Patent Publication Number: US-2012043249-A1

Title: Buffer material and packing device

Description:
TECHNICAL FIELD 
     The present invention relates to a buffer material and a packing device which protect a packing object from shocks. 
     BACKGROUND ART 
     When a packing object such as a personal computer, display and printer is packed, a buffer material is widely employed so as to interpose between a packing case and the packing object and thereby protect the packing object from the shocks caused by a falling or collision with other objects, of the packing case. 
     For example, as shown in  FIG. 11 , patent document 1 filed by the inventor of the present invention discloses a buffer material  1  for protecting a work W in a packing case  9  from shocks. This buffer material  1  includes a work-holding surface section  2  to hold the work W, supporting sections  3   a  and  3   b  formed, for example, on each of a pair of sides facing each other in the shorter direction of the work-holding surface section  2 , and work-movement-regulating sections  4   a  and  4   b  formed, for example, at each of a pair of sides facing each other in the longer direction of the work-holding surface section  2 . Here, at respective predetermined positions of the work-movement-regulating sections  4   a  and  4   b , cut-out portions  6   a  and  6   b  are formed so that projection sections  5   a  and  5   b  formed in the work W are inserted in them. By inserting the projection sections  5   a  and  5   b  into the respective cut-out portions  6   a  and  6   b , movement of the work W in the shorter direction is regulated. 
     PRIOR ART DOCUMENT 
     Patent Document 
     
         
         [Patent Document 1] Japanese Patent Application Laid-Open No. 2008-308178 
       
    
     DISCLOSURE OF THE INVENTION 
     Problems to be solved by the invention 
     By the way, the projection sections  5   a  and  5   b  are formed, for example, out of a sheet metal member. As generalization, when the projection sections  5   a  and  5   b  are made out of a thin sheet metal member (that is, when the sheet thickness of the sheet metal member is not sufficiently large compared to the length), the projection sections  5   a  and  5   b  may not secure sufficient strength. In particular, when their top portions are subjected to strong force, there is increased possibility of damage to the projection sections  5   a  and  5   b  (for example, their bending over from the base portion or overall curving). 
       FIG. 12  shows an enlarged plan view around the cut-out portion  6   a  formed in the work-movement-regulating section  4   a . In the patent document 1, the cut-out portion  6   a  is formed into the shape fitting that of the projection section  5   a . Here, for example, when the work W in a packed state is dropped in the direction indicated by the arrow in  FIG. 12  (that is, when the packing case  9  in the state illustrated in  FIG. 11  is turned over toward this side and dropped), a buffer area A of the buffer material  1  crushes due to the shock-load of the dropping, and the shock is relieved through the crushing, and thereby the work W is protected. When the buffer area A crushes, the projection section  5   a  is subjected to a certain magnitude of force from the buffer area A in the direction opposite to that indicated by the arrow in  FIG. 12 . 
     Here, there is a restriction that the sheet thickness of the projection sections  5   a  and  5   b  is not allowed to be sufficiently large, because of recent strong demands for the weight saving of the work W including the projection sections  5   a  and  5   b . In some cases there is no choice but to use the projection sections  5   a  and  5   b  not having sufficient strength. Accordingly, in packing processes, it is necessary to protect also these projection sections  5   a  and  5   b  from shocks, as well as the work W. 
     However, because the cut-out portion  6   a  is formed in the shape fitting that of the projection section  5   a  as described above, a top portion  8  of the projection section  5   a  is subjected to the force substantially equivalent to that a base portion  7  is subjected to. That is, because the top portion  8  is subjected to a strong force, the risk of damage of the projection section  5   a  increases when the projection sections  5   a  and  5   b  do not have sufficient strength (that is, when the sheet thickness is small compared to the length) as described above. On the other hand; if the buffer area A is made easier to crush, it may be possible to relieve the force the top portion  8  is subjected to, and consequently to avoid the damage of projection section  5   a . However, if the buffer area A is made too easy to crush, the possibility that the work W itself cannot be protected from shocks increases, in turn. 
