sheet S and the buffer member 201 is, for example, about 10 mm. The thickness here is the distance in the direction along the Z axis in FIG.

The material supply section 5 supplies the raw material C to the coarse crushing section 10 . The material supply section 5 is equipped with an automatic feeding mechanism, and continuously and automatically feeds the raw material C into the coarse crushing section 10. Raw material C is a material containing the above-mentioned cellulose fiber FB. Examples of materials containing cellulose fibers FB include waste paper such as paper and cardboard, pulp, pulp sheets, sawdust, wood waste, wood, and fabric.

By defibrating such raw material C in a defibrating section 30 described later, cellulose fibers FB are obtained as a defibrated product. Cellulose fiber FB is a fiber contained in plant fibers such as wood, and is a carbohydrate. Cellulose fiber FB is one of the main components of the sheet S manufactured by the sheet manufacturing apparatus 1. The sheet S may contain synthetic fibers such as polypropylene, polyester, and polyurethane in addition to the cellulose fibers FB. From the viewpoint of reducing environmental load, it is preferable to use fibers derived from natural products such as cellulose fiber FB. Hereinafter, the cellulose fibers FB and the like applied to the sheet S will be collectively referred to as simply fibers.

The crushing section 10 shreds the raw material C supplied from the material supply section 5 in air such as the atmosphere. The coarse crushing section 10 has a coarse crushing blade 11. The coarse crushing section 10 is, for example, a shredder or a cutter mill. The raw material C is shredded into small pieces by the crushing blade 11. The planar shape of the strip is, for example, several mm square or irregular. The pieces are collected in a quantitative supply section 50.

The metered material supply section 50 measures and supplies the strips to the hopper 12 at a constant rate. The quantitative material supply section 50 is, for example, a vibration feeder. The fine pieces supplied to the hopper 12 are conveyed to the inlet 31 of the defibrating section 30 via the pipe 20.

The defibrating section 30 includes an inlet 31, an outlet 32, a stator 33, and a rotor 34. The defibrating section 30 defibrates the pieces of the raw material C in a dry manner to generate fibers. The pieces of raw material C are introduced into the defibrating section 30 through the inlet 31 by suction airflow from the blowing section 41, which will be described later. Note that in this specification, dry method means that the method is not performed in a liquid, but is performed in air such as the atmosphere.

The stator 33 and the rotor 34 are arranged inside the defibrating section 30. The stator 33 has a substantially cylindrical inner surface. The rotor 34 rotates along the inner surface of the stator 33. The pieces of raw material C are sandwiched between the stator 33 and the rotor 34, and are defibrated into fibers by the shear force generated between them. The fibers are sucked out into the tube 40 from the outlet 32 of the defibrating section 30 by the suction airflow.

The fibers produced by fibrillation preferably have a fiber length of 1.0 mm or more. According to this, the mechanical strength of the sheet S is improved because the fibers are not excessively shortened. The fiber length is determined by a method based on ISO 16065-2:2007.

The pipe 40 communicates with the inside of the defibrating section 30 and the inside of the supply member 42 . The pipe 40 is provided with a mixing section 60 and a blowing section 41 . The mixing section 60 is arranged upstream of the blowing section 41. The pipe 40 supplies a mixture containing fibers, which will be described later, to the supply member 42 by means of a downstream airflow generated by the blowing section 41 .

Mixing section 60 includes hoppers 13 and 14, supply pipes 61 and 62, and valves 65 and 66. The mixing unit 60 mixes a binder and an additive into materials such as fibers that are conveyed through the air in the pipe 40 . This produces a mixture.

Hopper 13 feeds binding material into tube 40 . Hopper 13 communicates with the inside of tube 40 via supply tube 61. In the supply pipe 61, a valve 65 is arranged between the hopper 13 and the pipe 40. Valve 65 regulates the weight of binder supplied from hopper 13 to tube 40 . A valve 65 adjusts the mixing ratio of fibers and binder. The binding material may be supplied as a powder or may be supplied in a molten state.

