Packaging Structure

Abstract

This invention relates to a packaging structure that ensures protection for components and improves workability related to packaging. The disclosed packaging structure (8) includes a box (5) for housing components (4) and a lower tray (1) and a middle tray (2) formed of corrugated paper sheet. The lower tray (1) is disposed inside the box (5). The middle tray (2) is disposed inside the box (5) at a position above the lower tray (1). In addition, the lower tray has a lower opening (11) for inserting and securing components (4) and a lower first tab (13) disposed at the edge of the lower opening (11) and folded downward. The middle tray has a middle opening (21) for inserting and securing components (4) and a middle first tab (23) disposed at the edge of the middle opening (21), folded downward, and engaged with the lower opening (11) in a state of overlapping with the lower first tab (13).

Description

Technical Field

[0001] This invention relates to the packaging structure of components. Background Technology

[0002] In the past, packaging boxes were used to store components when moving parts manufactured in factories or workshops to warehouses or off-site locations. Inside a typical packaging box, there is a protective structure to stably hold the components and protect them from vibration and impact during handling. Specific examples of protective structures include longitudinal partitions that combine multiple corrugated cardboard pieces into a grid pattern, and square tube structures that bend a single corrugated cardboard piece into a cylindrical shape (see, for example, Patent Documents 1 and 2).

[0003] Prior art literature

[0004] Patent documents

[0005] Patent Document 1: Japanese Patent No. 2913259

[0006] Patent Document 2: Japanese Patent Application Publication No. 2015-187007 Summary of the Invention

[0007] The problem that the invention aims to solve

[0008] In conventional longitudinal partition structures, the cuts of multiple corrugated cardboard sheets must interlock to form a grid pattern, which can easily increase the labor and time required for packaging preparation. Similarly, in conventional rectangular tube structures, a portion of the corrugated cardboard, bent into a cylindrical shape, must be inserted through the narrow slits, leaving room for improvement in workability. On the other hand, if the number of corrugated cardboard sheets constituting the longitudinal partition structure is reduced, or if the insertion points in the rectangular tube structure are cut, the protective structure may be unintentionally simplified in an attempt to improve workability, potentially reducing the protective properties of the components.

[0009] One of the objectives of this invention is to provide a packaging structure that ensures protection for components and improves workability related to packaging, in view of the aforementioned problems. It should be noted that this invention is not limited to this objective; other objectives may also be defined as achieving the effects derived from the various components described in the "Detailed Embodiments" section below, i.e., effects not obtainable by conventional techniques.

[0010] Methods for solving problems

[0011] The disclosed packaging structure includes: a box containing a housing component; a lower tray formed of corrugated cardboard and disposed inside the box; and a middle tray formed of corrugated cardboard and disposed inside the box, positioned above the lower tray. The lower tray has: a lower opening for inserting and securing the component; and a lower first tab disposed at the edge of the lower opening and folded downwards. The middle tray has: a middle opening for inserting and securing the component; and a middle first tab disposed at the edge of the middle opening, folded downwards, and engaged with the lower opening in a state overlapping with the lower first tab.

[0012] Invention Effects

[0013] According to the disclosed packaging structure, the lower and middle pallets can be securely engaged with a simple structure, ensuring protection for components and improving the operability of the packaging operation. Attached Figure Description

[0014] Figure 1 This is an exploded perspective view used to illustrate the packaging structure as an example.

[0015] Figure 2 yes Figure 1 The diagram shows the unfolded lower tray.

[0016] Figure 3 yes Figure 1 The diagram shows the unfolded shape of the middle tray.

[0017] Figure 4 yes Figure 1 The diagram shows the unfolded upper tray.

[0018] Figure 5 It is an exploded perspective view showing the magnified structure used to support a component (motor).

[0019] Figure 6 (A) is a cross-sectional view illustrating the packaging structure without the component (motor), and (B) is a cross-sectional view illustrating the packaging structure with the component (motor) supported.

[0020] Figure 7 This is a top view used to illustrate the packaging structure with the supporting components (motor).

[0021] Figure 8 This is a cross-sectional view used to illustrate the packaging structure as a variation.

