JP7011867B1 - Manufacturing method of cushioning material for transport containers - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a cushion material for a transport container with less dust generation and easy to prepare, and a cushion material for a three-dimensional transport container which can be produced inexpensively and in a short period of time. A cushion material 10 includes a mountain portion 11, a valley portion 12, and an introduction slope 13. The foamed portion 21 of the main body is cut out from a foamed resin plate material, and a mountain meat portion 23 and a valley meat portion 25 are provided around the foamed portion 21. The skin member 15 is vacuum formed from a thermoplastic sheet and is surrounded by a closed curve c1. A pair of folding lines 19 parallel to each other, a forming portion 14 provided inside the folding lines 19, and a folding line 19 are formed. It is provided with an ear portion 20 formed of a flat flat surface provided on both sides on the outside. The molded portion 14 has a similar shape slightly larger than the side surface shapes of the mountain meat portion 23 and the valley meat portion 25 of the main body foaming portion 21, and the introduction slope skin portion 24 is formed. The coupling member 28 connects the selvage portion 20 and the main body foam portion 21. [Selection diagram] Fig. 2

Description

The present invention relates to a method for manufacturing a cushion material used for a transport container for accommodating a product.

There is known a transport container in which a cushioning material is arranged so that the product is not scratched or deformed, and the product is mounted on the cushion material. The cushion material is manufactured in a shape that can be stably accommodated according to the shape of the product to be accommodated. Cushion materials used when transporting products such as automobile parts between factories are often produced in small lots for products. As a document disclosing such a cushion material, for example, Patent Document 1 shows an example in which a cushion material is arranged on a channel of a transport container.

Japanese Patent No. 6813902

FIG. 1A shows a cushion material 2 fixed to a multi-stage channel 4 of a transport container 1 by a binding member 3 such as a binding band. The cushion material 2 is made by cutting out from a plate material of a foamed resin such as polyethylene, and a press blade type having a blade corresponding to the shape of the side surface of the target cushion material 2 is used for cutting out. The cushion material 2 cut out in this way has irregularities on the cut out surface, and the front and back surfaces of the original plate material are flat surfaces as they are. Hereinafter, such a cushion material 2 is a two-dimensional cushion material because the dimension of the plate thickness of the original plate material is constant. Since it can be handled only by the shape of the press blade type blade, it is convenient for the production of the cushion material 2 in a small lot.

The cushion material 2 shown in FIG. 1B accommodates the product 5 in the valley portion 76 between the mountain portions 75. Generally, the valley portion 76 receives the product in the direction of gravity, and the mountain portion 75 swings the product 5. It has a deterrent effect. In order to guide the product 5 to the valley portion 76 in the process of accommodating the product 5 in the cushion material 2, an introduction slope 77 is provided on the top of the mountain portion 75 to which the product 5 first abuts. The product 5 slides on the introduction slope 77 and is guided to the valley portion 76. At this time, the introduction slope 77 and the product 5 rub against each other. A foamable resin is generally used for the cushion material 2, and the surface is easily roughened by rubbing, and dust generation is unavoidable.

In order to cope with dust generation, a sliding material such as a polypropylene sheet or polyethylene tape may be attached to the surface where rubbing occurs. Adhesive adhesive such as double-sided tape is used for this attachment, but there is a possibility that peeling will occur and that the peeled adhesive will be transferred to the product containing it. Further, sticking the sliding material to the designated portion of the cushion material 2 has a problem that the work load is heavy and human error is likely to occur.

Another problem with the two-dimensional cushioning material cut out from the foamed resin plate is that it is difficult to apply to applications that require a three-dimensional shape. FIG. 1C shows a cushion material 7 using a frame-shaped product 6 as an example. The cushion material 7 is a two-dimensional cushion material in which introduction slopes 73 on which the product 6 slides are provided on the left and right sides of the mountain portion 71, and the valley portion 72 supports the direction of gravity. The introduction slope 73 acts as a guide to the vertical beam 61 of the product 6. On the other hand, the cushion material 7 does not have an introduction slope that guides the cross beam 63. Therefore, if the product 6 is not correctly positioned and then mounted on the cushion material 7, the end side 74 of the mountain portion 71 may be deformed or missing due to the cross beam 63 of the product 6. In order to create the introduction slope on the end side 74, the cushion material cut out by the press blade type must be further processed, and the processing is a cutting process on the foamed resin, so that there is a work limit.

There is a three-dimensional cushioning material whose up / down, left / right, and height directions can be freely set. Such a three-dimensional cushion material is molded using foamed beads or the like, but the cost of the mold used for molding is high, and it is difficult to handle small lots. Therefore, the current situation is that the cushion material cut out from the foamed resin plate material is used as it is, and there is a limit to the storage condition of the product.

