Multiple structure paper protector and the apparatus for its production

Abstract: A paper protector is described, using multiple sheets of paper, that can contain electronic goods, precision instruments or other objects requiring protection from shock. The paper protector has a multiple structure and is provided with a primary blank (10), consisting of a central panel (11), which contacts the contained object, inner panels (12) provided around the periphery of the central panel (11) and which are set upright and surround the object, and first mid panels (13) which are folded outwardly from the extremities of the inner panels (12); and a secondary blank, consisting of a second mid panel (23), having a central opening of approximately the same form as the central panel (11), which surrounds the periphery of the opening and is positioned either above or below the first mid panels (13), and outer panels (24) which surround the exterior of the inner panels (12) and are folded down from the extremities of the second mid panel (23); and forming spaces (55), having a width equivalent to that of the first and second mid panels (13 and 23), within the inner and outer panels (12 and 24) by positioning the first and second mid panels (13 and 23) one above the other and assembling the various components to maintain the above positional relationships.

Description: BACKGROUND OF THE INVENTION FIELD OF THE INVENTION This invention relates to a multiple structure protector made of paper formed with at least two blanks, making up the internal or external surfaces of the protector, and assembled as a three-dimensional body by means of gluing flaps provided where required, and the apparatus for its production. DESCRIPTION OF THE PRIOR ART Styrofoam is normally used to protect objects from shock, as can be seen, for example, in the packaging materials used for electronic goods. However, resinous protectors, such as molded products made of styrol, etc., or vacuum forming products made of vinyl chloride, etc., while readily allowing the formation of concavities to accommodate electronic goods or other objects, present problems in their disposal after use. That is, first there is the problem of the immense quantities to be disposed of and, secondly, since resin does not decompose and must be incinerated, there is the problem of its adverse effect on the environment. A third problem is the waste of resources, as such protectors, which are produced by processing petroleum based raw materials, become useless one the protected object is sold. However, that does not mean that there are no protectors which are made of substitute materials; for example, there are those made of paper material and molded to form required shapes and used to accommodate fruits or other products. However, such paper protectors are molded on cutting the paper material to form paper clay. Consequently, being easily damaged and presenting the risk of intrusion into the contained object of pulverized paper fibers, which are generated in large quantities, such protectors are not appropriate for objects such as electronic goods or precision instruments. Moreover, they also have the disadvantage of an unsightly appearance that does not match the object. A multiple structure paper protector is known from DE-B-12 15 578 and comprises at least two paper blanks forming the inner and outer surfaces of the protector and being assembled as a pre-dimensional body with gluing flaps provided where required, a central panel provided in the first blank, inner panels provided around the periphery of the central panel which are raised upright, first mid panels folded outward from the extremities of the inner panels, a central opening of approximately the same shape as the above central panel and provided in the second blank, and a second mid panel located in contact with the first mid panel and surrounding the exterior of the inner panels. It is an object of the present invention to provide a paper protector with a structure which allows objects such as electronic goods etc. to be accommodated as they are with resinous protectors by folding, tooling, gluing etc. multiple sheets of paper. It is also an object of the present invention to provide an apparatus for producing such multiple structure paper protectors. These objects are solved according to the present invention by a multiple structure paper protector including the features of claim 1 and an apparatus including the features of claim 4, respectively. The invention provides a multiple Structure paper protector formed of at least two blanks making up the internal or external surfaces of the protector, and assembled as a three-dimensional body by means of gluing flaps provided where required, is realized by providing a first blank, comprised of a central panel, which is in contact with the contained object, inner panels, provided around the periphery of the central panel, which are set upright and surround the object, and first mid panels, which are folded