Container with a load and method for manufacturing the same

Abstract

A container for carrying a load comprises a container, a plurality of flexible containers, and one or more cushioning materials. Each of the plurality of flexible containers comprises: a main body having a bottom portion and a side portion connected to the bottom portion; and contents housed within the main body, forming at least a first row and a second row arranged side-by-side. One or more cushioning materials are disposed between the first row and the second row. When the area of ​​the shape formed by projecting the main bodies of all the flexible containers constituting the first row onto an imaginary plane parallel to a pair of sidewalls of the container is denoted as x1, and the total area of ​​the one or more cushioning materials overlapping the shape on the imaginary plane is denoted as y1, then 5 ≤ (y1 / x1) × 100 ≤ 80.

Description

Technical Field

[0001] This invention relates to containers containing cargo and methods for manufacturing the same. Background Technology

[0002] Patent Document 1 discloses a conveying system for bagged products. This system utilizes a caster-equipped cage trolley that houses flexible containers (also known as "FIBCs"). The cage trolley is configured to perform filling and unloading operations on the flexible containers while they are still containing them. According to Patent Document 1, the storage, manual movement, truck-based transfer, and unloading of the filled flexible containers are always performed while the cage trolley is in use. This reduces the workload of operators moving the flexible containers and allows for the loading of large quantities of items into the flexible containers.

[0003] Existing technical documents Patent documents Patent Document 1: Japanese Patent Application Publication No. 6-087513 Summary of the Invention The technical problem that the invention aims to solve According to Patent Document 1, the dimensions and loading quantity of the aforementioned cage-carrying vehicle are predetermined based on the cargo box of a truck carrying flexible containers. Therefore, a predetermined number of flexible containers can be loaded neatly together with the cage-carrying vehicle into the cargo box or other container. Figure 3 and Figure 4 However, in reality, the number of flexible containers to be loaded into the container may not always reach a given quantity. In such cases, countermeasures are needed to restrict the movement of each cage car within the container during transport. Due to these countermeasures, new equipment may be required, or the workload of the operators may actually increase.

[0004] Therefore, instead of using a cage-like vehicle as described in Patent Document 1, consideration is given to using cushioning material to fill the space inside the container, thereby restricting the movement of the flexible container within. However, when filling the space inside the container with cushioning material as much as possible, a large amount of cushioning material is required, which may lead to reduced operational efficiency and wasted resources, and is therefore not preferred.

[0005] The purpose of this invention is to provide a container for loading, which can limit the movement of a flexible container while suppressing the amount of cushioning material used, and a method for manufacturing the same.

[0006] Technical solutions for solving technical problems The first aspect of the present invention relates to a container for carrying a load, comprising: a container; a plurality of flexible containers arranged within the container; and one or more cushioning materials. The container comprises: a rectangular bottom wall having opposing first and second sides, and opposing third and fourth sides; a first wall rising from the first side; a second wall rising from the second side; and a pair of side walls rising from the third and fourth sides. Each of the plurality of flexible containers comprises: a main body having a bottom portion and a side portion connected to the bottom portion; and contents housed within the main body. The plurality of flexible containers are arranged in at least a first column and a second column, with the flexible container closest to the first wall as the head and the flexible container closest to the second wall as the tail. One or more cushioning materials are disposed between the first column and the second column. The one or more cushioning materials are configured to contact at least the flexible containers at the tail of the first column and the flexible containers at the tail of the second column. When the area of ​​the shape formed by projecting the main body of all the flexible containers constituting the first column onto an imaginary surface parallel to the pair of sidewalls is denoted as x1, and the total area of ​​the one or more buffer materials overlapping the shape on the imaginary surface is denoted as y1, the following relationship is satisfied: 5≤(y1 / x1)×100≤80.

[0007] The second aspect of the present invention relates to a container for loading cargo, which is the same as the container for loading cargo in the first aspect. The plurality of flexible containers further form a third and a fourth column arranged side-by-side, with the flexible container closest to the first wall as the head and the flexible container closest to the second wall as the tail. The third column is formed above the first column, and the fourth column is formed above the second column. The container for loading cargo in the second aspect also includes one or more cushioning materials disposed between the third and fourth columns. The one or more cushioning materials disposed between the third and fourth columns are configured to contact at least the flexible containers at the tail of the third column and the tail of the fourth column. When the area of ​​the shape formed by projecting the main body of all the flexible containers constituting the third column onto the imaginary surface is denoted as x2, and the total area of ​​the one or more cushioning materials disposed between the third and fourth columns on the imaginary surface overlapping the shape is denoted as y2, the following relationship is satisfied: 5 ≤ (y2 / x2) × 100 ≤ 80.

[0008] The third aspect of the present invention relates to a container containing a load, which is the same container containing a load as the first or second aspect, wherein the flexible container at the end of the third column is configured to be closer to the first wall than the flexible container at the end of the first column, and the flexible container at the end of the fourth column is configured to be closer to the first wall than the flexible container at the end of the second column.

[0009] The fourth aspect of the present invention relates to a container containing a load, which is a container containing a load according to any one of the first to third aspects, wherein one or more cushioning materials disposed between the third column and the fourth column include one or more cushioning materials disposed simultaneously between the first column and the second column and between the third column and the fourth column, thereby contacting at least four flexible containers constituting each of the first to fourth columns.

[0010] The fifth aspect of the present invention relates to a container for carrying a load, which is a container for carrying a load according to any of the first to fourth aspects, wherein the container further has a top portion opposite to the bottom wall portion. The container for carrying a load in the fifth aspect further includes one or more cushioning materials disposed between the top portion and the flexible containers at the ends of the third and fourth columns.