Therefore, an object of the present invention is to provide a cushioning material for a transport container that generates less dust and is easy to prepare. Another object of the present invention is to provide a method for manufacturing a cushion material for a three-dimensional transport container that can be produced inexpensively and in a short period of time.

In order to achieve the above object, the method for manufacturing a cushion material of the present invention is a method for manufacturing a cushion material provided with an introduction slope that guides a product to be accommodated in a mountain portion, a valley portion, and the top of the mountain portion to the valley portion. There,
The foamed part of the main body is cut out from the foamed resin plate by a press blade so that a mountain meat part and a valley meat part are provided around it.
The molded portion having a shape similar to the side surface shape of the mountain meat portion and the valley meat portion of the main body foam portion and having the introduced slope skin portion formed thereof is vacuum formed into a thermoplastic sheet.
A pair of fold lines parallel to each other with the molded portion inside and at intervals corresponding to the plate thickness of the plate material of the main body foam portion, and flat flat surfaces provided on both sides on the outside of the pair of fold lines. Cut out the epidermis member from the thermoplastic sheet along a closed curve comprising an ear portion composed of
The selvage portion and the main body are in a state where the mountain portion and the valley portion of the main body foam portion are inserted into the molding portion and the selvage portion bent at the folding line sandwiches another portion of the main body foam portion. It is characterized in that the foamed portion is connected by a connecting member.

According to the present invention, by covering the foamed portion of the main body with the skin member, the product contained in the foamed portion of the main body does not come into direct contact with the foamed portion of the main body, and dust is not generated from the foamed portion of the main body. In addition, the skin member covers not only the introduction slope but also the peaks and valleys located below it, and is connected to the main body foaming portion at the ear portion below these lower fold lines. Therefore, unlike the attachment of the sliding material to the designated place, there is an effect that the work load is small and human error is unlikely to occur. In addition, it is said that a three-dimensional cushioning material can be easily obtained by a composite of a vacuum-formed skin member that can be produced inexpensively and in a short period of time and a main body foamed portion that is built up inside the skin member. effective.

It is a figure explaining the two-dimensional cushion material used for a transport container. It is a figure explaining the cushion material by Example 1. FIG. It is a figure explaining the cushion material by Example 2. FIG. It is a figure explaining the structure of the cushion material by Example 2. FIG. This is an example in which trimming is applied to the cushion material of the embodiment.

An embodiment of the present invention will be described with reference to the accompanying drawings.
[Example 1]
The cushion material 10 of the first embodiment will be described with reference to FIG. The cushion material 10 includes a main body foam portion 21, a skin member 15 that covers the main body foam portion 21, and a connecting member 28 that connects the two. The cushion material 10 is provided with an introduction slope 13 at the tops of the mountain portion 11, the valley portion 12, and the mountain portion 11.

The foamed portion 21 of the main body is created by cutting out from a foamed resin plate material by a press blade mold, and the main surfaces of the front and back surfaces of the original plate material are flat surfaces as they are, and are cut along the press blade mold around the main surface. Has sides. That is, the thickness dimension of the main body foam portion 21 is two-dimensional because it is the dimension of the original plate thickness of the plate material and is constant. The main body foam portion 21 has the same shape as the cushion material 2 shown in FIG. 1B, and corresponds to the mountain portion 11, the valley portion 12, and the introduction slope 13, the mountain meat portion 23, the valley meat portion 25, and the introduction, respectively. A slope meat portion 24 (top of a mountain meat portion 23) is provided.

The skin member 15 is a vacuum-formed member obtained by heating and softening a thermoplastic sheet such as polypropylene and cooling it while being deformed by vacuum pressure. After cooling, the skin member 15 is cut off from the thermoplastic sheet to surround it with a closed curve c1. It has been. A pair of folding lines 19 parallel to each other are provided with an interval D1 corresponding to the plate thickness d1 of the original plate material of the main body foam portion 21. The pair of fold lines 19 are formed by a groove or a lead ruled line, starting from the edge of the closed curve c1 and continuing to the other edge. A molded portion 14 is vacuum-formed between the folded lines 19. The molded portion 14 has a similar shape slightly larger than the side surface shapes of the mountain meat portion 23 and the valley meat portion 25 of the main body foaming portion 21. Corresponding to the mountain meat portion 23 and the valley meat portion 25, the mountain skin portion 16 and the valley skin portion 17 are provided in the molding portion 14. The mountain skin portion 16 also includes the introduced slope skin portion 18. The mountain meat portion 23, the valley meat portion 25, and the introduction slope meat portion 24 of the main body foaming portion 21 can be inserted into the molding portion 14. The introduction slope meat portion 24 is arranged with the introduction slope skin portion 18 inside.