[0022] Explanation of reference numerals in the attached figures:

[0023] 1...lower tray;

[0024] 2...Middle layer tray;

[0025] 3...Upper tray;

[0026] 4...motor;

[0027] 5...middle box;

[0028] 6...bottom;

[0029] 7...side view;

[0030] 8, 8'... Packaging structure;

[0031] 10... Lower layer upper surface;

[0032] 11, 11A, 11B... Lower layer openings;

[0033] 12...lower foot section;

[0034] 13, 13′...lower layer first protrusion;

[0035] 14...Second protrusion of the lower layer;

[0036] 15... Lower layer retaining hole;

[0037] 16...lower longitudinal section;

[0038] 17...lower horizontal section;

[0039] 18...lower layer locking section;

[0040] 20... Upper surface of the middle layer;

[0041] 21...Middle layer opening;

[0042] 22...Middle layer foot;

[0043] 23...First protrusion of the middle layer;

[0044] 24...Second protrusion of the middle layer;

[0045] 25... Cover clearance hole;

[0046] 26...Middle layer wall;

[0047] 27...Middle layer insertion section;

[0048] 30... Upper surface of the upper layer;

[0049] 31... Upper opening;

[0050] 32...Upper abutment section;

[0051] 33...Upper locking section;

[0052] 41...Motor section;

[0053] 42...motor housing;

[0054] 43... Connector section;

[0055] 44...protrusion;

[0056] 45... Gearbox section;

[0057] 46... Gearbox housing;

[0058] 47... Output shaft;

[0059] 48... Mounting pins;

[0060] 49... gaskets;

[0061] 50...covering;

[0062] W1~W6... Width dimensions. Detailed Implementation

[0063] The disclosed packaging structure can be implemented through the following embodiments. This packaging structure is a component packaging structure. The types of components mentioned herein are not limited, and include, for example, various motors. In the following embodiments, a specific example of the component is described as a motor 4 with a speed reducer.

[0064] [Example]

[0065] [1. Structure]

[0066] Figure 1 This is an exploded perspective view showing the packaging structure 8 as an embodiment and the motor 4 (an example of a component related to the packaging structure 8). The motor 4 is, for example, a small DC motor with a speed reducer used as a drive source for automotive electronics, industrial machinery, precision equipment, office equipment, home appliances, tools, toys, models, etc. The motor 4 includes a motor section 41 and a speed reducer section 45.

[0067] The motor unit 41 has a structure in which a rotor (not shown) and a stator are built into the motor housing 42. A connector unit 43 for connecting a wiring harness is provided near the motor unit 41. Electricity and control signals for driving the rotor to rotate are input to the motor unit 41 via the wiring harness. In addition, a protrusion 44 is provided on the motor housing 42. The protrusion 44 refers to the portion of the shaft end of the built-in rotor, the bearing (the bearing that supports the shaft so that it can rotate relative to the motor housing 42), and is a cylindrical portion that protrudes outward toward the outside of the motor housing 42.

[0068] The reducer unit 45 has a structure in which a reduction mechanism (not shown) is built into the reducer housing 46. The rotational motion of the rotor generated by the motor unit 41 is reduced by the reduction mechanism and then output to the outside of the motor 4 from the output shaft 47 connected to the reduction mechanism. It should be noted that when the reduction mechanism is composed of a combination of a worm and a helical gear (worm wheel), the output shaft 47 is fixed to the helical gear in a manner coaxial with the rotation axis of the helical gear.

[0069] exist Figure 1 In the example shown, the output shaft 47 is configured to pass through the center of a circular hole formed at the intersection of the shaft and the top surface of the hollow cylindrical reducer housing 46. Furthermore, a gasket 49 is mounted on the top surface of the reducer housing 46 to surround the output shaft 47. The gasket 49 is a component used to seal the gap between the motor 4 and its mounting object. Additionally, mounting feet 48 are bulging out on the cylindrical surface of the hollow cylindrical reducer housing 46, and a cover portion 50 is also protruding. The mounting feet 48 are boss-shaped portions for mounting fasteners (bolts, nuts, screws, rivets, clips, etc.) for fixing the motor 4 to its mounting object. Furthermore, the cover portion 50 corresponds to the joint between the cover member of the reducer housing 46 and the container body, and is shaped such that an annular region, which is part of the cylindrical surface of the reducer housing 46, protrudes radially outward.