[0011] The sixth aspect of the present invention relates to a method for manufacturing a container containing a load, comprising the following steps: preparing a container having a rectangular bottom wall having opposing first and second sides and opposing third and fourth sides, a first wall standing from the first side, a second wall standing from the second side, and a pair of side walls standing from the third and fourth sides; preparing a plurality of flexible containers, each of the flexible containers comprising: a main body having a bottom portion and a side portion connected to the bottom portion, and contents contained within the main body; preparing one or more cushioning materials; arranging the plurality of flexible containers on the bottom wall to form at least a first column and a second column arranged side by side with the flexible container closest to the first wall as the head of the column and the flexible container closest to the second wall as the tail of the column; and distributing the one or more cushioning materials between the first column and the second column. The configuration of the above-mentioned one or more cushioning materials includes the following steps: configuring the above-mentioned one or more cushioning materials to contact at least the flexible container at the end of the first column and the flexible container at the end of the second column; and configuring the above-mentioned one or more cushioning materials in such a way that the area of ​​the shape obtained by projecting the main body of all the flexible containers constituting the first column onto an imaginary surface parallel to the pair of sidewalls is denoted as x1, and the total area of ​​the above-mentioned one or more cushioning materials overlapping with the shape on the imaginary surface is denoted as y1, so that 5≤(y1 / x1)×100≤80.

[0012] Invention Effects According to the present invention, a container for loading is provided that can limit the movement of a flexible container while suppressing the amount of cushioning material used, and a method thereof is provided for manufacturing the same. Attached Figure Description

[0013] Figure 1This is a perspective view showing the overall structure of a loading container according to one embodiment.

[0014] Figure 2 This is a perspective view showing a structural example of a flexible container.

[0015] Figure 3 Perspective from the side and top surface Figure 1 A diagram of the loading container.

[0016] Figure 4 A perspective from another angle Figure 1 A diagram of the loading container.

[0017] Figure 5 This is a top view showing an example of the structure of a cushioning material.

[0018] Figure 6 This is a diagram illustrating the method for calculating the area of ​​overlap between the cushioning material and the flexible container.

[0019] Figure 7 This is a diagram illustrating the method for calculating the area of ​​overlap between the cushioning material and the flexible container.

[0020] Figure 8 This is a flowchart illustrating a method for manufacturing a loading container according to one embodiment.

[0021] Figure 9 This is a diagram showing the structure of a modified loading container.

[0022] Figure 10 This is a diagram illustrating the structure of a loading container involved in another variation.

[0023] Figure 11 This is a diagram illustrating the structure of the loading container involved in the embodiment. Detailed Implementation

[0024] Hereinafter, with reference to the accompanying drawings, an embodiment of the present invention will be described, including a container containing a load and a method for manufacturing the container containing a load.

[0025] <1. Overall Structure> Figure 1 This is a perspective view showing the overall structure of the container 1 (hereinafter also referred to as "loading container 1") containing the cargo. Figure 1As shown, the loading container 1 includes a container 2, a plurality of flexible containers 3 (hereinafter also referred to as "flexible containers 3") containing contents, and cushioning material 4. Thus, the loading container 1 is configured for transporting the plurality of flexible containers 3. The method of transporting the loading container 1 is not particularly limited; for example, it can be used for land transport based on vehicles or railways, sea transport based on ships, or air transport based on airplanes. As explained below, according to the loading container 1 of the present invention, even if there is residual space within the container 2, the amount of cushioning material 4 used can be suppressed while limiting the movement of the flexible containers 3 during transport.

[0026] <2. Container> Container 2 is a sturdy container configured to load and transport multiple flexible containers 3. In this embodiment, container 2 has a generally cuboid shape, comprising a bottom wall portion 20, a first wall portion 21, a second wall portion 22, a pair of side walls 23 and 24, and a top portion 25 opposite to the bottom wall portion 20. These portions 20-25 define an internal space V of the generally cuboid. The bottom wall portion 20 is rectangular, having a first side 201 and a second side 202 opposite to each other, and a third side 203 and a fourth side 204 opposite to each other. In this embodiment, the first side 201 and the second side 202 are shorter sides, and the third side 203 and the fourth side 204 are longer sides. The top portion 25 also has the same shape as the bottom wall portion 20. Hereinafter, the direction along the first side 201 and the second side 202 will be referred to as the “width direction” of container 2, the direction along the third side 203 and the fourth side 204 will be referred to as the “depth direction” of container 2, the side of the first side 201 (the side of the first wall portion 21) will be referred to as the inner side, and the side of the second side 202 (the side of the second wall portion 22) will be referred to as the near front side.

[0027] The first wall portion 21 rises upward from the first side 201. The lower end of the first wall portion 21 is fixed to the bottom wall portion 20 without movement, and the upper end of the first wall portion 21 is fixed to the top portion 25 without movement. That is, in this embodiment, the inner side of the internal space V is always closed by the first wall portion 21.

[0028] A pair of sidewall portions 23 and 24 rise upwards from the third side 203 and the fourth side 204, respectively. The pair of sidewall portions 23 and 24 are connected to the top surface portion 25 at their upper ends. In this embodiment, the lower ends of the pair of sidewall portions 23 and 24 are fixed immovably to the bottom wall portion 20, and the upper ends of the pair of sidewall portions 23 and 24 are fixed immovably to the top surface portion 25. The near-front ends of the bottom wall portion 20, the pair of sidewall portions 23 and 24, and the top surface portion 25 define the loading and unloading outlets of the container 2.

[0029] The second wall portion 22 has: a first door 22a, which is rotatably connected to the front end of the side wall portion 23; and a second door 22b, which is rotatably connected to the front end of the side wall portion 24. The first door 22a and the second door 22b function as opening and closing mechanisms for the loading and unloading outlets of the container 2, respectively, by rotating relative to the side wall portion 23 and the side wall portion 24. Figure 1 The diagram shows the first door 22a and the second door 22b with the loading and unloading outlets open. The first door 22a and the second door 22b close to each other at the center of the loading and unloading outlets, thus sealing the loading and unloading outlets and forming a second wall portion 22 that rises from the second side 202.