The pair of fold lines 19 are "mountain fold" fold lines with respect to the molded portion 14. The ears 20 formed of a flat flat surface are provided on both sides outside the pair of fold lines 19. When the main body foam portion 21 is inserted into the molded portion 14 and the pair of fold lines 19 are bent, the selvage portion 20 has a main surface 29 (front and back main surfaces 29) of the main body foam portion 21 below the fold lines 19. The mountain meat portion 23, the valley meat portion 25, and other parts other than the introduction slope meat portion 24 of the main body foaming portion 21 are directly opposed to each other and sandwiched therein.

Generally, in vacuum forming, when convex molding having a height exceeding 100 to 180 mm is performed, the thermoplastic sheet becomes too thin or breaks. By bending at the pair of folding lines 19 in this way, it is possible to overcome the height limitation which is a drawback of vacuum forming and to cover the main body foam portion 21 having a relatively high height h.

The connecting member 28 penetrates the selvage portions 20 on both sides and the main body foaming portion 21 sandwiched between them to integrate them, and is provided one or more. In the example of the figure, rivets are used as the connecting member 28, and these are connected at equal intervals along the fold line 19. As the binding member, rivets, bolts, screws, and binding bands can be used. For example, the rivets disclosed in Japanese Patent No. 5840725 are suitable. When using rivets and bolts, it is preferable to stick out the head to the ears 20 on both sides and fix the rivets and bolts so as to sandwich the foamed portion 21 of the main body. If a pilot hole is required when using rivets and bolts, a pilot hole is formed for the foamed portion 21 of the main body when punching from the foamed resin plate material with a press blade mold, and for the skin member 15 when cutting from the thermoplastic sheet. You should keep it. As the binding member, if a taper screw such as a wood screw, a drill screw, or a tacker to be driven from the selvage portion 20 on one side into the foam portion 21 of the main body is used, it is not necessary to provide a pilot hole.

When a binding band is used as the binding member 28, the binding band may not only bond the skin member 15 and the foamed portion 21 of the main body, but also fix the cushion material 10 to the channel 4 of the transport container 1. .. That is, it penetrates the selvage portions 20 on both sides and the main body foam portion 21 sandwiched between them, and binds the channels 4 so as to be housed in one loop.

By covering the main body foam portion 21 with the skin member 15, the product 5 (FIG. 1) housed in the main body foam portion 21 does not come into direct contact with the main body foam portion 21, and dust is generated from the main body foam portion 21. There is no. Further, the epidermis member 15 covers not only the introduction slope skin portion 18 but also the mountain skin portion 16 and the valley skin portion 17 located below the introductory slope skin portion 18, and the ears below these lower fold lines 19. Since the portion 20 is connected to the main body foam portion 21, the work load is small and human error is unlikely to occur, unlike the case where the sliding material is attached to the designated portion. If the binding member also binds to the channel 4, there is an effect that the work man-hours are hardly increased.

In the above embodiment, the introduction slope meat portion 24 is provided in the mountain meat portion 23 of the main body foaming portion 21, but the mountain meat portion above the starting position of the introduction slope meat portion 24 (s1 in FIG. 2B). It may be a main body foam portion 21 such that 23 is cut. In this case, the introduction slope meat portion 24 does not exist in the main body foam portion 21, but the epidermis member 15 remains the mountain skin portion 16 having the introduction slope skin portion 18. Since the introduction slope meat portion 24 does not exist in the main body foam portion 21, the inside of the introduction slope skin portion 18 of the skin member 15 is in a hollow state, but the main function of the introduction slope skin portion 18 guides the product at the time of mounting. Therefore, since it is not expected to have an effect of suppressing rocking during storage / transportation, such deformation is possible.

[Example 2]
FIG. 3A shows an example corresponding to the three-dimensional cushion material 30. Further, FIG. 3B shows the product 80 held by the cushion material 30. It is assumed that the shape of the product 80 is complex and in this example it is specified to be held at the positions of the two openings 81, 82. The cushion material 30 is provided with a jaw portion 35 on which the product 80 is placed on the right side surface.