     That is, when the shape of the cut-out portion  6   a  was made to fit that of the projection section  5   a  and the projection sections  5   a  and  5   b  do not have sufficient strength, as presented in the patent document 1, packing designers need to make complex buffer designs specifically for each product so as to achieve both the protection of the work W and the prevention of damage of the projection section  5   a.    
     The present invention is made in order to solve the above-described problem, and its object is to provide a buffer material and packing device having sufficient buffering performance but not requiring complex buffer designs. 
     Means for solving the Problem 
     In order to solve the above-described problem, a buffer material of the present invention includes: a work-holding surface section which is substantially quadrilateral in shape and holds a work; a work-movement-regulating section which is formed at least one side of a predetermined pair of facing sides of the work-holding surface section, and, by its one predetermined surface&#39;s being in contact with the work, regulates the movement of the work in the direction of the contact; a cut-out portion which is formed at a predetermined position in the work-movement-regulating section so that a projection section formed on the work is inserted in it: 
     wherein the cut-out portion is cut out in such a manner that the distance between an inner wall surface formed by the cut-out portion in the work-movement-regulating section and the facing surface of the projection section which is opposite to the inner wall surface increases with increasing distance in the opposite direction from the surface in contact with the work, of the work-movement-regulating section. 
     Further, a packing device of the present invention includes a packing case and buffer material for protecting a work in the packing case from shocks, wherein the buffer material includes: a work-holding surface section which is substantially square in shape and holds a work; a work-movement-regulating section which is formed at least one side of a predetermined pair of facing sides of the work-holding surface section, and, by its one predetermined surface&#39;s being in contact with the work, regulates the movement of the work in the direction of the contact; a cut-out portion which is formed at a predetermined position in the 
     work-movement-regulating section so that a projection section formed on the work is inserted in it: and further in the buffer material, the cut-out portion is cut out in such a manner that the distance between an inner wall surface formed by the cut-out portion in the work-movement-regulating section and the facing surface of the projection section which is opposite to the inner wall surface increases with increasing distance in the opposite direction from the surface in contact with the work, of the work-movement-regulating section. 
     Advantageous Effects of Invention 
     According to the present invention, there is provided a buffer material and packing device having sufficient buffering performance but not requiring complex buffer designs. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view for describing an exemplary configuration of a packing device according to the first exemplary embodiment of the present invention. 
         FIG. 2  is an enlarged plan view around a cut-out portion shown in  FIG. 1 . 
         FIG. 3  is diagrams showing a transition of the buffer area crushing when the packing case containing a work is dropped in the direction indicated by the arrow, where (a) shows a state diagram for an initial stage of the crush, and (b) shows a state diagram for a final stage of the crush. 
         FIG. 4  is an enlarged plan view around the cut-out portion showing the first example of a shape of the cut-out portion in the first exemplary embodiment. 
         FIG. 5  is an enlarged plan view around the cut-out portion showing the second example of a shape of the cut-out portion in the first exemplary embodiment. 
         FIG. 6  is an enlarged plan view around the cut-out portion showing the third example of a shape of the cut-out portion in the first exemplary embodiment. 
         FIG. 7  is an enlarged plan view around the cut-out portion showing the fourth example of a shape of the cut-out portion in the first exemplary embodiment. 
         FIG. 8  is a partial perspective view of a first buffer material for describing an exemplary configuration of the first buffer material according to the second exemplary embodiment of the present invention. 
         FIG. 9  is a diagram for describing the way a shock-load due to the dropping of the packing case is dispersed by a triangular hole portion, when the packing case containing a work is dropped in the direction indicated by a thin arrow in the diagram, and is a plan view of the work-contacting surface of the first buffer material shown in  FIG. 8 . 
         FIG. 10  is a fragmentary perspective view for describing another exemplary configuration of the first buffer material of the second exemplary embodiment shown in  FIG. 8 . 
         FIG. 11  is a perspective view for describing a structure of buffer material as a related art. 
         FIG. 12  is an enlarged plan view around a cut-out portion formed in the work-movement-regulating sections shown in  FIG. 11 . 