The binder binds the fibers together. A thermoplastic or thermosetting resin is used as the bonding material. Examples of resins include shellac, pine resin, dammar, polylactic acid, plant-derived polybutylene succinate, plant-derived polyethylene, and Kaneka's PHBH (registered trademark) (Poly (3-hydroxybutyrate-co-3-hydroxyhexanoate)). Examples include resins derived from natural products such as, and known synthetic resins. As the binding material, one of these types may be used alone or two or more types may be used in combination. From the viewpoint of reducing environmental load, the binding material is preferably a resin derived from a natural product.

Hopper 14 supplies additive into tube 40 . Hopper 14 communicates with the interior of tube 40 via supply tube 62 . In the supply pipe 62, a valve 66 is located between the hopper 14 and the pipe 40. Valve 66 regulates the weight of additive fed into tube 40 from hopper 14 . A valve 66 adjusts the mixing ratio of additives to fibers and binder.

Examples of additives include colorants, flame retardants, antioxidants, ultraviolet absorbers, aggregation inhibitors, antibacterial agents, fungicides, waxes, and mold release agents. Note that the additive is not an essential component in the sheet S, and the hopper 14, supply pipe 62, etc. may be omitted. Alternatively, the additive may be mixed with the binder in advance and supplied from the hopper 13.

The blower section 41 is, for example, an airflow generating device such as a blower. The blower section 41 conveys the material containing fibers to the downstream pipe 40 by means of a downstream airflow. The blower section 41 generates a suction airflow that sucks the fibers from the defibration section 30 in addition to the above-mentioned airflow. The volumetric flow rate of the airflow heading downstream of the blowing section 41 is controlled by the control section 28 . The volume flow rate can be changed by, for example, the rotation speed of the blower fan included in the blower section 41.

The fibers, binder, etc. are mixed while being conveyed through the tube 40 to the supply member 42 to form a mixture. The mixture is introduced into a feed member 42 that connects the downstream end of the tube 40 and the forming section 100.

The supply member 42 arranges the flow of the mixture supplied from the pipe 40 and guides it to the forming section 100. The supply member 42 is connected to the dispersion section 101 of the forming section 100. Specifically, the inside of the supply member 42 communicates with the inside of the drum section 101b of the dispersion section 101. Thereby, the mixture flows from the supply member 42 into the drum section 101b.

The forming section 100 forms a web W by depositing a mixture containing fibers, a binder, and the like in the air. The web W has a wide band shape in the direction along the Y axis. The forming section 100 has a dispersion section 101 and a deposition section 102. The dispersion section 101 is arranged inside the deposition section 102 . The interior of the dispersion section 101 communicates with the pipe 40 via the supply member 42 . A web conveyance section 70 is arranged below the deposition section 102 .

The dispersion section 101 includes a rotating member 101a and a drum section 101b that accommodates the rotating member 101a. The forming section 100 takes the mixture from the supply member 42 into the dispersion section 101 and deposits it on the mesh belt 122 of the web conveyance section 70 in a dry manner.

Specifically, the rotating member 101a is a member that includes +-shaped blades when viewed from the side in the -Y direction. The rotating member 101a is driven by a motor or the like and rotates around a rotation axis along the Y-axis.

The drum portion 101b is a substantially columnar member, and the height direction of the substantially columnar shape is along the Y axis. The lower part of the drum part 101b is formed of metal mesh. The mesh of the metal mesh allows fibers, binders, etc. contained in the mixture to pass through.

A mixture (not shown) is introduced into the drum section 101b and loosened by the rotating rotating member 101a. The plurality of fibers in the mixture are untangled and separated into individual fibers, which then pass through the mesh of the drum portion 101b. Thereby, the dispersion section 101 disperses the fibers, binder, etc. contained in the mixture into the air within the deposition section 102 .

The deposition section 102 is a substantially box-shaped member. The deposition section 102 is arranged below the dispersion section 101. In the deposition section 102, the supply member 42 is arranged above the top surface, and the dispersion section 101 is arranged inside the top surface. A region corresponding to the bottom surface of the deposition section 102 is open downward. The dispersion section 101 is located within the deposition section 102 and faces the upper surface of the mesh belt 122 of the web conveyance section 70 . The deposition section 102 is made of, for example, resin or metal.