The cushion material 30 has a main body foamed portion 40, a skin member 50 that covers the main body foamed portion 40, and a connecting member 39 that connects the two. The cushion material 30 is inserted into the openings 81 and 82 of the product 80 to support the product 80. The cushion material 30 is provided with a mountain portion 31 and a valley portion 34, and introduction slopes 32a, 32b, 33a, 33b are provided on the top of the mountain portion 31 (33b is the back side direction of the drawing). .. The introduction slopes 32a and 32b are left and right upward surfaces in the drawing, and the introduction slopes 33a and 33b are front and back upward surfaces in the drawing. The introduction slopes 32a and 32b are introduction slopes that guide the beams 81a and 82a of the product 80, and the introduction slopes 33a and 33b are introduction slopes that guide the beams 81b and 82b of the product 80.

FIG. 4 shows each member constituting the cushion material 30. In FIG. 4A, the main body foamed portion 40 is formed by stacking two foamed resins 40a and 40b, which are cut out from a plate material by a press blade mold, on the front and back surfaces. The foamed resins 40a and 40b have different shapes depending on the details, but are the same in that the mountain meat portion 42 and the valley meat portion 43 are provided. However, there is no portion corresponding to the introduction slopes 32a, 32b, 33a, 33b, and the upper mountain portion is cut from the starting position s2 of the introduction slopes 32a, 32b, 33a, 33b. Further, the foamed portion 40 of the main body is provided with a jaw meat portion 44 on which the product 80 is placed on the right side surface.

The skin member 50 is a member obtained by vacuum forming a thermoplastic sheet such as polypropylene, and is surrounded by a closed curve c2. A pair of parallel folding lines 54 are provided by opening only the interval D2 corresponding to the interval d2 (FIG. 4C) in which the plate thickness of the original plate material of the main body foam portion 40 is totaled. Further, the pair of parallel fold lines 56 are also spaced by the interval D2. Each of these pair of fold lines 54, 56 begins at the edge of the closed curve c2 and continues to the other edge. The molding portion 58 existing between the pair of fold lines 54 includes the mountain skin portion 51, the valley skin portion 52, and the valley skin portion 52. The introduction slope skin portions 46a, 46b, 47a, 47b are provided. The introduction slope skins 46a and 46b correspond to the introduction slopes 32a and 32b, and the introduction slope skins 47a and 47b correspond to the introduction slopes 33a and 33b. The introduction slope skin portions 46a, 46b, 47a, 47b are slopes that diverge downward from the top in all directions toward the position s2, and form a three-dimensional slope. The molded portion 59 present between the pair of fold lines has a jaw skin portion 57. Between the two pairs of fold lines 54 and 56, a fold line 53 that bends downward so as to be perpendicular to these is provided.

The molded portion 58 existing between the pair of folded lines 54 has a similar shape slightly larger than the side surface shapes of the mountain meat portion 42 and the valley meat portion 43 of the main body foamed portion 40, and the main body foamed inside the molded portion 58. The portion 40 can be partially inserted. On the other hand, the jaw skin portion 57 existing between the pair of fold lines 56 allows the jaw meat portion 44 of the main body foaming portion 40 to be inserted when the jaw skin portion 57 is bent at the fold line 53.

The selvages 55 made of a flat flat surface are provided on both sides outside the pair of fold lines 54. When the selvage portion 55 is bent along the pair of folding lines 54, the selvage portion 55 sandwiches the main body foaming portion 40 further below the folding line 54 on the lower side of the mountain meat portion 42 and the valley meat portion 43.

On the other hand, on both sides outside the pair of fold lines 56, selvages 48 formed of a flat flat surface are provided. The selvage portion 48 sandwiches the main body foam portion 40 when bent at the pair of fold lines 56 and 53. The connecting member 39 penetrates the selvage portions 55 on both sides and the main body foaming portion 40 sandwiched between them to integrate them. In the illustrated example, the rivets disclosed in Japanese Patent No. 5840725 were utilized.

In this embodiment, the main body foam portion 40 does not have an introduction slope corresponding to the introduction slopes 32a, 32b, 33a, 33b, and the inside of the introduction slope skin portions 46a, 46b, 47a, 47b of the skin member 50 is Although it is in a hollow state, the main function of the introduction slope is to guide the product at the time of mounting, and it cannot be expected to have the effect of suppressing rocking during storage / transportation. However, there is an effect that the directions of the introduction slopes 32a, 32b, 33a, 33b of the cushion material 30 can be set in various directions.

Vacuum forming is relatively inexpensive and can be manufactured in small lots, and vacuum forming dies are significantly cheaper than injection molding and can be made in a short time. Are known. The skin member 50 is created by such vacuum forming, while the mountain portion 31 and the valley portion 34 that suppress the swing during storage / transportation are built up by the main body foaming portion 40 inside the skin member 50. Therefore, the three-dimensional cushion material 30 can be easily obtained easily. In addition, the skin member 50 made of the thermoplastic sheet is more resistant to friction than the foamed portion 40 of the main body in which the resin is foamed, and the surface is less likely to be roughened by rubbing and dust generation is suppressed. There is. Further, unlike the case where the sliding material is attached to a designated place, since the skin member 50 is covered with the foamed portion 40 of the main body, there is an effect that the work load is small and human error is unlikely to occur.