[0030] <3. Flexible Containers> Figure 2 This is a perspective view showing an example of a flexible container 3. The flexible container 3 is a foldable, bag-shaped container, including those made of synthetic resin, natural fibers, or paper. The flexible container 3 has a main body 30 for containing contents. The main body 30 has a bottom portion 300 and side portions 301 connected to the bottom portion 300. The planar shape of the bottom portion 300 is square in this embodiment, but it can also be circular. A discharge port for discharging contents may also be provided on the bottom portion 300. The side portions 301 are configured to stand upright from the periphery of the bottom portion 300, forming a generally rectangular shape when viewed from the side when contents are contained within the main body 30.

[0031] The flexible container 3 may also have a hanging strap 302 mounted on the main body 30 and an upper panel 303 for at least partially covering the contents from above. Additionally, the flexible container 3 may have a bag-shaped inner bag housed within the main body 30 and directly containing the contents. The contents contained in the flexible container 3 are not particularly limited, and examples include synthetic resins, grains, vegetables, sand, stones, fertilizers, and industrial pharmaceuticals. In this embodiment, the contents are granules of a water-absorbing resin.

[0032] Figure 3 It is a side view from the top surface and the 23 side walls. Figure 1 A diagram of the loading container 1. Figure 4 This is a side view of the loading container 1 from the side wall 24. (See diagram.) Figure 3 and Figure 4As shown, multiple flexible containers 3 containing contents are arranged from the inside of container 2 toward the front, forming a row of flexible containers extending in the depth direction within the loading container 1. The row of flexible containers includes a first row 31 and a second row 32 arranged side by side on the bottom wall 20, and a third row 33 formed on the first row 31 and a fourth row 34 formed on the second row 32. The third row 33 and the fourth row 34 are arranged side by side. The flexible container 33h at the end of the third row is configured to be closer to the first wall 21 (inside) than the flexible container 31j at the end of the first row, and the flexible container 34h at the end of the fourth row is configured to be closer to the first wall 21 (inside) than the flexible container 32j at the end of the second row.

[0033] Here, "side-by-side" for two or more flexible container columns means that the most recent front flexible container 3 (e.g., 31j) constituting a certain flexible container column (e.g., the first column 31) and the most recent front flexible container 3 (e.g., 32j) constituting a flexible container column arranged next to that flexible container column (e.g., the second column 32) are arranged adjacent to each other in the width direction of the container 2. In this embodiment, each flexible container column is composed of the same number of flexible containers 3, and the flexible containers 3 in the same order, starting from the first flexible container 3 of each flexible container column, are arranged in a state where they are completely adjacent to each other in the width direction of the container 2 (when viewed from the side of the side wall 23 (or side wall 24), the second column 32 (or the first column 31) located on the opposite side of the first column 31 (or the second column 32) is not visible). However, as long as the above-described "side-by-side" condition is met, two or more flexible container columns may not necessarily be composed of the same number of flexible containers 3, for example, they may be configured to include flexible containers 3 of different sizes.

[0034] All the flexible containers constituting the loading container 1 of the present invention can be arranged such that the maximum gap between two adjacent flexible containers 3 in the depth direction of the loading container 1 is less than 10cm, less than 5cm, less than 3cm, or less than 1cm.

[0035] The first column 31 and the second column 32 each consist of 10 flexible containers 3, and the third column 33 and the fourth column 34 each consist of 8 flexible containers 3. In this specification, the flexible containers 3 constituting the first column 31 to the fourth column 34 are sometimes referred to as 31a to 31j, 32a to 32j, 33a to 33h, and 34a to 34h, respectively. Flexible containers 31a, 32a, 33a, and 34a are the innermost (closest to the first wall portion 21) flexible containers, while flexible containers 31j, 32j, 33h, and 34h are the frontmost (closest to the second wall portion 22) flexible containers in their respective columns.

[0036] In this embodiment, the flexible containers 3 are arranged in the first row 31 to the fourth row 34, each placed on a tray 5 having an upper surface that is the same as but slightly wider than the bottom surface 300. The trays 5 in each row are arranged in the internal space V in a manner that minimizes gaps between them in the depth direction and prevents them from overlapping. The trays 5 containing flexible containers 31a, 32a, 33a, and 34a are either in contact with the first wall portion 21 or separated from it by a gap of approximately 1 cm to 2 cm. Similarly, the trays 5 containing flexible containers 31a to 31j and 33a to 33h are either in contact with the side wall portion 23 or separated from it by a gap of approximately 1 cm to 2 cm, and the trays 5 containing flexible containers 32a to 32j and 34a to 34h are either in contact with the side wall portion 24 or separated from it by a gap of approximately 1 cm to 2 cm. Furthermore, the pallets 5 are arranged with gaps of approximately 10cm to 20cm between the first column 31 and the second column 32, and between the third column 33 and the fourth column 34. Thus, each flexible container 3 is arranged within the internal space V in a manner that allows it to contact the inner walls of adjacent flexible containers 3 and container 2, but the contact areas are not subject to excessive friction. This arrangement of the flexible containers 3 prevents breakage of the flexible containers 3 during transport of the loaded container 1.

[0037] On the other hand, as described above, if the flexible containers 3 are arranged in a manner that minimizes friction between the flexible containers 3 and the inner wall of the container 2 or other flexible containers 3, the flexible containers 3 become easier to move during the transport of the loading container 1. Furthermore, even when gaps remain between the flexible containers 31j, 32j, 33h, and 34h at the end of the column and the second wall portion 22, the flexible containers 3 also become easier to move. This movement of the flexible containers 3 includes not only the case where the flexible containers 3 move together with the pallet 5 from their initial configuration position, but also the case where the flexible containers 3 shift position relative to the pallet 5 (at least a portion of the bottom portion 300 protrudes from the upper surface of the pallet 5). The loading container 1 is equipped with a cushioning material 4 to limit such movement of the flexible containers 3.