The mixture is discharged from inside the dispersion section 101 into the air in the deposition section 102 and guided above the mesh belt 122 by gravity and the suction force of the suction mechanism 110 . Therefore, the mixture is deposited on the upper surface of the mesh belt 122 via the first base material N1, which will be described later. That is, the deposition unit 102 forms the web W by depositing a mixture containing dispersed fibers.

With the above configuration, a plurality of fibers in the web W are oriented along the XY plane. That is, the basis of the orientation state of the sheet S is formed in which the plurality of fibers are aligned along the main surfaces f1 and f2 described above.

The web conveyance section 70 includes a mesh belt 122 and a suction mechanism 110. The mesh belt 122 is an endless belt, and is stretched by four tension rollers 121.

The mesh belt 122 has enough strength to hold the web W and the like without interfering with suction by the suction mechanism 110. The mesh belt 122 is made of metal or resin, for example. The mesh hole diameter of the mesh belt 122 is not particularly limited, but is preferably 60 μm or more and 125 μm or less.

At least one of the four tension rollers 121 is rotationally driven by a motor (not shown). The upper surface of the mesh belt 122 moves downstream as the tension roller 121 rotates. In other words, the mesh belt 122 rotates clockwise in FIG. 9 . As the mesh belt 122 rotates, a first base material N1 and a web W, which will be described later, are conveyed downstream.

A base material supply section 71 is arranged in the -X direction of the web conveyance section 70. The base material supply unit 71 rotatably supports a roll-shaped first base material N1. The first base material N1 is continuously supplied from the base material supply section 71 to the upper surface of the mesh belt 122.

The web W is sandwiched between the first base material N1 and a second base material N2, which will be described later. For example, a woven fabric or a nonwoven fabric is applied to the first base material N1 and the second base material N2. It is preferable that the first base material N1 has a structure that does not hinder the suction of the suction mechanism 110. For example, a polyester long fiber nonwoven fabric manufactured by a spunbond method is applied to the first base material N1 and the second base material N2.

Since the sheet S is formed by laminating the first base material N1, the web W, and the second base material N2, the mechanical strength is improved. Note that in the sheet S, the first base material N1 and the second base material N2 are not essential components, and either one or both may be omitted.

When the base material supply unit 71 supplies the first base material N1 to the mesh belt 122, the first base material N1 is conveyed on the mesh belt 122 in the +X direction. While the first base material N1 is being conveyed, the mixture descends from the deposition section 102 and is deposited on the upper surface. Thereby, the web W is continuously formed on the upper surface of the first base material N1. The mesh belt 122 conveys the web W together with the first base material N1 downstream.

The suction mechanism 110 is arranged below the dispersion section 101. Suction mechanism 110 facilitates deposition of the mixture onto mesh belt 122. The suction mechanism 110 sucks air in the deposition section 102 through the mesh belt 122 and the plurality of holes in the first base material N1. The plurality of holes in the mesh belt 122 and the first base material N1 allow air to pass through, but it is difficult for fibers, binding materials, etc. contained in the mixture to pass therethrough. The mixture discharged from the dispersion section 101 into the deposition section 102 is sucked downward together with air. The suction mechanism 110 employs a known suction device such as a blower.

Thereby, the mixture in the deposition section 102 is deposited on the upper surface of the first base material N1 by the suction force of the suction mechanism 110 in addition to gravity, and becomes the web W. The web W contains a relatively large amount of air and is soft and swollen. The web W is conveyed downstream together with the first base material N1 by the mesh belt 122.

A humidifying section 139 is provided in the +X direction of the depositing section 102 at a position facing the web W above the mesh belt 122. The humidifier 139 sprays water onto the web W on the mesh belt 122 to humidify it. This suppresses scattering of fibers, binding materials, etc. contained in the web W. Alternatively, a water-soluble additive or the like may be included in the water used for humidification, and the web W may be impregnated with the additive in parallel with humidification.