outwardly from the extremities of the inner panels; a second blank, consisting of a central opening with approximately the same configuration as the above central panel, a second mid panel, which surrounds the periphery of that opening and is positioned either above or below the first mid panels above, and outer panels, which surround the exterior of the above inner panels and are folded down from the extremities of the second mid panel; and a space within the inner and outer panels having a width approximately equivalent to that of both the first and second mid panels. It is possible to manufacture a paper protector such as this by using an apparatus consisting of a lower mold, which is provided with a frame section having a support surface which commonly supports the first and second mid panels of the above two blanks, since the blanks are fitted one on top of the other, and an inner chamber within this frame section into which the central panel of one of the blanks is pressed; a central mold for the purpose of piercing the central opening of the other blank and holding the first and second mid panels stationary on the above support surface; and an upper mold, which has a peripheral rim for the purpose of forming and folding the outer panels of this blank, which protrude beyond the periphery of the central mold, around the external surfaces of the frame section and guide projections fitted into the lower surface of the above peripheral rim for the purpose of folding the gluing flaps provided on a portion of the blank in the direction of contact with the above outer panels approximately where the folds of the outer panels are located and bonding them. The paper of this invention is any paper generally referred to as that made of vegetable fiber; however, it also includes that produced of synthetic resins, such as so-called resin paper or others, which do not cause any harm when incinerated or which are considered to pose no problems under normal handling conditions. BRIEF DESCRIPTION OF THE DRAWINGS Fig. 1: An overall lateral view illustrating an example of the paper protector production apparatus pertaining to this invention. Fig. 2: Front view of the same apparatus. Fig. 3: Plane view of the same. Fig. 4: Expanded view of the first blank relating to example 1 of this invention. Fig. 5: Expanded view of the second blank relating to example 1. Fig. 6: Cross-sectional view of the metal mold apparatus of example 1 that forms the blanks. Fig. 7: Cross-sectional explanatory view of the gluing tab folding process. Fig. 8: Cross-sectional explanatory view of same. Fig. 9: Cross-sectional explanatory view of same. Fig. 10: Cross-sectional view illustrating the paper protector of example 1 in use. Fig. 11: Expanded view of the first blank relating to actual example 2 of this invention. Fig. 12: Expanded view of the second blank relating to example 2. Fig. 13: Cross-sectional view of the metal mold apparatus of example 2 that forms the blanks. Fig. 14: Cross-sectional view of the blank folding process of the metal mold apparatus. Fig. 15: Cross-sectional view illustrating the same process. Fig. 16: Cross-sectional view of folding process details. Fig. 17: Cross-sectional view of same details. Fig. 18: Cross-sectional view of same details. Fig. 19: Longitudinal cross-sectional view of the paper protector of example 2. Fig. 20: Lateral cross-sectional view of the same. Fig. 21: Perspective drawing of the above paper protector in use. DESCRIPTION OF THE PREFERRED EMBODIMENTS In the drawings Figs. 1-3 illustrate actual examples of the apparatus pertaining to this invention. Figs. 4-10 relate to actual example 1 while Figs. 11-21 relate to actual example 2. To explain the apparatus that drives the metal mold apparatus, the illustrated one has a lower plate (3) with guide rails (2), which are generally horizontal, installed on a base (1), and an upper plate (5) that can move vertical because of the elevating mechanism (4) installed above the central work area; the lower plate (3) is capable of moving back and forth between the work area and the standby position because of a hydraulic mechanism (6), installed beside the guide rails. The lower mold (30) is fitted to the upper surface of the lower plate through lower plate heater (7), and the upper mold (50) is fitted to the lower surface of the upper plate (5) through the upper plate heater (8). These heaters (7 and 8) are capable of applying heat selectively to the lower plate, the upper plate or both. The paper protector illustrated in actual example 1 is formed with two blanks, (10 and 20). The first blank (10), shown in Fig. 4, has a central panel (11) which is somewhat larger than the plane surface area of object M to be protected and of a similar configuration allowing the object to be accommodated; multiple inner panels (12a, 12b...) which are provided in succession around the exterior of the central panel (11) and which have the necessary height to make it possible to form walls to surround the concavity (58), which receives the object; an equal number of mid panels (second mid panels) (13a, 13b...) provided in succession along the outside edges of inner panels (12a, 12b...) for the purpose of providing spaces (55) around the outside of the concavity that receives the object; and outer panels (14a, 14b...) which are provided in succession along the outer edges of mid panels (13a, 13b...) to surround the outer edges of inner panels (12a, 12b...) at a fixed spacing. The blanks are cut from patterns in sheets, but in the example 1, one blank (10) is handled without being detached from sheet material S and outer edge Q is used for mounting to the apparatus. However, any surplus portions that are neither a part of blank B nor of outer edge Q should be removed in advance. R indicates the portions to be removed. Furthermore, in Fig. 4, the fine line U indicates the stamped-out portions, the single-dot chain line V indicates the hump-fold portions and the double-dot chain line W is the trough-fold portions. These folded portions should be tooled in advance. Furthermore, the primary blank (10) is glued so that the object received M can be secured appropriately without allowing the folded and formed portions to deform while in a free state; the locations for providing gluing flaps for that purpose and the sections to which they are bonded can be set at random. As the means of gluing, in the case of actual example 1, a heat-sensitive adhesive is applied in advance to the outer surface of the primary blank (10). In this example, a heat-sensitive adhesive is applied over the entire outer surface of blank (10) before or after, it is punched out of sheet material S. A two-liquid type adhesive can also be used instead of heat-sensitive adhesive, in which case one of them is applied to the above adhesive application points. These points are indicated by X and Y. The central panel (11) may be triangular, pentagonal or polygonal having more sides or other configurations, while the inner panels, etc., can be modified in accordance with that configuration; actual example 1, however, is explained by referring to a four-sided box configuration. The other blank, the secondary blank (20), is indicated in Fig. 5, and is positioned under the primary blank (10). Moreover, it is provided with reinforcement sections that are large enough to allow them to receive the central panel (11) and inner panels (12a-12), which rise up from its four sides; these reinforcement sections are made up of inner panel reinforcements (22a-22d), which come into contact with the inner panels (12a-12d), and central panel reinforcements (21a-21d), which are provided in succession along the inner edges of reinforcements (22a-22d) and come into contact with the edges of the four sides of the central panel (11). The external circumference of the above reinforcement sections is surrounded by the rim-shaped mid panel reinforcement (second mid panel) 23, which overlaps the mid panels (13a-13d) of the primary blank (10). Furthermore, the outer panel reinforcements (24a-24d), which overlap the lower sides of the outer panels (14a-14d), are formed in succession along the outer edges of the mid panel reinforcement (23) and gluing flaps (25a-25d) to bond together the outer panel reinforcements (24a-24d) are formed in the extremities of the reinforcements (24b and 24d) after folding. Since other compositions can be the same as those of the primary blank (10), explanations are given invoking those symbols. The makeup of the apparatus for producing a protector from such primary and secondary paper blanks (10 and 20) is as indicated below (Fig. 6). Lower Mold The lower mold (30) is a component for receiving and supporting the above sheet material S and is provided with a rim-shaped material holder (31) for receiving the unused edge material Q around the periphery of the primary and secondary blanks (10, 20) and the frame (33), within which is provided a support surface (32) in a position corresponding to the external configuration of the central panel (11) of the protector. It is also possible to remove the blanks (10 and 20) from the sheet material S in advance, retain them by means of suction disks, and set them into the lower mold, in which case the material holder (31) is not necessary. The support surface (32) is approximately the same height as the material holder (31) and the width of its surface is approximately equivalent to that of the mid panels (13a-13d) of the primary blank (10) and mid panel reinforcement (23) of the secondary blank (20). The height of the interior sides of the frame (33) is approximately equivalent to that of the inner panels (12a-12d) and inner panel reinforcements (22a-22d) of the primary and secondary blanks (10 and 20), while the exterior sides of the frame (33) are set at a height greater than that of the outer panels (14a-14d) and outer panel reinforcements (24a-24d). The interior sides of the lower mold surrounded by the frame (33) make up the central chamber (34), within which the central panel (11) of the primary blank (10) is pressed. Consequently, the configuration of its bottom surface corresponds approximately to that of the cavity, which accommodates the object within the protector. When words such as "corresponds" or "equivalent" are used for this invention, they mean approximately corresponding for equivalent taking into consideration the thickness of sheet material S. The inner surfaces of the above central chamber 34 are sloped to facilitate removal of the protector after production. The edge retainer (40) is used to hold down and retain the unused edge material Q the in lower mold (30) and, together with sheet material S, is held stationary within the projecting rim (35) along the outer extremity of the material holder (31). The panel holder (36), which holds the central panel (11), is provided within the interior surface of the support surface (32). This panel holder (36) can be restored to its upper fixed position within the central chamber (34) by means of thrust springs (37), which push up the central panel of the paper protector that has been formed thereby facilitating its removal. The support springs (38) for the material holder (31) and the retainers (39) pierce and hold the blanks in place. Central Mold The central mold (41) is equipped with a downward-facing projection (42) for the purpose of pressing the central panel (11) of the primary blank (10) down within the central chamber (34) of lower mold 30, while making the inner panels (12a-12d) located along the periphery of the central panel upright, and folding the reinforcements of the secondary blank; and overhead (43), which projects out in all directions above the upper surface of the projection (42) and restrains the mid panels (13a-13d) of the primary blank (10) and the mid panel reinforcement (23) of the secondary blank (20) on the above frame (33), folding them outwardly. The outer surfaces of the projection (42) are provided with a slope and the exterior of the overhead (43) is smaller than that of the frame (33) of the lower mold. This central mold (41) is suspended from the upper mold by means of springs (44); moreover, it is also possible to similarly suspend the above edge retainer (40) from the upper mold by using springs (45). However, the edge retainer (40) is designed to retain the blanks (10 and 20) first. Upper Mold The upper mold (50) has a downward-facing peripheral rim (51), fits over the outer surface of the frame (33) of the lower mold (30) for the purpose of forming the outer panels (14a-14d) of the primary blank (10) and the outer panel reinforcements (24a-24d) of the secondary blank (20) in conformance with the configuration of the frame (33). The inner surface (52) of the peripheral rim (51) is provided with an appropriate slope in order to fold down the outer panels (14a-14d) and the outer panel reinforcements (24a-24d) and extract them afterward. Downward projecting guide projections (53) are provided at the lower extremity of the peripheral rim (51) in a location accommodating the gluing flaps (15a-15d and 24a-24d) for the purpose of folding said gluing flaps (15a-15d and 24a-24d) prior to folding the outer panels and their reinforcements (14a-14b and 24a-24d) (refer to Figs. 7-9). The above lower mold (30) is installed in the upper surface of the above lower plate (3) through the heater (7) and the central mold (41) and upper mold (50) are both installed at the lower surface of the upper plate (5) through the heater (8). Production Processes The Setting Process Sheet material S containing the primary blank (10) and sheet material S containing the secondary blank (20), which are stamped out in a prescribed configuration and which include fold lines, are placed onto the material holder (31) of the lower mold (30) and the edge material Q is held firmly in place by the edge retainer (40). At this time, the central panel (11) is positioned on the panel holder (36). Concavity Formation Process The upper mold (50) descends over the central panel (11) of the primary blank (10) on the support surface (32) and the central panel (11) and the reinforcements of the secondary blank (20) become restrained between the projection (42) of the central mold (41) and the lower panel holder (36); the central panel (11) is then pressed into the central chamber (34) of the lower mold (30). Simultaneously, the four inner panels (12a-12d), together with the inner panel reinforcements (22a-22d), rise upright along the inner surface of frame (33); furthermore, the mid panels (13a-13d) slip under the mid panel reinforcement (23), are folded outwardly at their border with inner panels (12a-12d) and are restrained between the support surface (32) of the lower mold (30) and the overhead (43) of the upper mold (41). At this stage, the concavity (58) that receives the object is formed and, in addition, both blanks (10 and 20) are separated from edge material Q at the stamp-out portion U. Outer Panel Folding Process From the above