[0038] <4. Cushioning Materials> Figure 5 This is a top view showing a structural example of the cushioning material 4. There are no particular limitations on the cushioning material 4; any material can be used. The cushioning material 4 of this embodiment is a bag-shaped airbag used during container transport, comprising: a main body 40 having a vent (not shown); and a valve device 41 for opening and closing the vent. The main body 40 is constructed of a sheet-like material with air-tight properties, such as synthetic resin, paper, metal, or composite materials thereof, and is bag-shaped with a generally rectangular shape. It should be noted that... Figure 5The surface of the main body 40 shown is the surface used opposite to the flexible container 3, and has the largest area in the main body 40. The valve device 41 is configured to open a vent for filling the main body 40 with gas, or to open a vent for discharging gas from the main body 40 to the outside, or to close a vent for maintaining the internal pressure inside the main body 40. It should be noted that a dedicated gas filling device or the like is used to fill the main body 40 with gas.

[0039] In this embodiment, the filling gas is air, but it is not particularly limited. The internal pressure of the buffer material 4 can be appropriately adjusted according to the size of the space in which the buffer material 4 is disposed (the width of the gap to which the buffer material 4 should be filled), the weight of the flexible container 3 that suppresses movement, etc. As a more specific example, the internal pressure of the buffer material 4 can be 0.001 kgf / cm³. 2 ~0.50 kgf / cm 2 0.01 kgf / cm 2 ~0.30 kgf / cm 2 0.05 kgf / cm 2 ~0.20 kgf / cm 2 If the internal pressure of the cushioning material 4 is within the above-mentioned range, it is possible to further limit the amount of cushioning material 4 used while further restricting the movement of the flexible container 3. In addition, the internal pressure of the cushioning material 4 is a gauge pressure based on the pressure (atmospheric pressure) around the cushioning material 4, which refers to the force actually applied to the cargo that the cushioning material 4 contacts.

[0040] The inventors conducted in-depth research and discovered that by positioning the cushioning material 4 between the flexible containers 3 at least in contact with the end of the row of flexible containers arranged side-by-side within the container 2, the movement of the flexible containers 3 can be effectively restricted. Based on this insight, in the loading container 1, cushioning material 4A is positioned between flexible containers 31j and 32j, and cushioning material 4B is positioned between flexible containers 33h and 34h. The internal pressure of cushioning material 4A is adjusted to contact both flexible containers 31j and 32j, and air from the main body 40 presses them down. The internal pressure of cushioning material 4B is adjusted to contact both flexible containers 33h and 34h, and air from the main body 40 presses them down. Furthermore, as... Figure 3 and Figure 4 As shown, the cushioning material 4 can reach not only between the flexible containers 3, but also the gaps in the trays 5 on which they are placed.

[0041] In order for the cushioning material 4A to restrict the movement of the flexible containers 31a-31j and 32a-32j, the cushioning material 4A needs to be able to contact the flexible containers 31a-31j and 32a-32j over a certain area. The inventors discovered the following insights through further research. Figure 6 This is a diagram illustrating the situation. Now, let x1 denote the area of ​​the shape formed by projecting the main body 30 of all the flexible containers 31a to 31j constituting the first column 31 onto an imaginary surface P0 parallel to the pair of sidewalls 23 and 24. Additionally, let y1 denote the area in the imaginary surface P0 where the cushioning material 4A overlaps with the aforementioned shape. If the loading container 1 satisfies 5 ≤ ​​(y1 / x1) × 100, then by configuring the cushioning material 4A, the movement of the flexible containers 31a to 31j and 32a to 32j can be restricted. On the other hand, if the loading container 1 satisfies (y1 / x1) × 100 ≤ 80, then it can be said that the amount of cushioning material 4 used is suppressed.

[0042] The value of (y1 / x1)×100 can be 5-70, 5-60, 5-50, 5-40, 5-30, 5-20, 5-15, 10-70, 10-60, 10-50, 10-40, 10-30, 10-20, 10-15, 15-70, 15-60, 15-50, 15-40, 15-30, 15-20, 20-70, 20-60, 20-50, 20-40, or 20-30. The same applies to the value of (y2 / x2)×100, which will be discussed later.

[0043] When the main body 30 of the flexible container 3 expands while containing contents (i.e., when a portion of the side portion 301 of the flexible container 3 protrudes outward), the shape of the main body 30 of the flexible containers 31a to 31j is approximately the circumscribed quadrilateral P1 of the entire main body 30 of the flexible containers 31a to 31j in the imaginary plane P0. Therefore, the area x1 is considered to be the area of ​​the circumscribed quadrilateral P1. The longitudinal direction L1 of the circumscribed quadrilateral P1 is the same as the maximum length of the main body 30 of the flexible containers 31a to 31j containing contents (the maximum length of the main body 30 in the vertical direction). The transverse direction W1 of the circumscribed quadrilateral P1 is the same as the maximum length at a certain height based on the bottom wall portion 20, from the inner end of the main body 30 of the flexible container 31a to the near-front end of the main body 30 of the flexible container 31j. Therefore, the area x1 of the circumscribed quadrilateral P1 can be calculated according to the following formula (1).