[0070] Figure 1 The packaging structure 8 shown includes a middle box 5 (case) for housing the motor 4, a lower tray 1, a middle tray 2, and an upper tray 3. The lower tray 1, middle tray 2, and upper tray 3 are buffer components formed from corrugated cardboard sheets to suppress the shaking and movement of the motor 4 during the handling of the middle box 5 containing the motor 4, and to mitigate external forces that may act on the motor 4. The corrugated cardboard sheets mentioned here include paper corrugated paper, plastic corrugated paper, etc. Furthermore, the middle box 5 can be formed from a material that provides good overall weight and shape stability for the transport motor 4; for example, it can be formed from corrugated cardboard sheets or other materials.

[0071] The middle box 5 is a flat, rectangular container (drawer-shaped inner box, cardboard box) with an open upper surface. The middle box 5 has a bottom surface 6 and four side surfaces 7 that rise upwards from the four outer perimeters surrounding the bottom surface 6. Multiple motors 4 can be accommodated inside a middle box 5. Figure 1 The middle box 5 shown can accommodate twenty motors 4. The middle box 5, which contains the motors 4, is transported, for example, neatly packed into an outer box (not shown) that is larger than the middle box 5. It should be noted that, considering the ease of handling the middle box 5 based on manual operation, carrying handles can also be formed on a pair of opposite sides 7.

[0072] [A. Lower tray]

[0073] The lower tray 1 is a basin-shaped (or surface-shaped, tray-shaped) component disposed inside the middle box 5. In this embodiment, the lower tray 1 is laid inside the middle box 5 in a nearly horizontal state (nearly parallel to the bottom surface 6). Here, in Figure 2 The diagram below shows the unfolded view of the lower tray 1. Figure 2 The solid line in the diagram represents the cut line. Additionally, Figure 2 The dashed line in the image represents the peak-to-trough line when viewing the lower tray 1 from above. Figure 2 The double-dotted line in the image represents the valley fold line when viewed from above on the lower tray 1. The corrugated board direction (corrugated line direction, the direction in which the hollow portion of the core paper extends) of the corrugated board sheet constituting the lower tray 1 is as follows: Figure 2 The left and right directions within. Additionally, in Figure 5 The image shows an enlarged 3D view of the peak and valley folds.

[0074] like Figure 1 , Figure 2 , Figure 5 As shown, the lower tray 1 is provided with a lower upper surface portion 10, a lower opening portion 11, a lower foot 12, a lower first protrusion 13, a lower second protrusion 14, and a lower retaining hole 15. Figure 2 The lower tray 1 shown houses motors 4 arranged in two columns horizontally and ten rows vertically, with the length of the motors 4 parallel to the corrugation direction of the corrugated paper sheet. Each motor 4 is housed in a location with two lower openings 11, a lower first tab 13, and a lower second tab 14. The lower second tab 14 has a lower vertical section 16 and a lower horizontal section 17, and the portion of the lower opening 11 where the lower first tab 13 is folded in has a lower locking section 18. It should be noted that the number of columns in the arrangement of the motors 4 can be set to two or more (e.g., three, five, ten columns, etc.). Similarly, the number of rows can be set to two or more (e.g., two, three, five, etc.).

[0075] about Figure 2 The diagram shows a layout of cut lines, peaks, and valleys arranged in two columns and ten rows. The layout of the first column from the left is such that the layout of the second column is exactly the same. Figure 2 The congruent shapes after horizontal parallel shifting. Additionally, the layout shape of the odd-numbered rows from the top is such that the layout shape of the even-numbered rows is... Figure 2 The shape is rotationally symmetrical after rotating 180° within the paper. With the layout shape described above, the motor 4 can be efficiently accommodated within the limited space of the middle box 5.

[0076] The lower upper surface portion 10 forms the upper surface of the lower tray 1 when the lower tray 1 is placed inside the middle box 5. The lower upper surface portion 10 is formed as a rectangle almost the same size as the bottom surface 6 of the middle box 5, and is almost parallel to the bottom surface 6 of the middle box 5. Furthermore, the lower opening portion 11 is a hole for inserting and securing the motor 4. Figure 5 , Figure 6 As shown in (A) and (B), the lower opening 11 of this embodiment includes a lower opening 11A for inserting the mounting foot 48 and a lower opening 11B for inserting the motor part 41.