A dancer roller 141 is arranged downstream of the web conveyance section 70. After the web W is peeled off from the tension roller 121 on the most downstream side, it is drawn into the dancer roller 141. The dancer roller 141 secures machining time downstream. Specifically, the molding in the molding section 150 is a batch process. Therefore, the dancer roller 141 is moved up and down to delay the time for the web W continuously conveyed from the deposition section 102 to reach the forming section 150.

A base material supply section 72 is arranged downstream of the dancer roller 141 and upstream of the forming section 150. The base material supply unit 72 rotatably supports a roll-shaped second base material N2. The second base material N2 is continuously supplied to the upper surface of the web W from the base material supply section 72. Thereby, the web W is sent out to the forming section 150 while being sandwiched between the lower first base material N1 and the upper second base material N2.

The molding section 150 is a hot press device and includes an upper substrate 152 and a lower substrate 151. The molding unit 150 molds the first base material N1, the web W, and the second base material N2 into a continuous form sheet S. The upper substrate 152 and the lower substrate 151 are pressurized with the web W sandwiched therebetween, and are heated by a built-in heater.

The web W is compressed from above and below by pressure to increase its density, and the binding material is melted by heating and spreads between the fibers. When heating is completed in this state and the binding material is solidified, the fibers are bonded to each other by the binding material. As a result, a continuous document-like sheet S consisting of three layers of the first base material N1, the web W, and the second base material N2 is formed. At this time, the orientation state of the sheet S is fixed. The continuous form sheet S advances to the downstream cutting section 160.

In addition, in the molding section 150, molding may be continuously performed using a heating roller and a pressure roller instead of the heating press device. In this case, the dancer roller 141 may be omitted.

The cutting unit 160 cuts the sheet S from a continuous form into a single form. Although not shown, the cutting section 160 includes a vertical blade and a horizontal blade. The vertical blade and the horizontal blade are, for example, a rotary cutter. Further, an ultrasonic cutter or the like may be used instead of the rotary cutter.

The vertical blade cuts the continuous form sheet S in a direction parallel to the traveling direction. The horizontal blade cuts the continuous form sheet S in a direction intersecting the traveling direction. The sheet S is processed into a substantially rectangular cut and stored in the tray 170. The sheet S is manufactured through the above steps.

The sheet manufacturing apparatus 1 may have a processing unit (not shown) downstream of the cutting section 160 or the tray 170. The processing unit forms the first notch 211a and the second notch 211b in the cut-shaped sheet S. For example, a wheel cutter, a partial cutter, a Thomson type (BIKU type), etc. are applied to the processing section. Note that the buffer member 201 may be manufactured from the sheet S using another device.

According to this embodiment, the following effects can be obtained.

The cushioning material 200 has a simple configuration and is easy to assemble. Specifically, since the four buffer members 201 are assembled, the labor required for assembly is reduced compared to the conventional one. In addition, the structure is simpler and has fewer parts than before. With these, it is possible to provide the cushioning material 200 and the cushioning material structure with a simple configuration and easy assembly.

Since the four buffer members 201 have the same shape, they can be made into one type of component and can be made common. Furthermore, since the first notch 211a and the second notch 211b are assembled by fitting together, positional displacement is less likely to occur, and the cushioning material 200 can be assembled steadily.

2. Second Embodiment A cushioning material 300 according to a second embodiment is formed by assembling cushioning members 301 made from the sheet S described above. In the cushioning material 300 of this embodiment, a cushioning member 301 having a different shape from the cushioning member 201 is applied to the cushioning material 200 of the first embodiment. In the following description, configurations that are different from the first embodiment will be described, and configurations that overlap with the first embodiment will be omitted.

The buffer material 300 includes four buffer members 301. As shown in FIG. 10, the buffer member 301 is plate-shaped and approximately rectangular. Here, in FIG. 10, the buffer member 301 on the left is viewed from the side in the direction normal to the main surface f1, and the buffer member 301 on the right is viewed from the side in the direction normal to the side surface f5. Indicates the condition. In the buffer member 301, the main surfaces f1 and f2 coincide with the same surface of the sheet S. Further, side surfaces f3, f4, f5 of the buffer member 301 and a side surface f6 (not shown) are surfaces that coincide with or are parallel to the same surface of the sheet S.