[0044] x1=L1×W1 (1) On the other hand, when the bottom part 300 of the flexible container 3 is circular or square, and the main body 30 does not expand even when containing contents (i.e., when the side part 301 of the flexible container 3 containing contents is approximately vertical when viewed from the side), the area x1 is calculated by (the area of ​​the shape of the main body 30 of any one of the flexible containers 3 constituting the first column 31 projected onto the imaginary surface P0) × (the number of flexible containers 3 constituting the first column). The area of ​​the projected shape of any one flexible container 3 is calculated by (the diameter of the bottom part 300 or the length of one side) × (the length of the side part 301 in the vertical direction). That is, when the flexible container 3 meets the above conditions, the area x1 can also be calculated based on the flexible container 3 excluding contents.

[0045] The shape of the cushioning material 4A on the imaginary surface P0 is approximately the same as the circumscribed quadrilateral P2 of the main body 40 of the cushioning material 4A. Therefore, the area y1 is considered to be the area of ​​the overlapping portion of the circumscribed quadrilateral P2 and the circumscribed quadrilateral P1. The longitudinal direction L2 of the circumscribed quadrilateral P2 is the same as the maximum length of the main body 40 in the longitudinal direction, and the transverse direction W2 is the same as the maximum length of the main body 40 in the width direction (see reference). Figure 5 The area y1 is calculated by subtracting the area z1 of the portion of circumscribed quadrilateral P2 that extends beyond circumscribed quadrilateral P1 from (L2×W2), which represents the area of ​​circumscribed quadrilateral P2. Specifically, as... Figure 7 As shown, if the length of the circumscribed quadrilateral P2 extending from the circumscribed quadrilateral P1 in the vertical direction is denoted as dL, and the length of the circumscribed quadrilateral P2 extending from the circumscribed quadrilateral P1 in the horizontal direction is denoted as dW, the area y1 can be calculated according to the following formula (2).

[0046] y1=(L2-dL)×(W2-dW) (2) The length dL can be determined, for example, based on the measured distance from the bottom wall portion 20 to the lower or upper end of the cushioning material 4A, the height of the tray 5, and the length L1. Additionally, the length dW can be determined based on the measured distance from the near-front end of the main body portion 30 of the flexible container 31j to the near-front end of the cushioning material 4A.

[0047] The above explanation uses the case where a buffer material 4A is arranged between the first column 31 and the second column 32 as an example. However, in addition to buffer material 4A, one or more buffer materials 4 may be further arranged between the first column 31 and the second column 32. In this case, the area y1 becomes the sum of the areas of each buffer material 4 (including buffer material 4A) arranged between the first column 31 and the second column 32 and the circumscribed quadrilateral P1. Furthermore, there is no particular limitation on the position of the one or more buffer materials 4 other than buffer material 4A in the depth direction. In addition, the above explanation uses the relationship between the flexible containers 31a to 31j constituting the first column 31 and the buffer material 4 as an example, but the relationship between the flexible containers 32a to 32j constituting the second column 32 and the buffer material 4 also applies. Therefore, in the loading container 1, at least one of the first column 31 and the second column 32 needs to satisfy 5 ≤ (y1 / x1) × 100 ≤ 80, and preferably both the first column 31 and the second column 32 satisfy 5 ≤ (y1 / x1) × 100 ≤ 80.

[0048] Furthermore, in the loading container 1, it is preferable that the relationship between any one of the third column 33 and the fourth column 34 (preferably both the third column 33 and the fourth column 34) and the cushioning material 4B satisfies 5 ≤ ​​(y2 / x2) × 100 ≤ 80. x2 is the area of ​​the shape on which the main body 30 of the flexible containers 33a-33h or 34a-34h is projected onto the imaginary surface P0. Area x2 can be calculated in the same way as area x1. y2 is the area on the imaginary surface P0 where the cushioning material 4B overlaps with the aforementioned shape. Area y2 can be calculated in the same way as area y1. In addition to the cushioning material 4B, the loading container 1 may also include one or more cushioning materials 4 arranged between the third column 33 and the fourth column 34. In this case, area y2 becomes the sum of the areas where each cushioning material 4 (including cushioning material 4B) disposed between the third column 33 and the fourth column 34 overlaps with the aforementioned shape. Furthermore, the position of the one or more cushioning materials 4 other than the cushioning material 4B in the depth direction is not particularly limited.

[0049] <5. Method for manufacturing the loading container> Figure 8 This is a flowchart illustrating the manufacturing method of the loading container 1 according to this embodiment. This manufacturing method is performed when transporting multiple flexible containers 3 containing contents. The manufactured loading container 1 is loaded onto a vehicle, ship, or aircraft and transported to its destination. The following steps S1 to S13 can be performed by humans or by machines such as robots.

[0050] First, prepare container 2, multiple flexible containers 3 containing contents, and multiple cushioning materials 4 (step S1). In step S1, container 2 is empty. Each flexible container 3 contains contents housed within the main body 30. Furthermore, each cushioning material 4 is not filled with gas. The number of cushioning materials 4 and their placement are predetermined based on the number and arrangement of the flexible containers 3, satisfying 5 ≤ (y / x) × 100 ≤ 80. Container 2 can also be loaded onto a transport vehicle. It should be noted that the orientation of the loaded container 1 during transport is not particularly limited; the loaded container 1 can be loaded onto the transport vehicle with either the first wall 21 or the second wall 22 facing the direction of travel during transport.

[0051] Next, the flexible container 3 is sequentially moved into the internal space V of the container 2 via the loading / unloading outlet (step S2). The flexible container 3 can also be moved in together with the pallet 5. Step S2 can be performed continuously in parallel with the following steps S3 to S13, or it can be performed while being appropriately paused.