state of conditions, the upper mold (50) continues to descend and is eventually fitted within the lower mold (30); the outer panels (14a-14d) and the outer panel reinforcements (24a-24d), which project outwardly, are folded downward along the fold lines at their border with the mid panels (13a-13d) and their reinforcement (23); thereupon, the gluing flaps (15a-15d and 25a-25d) are bonded and, in this manner, a paper protector with fixed spaces (55) within the outer panels (12a-12d) is formed (Fig. 7). With this process, the gluing flaps (15a-15d and 25a-25d) are first folded within the outer panels (14a-14d) and their reinforcements (24a-24d). In this procedure, since the projections (53) at the lower extremity of the upper mold first fold the gluing flaps (15a-15d and 25a-25d) downwardly, after which the outer panels (14a-14d) and their reinforcements (24a-24d) are folded by the lower extremity of the projections of the upper mold, the gluing flaps (15a-15d and 25a-25d) which had been folded first, can be inserted within the outer panels (14a-14d, 24a-24d) (Fig. 7-Fig. 9). These gluing flaps (15a-15d and 25a-25d) are bonded to outer panels (14a-14d) and their reinforcements (24a-24d) through the application of heat when the gluing flaps and outer panels are under pressure. Retractable glue application nozzles (56) are installed and glue can be applied prior to the insertion of the gluing flaps. The paper protector in completed form and bonded at the gluing flaps is forced up from the lower panel holder (36) by the action of the springs as the upper mold (50) and central mold (41) rise and separate from the lower mold (30). Consequently, the product can be easily removed from the lower mold (30) and efficient operations can be maintained. The paper protector (57) produced in this manner protects object M accommodated in the storage concavity (58) due to the spaces (55) formed by mid panels (13a-13d) between the inner panels (12a-12d) and outer panels (14a-14d). This protector is further packaged and dressed by outer packaging made up of outer box A, lid B, etc. The following is an explanation of actual example 2 indicated in the diagrams beginning with Fig. 11. The primary blank (60)indicated in Fig. 11 forms the outer surface of the paper protector and the concavity in which the item is accommodated is formed by a secondary blank (70) indicated in Fig. 12. Therefore, since the secondary blank (70) of the example 2 corresponds to one of the blanks noted in the EXTENT OF PATENT CLAIMS and the primary blank (60) corresponds to the other, the composition of this actual example is opposite to that of actual example 1, in which the concavity (58) is formed by the primary blank (10). The primary blank 60 of the example 2 consists of central cavity C, stamped out in a configuration large enough to receive the contained object M; a rim-shaped front panel (63) (second mid panel), which surrounds central cavity C; and outer panels (64a, 64d, 64c, 64d) installed so that they can be folded outwardly from the four sides of front panel (63). The above front panel (63) should be referred to as a mid panel since it is positioned between the inner and outer panels. In order to maintain the three-dimensional configuration and avoid deformation in the folded state, gluing flaps (65a-65d) are provided at both extremities of the long outer panels (64b and 64d) of the primary blank (60) and a means of bonding with the above-mentioned heat-sensitive adhesive, etc., is provided between them and the outer panels (64a and 64c) which they contact. Though the glue points are indicated by X and Y, they can be situated anywhere. In the case of actual example 2, a means of gluing virtually the entire surface of the front panel (63) of the primary blank (60) has been provided. The central opening C of the primary blank (60) has a complex configuration; however, this allows it correspond to the configuration of the sides of the contained object M, indicated in Fig. 21, and on one side of opening C, in particular, a folded portion (66) is provided as a concavity to receive accessories, etc., to be accommodated together with object M. (66a) indicates the upper level section, which is positioned lower than the front panel (63), and (66b) is the wall section, which is folded downward from Tthere; (66c) is the lower level section, which is folded outwardly from the bottom of the wall section (66b). The secondary blank (70) of example 2 illustrated in Fig. 12 consists of a central panel (71), which is located at the center of the blank and which contacts the contained object M; inner panels (72a-72d), which rise upright to surround the central panel (71); and first mid panels (73a-73d), which are folded outwardly from the extremities of the inner panels (72a-72d). Folded inner panels (72a' and 72c') are provided in the inner panels (72a and 72c) and folded mid panels (73a' and 73c') are provided in the first mid panels (73a and 73c), to bring them into correspondence with the folded