     
    
    
     MODE FOR CARRYING OUT THE INVENTION 
     First Exemplary Embodiment 
       FIG. 1  is a perspective view for describing an exemplary configuration of a packing device  10  according to the first exemplary embodiment of the present invention. This packing device  10  includes a packing case  12 , first buffer material  14  and second buffer material  16 . The packing case  12 , the first buffer material  14  and the second buffer material  16  are formed out of the same or the same kind of elastic sheet-shaped members, for example, corrugated cardboard. In the description given below, this sheet-shaped member is assumed to be corrugated cardboard. 
     The packing case  12  includes a bottom surface section  20 , side surface sections  22 ,  24 ,  26  and  28  and a ceiling surface section  30 . The ceiling surface section  30  includes ceiling flaps  30   a - 30   d  which can be opened and closed. As recognized from  FIG. 1 , inside the packing case  12 , the first buffer material  14 , work W and the second buffer material  16  are arranged in order from the bottom. 
     The first buffer material  14  includes a work-holding surface section  40 , supporting sections  42   a  and  42   b , and work-movement-regulating sections  44   a  and  44   b.    
     The work-holding surface section  40  is substantially quadrilateral in shape and holds the work W. The supporting sections  42   a  and  42   b  are formed, for example, on each side of a pair of facing sides, on the work-holding surface section  40 , facing each other in the shorter direction (the direction indicated by arrow Y 2  in  FIG. 1 ), and extends in the first direction (the direction indicated by arrow X 1  in  FIG. 1 ) which intersects with the work-holding surface section  40  at substantially right angles. The supporting sections  42   a  and  42   b  support the first buffer material  14 , by having their top portions in contact with the bottom surface section  20  of the packing case  12 . 
     Work-movement-regulating sections  44   a  and  44   b  are formed, for example, at each side of a pair of facing sides, on the work-holding surface section  40 , facing each other in the longer direction (the direction indicated by arrow Y 1  in  FIG. 1 ). The work-movement-regulating sections  44   a  and  44   b  are formed in the shape of, for example, a hollow rectangular parallelepiped. By the contact of predetermined surfaces of the rectangular parallelepiped with the work W, the movement of the work W in the longer direction is regulated. 
     At respective predetermined positions in the work-movement-regulating sections  44   a  and  44   b , cut-out portions  206   a  and  206   b  are formed so as to have projection sections  204   a  and  204   b , formed on the work W, inserted in them.  FIG. 2  shows an enlarged plan view around the cut-out portion  206   a . Here, the cut-out portion  206   b  may be different from in the position, direction or size of its formation. However, its shape is identical with the cut-out portion  206   a , and therefore the description of the cut-out portion  206   b  will be omitted. 
     As recognized from  FIG. 2 , the cut-out portion  206   a  is cut out in such a manner that the distance between an inner wall surface  350  formed by the cut-out portion  206   a  in the work-movement-regulating section  44   a  and the facing surface  370  of the projection section  204   a  which is opposite to the inner wall surface  350  gradually increases with increasing distance in the opposite direction (that is, toward the left side edge portion in the longer direction) from the surface  301 , in contact with the work, of the work-movement-regulating section  44   a . That is, when the distance between the facing surface  370  and the inner wall surface  350  at the base portion  300  of the projection section  204   a  is expressed by S 1 , the distance between the facing surface  370  and the inner wall surface  350  at the middle portion  304  of the projection section  204   a  by S 2 , and the distance between the facing surface  370  and the inner wall surface  350  at the top portion  302  of the projection section  204   a  by S 3 , the relation between the distances S 1 -S 3  is expressed as distance S 3 &gt;distance S 2 &gt;distance S 1 . The area between the near side edge portion  250  of the work-movement-regulating section  44   a  and the inner wall surface  350  of the cut-out portion  206   a  is a buffer area A which crushes to protect the work W when being subjected to a shock-load. 