The buffer material 300 is formed by assembling four buffer members 301. The four buffer members 301 have the same shape. Specifically, each buffer member 301 includes a concave portion 311a on the first side E1, and a convex portion 311b on the second side E2 opposing along the first side E1.

The concave portion 311a and the convex portion 311b have shapes that can be fitted into each other and are arranged at corresponding positions. Specifically, the concave portion 311a and the convex portion 311b are arranged to face each other in a direction orthogonal to the first side E1 and the second side E2 when the main surface f1 is viewed from the side from the normal direction. The concave portion 311a and the convex portion 311b are arranged approximately at the center of the first side E1 or the second side E2 in the direction along the Z axis. The concave portion 311a is a substantially rectangular depression, and the convex portion 311b is a substantially rectangular protrusion. The depression and the protrusion have shapes that overlap in a plane.

The width A1 of the concave portion 311a in the direction orthogonal to the first side E1 is approximately equal to the width A2 of the convex portion 311b in the direction orthogonal to the second side E2. Although not shown, the length of the concave portion 311a along the first side E1 and the length of the convex portion 311b along the second side E2 are approximately equal. Note that in the buffer member 301, the arrangement, shape, etc. of the recess 311a and the projection 311b are not limited to the above configuration.

As shown in FIG. 11, the buffer material 300 is made up of four buffer members 301, a first buffer member 301a, a second buffer member 301b, a third buffer member 301c, and a fourth buffer member 301d. It has the cushioning material structure described in . As described above, the first buffer member 301a, the second buffer member 301b, the third buffer member 301c, and the fourth buffer member 301d have the same shape.

Among the four buffer members 301, two buffer members 301, the first buffer member 301a and the third buffer member 301c, are arranged apart from each other in the direction along the Y-axis. The main surfaces f1 and f2 of each of the first buffer member 301a and the third buffer member 301c are along the XZ plane and mutually.

Among the four buffer members 301, the other two buffer members 301, the second buffer member 301b and the fourth buffer member 301d, are arranged apart from each other in the direction along the X-axis. The main surfaces f1 and f2 of each of the second buffer member 301b and the fourth buffer member 301d are along the YZ plane and mutually.

In the buffer material 300, the first buffer member 301a, the second buffer member 301b, the third buffer member 301c, and the fourth buffer member 301d are assembled as follows. In the first buffer member 301a and the second buffer member 301b, the convex portion 311b of the first buffer member 301a and the concave portion 311a of the second buffer member 301b fit into each other, and their main surfaces f1 are orthogonal to each other.

In the second buffer member 301b and the third buffer member 301c, the convex portion 311b of the second buffer member 301b and the recess 311a of the third buffer member 301c fit into each other, and their main surfaces f1 are perpendicular to each other. Although illustration is omitted, the third buffer member 301c and the fourth buffer member 301d are such that the convex portion 311b of the third buffer member 301c and the concave portion 311a of the fourth buffer member 301d fit into each other, and the respective main surfaces f1 are orthogonal. In the fourth buffer member 301d and the first buffer member 301a, the convex portion 311b of the fourth buffer member 301d and the recess 311a of the first buffer member 301a fit into each other, and their main surfaces f1 are perpendicular to each other.

The buffer material 300 has a rectangular frame shape when viewed in plan from a direction perpendicular to all normal directions of the four main surfaces f1 of the four buffer members 301, that is, from a direction along the Z axis. In the cushioning material 300, an article (not shown) is stored in a region 300p surrounded by the four cushioning members 301.

The cushioning material 300 has a surface other than the main surfaces f1 and f2, that is, one of the above-mentioned side surfaces f5 and f6, facing the direction along the X-axis and the Y-axis. Therefore, when an external force acts on the cushioning material 300 from a direction substantially along the X-axis and the Y-axis, it is possible to receive the external force at either side f5 or f6.