sections of central opening C. The first mid panels (73a-73d) are the portion that overlaps the front panel (63) of the primary blank (60) from the bottom and, since these are important overlapping sections of the primary and secondary blanks (60 and 70), the first mid panels (73a-73d) act as gluing flaps in the case of example 2. The central panel (71) has a rectangular opening (76) for the purpose of forming a concavity where required and concavity retainers (76a-76d) are provided in this opening (76); concavity (67), made up of separate parts, fits within this and is bonded. The blank for this cavity (67) can be formed by using the central opening C of the primary blank (60); it is provided in a configuration such as that indicated in Fig. 11 and is made up of side sections (67a-67d), which rise upright in a central rectangular configuration. Furthermore, spacers (77a-77d) are provided on all four sides between the central panel (71) and inner panels (72a-72d) in order to maintain a fixed spacing of the outer panels (64a-64d); of these, the various spacers (77b and 77d) along the sides are provided with gluing flaps (75a-75d) at their extremities. Supports (78), which support the upper level section (66a) of the primary blank (60) from the bottom, are formed in close proximity to the spacer (77b) sections; each support (78) is bonded to the wall seciton (66b) of the bottom of the upper level section by means of gluing flaps (79). Furthermore, the upper surfaces of the first mid panels (73b and 73d) themselves become gluing flaps and gluing flaps (75k, 75l, 75m and 75n) are provided at their extremities in a lateral direction. The entire surfaces of the primary and secondary blanks can be bonded when added strength is needed, while spot bonding is satisfactory when there is no special strength requirement. For example, the surface of the first mid panels (73b and 73d) and the lower surface of the second mid panel (63) in Fig. 11 can be entirely bonded. The composition of the metal mold apparatus used to produce paper protectors from the above blanks (60 and 70) is as indicated in Figs. 13-18. In this explanation, the metal mold apparatus shall be treated as a structure that retains the material as sheets, though, of course, it is also possible to remove the edge material Q in advance and transfer the blanks (60 and 70) into the mold by retaining them with suction disks, etc. Lower Mold The lower mold (80) is a component for supporting the sheet material S, as is the lower mold (30) of actual example 1, since its fundamental composition has much in common with the lower mold (30), the same symbols shall be used and the explanation shall not be repeated. The lower mold (80) of example 2 is characterized by having a projection (81) in the center of the frame (33) as well as numerous grooves (82a...) provided in the wall surface of the frame (33). In order to form an opening (76) in the center of the secondary blank, the centrally positioned projection (81) pierces the central hole (76e) of the opening (76) and is inserted into the guide hole (87) of the central mold (85). (83) is a hole formed in the panel holder (36), which forms the opening (76). Plurality of grooves (82a...) are formed in locations corresponding to the spacers (77a-77d) of the secondary blank (70) in order to allow the central panel (71) to descend to a fixed position without bending the spacers (77a-77d) (Figs. 13-14). Figs. 16-18 are lateral cross-sectional views of the central section. Central Mold Since the central mold (85) satisfies a function similar to that of the central mold of actual example 1, only an explanation of the differences will be given, namely, that it has a guide projection (86) for the purpose of forming an opening (76). This guide projection (86) has a guide hole (87) at its center, as indicated above; it forces the concavity (67) and its retainers (76a-76d) down into the lower mold (80) and has a lower surface (88) to carry out any necessary folding. Furthermore, the central mold (85) is provided with inwardly retractable panel springs (89) over the entire length of the support (78) of the secondary blank (70) for the purpose of restraining upper level section (66a, etc.) including support (78), in a fixed position (refer to Fig. 16). Upper Mold The symbols of example 1 apply as well to the upper mold (90) since it has fundamentally the same composition. That is, the upper mold (90) has a downward-facing peripheral rim (51) that fits within the frame (33) of the lower mold, and it is a component which produces the outer configuration of the protector primarily by means of the peripheral rim (51). The upper mold (90) is characterized by having a composition which works in union with the leaf springs (89) to stretch out the support (78) and the stepped construction of its lower section. For that purpose, leaf springs (91), are first used to force wall section (66b) of the primary blank (60) toward the inside; the convex stepped section (92), which