[0052] Next, in order to form the first column 31 and the second column 32, two consecutive flexible containers 3 from the flexible containers 3 that were moved in step S2 are arranged on the bottom wall portion 20 (step S3). For example, the two flexible containers 3 initially moved in step S2 are arranged on the bottom wall portion 20 respectively, opposite to the first wall portion 21. In this case, the two flexible containers 3 become the first flexible container 31a of the first column 31 and the first flexible container 32a of the second column 32, respectively. On the other hand, if step S3 is performed again after step S6 (described later), two consecutive flexible containers 3 are arranged adjacent to the flexible containers 3 arranged in the previous step S3, near the front side of them. That is, step S3 is the step of arranging the flexible containers 3 constituting the first column 31 and the second column 32 sequentially from the inside to the near front side.

[0053] Next, based on the predetermined configuration, a determination is made as to whether the cushioning material 4 should be placed between the two flexible containers 3 configured in the previous step S3 (step S4). If it is determined in step S4 that the cushioning material 4 should be placed (yes), then step S5 is executed. If it is determined in step S4 that the cushioning material 4 should not be placed (no), step S5 is skipped, and then step S6 is executed.

[0054] In step S5, after the two flexible containers 3 arranged in the previous step S3 are positioned with the cushioning material 4 sandwiched between them, gas is filled into the main body 40 using a dedicated gas filling device. As described above, the amount of gas filled is appropriately adjusted according to the size of the gap between the flexible containers 3 and / or the weight of the flexible containers 3, so that the cushioning material 4 applies a moderate pressing force to the flexible containers 3. After step S5 is completed, step S6 is executed.

[0055] In step S6, two consecutive flexible containers 3 that were moved in step S2 are respectively arranged on top of the two flexible containers 3 arranged in the previous step S3, corresponding to them. For example, if flexible containers 31a and 32a were arranged in the previous step S3, two new flexible containers 3 are arranged on flexible containers 31a and 32a respectively. That is, the two new flexible containers 3 become the flexible container 33a at the beginning of the third column 33 and the flexible container 34a at the beginning of the fourth column 34, respectively. In other words, step S6 is the step of forming the third column 33 on top of the first column 31 and forming the fourth column 34 on top of the second column 32.

[0056] Next, based on the predetermined configuration, a determination is made as to whether the cushioning material 4 should be placed between the two flexible containers 3 configured in the previous step S6 (step S7). If it is determined in step S6 that the cushioning material 4 should be placed (yes), then step S8 is executed. If it is determined in step S7 that the cushioning material 4 should not be placed (no), then step S3 is executed again.

[0057] In step S8, following the same procedure as in step S5, after arranging the two flexible containers 3 arranged in the previous step S6 with the cushioning material 4 sandwiched between them, gas is filled into the main body 40 using a dedicated gas filling device. After step S8 is completed, step S9 is executed.

[0058] In step S9, it is determined whether the third column 33 and the fourth column 34 are completed. In other words, it is determined whether the flexible containers 3 arranged in the previous step S6 belong to the end of the third column 33 and the fourth column 34 (flexible container 33h and flexible container 34h), respectively. If it is determined that the third column 33 and the fourth column 34 are not completed (no), the process returns to step S3 and proceeds to step S9. If it is determined that the third column 33 and the fourth column 34 are completed (yes), step S10 is executed.

[0059] In step S10, the first column 31 and the second column 32, located closer to the front than the third column 33 and the fourth column 34, are arranged. Specifically, two consecutively loaded flexible containers 3 are arranged adjacent to each other on the front side of the flexible containers 3 configured in the previous step S3 or the previous step S10.

[0060] In step S11, based on the predetermined configuration, a determination is made as to whether the cushioning material 4 should be placed between the two flexible containers 3 configured in the previous step S10. If it is determined in step S11 that the cushioning material 4 should be placed (Yes), then step S12 is executed. If it is determined in step S11 that the cushioning material 4 should not be placed (No), then step S10 is executed again.

[0061] Step S12 follows the same procedure as step S5. After arranging the two flexible containers 3 as arranged in the previous step S10 with the cushioning material 4 sandwiched between them, gas is filled into the main body 40 using a dedicated gas filling device. After step S12 is completed, step S13 is executed.

[0062] In step S13, it is determined whether the first column 31 and the second column 32 are completed. In other words, it is determined whether the flexible containers 3 arranged in the previous step S10 belong to the end of the first column 31 and the second column 32 (flexible containers 31j and 32j, respectively). If it is determined that the first column 31 and the second column 32 are not completed (no), the process returns to step S10 and proceeds to step S13. If it is determined that the first column 31 and the second column 32 are completed (yes), the loading container 1 is manufactured when the loading and unloading outlets of the container 2 are closed using the first door 22a and the second door 22b. Furthermore, if it is determined to be "yes" in step S13, and it was determined in the previous step S11 that the cushioning material 4 should be configured, the configuration of the cushioning material 4 and the filling of gas are performed in the following step S12. That is, in this step S12, the cushioning material 4 is configured between the first column 31 and the second column 32 in such a way that it is at least in contact with the flexible containers 31j and 32j.

[0063] <6. Characteristics> According to the loading container 1 described in the above embodiment, even when gaps remain between the rows of flexible containers arranged in container 2, the movement of the flexible containers 3 can be restricted while suppressing the amount of cushioning material 4 used. In particular, when multiple flexible containers 3 are loaded into container 2, in order to avoid the bags of the flexible containers 3 breaking, each flexible container 3 needs to be configured so as not to experience strong friction from other flexible containers 3 or the inner wall of container 2. Therefore, it is considered that the flexible containers 3 are easy to move during transportation, but according to the loading container 1, the movement of the flexible containers 3 can be restricted while avoiding the bags of the flexible containers 3 breaking. In particular, as in this embodiment, when the flexible container 33h at the end of the third column 33 is positioned further inward than the flexible container 31j at the end of the first column 31, and the flexible container 34h at the end of the fourth column 34 is positioned further inward than the flexible container 32j at the end of the second column 32, a large gap is created between the flexible containers 33h at the end of the third column 33 and the flexible containers 34h at the end of the fourth column 34 and the second wall portion 22 (i.e., an environment where the flexible containers 33a-33h and 34a-33h can easily move), but the cushioning material 4B can be arranged as described above, thereby restricting the movement of the flexible containers 33a-33h and 34a-34h.