Furthermore, the cushioning material 300 has either of the above-mentioned side surfaces f3 and f4 facing in the direction along the Z-axis. Therefore, when an external force acts on the cushioning material 300 from a direction substantially along the Z-axis, it is possible to receive the external force at either side f3 or f4. As described above, the cushioning material 300 protects the articles stored in the region 300p due to the above-described cushioning performance against external forces acting from directions substantially along each of the XYZ axes.

According to this embodiment, effects similar to those of the first embodiment can be obtained.

3. Third Embodiment A cushioning material 400 according to a third embodiment is formed by assembling cushioning members 401 made from the sheet S described above. In the cushioning material 400 of this embodiment, cushioning members 401a and 401b having different shapes from the cushioning member 201 are applied to the cushioning material 200 of the first embodiment. In the following description, configurations that are different from the first embodiment will be described, and configurations that overlap with the first embodiment will be omitted.

The buffer material 400 includes four buffer members 401. The four buffer members 401 are composed of two types of buffer members 401a and 401b. The buffer member 401a includes a first buffer member 401a1 and a third buffer member 401a2, which will be described later. The buffer member 401b includes a second buffer member 401b1 and a fourth buffer member 401b2, which will be described later.

As shown in FIG. 12, the buffer member 401a is plate-shaped and approximately rectangular. Here, in FIG. 12, the left buffer member 401a is shown in a side view from the normal direction of the main surface f1, and the right buffer member 401a is shown in a side view from the normal direction to the side surface f5. Indicates the condition. In the buffer member 401a, the main surfaces f1 and f2 coincide with the same surface of the sheet S. Further, side surfaces f3, f4, f5 of the buffer member 401a and a side surface f6 (not shown) are surfaces that coincide with or are parallel to the same surface of the sheet S.

The buffer member 401a, that is, the first buffer member 401a1 and the third buffer member 401a2, includes a first recess 411a on a first side E1, and a second recess 411b on a second side E2 opposing along the first side E1. have the same shape.

Specifically, the first recess 411a and the second recess 411b are arranged to face each other in a direction orthogonal to the first side E1 and the second side E2 when the main surface f1 is viewed from the side in the normal direction. The first recess 411a and the second recess 411b are arranged approximately at the center of the first side E1 or the second side E2 in the direction along the Z axis. The first recess 411a and the second recess 411b are approximately rectangular depressions.

The width A1 of the first recess 411a in the direction orthogonal to the first side E1 is approximately equal to the width A2 of the second recess 411b in the direction orthogonal to the second side E2. The widths A1 and A2 are less than or equal to the thickness B of the buffer member 401a. Although not shown, the length of the first recess 411a along the first side E1 and the length of the second recess 411b along the second side E2 are approximately equal. In addition, in the buffer member 401a, the length of the area other than the first recess 411a and the second recess 411b in the direction along the main surface f1 and perpendicular to the Z axis is defined as length M. The length M is equal to the length of the long side of the buffer member 401a.

As shown in FIG. 13, the buffer member 401b is plate-shaped and approximately rectangular. Here, in FIG. 13, the buffer member 401b on the left is viewed from the side in the direction normal to the main surface f1, and the buffer member 401b on the right is viewed from the side in the direction normal to the side surface f5. Indicates the condition. In the buffer member 401b, the principal surfaces f1 and f2 coincide with the same surface of the sheet S. Further, side surfaces f3, f4, f5 of the buffer member 401b and a side surface f6 (not shown) are surfaces that coincide with or are parallel to the same surface of the sheet S.

The buffer members 401b, that is, the second buffer member 401b1 and the fourth buffer member 401b2, include a first convex portion 411c on the third side E3, and a second convex portion 411d on the fourth side E4 opposing along the third side E3. have the same shape.

Specifically, the first convex portion 411c and the second convex portion 411d are arranged to face each other in a direction orthogonal to the third side E3 and the fourth side E4 when the main surface f1 is viewed from the side from the normal direction. The first convex portion 411c and the second convex portion 411d are arranged approximately at the center of the third side E3 or the fourth side E4 in the direction along the Z axis. The first convex portion 411c and the second convex portion 411d are approximately rectangular extensions. The recess of the buffer member 401a and the protrusion of the buffer member 401b have shapes that overlap in a plan view.