thereupon forces the wall section (66b) into the concave stepped section (84) of the lower mold; and thrust springs (93), which force the front panel (63) to both the right and left of this fold section (66) against the support surface (32) of the lower mold (80). Production Processes Setting Process A secondary blank (70) is positioned under the above primary blank (60); edge material Q is placed on the material holder (31) of the lower mold (80) and is set so that the front panel (63) surrounding the central opening C is positioned over the support surface (32) (Fig. 13). Central Mold Lowering Process When the central mold (85) is lowered by the descent of the upper plate, its central projection (42) pierces through the central opening C of the primary blank (60) and, while holding the front panel (71) of the secondary blank (70) down together with the panel holder (36), forces it within the central chamber (34) (Fig. 14). At this time, the supporter (78) of the secondary blank (70) is restrained on the top of the support surface (32) and, in addition, spacers (77a and 77b) are also forced down to the prescribed position. Upper Mold Lowering Process The upper plate descends further to the point at which the upper mold (90) fits within the lower mold (80). At this point, since the projections (53) at the lower extremities of each of the corners of the peripheral rim (51) first fold the gluing flaps (65a-65d) of the primary blank (60), the procedure of their first being folded within the outer panels is the same as in the case of the previously-described actual example 1. At this stage, the folded section (66) is formed when the convex stepped section (92), which forms the folded section (66), presses the wall section (66b) and the lower stepped section (66c) of the outer panel (64b) into the concave stepped section (85) thrust springs (93) restrain the front panel (63) against the support surface (32) so that this panel (63) is not dragged into this complex formation (Fig. 18). Meanwhile, the concavity retainers (76a-76d) in the central panel (71) of the secondary blank (70) are raised and formed when the central mold (85) is lowered. It is, therefore, possible to raise the sides (67a-67d) upright, bring them into contact with the cavity retainers (76a-76d) and simultaneously form the concavity by setting the concavity segments (67), which are formed by being punched out separately using primary blank (60), onto the central projection (81) of the lower mold. The paper protector (95) of actual example 2 produced in this manner has a structure such as the one illustrated in Figs. 19-20. That is, through the formation of the concavity (96), which has having the configuration of the central opening C at its center, the formation of the second concavity (97) where required on the central panel, the formation of spaces (98) between the inner panels (72a-72d) and outer panels (64a-64d) and the reinforcement of these spaces (98) by spacers (77a-77d), it becomes possible to protect the contained object M from external forces. Fig. 21 illustrates a paper protector (95) in use in accordance with example 2. As can be clearly seen from the illustration, object M has been furnished on both the right and left with a pair of protectors (95) having symmetrical central openings C, making it possible to use this as a configuration for retaining contained object M. The protector (95) of example 2 can, of course, also be modified so that it can be used singly for the protection of the contained objects. According to this invention, it is possible to obtain paper protectors that have a multiple structure capable of accommodating electronic apparatuses, precision equipment and other products and protect them from shock as resinous protectors do, by folding, tooling, bonding or otherwise processing multiple sheets of paper. Since this paper protector is made up of multiple blanks, as indicated above, the structure is multi-layered and sturdy and, since reinforcing projections are provided between the inner and outer surfaces, it is possible to satisfactorily protect even large items. Moreover, since it is possible to form irregular shapes, such as concavities (58), to accommodate the external configurations of objects, it is effectual in that it can accommodate a wide variety of such objects. The paper protector according to this invention exhibits a number of outstanding characteristics. It lends itself particularly well to surface printing since paper in sheet form is used. It is also possible to obtain the degree of strength required by changing the material, thickness, etc., appropriate to the different in purposes and the items to be accommodated. Packaging operations are simplified due to the uniformity that can be possible to realized and it is also suitable for automation. Being a paper product, it can is also be reused and, in addition, recycled paper material can also be used. Furthermore, if incinerated, it does not generate noxious gases as resins do.