In each of the above embodiments, the molded portions 14, 58, 59 of the skin members 15 and 50 cover all the surfaces of the main body foamed portions 21 and 40, but when the vacuum formed product is trimmed, the main body foamed portions are covered. The portion of the foams 21 and 40 to be exposed may be trimmed and removed from the skin members 15 and 50. The cushion material 10A shown in FIG. 5 corresponds to the cushion material 10 of FIG. Of the epidermis member 15A shown in FIG. 5B, the portions corresponding to the mountain skin portion 16, the valley skin portion 17, and the selvage portion 20 are partially trimmed. Therefore, the product is directly supported by the foamed resin of the foamed portion 21 of the main body. The trimming portion 22a is an example in which a part of the trimming portion 22a is trimmed across the mountain skin portion 16 and the ear portion 20, and the trimming portion 22b is one of the trimming portions 22b straddling the mountain skin portion 16, the valley skin portion 17, and the ear portion 20. The portion is trimmed, and the trimming portion 22c is an example in which a part of the valley skin portion 17 is trimmed. In this way, depending on the location where the product comes into contact, when the location where it is desirable to receive it with the foamed resin of the main body foam portion 21 and the location where it is desirable to receive it with the skin member 15A are combined, the mountain skin portion 16, the valley skin portion 17, or the valley skin portion 17 or It can be dealt with by partially selecting and trimming the portion of the ear portion 20 straddling a part or one of them.

1 Transport container 2, 7, 10, 10A, 30 Cushion material 3 Bundling member 4 channel 5, 6, 80 Product 14, 58, 59 Molding part 15, 15A, 50 Skin member 11, 31, 71, 75 Yamabe 12, 34, 72, 76 Valleys 22a, 22b, 22c Trimming points 23, 42 Mountains 25,43 Valleys 16,51 Mountains 17,52 Valleys 13,32a, 32b, 33a, 33b, 73, 77 Introduction slope
24 Introduced slope meat part 18, 46a, 46b, 47a, 47b Introduced slope skin part 19, 53, 54, 56 Folded line 20, 48, 55 Ear part 21, 40 Body foam part 28, 39 Coupling member 29 Main surface 35 chin Part 44 Jaw meat part 57 Jaw skin part 40a, 40b Foamed resin 61 Vertical beam 63 Cross beam 74 End side 81a, 81b, 82a, 82b Beam 81, 82 Opening

Claims (4)

It is a method of manufacturing a cushion material provided with an introduction slope that guides a product to be accommodated in a mountain part, a valley part, and a mountain part to the valley part.
The foamed part of the main body is cut out from the foamed resin plate by a press blade so that a mountain meat part and a valley meat part are provided around it.
The molded portion having a shape similar to the side surface shape of the mountain meat portion and the valley meat portion of the main body foam portion and having the introduced slope skin portion formed thereof is vacuum formed into a thermoplastic sheet.
A pair of fold lines parallel to each other with the molded portion inside and at intervals corresponding to the plate thickness of the plate material of the main body foam portion, and flat flat surfaces provided on both sides on the outside of the pair of fold lines. Cut out the epidermis member from the thermoplastic sheet along a closed curve comprising an ear portion composed of
The selvage portion and the main body are in a state where the mountain portion and the valley portion of the main body foam portion are inserted into the molding portion and the selvage portion bent at the folding line sandwiches another portion of the main body foam portion. A method for manufacturing a cushion material for a transport container, which comprises connecting the foamed portion with a connecting member .
The method for manufacturing a cushion material for a transport container according to claim 1, wherein the main body foam portion has an introduction slope meat portion arranged inside the introduction slope skin portion on the top of the mountain meat portion. ..
The cushion for a transport container according to claim 1, wherein the introduction slope skin portion is formed with an introduction slope that inclines downward from the top in all directions , and the inside of the introduction slope that inclines downward in all directions is hollow. Material manufacturing method .
As the location of the main body foam portion that directly supports the product to be accommodated, the ridge portion, the valley skin portion, or the ear portion provided in the molding portion corresponding to the mountain portion and the valley portion of the cushion material, respectively. The first aspect of the present invention is characterized in that the portion of the surface skin portion selected across a part or any of them is partially trimmed to expose the main body foam portion below the portion of the surface skin portion. The method for manufacturing a cushioning material for a transport container according to the description.

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