[0077] Regarding the positional relationship between the lower opening 11A and the lower opening 11B corresponding to a motor 4, Figure 2 In the middle, in the odd-numbered rows from the top, the lower opening 11A is located on the left and the lower opening 11B is located on the right. On the other hand, in the even-numbered rows, the lower opening 11A is located on the right and the lower opening 11B is located on the left. The shapes of the lower openings 11A and 11B are set to correspond to the shape of the motor 4, and they can also be formed integrally.

[0078] The lower foot portions 12 are four planar portions that hang downwards from the four outer peripheries surrounding the lower upper surface portion 10. The lower foot portions 12 are formed by folding the outer periphery of the lower tray 1 downwards. The height of each lower foot portion 12 is almost the same. Furthermore, the lower end of each lower foot portion 12 is in contact (abuts) with the bottom surface 6. Therefore, the lower upper surface portion 10 is almost parallel to the bottom surface 6. It should be noted that the height of the lower foot portions 12 corresponds to the vertical separation distance between the lower upper surface portion 10 and the bottom surface 6.

[0079] The lower first tab 13 is located at the edge of the lower opening 11A and is folded downwards. The lower first tab 13 is configured, for example, to contact the bottom surface 6 of the middle box 5. Preferably, the lower first tab 13 is configured to be almost perpendicular to the upper surface portion 10 of the lower layer. Figure 2 As shown, the opening area of ​​the lower layer opening 11A before the lower layer first protrusion 13 is folded downward is reduced by an amount corresponding to the size of the lower layer first protrusion 13. On the other hand, as Figure 5 As shown, by folding the lower first protrusion 13 downwards, the opening area of ​​the lower opening 11A is enlarged, ensuring sufficient width when the mounting foot 48 is inserted. At this time, the end edge of the lower opening 11A formed by the folded lower first protrusion 13 becomes the lower locking portion 18 for locking the middle first protrusion 23 (described later). Here, the width dimension of the lower locking portion 18 (…) Figure 2 The vertical dimension is set to W1.

[0080] The lower second protrusion 14 is located at the edge of the lower opening 11B, folded downwards, and contacts the bottom surface 6 of the middle box 5. For example... Figure 2 As shown, the lower opening 11B is not formed before the lower second protrusion 14 is folded downwards. On the other hand, as... Figure 5 As shown, by folding the lower second protrusion 14 downwards, the lower opening 11B is fully exposed, ensuring sufficient width when the motor part 41 is inserted. It should be noted that... Figure 5 The lower second protrusion 14 shown is folded inward in a crank-like shape facing downward.

[0081] In this embodiment, the lower second protrusion 14 has a lower vertical portion 16 and a lower horizontal portion 17. The lower vertical portion 16 is a planar portion extending downward from the lower upper surface portion 10, and the lower horizontal portion 17 is a planar portion that contacts the bottom surface 6 and extends almost horizontally along the bottom surface 6. By providing the lower vertical portion 16 and the lower horizontal portion 17, the lower part and the side of the motor portion 41 are simultaneously covered by the lower second protrusion 14. It should be noted that the lower vertical portion 16 may be perpendicular to the lower upper surface portion 10 or inclined relative to the lower upper surface portion 10. The surface slope of the lower vertical portion 16 can be appropriately set according to the shape of the motor housing 42 that contacts the lower vertical portion 16.

[0082] The lower retaining hole 15 is a hole extending at least to the lower longitudinal portion 16 of the lower second protrusion 14, and is the portion where the protrusion 44 is inserted when the motor portion 41 is inserted into the lower opening 11B. Thus, the protrusion 44 is firmly supported on the lower second protrusion 14, and the entire motor 4 is stably fixed. Furthermore, as... Figure 5 As shown, in this embodiment, the lower layer retaining hole 15 is shaped to extend further down the lower layer upper surface portion 10 than the boundary between the lower layer upper surface portion 10 and the lower layer vertical portion 16. Therefore, when the motor 4 is to be inserted from top to bottom, it is easy to insert the protrusion 44 into the lower layer retaining hole 15.