     The following description will be made referring to  FIG. 1  again. The second buffer material  16  includes a work-holding surface section  50  and supporting sections  52   a  and  52   b . The work-holding surface section  50  is a space for holding the work W from the direction opposite to that of the work-holding surface section  40  of the first buffer material  14  (that is, from the ceiling side). The work-holding surface section  50  is formed in a shape of substantially quadrilateral. The supporting sections  52   a  and  52   b  are formed, for example, on each side of a pair of facing sides, on the work-holding surface section  50 , facing each other in the shorter direction (the direction indicated by arrow Y 2  in  FIG. 1 ), and extends in the first direction (the direction indicated by arrow X 2  in  FIG. 1 ) which intersects with the work-holding surface section  50  at substantially right angles. The top portions of the supporting sections  52   a  and  52   b  are bent inside to form contact sections  54   a  and  54   b . The contact sections  54   a  and  54   b  are in contact with the ceiling surface section  30  of the packing case  12 . That is, when the work W is packed, the second buffer material  16  is arranged at the ceiling area of the packing case  12 . The work-holding surface section  50  holds the work W from the ceiling side by a pressing force toward the bottom direction which the contact sections  54   a  and  54   b  are subjected to. 
       FIG. 3  shows a transition of a crushing of the buffer area A when the packing case  12  containing the work W is dropped in the direction indicated by the arrow in the figure (that is, when the packing case  12  in the state illustrated in  FIG. 1  is turned over toward this side and dropped). To be more specific,  FIG. 3(   a ) shows a state diagram for an initial stage of the crushing, and  FIG. 3(   b ) shows a state diagram for a final stage of the crushing. When subjected to a shock-load due to the dropping, first, at the base portion  300  of the projection section  204   a , the facing surface  370  and the inner wall surface  350  become in contact with each other, and consequently a base-side region A- 1  of the buffer area A crushes ( FIG. 3  ( a ) is referred to). In this stage, at the top portion  302  of the projection section  204   a , the facing surface  370  and the inner wall surface  350  have not become in contact with each other yet. After that, at the middle portion  304  of the projection section  204   a , the facing surface  370  and the inner wall surface  350  gradually become in contact with each other, and consequently the middle region A- 2  of the buffer area A crushes. In the final stage, the facing surface  370  and the inner wall surface  350  become in contact with each other at the top portion  302  of the projection section  204   a , and consequently the top-portion-side region A- 3  of the buffer area A crushes ( FIG. 3  ( b ) is referred to). In this situation, the shock which the projection section  204  is subjected to is largest at the base portion  300 , is relieved gradually as it propagates to the middle portion  304 , and is fairly weakened or completely vanished when reaching the top portion  302 . There may be a case where the shock-load due to the dropping is relatively weak, and therefore the buffering motion ends at the middle portion  304  before the shock-load reaches the top portion  302 . 
     As has been described above, the top portion  302  of the projection section  204   a  inserted in the cut-out portion  206   a  having the shape such as of this exemplary embodiment is never subjected to so strong shock as that the base portion is subjected to. Accordingly, damage (bending over from the base portion or overall curving) of the projection section  204   a  is avoided. 
     Moreover, by making the cut-out portion  206   a  into the shape described above, it becomes unnecessary to be concerned about at least the damage of the projection section  204   a . Packing designers are relieved from complex buffer designs. That is, it becomes possible to achieve both the protection of work W and the prevention of damage of the projection section  204   a  without requiring a lot of effort. 
     Further, in the normal state, because the base portion  300  of the projection section  204   a  is supported by the entrance portion of the cut-out portion  206   a  (that is, the portion where the distance between the facing surface  370  of the projection section  204   a  and the inner wall surface  350  is smallest), the movement of work W in the shorter direction (the direction indicated by arrow Y 2  in  FIG. 1 ) is regulated as in the case the cut-out portion is formed into the shape fitting the projection section  204   a.    
     Here, the shape and size of cut-out portion  206   a  may be determined appropriately according to the characteristics of work W (the weight of work W itself and the strength of projection section  204   a ). It is not necessary to form a cut-out portion in both of the work-movement-regulating sections  44   a  and  44   b . The number of cut-out portions is not necessary to be one, and, for example, a plurality of cut-out portions may be formed according to the work W. 
     The shape of the cut-out portion  206   a  can be those described below, for example. 