[0064] <7. Variations> The embodiments of the present invention have been described above, but the present invention is not limited to the above embodiments. Various modifications can be made without departing from its spirit. For example, the following modifications can be made. In addition, the spirit of the following variations can be appropriately combined.

[0065] (1) The number of flexible containers 3 is not limited to the number described in the above embodiment and can be appropriately changed. For example, in the loading container 1, the third column 33 and the fourth column 34 can be omitted. That is, the multiple flexible containers 3 may not be stacked vertically. Therefore, the cushioning material 4B may also be omitted, and the loading container 1 may also have a cushioning material 4A. On the other hand, in the loading container 1, more than three flexible containers 3 may be stacked vertically. In addition, more than three columns of multiple flexible containers 3 may be arranged on the bottom wall portion 20. Furthermore, the first column 31 and the second column 32 may be defined in the opposite way to the above embodiment. Similarly, the third column 33 and the fourth column 34 may be defined in the opposite way to the above embodiment.

[0066] (2) The top part 25 of container 2 can also be omitted. In addition, multiple flexible containers 3 can be loaded into container 2 without using tray 5.

[0067] (3) In the case where container 2 has a top surface 25, such as Figure 9As shown, the loading container 1 may also include one or more cushioning materials 4 disposed between the top surface 25 and the flexible containers 3 of the third and fourth columns. In this case, the one or more cushioning materials 4 are preferably disposed between the top surface 25 and the flexible containers 3 (flexible containers 33h and flexible containers 34h) at the end of the third and fourth columns.

[0068] (4) such as Figure 10 As shown, the cushioning material 4, including the cushioning material 4B, can also be configured to span not only between the third column 33 and the fourth column 34, but also between the first column 31 and the second column 32. That is, the loading container 1 can also have one or more cushioning materials 4 simultaneously configured between the first column 31 and the second column 32 and between the third column 33 and the fourth column 34, thereby contacting at least four flexible containers 3 constituting each of the columns from the first column 31 to the fourth column 34. In addition, the cushioning material 4 can also contact two or more flexible containers 3 belonging to the same column of flexible containers that are consecutive in the depth direction.

[0069] (5) The cushioning material 4 is not limited to an airbag, and any material known as a packaging material may be used. For example, the cushioning material 4 may also be a material in which bead-shaped foamed cushioning material is filled in the main body of the bag.

[0070] Example Embodiments of the present invention will now be described in detail. However, the present invention is not limited to these embodiments.

[0071] Container 2X, 32 flexible containers 3X, and 3 cushioning materials 4X were prepared. Container 2X is a known transport container (25.6 tons) with the same structure as container 2 described in the above embodiment. Each flexible container 3X contains absorbent resin particles. The bottom of each flexible container 3X is square, with one side length of 0.9m. Furthermore, the vertical length of the side surface of each flexible container 3X is 1.3m. The cushioning materials 4X are airbags, each with an internal pressure of 0.06 kgf / cm². 2 ~0.10 kgf / cm 2 It can be used within the specified range. At this time, the length of the outer quadrilateral of the main body of the cushioning material 4X is 1.1m and the width is 0.8m.

[0072] Using container 2X, flexible container 3X, and cushioning material 4X, the loading container 1X of the embodiment is manufactured according to the manufacturing method described above. Specifically, as... Figure 11As shown, 20 flexible containers 3X ​​are arranged side-by-side to form the first and second columns (10 containers in each column), and 12 flexible containers 3X ​​are arranged side-by-side to form the third and fourth columns (6 containers in each column). Each flexible container 3X is placed on a tray. The height of each tray is 0.12m. Furthermore, each flexible container 3X hardly expands even when containing its contents. It should be noted that... Figure 11 In the diagram, the first wall side of container 2X is indicated as left, and the second wall side of container 2X is indicated as right.

[0073] A cushioning material 4X is disposed between the flexible containers 3X ​​at the ends of the first and second columns. The upper end of this cushioning material 4X is aligned with the upper end of the main body of the flexible containers 3X ​​at the ends of the first and second columns. Another cushioning material 4X is disposed between the flexible containers 3X ​​at the ends of the third and fourth columns, and between the flexible containers 3X ​​below these (those in the first and second columns). The remaining cushioning material 4X is disposed between the flexible containers 3X ​​on one inner side of the flexible containers 3X ​​at the ends of the third and fourth columns, and between the flexible containers 3X ​​below these (those in the first and second columns). The two cushioning materials 4X disposed between the third and fourth columns are each configured with a height of 2.1m from the bottom wall 20 to its upper end (i.e., a height of 1m from the bottom wall 20 to its lower end).

[0074] In the loading container 1X, the area x1, based on the length of one side of the bottom portion of the flexible container 3X, the vertical length of the side portion, and the number of flexible containers 3X ​​constituting the first and second columns, is calculated as 0.9 × 1.3 × 10 = 11.7 (m²). 2 The area y1, based on the area of ​​the circumscribed quadrilateral of one cushioning material 4X, the vertical arrangement of the two cushioning materials 4X, and the height of the tray, is calculated as 0.8 × 1.1 + 2 × 0.8 × (1.3 + 0.12 - 1) = 1.552 (m). 2 Therefore, (y1 / x1)×100≈13.26, confirming the range where 5≤(y1 / x1)×100≤80.

[0075] It should be noted that, similarly, the area multiplied by 2 is calculated as 0.9 × 1.3 × 6 = 7.02 (m²). 2 Additionally, the area y2 is calculated as 2 × 0.8 × (2.1 - 0.12 - 1.3 - 0.12) = 0.896 (m²). 2 Therefore, (y2 / x2)×100≈12.76. In the relationship between the third and fourth columns and the buffer material, it is also confirmed that the range of 5≤(y2 / x2)×100≤80 is satisfied.