The width A3 of the first convex portion 411c in the direction perpendicular to the third side E3 and the width A4 of the second convex portion 411d in the direction perpendicular to the fourth side E4 are approximately equal. The widths A3 and A4 are less than or equal to the thickness B of the buffer member 401b. Although not shown, the length of the first convex portion 411c along the third side E3 and the length of the second convex portion 411d along the fourth side E4 are approximately equal, and the first side of the first concave portion 411a described above The length along E1 and the length along the second side E2 of the second recess 411b are also approximately equal.

In the buffer member 401b, the length M from the tip of the first convex portion 411c to the tip of the second convex portion 411d in the direction along the main surface f1 and perpendicular to the Z axis is equal to the length M in the buffer member 401a described above. be equivalent to. Here, the arrangement, shape, etc. of the first concave portion 411a and the second concave portion 411b of the buffer member 401a, and the first convex portion 411c and the second convex portion 411d of the buffer member 401b are not limited to the above configuration.

As shown in FIG. 14, the buffer material 400 is made up of four buffer members 401, a first buffer member 401a1, a second buffer member 401b1, a third buffer member 401a2, and a fourth buffer member 401b2. It has the cushioning material structure described in .

The first buffer member 401a1 and the third buffer member 401a2, which are the two buffer members 401a, are arranged apart from each other in the direction along the Y-axis. The main surfaces f1 and f2 of the first buffer member 401a1 and the third buffer member 401a2 are along the XZ plane.

The second buffer member 401b1 and the fourth buffer member 401b2, which are the two buffer members 401b, are arranged apart from each other in the direction along the X-axis. The main surfaces f1 and f2 of the second buffer member 401b1 and the fourth buffer member 401b2 are along the YZ plane.

When the buffer material 400 is assembled, the first side E1 of the first buffer member 401a1 and the third side E3 of the second buffer member 401b1 are arranged along each other. Further, in the direction along the first side E1, that is, the direction along the Z axis, the first recess 411a, the second recess 411b, the first projection 411c, and the second projection 411d are arranged correspondingly.

Specifically, the second recess 411b of the first buffer member 401a1 and the first protrusion 411c of the second buffer member 401b1 fit into each other. The second convex portion 411d of the second buffer member 401b1 and the first recess 411a of the third buffer member 401a2 fit into each other. A second concave portion 411b (not shown) of the third buffer member 401a2 and a first convex portion 411c (not shown) of the fourth buffer member 401b2 fit into each other. The second convex portion 411d of the fourth buffer member 401b2 and the first recess 411a of the first buffer member 401a1 fit into each other. Thereby, the cushioning material 400 is assembled.

Articles are stored in a region 400p surrounded by the first buffer member 401a1, the second buffer member 401b1, the third buffer member 401a2, and the fourth buffer member 401b2.

According to this embodiment, the following effects can be obtained.

The cushioning material 400 has a simple configuration and is easy to assemble. Specifically, since the two buffer members 401a and the two buffer members 401b are assembled, the labor required for assembly is reduced compared to the conventional case. Furthermore, the structure is simpler and has fewer parts than before. As a result, it is possible to provide a cushioning material 400 and a cushioning material structure that have a simple configuration and are easy to assemble.

There are only two types of parts, and the number of types can be reduced compared to the conventional method. In addition, since it is assembled by fitting, it is difficult for misalignment to occur and it can be assembled easily.

200, 300, 400...Buffer material, 200p, 300p, 400p...Region, 201, 301, 401, 401a, 401b...Buffer member, 201a, 301a, 401a1...First buffer member, 201b, 301b, 401b1...Second buffer Members, 201c, 301c, 401a2... Third buffer member, 201d, 301d, 401b2... Fourth buffer member, 211a... First notch, 211b... Second notch, 290... Outer box, 311a... Recess, 311b ...Protrusion, 411a...First recess, 411b...Second recess, 411c...First protrusion, 411d...Second protrusion, A...Width, B...Thickness, E1...First side, E2...Second side , E3...Third side, E4...Fourth side, K...Length, L1, L2...Depth, f1, f2...Main surface, FB...Cellulose fiber.