[0083] [B. Middle Layer Tray]

[0084] The middle tray 2 is a basin-shaped component disposed inside the middle box 5, positioned above the lower tray 1. In this embodiment, the middle tray 2, like the lower tray 1, is laid almost horizontally inside the middle box 5. Figure 3 The diagram below shows the unfolded view of the middle tray 2. Figure 3 The solid line in the diagram represents the cut line. Additionally, Figure 3 The dashed line in the image represents the peak-to-trough line when viewed from above on the middle tray 2. Figure 3 The double-dotted line in the image represents the valley fold line when viewed from above for the middle tray 2. The corrugated board material constituting the middle tray 2 has the following flute direction: Figure 3The left and right directions within the middle tray. The corrugation direction of the middle tray 2 is the same as that of the lower tray 1. Additionally, in... Figure 5 The image shows an enlarged 3D view of the state after the peak and valley lines are folded in.

[0085] like Figure 1 , Figure 3 , Figure 5 As shown, the middle tray 2 is provided with a middle upper surface portion 20, a middle opening portion 21, a middle foot 22, a middle first protrusion 23, and a middle second protrusion 24. Figure 3 The middle tray 2 shown houses motors 4 arranged in two horizontal rows and ten vertical rows. Each motor 4 is provided with a middle opening 21, a first middle tab 23, and a second middle tab 24. In other words, the middle openings 21 are arranged in two rows when viewed from above. A cover clearance hole 25 is provided in the portion of the middle opening 21 where the first middle tab 23 is folded in. Furthermore, the first middle tab 23 is provided with a middle wall portion 26 and a middle insertion portion 27.

[0086] The upper surface portion 20 of the middle layer forms the upper surface of the middle tray 2 when the middle tray 2 is laid on the middle box 5. The upper surface portion 20 of the middle layer is formed into a rectangle with a size almost the same as the bottom surface 6 of the middle box 5 and the upper surface portion 10 of the lower layer, and is almost parallel to the upper surface portion 10 of the lower layer. In addition, the middle layer opening 21 is a hole for inserting and fixing the motor 4. The shape of the middle layer opening 21 is set to correspond to the shape of the motor 4. In this embodiment, the motor housing 42 and the reducer housing 46 are inserted into the middle layer opening 21. However, the middle layer opening 21 does not contact the gasket 49 of the motor 4. As a result, wear and deformation of the gasket 49 are suppressed, and the maintenance of the motor 4 is improved.

[0087] The middle layer feet 22 are four planar portions that hang downwards from the four outer peripheries surrounding the upper surface portion 20 of the middle layer. The middle layer feet 22 are formed by folding the outer periphery of the middle layer tray 2 downwards. The height of each middle layer foot 22 is almost the same. Furthermore, the lower edge of each middle layer foot 22 is in contact (abuts) with the upper surface portion 10 of the lower layer. Thus, the upper surface portion 20 of the middle layer is almost parallel to the upper surface portion 10 of the lower layer. It should be noted that the height of the middle layer feet 22 corresponds to the vertical separation distance between the upper surface portion 20 of the middle layer and the upper surface portion 10 of the lower layer.

[0088] The middle layer first protrusion 23 is located at the edge of the middle layer opening 21, folded downwards, and engaged with the lower layer opening 11 in a state of overlap with the lower layer first protrusion 13. Like the lower layer first protrusion 13, the middle layer first protrusion 23 is preferably disposed almost perpendicular to the upper surface portion 20 of the middle layer. Figure 3In the middle tray 2 shown, one first protrusion 23 is provided at each of all the middle openings 21 (a total of twenty locations). The first protrusion 23 is located at one end of the middle opening 21 (in... Figure 3 In the middle, for the odd-numbered rows from the top, it is the left end of each middle layer opening 21, and for the even-numbered rows, it is the right end of each middle layer opening 21.

[0089] The second protrusion 24 in the middle layer is a portion located at a different position from the first protrusion 23 in the middle layer, within the edge of the middle layer opening 21, and is folded upwards. The second protrusion 24 is preferably folded in a state perpendicular to the upper surface portion 20 of the middle layer, or in a state further rotated from perpendicularity. The second protrusion 24 becomes the portion that engages with the upper layer locking portion 33, described later.

[0090] exist Figure 3 In the middle layer tray 2 shown, the second middle layer tab 24 is not provided in all the middle layer openings 21, but rather in the middle layer openings 21 arranged in multiple rows. For example, it is only provided on the central side of the middle layer openings 21 arranged in two rows. In other words, it is only provided on the other end side of each middle layer opening 21 (in... Figure 3 In this configuration, a second protrusion 24 is provided at the central position of the two rows (the right end of the middle layer opening 21 in the odd-numbered rows from the top, and the left end of the middle layer opening 21 in the even-numbered rows from the top). In other words, the second protrusion 24 is provided in... Figure 3 The middle layer second protrusion 24 is provided at a total of ten locations, specifically the right end of the left middle layer opening 21 in the odd-numbered row (which consists of only two columns) and the left end of the right middle layer opening 21 in the even-numbered row (which consists of only two columns).