       FIG. 4  is an enlarged plan view around the cut-out portion showing the first example of a shape of the cut-out portion  206   a  in the first exemplary embodiment. In the case of the cut-out portion  206   a  shown in  FIG. 4 , two sides  380   a  and  380   b  both facing to the projection section  204   a  may be cut out into a curved line shape (in a curved surface shape, when described in three dimensions). 
       FIG. 5  is an enlarged plan view around the cut-out portion showing the second example of a shape of the cut-out portion  206   a  in the first exemplary embodiment. In the case of the cut-out portion  206   a  shown in  FIG. 5 , a side  382  located on the apex-portion side of the projection section  204   a  does not need to be a straight line but may be a curved line. In  FIG. 5 , the case with a side  382  curving outward is illustrated as an example, but the side  382  may be curved inward. 
       FIG. 6  is an enlarged plan view around the cut-out portion showing the third example of a shape of the cut-out portion  206   a  in the first exemplary embodiment. In the case of the cut-out portion  206   a  shown in a  FIG. 6 , two sides  380   a  and  380   b  both facing to the projection section  204   a  may be cut out into a saw-tooth-like shape (in a step-like shape, when described in three dimensions). 
       FIG. 7  is an enlarged plan view around the cut-out portion showing the fourth example of a shape of the cut-out portion  206   a  in the first exemplary embodiment. Here, the sheet thickness of the projection section  204  gradually increases making a first angle θ 1 , as it approaches the top portion. In this case, the two sides  380   a  and  380   b  of the cut-out portion  206   a  are cut out such that they gradually expand making a first angle θ 2  which is larger than the first angle θ 1 . 
     That is, what is necessary is that the cut-out portion  204   a  is cut out in such a shape that the distance between the inner wall surface  350  formed by the cut-out portion  206   a  in the work-movement-regulating section  44   a  and the facing surface  370 , of the projection section  204   a , opposite to the inner wall surface  350  gradually increases with increasing distance in the opposite direction, and therefore the shape of the cut-out portion  204   a  is not limited to those shown in FIGS.  2  and  4 - 7  described above. 
     Second Exemplary Embodiment 
       FIG. 8  is a fragmentary perspective view of a first buffer material  400  for describing an exemplary configuration of the first buffer material  400  according to the second exemplary embodiment of the present invention. Here, in the first buffer material  400  of the second exemplary embodiment, reference signs identical with that in the first buffer material  14  of the first exemplary embodiment are assigned to the components identical with that in the first buffer material  14 , and their descriptions are omitted. Additionally, although they are not shown in  FIG. 8 , the components other than the first buffer material  400  of the packing device  10 , that is, the packing case and the second buffer material are identical with the packing case  12  and the second buffer material  16 , respectively, of the first exemplary embodiment. 
     The first buffer material  400  is different from the first buffer material  14  in that it further has a triangular hole portion  450  formed at a predetermined position in a surface  402 , in contact with the work W, of the work-movement-regulating section  44   a . More specifically, the triangular hole portion  450  is formed between the cut-out portion  206   a  and the edge portion on the side near the cut-out portion  206   a  (an edge portion  404  in the case of  FIG. 8 ) in the direction the work-movement-regulating section  44   a  extends (the direction indicated by arrow Y 2  in  FIG. 8 ), with its apex portion  452  directed toward the edge portion  404 . Here, the triangular hole portion  450  is substantially a equilateral triangle in shape, and symmetrically arranged with respect to the center line L about the width direction (the direction indicated by arrow X in  FIG. 8 ) of the surface  402  in contact with the work. 
       FIG. 9  is a diagram for describing the way a shock-load due to the dropping of the packing case  12  is dispersed by a triangular hole portion  450 , when the packing case  12  containing the work W is dropped in the direction indicated by a thin arrow in the diagram, wherein the diagram being a plan view of the surface  402 , in contact with the work, of the first buffer material  400  shown in  FIG. 8 . 
     When the packing case  12  collides with a floor, the triangular hole portion  450  is subjected to a shock-load from the direction indicated by a thick arrow in  FIG. 9 . Through the crushing of the two sides adjacent to each other containing the apex portion  452  of the triangular hole portion  450 , in the two respective directions indicated by the arrow outlines with blank inside in  FIG. 10 , the shock-load is dispersed in these two respective directions. Here, as described above, the triangular hole portion  450  is a equilateral triangle in shape, and symmetrically arranged with respect to the center line L about the width direction of the surface  402  in contact with the work. Therefore, in this case, the magnitudes of the dispersed shock-loads in the two respective directions become the same. 