[0076] The aforementioned loading container 1X was transported from Japan to its overseas destination. The transportation route consisted of land transport, sea transport, and land transport again. It should be noted that during land transport, the loading container 1X was positioned with its first wall facing the direction of travel. The loading and unloading outlets of the loaded container 1X upon arrival at its destination were opened, and a photograph of the interior of the loading container 1X at the time of manufacture was compared to confirm whether any of the flexible containers 3X ​​had moved. No movement of the flexible containers 3X ​​was confirmed. Furthermore, it was also confirmed whether any of the flexible containers 3X ​​were ruptured, but no rupture was found. Thus, it is confirmed that, according to the present invention, it is possible to limit the movement of the flexible containers while suppressing the amount of cushioning material used.

[0077] Explanation of reference numerals in the attached figures 1. 1X Loading Container 2. 2X Container 3. Flexible containers: 31a~31j, 32a~32j, 33a~33h, 34a~34h, 3X 4. 4A, 4B, 4X cushioning materials 31 First column 32 Second column 33 Third column 34. Fourth column.

Claims

1. A container for carrying a load, characterized in that, have: A container comprising: a rectangular bottom wall having opposing first and second sides and opposing third and fourth sides; a first wall erected from the first side; a second wall erected from the second side; and a pair of side walls erected from the third and fourth sides. A plurality of flexible containers are arranged within the container, each of the plurality of flexible containers comprising: a main body having a bottom portion and a side portion connected to the bottom portion, and contents contained within the main body portion; the plurality of flexible containers are arranged in at least a first column and a second column, with the flexible container closest to the first wall portion as the head of the column and the flexible container closest to the second wall portion as the tail of the column; and One or more cushioning materials are disposed between the first column and the second column. The one or more cushioning materials are configured to contact at least the flexible container at the end of the first column and the flexible container at the end of the second column. When the area of ​​the shape formed by projecting the main body of all the flexible containers constituting the first column onto an imaginary surface parallel to the pair of sidewalls is denoted as x1, and the total area of ​​the one or more cushioning materials overlapping the shape on the imaginary surface is denoted as y1, the following relationship is satisfied: 5≤(y1 / x1)×100≤80.

2. The container for carrying the load according to claim 1, wherein, The plurality of flexible containers also form a third and a fourth column, arranged side by side with the flexible container closest to the first wall as the first column head and the flexible container closest to the second wall as the last column head. The third column is formed above the first column, and the fourth column is formed above the second column. The container containing the load also includes one or more cushioning materials disposed between the third and fourth columns. One or more cushioning materials disposed between the third column and the fourth column are configured to contact at least the flexible container at the end of the third column and the flexible container at the end of the fourth column. When the area of ​​the shape formed by projecting the main body of all the flexible containers constituting the third column onto the imaginary surface is denoted as x2, and the total area of ​​the overlap between the shape and one or more buffer materials disposed on the imaginary surface between the third and fourth columns is denoted as y2, the following relationship is satisfied: 5≤(y2 / x2)×100≤80.

3. The container for carrying the load according to claim 2, wherein, The flexible container at the end of the third column is configured to be closer to the first wall than the flexible container at the end of the first column, and the flexible container at the end of the fourth column is configured to be closer to the first wall than the flexible container at the end of the second column.

4. The container for carrying the load according to claim 2, wherein, One or more cushioning materials disposed between the third column and the fourth column include one or more cushioning materials disposed simultaneously between the first column and the second column and between the third column and the fourth column, thereby contacting at least four flexible containers constituting each of the first column to the fourth column.

5. The container for carrying the load according to claim 3, wherein, One or more cushioning materials disposed between the third column and the fourth column include one or more cushioning materials disposed simultaneously between the first column and the second column and between the third column and the fourth column, thereby contacting at least four flexible containers constituting each of the first column to the fourth column.

6. The container for carrying the load according to claim 2, wherein, The container also has a top portion, which is opposite to the bottom wall portion. The container also includes one or more cushioning materials disposed between the top surface and the flexible containers at the ends of the third and fourth columns.

7. The container for carrying the load according to claim 3, wherein, The container also has a top portion, which is opposite to the bottom wall portion. The container also includes one or more cushioning materials disposed between the top surface and the flexible containers at the ends of the third and fourth columns.

8. A method for manufacturing a container containing a load, characterized in that, Includes the following steps: Prepare a container, the container comprising: a rectangular bottom wall having opposing first and second sides and opposing third and fourth sides, a first wall standing from the first side, a second wall standing from the second side, and a pair of side walls standing from the third and fourth sides; Prepare multiple flexible containers, each of the multiple flexible containers comprising: a main body having a bottom surface and a side surface connected to the bottom surface, and contents contained within the main body; Prepare one or more cushioning materials; The plurality of flexible containers are arranged on the bottom wall portion, forming at least a first column and a second column arranged side-by-side with the flexible container closest to the first wall portion as the column head and the flexible container closest to the second wall portion as the column tail; and One or more buffer materials are disposed between the first column and the second column. The steps of configuring the one or more cushioning materials include the following operations: The one or more cushioning materials are configured to contact at least the flexible containers at the end of the first column and the flexible containers at the end of the second column; and When the area of ​​the shape formed by projecting the main body of all the flexible containers constituting the first column onto an imaginary surface parallel to the pair of sidewalls is denoted as x1, and the total area of ​​the one or more cushioning materials overlapping the shape on the imaginary surface is denoted as y1, the one or more cushioning materials are arranged in such a way that 5 ≤ (y1 / x1) × 100 ≤ 80.

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