[0091] like Figure 3 As shown, the opening area of ​​the middle layer opening 21 before the middle layer first protrusion 23 and the middle layer second protrusion 24 are folded in is reduced by an amount corresponding to the size of the middle layer first protrusion 23 and the middle layer second protrusion 24. On the other hand, as Figure 5 As shown, by folding the first protrusion 23 of the middle layer downward and the second protrusion 24 of the middle layer upward, the opening area of ​​the middle layer opening 21 is enlarged, ensuring sufficient width when inserting the motor housing 42 and the reducer housing 46.

[0092] In this embodiment, the first protrusion 23 of the middle layer has a middle layer wall portion 26 and a middle layer insertion portion 27. The middle layer wall portion 26 is the folded-in base end side (i.e., upper side) portion of the first protrusion 23 of the middle layer, and the middle layer insertion portion 27 is the folded-in front end side (i.e., lower side) portion. Here, the width dimension of the middle layer insertion portion 27 is ( Figure 3The vertical dimension of the middle layer wall 26 is set to W2, and the width dimension of the middle layer wall 26 is set to W2. Figure 3 The vertical dimension of the middle layer is set to W3. Additionally, the width dimension of the second protrusion 24 in the middle layer is set to W3. Figure 3 The vertical dimension is set to W4.

[0093] The width W2 of the middle insert portion 27 is almost the same as the width W1 of the lower locking portion 18, thereby allowing the middle insert portion 27 to be inserted into and locked inside the lower locking portion 18. Furthermore, the width W3 of the middle wall portion 26 is set to be larger than the width W2 of the middle insert portion 27. As a result, the lower end face of the middle wall portion 26, which forms the step between the middle wall portion 26 and the middle insertion portion 27, comes into contact with the surface of the lower upper surface portion 10.

[0094] It should be noted that the lower end (front end) of the middle layer insertion portion 27 can also contact the bottom surface 6 of the middle box 5. Therefore, not only the lower first protrusion 13, but also the middle first protrusion 23 contacts the bottom surface 6, thereby improving the shape stability of the middle layer tray 2. Alternatively, the lower end (front end) of the middle layer insertion portion 27 can be slightly separated from the bottom surface 6 of the middle box 5. This can suppress buckling deformation of the middle first protrusion 23. It should be noted that in this case, the middle first protrusion 23 is not in contact with the bottom surface 6, but the load acting on the middle layer tray 2 is transferred from the lower end face of the middle wall portion 26 to the lower tray 1, and then via the lower first protrusion 13 to the bottom surface 6. Therefore, even though the middle first protrusion 23 is not in contact with the bottom surface 6, the surface rigidity of the middle layer tray 2 can be maintained.

[0095] The cover clearance hole 25 is a hole that opens at least in the middle wall portion 26 of the middle layer first protrusion 23, and is the portion where the cover portion 50 of the outer surface of the reducer housing 46 is inserted when the motor 4 is inserted into the middle layer opening 21. The cover portion 50 is inserted (swimmed) into the cover clearance hole 25 in a non-contact state. This ensures a certain clearance dimension between the cover clearance hole 25 and the cover portion 50. Furthermore, as... Figure 5 As shown, in this embodiment, the cover clearance hole 25 is formed to extend further towards the middle upper surface portion 20 than the boundary between the middle upper surface portion 20 and the middle wall portion 26. Therefore, when the motor 4 is to be inserted from top to bottom, it is easy to insert the cover portion 50 of the reducer housing 46 into the cover clearance hole 25.