Claims (6)

It is assembled from four plate-shaped buffer members containing cellulose fibers,
The cellulose fibers are oriented along the main surface of the buffer member,
Among the four buffer members, two of the buffer members are spaced apart from each other and their main surfaces are arranged along each other, and the other two buffer members are spaced apart from each other and have their main surfaces arranged along each other. the faces are placed along each other,
When viewed in plan from a direction perpendicular to all normal directions of the four main surfaces of the four buffer members, it has a rectangular frame shape,
A cushioning material in which an article is stored in an area surrounded by the four cushioning members in a plan view. The four buffer members have the same shape and include a first notch on a first side and a second notch on a second side opposite to the first side,
When the main surface is viewed from the normal direction, the first notch and the second notch are arranged diagonally in the buffer member,
The four buffer members include a first buffer member, a second buffer member, a third buffer member, and a fourth buffer member,
The second notch of the first buffer member and the first notch of the second buffer member fit into each other, and the second notch of the second buffer member and the third The first notch portions of the buffer member fit into each other, the second cutout portion of the third buffer member and the first cutout portion of the fourth buffer member fit into each other, and the The cushioning material according to claim 1, wherein the second notch of the fourth cushioning member and the first notch of the first cushioning member are assembled by fitting each other. In the first notch and the second notch, a width A perpendicular to the first side or the second side is equal to or less than the thickness B of the buffer member,
Claim 2, wherein the sum of the depth L1 of the first notch and the depth L2 of the second notch in the direction along the first side is equal to or less than the length K of the buffer member. Cushioning material described in . The four buffer members have the same shape and include a concave portion on a first side and a convex portion on a second side opposite to the first side,
When the main surface is viewed from the normal direction, the concave portion and the convex portion are arranged to face each other in a direction orthogonal to the first side and the second side,
The four buffer members include a first buffer member, a second buffer member, a third buffer member, and a fourth buffer member,
The convex portion of the first buffer member and the concave portion of the second buffer member fit into each other, and the convex portion of the second buffer member and the concave portion of the third buffer member fit into each other. The convex part of the third buffer member and the concave part of the fourth buffer member fit into each other, and the convex part of the fourth buffer member and the concave part of the first buffer member fit together, The cushioning material according to claim 1, which is assembled by fitting into each other. The four buffer members include a first buffer member, a second buffer member, a third buffer member, and a fourth buffer member,
The first buffer member and the third buffer member have the same shape with a first recess on a first side and a second recess on a second side opposing along the first side,
The second buffer member and the fourth buffer member have the same shape including a first convex portion on a third side and a second convex portion on a fourth side opposing along the third side,
the first side and the third side are arranged along each other;
In the direction along the first side, the first recess, the second recess, the first protrusion, and the second protrusion are arranged correspondingly,
The second concave portion of the first buffer member and the first convex portion of the second buffer member fit into each other, and the second convex portion of the second buffer member and the first convex portion of the third buffer member fit into each other. the second concave portion of the third buffer member and the first convex portion of the fourth buffer member fit together, and the second convex portion of the fourth buffer member engages with each other; The cushioning material according to claim 1, wherein the first recess and the first recess of the first cushioning member are assembled by fitting each other. It is assembled from four plate-shaped buffer members containing cellulose fibers,
The cellulose fibers are oriented along the main surface of the buffer member,
Among the four buffer members, two of the buffer members are spaced apart from each other and their main surfaces are arranged along each other, and the other two buffer members are spaced apart from each other and have their main surfaces arranged along each other. the faces are placed along each other,
When viewed in plan from a direction perpendicular to all normal directions of the four main surfaces of the four buffer members, it has a frame shape,
A cushioning material structure in which articles are stored in an area surrounded by the four cushioning members when viewed from above.

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