     As has been described above, by providing a triangular hole portion  450  such as that in the present exemplary embodiment, it becomes possible to disperse the shock-load in any direction desirable for the dispersion in accordance with the work W. With this configuration, the direction of the shock-load can be controlled certainly and easily. Accordingly, there may not be a case where the direction of the shock-load is uncertain and consequently, for example, concentrated at one unexpected point (a region of particularly low strength, for example, a region extremely easy to crush). Therefore, damage of the work W is avoided certainly. 
     In addition, because the direction of dispersing the shock-load can be controlled, the buffering range can be designed to be that of minimum necessary. Accordingly, the first buffer material, thus the packing device, can be smaller in size. 
     In the above description, the triangular hole portion  450  was described to be substantially an equilateral triangle in shape and the position for arranging the triangular hole portion  450  was to be the center with respect to the width direction of the surface  402  in contact with the work. However, the shape and arranging position of the triangular hole portion  450  are not limited to those described above. The shape and arranging position of the triangular hole portion  450 , and additionally the size and number of it, can be changed appropriately according to, for example, the characteristics of the work W (the weight and shape of the work W). 
     Here,  FIG. 10  is a fragmentary perspective view of the first buffer material  500  for describing another exemplary configuration of the first buffer material  500  of the second exemplary embodiment shown in  FIG. 8 . In the first buffer material  500 , the above-mentioned triangular hole portions  450  are formed at predetermined positions near the each end of the cut-out portion  206   a , respectively. By doing this, the work W held by the cut-out portion  206   a  can be protected from the shock-loads applied from the both ends in the shorter direction (the direction indicated by arrow Y 2  in  FIG. 10 ). 
     Modified Embodiment 
     In the first and second exemplary embodiments described above, the work-movement-regulating sections of the first buffer material do not need to be formed at each of a pair of facing sides, facing each other, of the work-holding surface section, but it may be possible that only one of them is formed at one of the sides. Further, the work-movement-regulating sections do not need to be formed over the entire region of each side, but may be formed at only a part of the sides. Further, the work-movement-regulating sections can be formed at each of a pair of facing sides facing each other in the shorter direction (the Y 2  direction in  FIG. 1 , for example). 
     In the first and second exemplary embodiments described above, the shape of respective work-holding surface sections of the first and second buffer materials docs not need to be rectangular but may be square. 
     Further, in the first and second exemplary embodiments described above, there are no restrictions on the production means of the work-movement-regulating section of the first buffer material. For example, the work-movement-regulating section can be produced by folding a plurality of times a flap portion provided connectively to the work-holding surface section of the first buffer material, or by producing the work-movement-regulating section as a member independent of the work-holding surface section and fixing it at a predetermined position on the work-holding surface section by means of gluing, for example. 
     As above, the present invention has been described with reference to the exemplary embodiments, but the present invention is not limited to the above-described exemplary embodiments. Various changes which are easily understood by those skilled in the art within the scope of the present invention may be made with respect to the configurations and details of the present invention. 
     This application claims priority based on Japanese Patent Application No. 2009-098890, filed on Apr. 15, 2009, the disclosure of which is incorporated herein in its entirety. 
     DESCRIPTION OF SYMBOLS 
     
         
         
           
               10  packing device 
               12  packing case 
               14 ,  400 ,  500  first buffer material 
               40  work-holding surface section 
               42   a ,  42   b  supporting section 
               44   a ,  44   b  work-movement-regulating section 
               204   a ,  204   b  projection section 
               206   a ,  206   b  cut-out portion 
               300  base portion 
               302  top portion 
               304  middle portion 
               350  inner wall surface 
               370  facing surface 
               402  surface in contact with a work 
               404  edge portion 
               450  triangular hole portion 
               452  apex portion A buffer area 
             A- 1  base side region 
             A- 2  middle region 
             A- 3  top-portion side region 
             W work