Claims: Multiple structure paper protector comprising at least two paper blanks (10, 20; 60, 70) forming the inner and outer surfaces of the protector and being assembled as a three-dimensional body with gluing flaps (15, 25; 65, 73) provided where required, a central panel (11; 71) provided in the first blank and contacting the contained object (M), inner panels (12; 72) provided around the periphery of the central panel (11; 71) which are raised upright to surround the object (M), first mid panels (73) folded outward from the extremities of the inner panels (12; 72), a central opening (C) of approximately the same shape as the above central panel (11; 71) and provided in the second blank, a second mid panel (13; 63) located either above or below the first mid panel (73) and surrounding the exterior of the inner panels (12; 72), outer panels (14; 64) folded down from the extremities of the second mid panels (13; 63), and spaces (55; 98) of a width approximately the same as the first (73) and second (13; 63) mid panels provided between the inner (12; 72) and outer (14; 64) panels. Multiple structure paper protector according to claim 1, characterized by reinforcements (21-24) for the purpose of connecting the inner and outer panels of either one blank or the other or both (10, 20; 60, 70), and maintaining the width of the space (55; 98) between them in the required configuration. Multiple structure paper protector according to claim 1, characterized by cut-outs provided in the central panel (11; 71) to form concavities or convexities, and tabs inserted into the cut-outs to form the concavities or convexities, making use of stamped-out sections to form a central opening with approximately the same configuration as the central panel of the other blank. Apparatus for producing multiple structure paper protectors comprising at least two paper blanks (10, 20; 60, 70) forming the inner and outer surfaces of the protector and being assembled as a three-dimensional body with gluing flaps provided where required, the apparatus comprising a lower mold (30; 80) provided with a frame section (33) having a support surface (32) which commonly supports first and second mid panels of the two blanks fitted one on top of the other, a central opening (34) within the frame (33) into which the central panel of the first blank is pressed, a central mold (41; 85) which penetrates the central opening of the second blank and serves to hold the first and second mid panels stationary on the support surface (32), an upper mold (50; 90) which has a peripheral rim (51) for the purpose of forming and folding the portions of the outer panels of the blank that project beyond the periphery of the central mold (41; 85) around the external surface of the frame (33), and guide projections (53) fitted into the lower surface of the peripheral rim (51) for the purpose of folding the gluing flaps provided on a portion of the blank in the direction of contact with the outer panels approximately at the location of the outer panel folds, and bonding them. Apparatus according to claim 4, characterized by a lower plate (3) that has a lower mold (30; 80) installed through a heater (7), an upper plate (5) with upper (50; 90) and central (41; 85) molds capable of vertical movement installed through a heater (8), a mechanism on the upper plate (5) for lowering the central (41; 85) and upper (50; 90) molds down over the lower mold (30; 80) installed on the top of the lower plate (3), and the capability of selectively operating either the lower mold heater (7), the upper mold heater (8) or both.

Inventors: SATO SHIZUO, SATO, SHIZUO
Applicants: SATO SHIZUO, SATO, SHIZUO
Application year: 1993
Main classification: B65D5
IPC codes: B65D81, B65D85, B65D77, B65D5