[0096] [C. Upper tray]

[0097] The upper tray 3 is a planar component disposed inside the middle box 5 on the upper surface of the middle tray 2. The upper tray 3 is placed directly on the middle tray 2 in a manner that makes almost face-to-face contact with the upper surface portion 20 of the middle tray. In this embodiment, the upper tray 3, like the lower tray 1 and the middle tray 2, is laid almost horizontally inside the middle box 5. Here, in... Figure 4 The diagram below shows the unfolded view of the upper tray 3. Figure 4 The solid lines in the diagram represent the cutting lines. The corrugated paper sheet constituting the upper tray 3 has the following flute direction. Figure 4 The vertical direction within the tray. The corrugation direction of the upper tray 3 is orthogonal to the corrugation directions of the lower tray 1 and the middle tray 2. Additionally, in... Figure 5 The example shown is a magnified perspective view of the main parts of the upper tray 3.

[0098] like Figure 1 , Figure 4 , Figure 5 As shown, the upper tray 3 is provided with an upper surface portion 30, an upper opening portion 31, an upper abutment portion 32, and an upper locking portion 33. Figure 4 The upper tray 3 shown houses the motors 4 arranged in two rows and ten columns, with an upper opening 31 provided at each location housing the motors 4. In other words, the upper openings 31 are arranged in two rows when viewed from above.

[0099] The upper surface portion 30 forms the upper surface of the upper tray 3 when the upper tray 3 is laid on the middle box 5. The upper surface portion 30 is formed into a rectangle with almost the same size as the lower surface portion 10 and the middle surface portion 20. The upper opening portion 31 is a hole for inserting and securing the motor 4. The shape of the upper opening portion 31 is set to correspond to the shape of the motor 4. In this embodiment, the motor housing 42 and the reducer housing 46 are inserted into the upper opening portion 31. However, the upper opening portion 31 does not contact the gasket 49 of the motor 4. This suppresses wear and deformation of the gasket 49, improving the maintenance condition of the motor 4.

[0100] The upper abutment portion 32 is located at the edge of the upper opening 31, where it abuts against the front end of the output shaft 47 when the motor 4 is inserted into the upper opening 31. This suppresses movement of the output shaft 47 caused by vibration during transport and prevents contact between adjacent motors 4, thus improving the maintenance of the motor 4.

[0101] The upper locking part 33 is a wedge-shaped portion formed at the edge of the upper opening 31. For example... Figure 4 , Figure 5 As shown, the upper locking portion 33 is formed into a trapezoidal shape (inverted cone shape) such that the upper opening 31 expands outward. Here, the width dimension of the boundary portion between the upper opening 31 and the upper locking portion 33 is ( Figure 4 The vertical dimension in the upper layer is set to W5, and the maximum width dimension in the upper locking part 33 is set to W5. Figure 4 The vertical dimension is set to W6.

[0102] The upper locking portion 33 is formed such that the width W5 of the boundary portion between the upper opening 31 and the upper locking portion 33 is narrower than the width of other portions of the upper locking portion 33 (e.g., the largest width W6 in the upper locking portion 33). Furthermore, the width W5 of the boundary portion between the upper opening 31 and the upper locking portion 33 is set to be narrower than the width W4 of the middle second protrusion 24, and the largest width W6 in the upper locking portion 33 is set to be wider than the width W4 of the middle second protrusion 24 (W5 < W4 < W6). Therefore, the middle second protrusion 24 can be inserted into and locked into the upper locking portion 33.

[0103] exist Figure 4 In the upper tray 3 shown, the upper locking part 33 is not provided in all the upper openings 31, but only in the central side of the two rows of upper openings 31. In other words, the upper locking part 33 is provided for... Figure 4 The upper locking part 33 is located at the right end of the left side of the upper opening 31 in the odd-numbered row with only two columns from the top, and at the left end of the right side of the upper opening 31 in the even-numbered row with only two columns. Therefore, the upper locking part 33 is provided at a total of ten locations.

[0104] [2. Containment Status]

[0105] Figure 6 (A) is a cross-sectional view illustrating the packaging structure 8 without the motor 4. In the lower tray 1, the lower end of the lower foot 12 (over the entire circumference of the lower tray 1), the lower end of the lower first tab 13, and the lower horizontal portion 17 of the lower second tab 14 contact the bottom surface 6 of the middle box 5. In the middle tray 2, the lower end of the middle foot 22 (over the entire circumference of the middle tray 2) contacts the lower upper surface portion 10, the middle first tab 23 is engaged with the lower engaging portion 18, and the middle second tab 24 is engaged with the upper engaging portion 33. Since the upper tray 3 is laid on the upper surface of the middle tray 2, it is in overall contact with the middle upper surface portion 20.

[0106] Figure 6 (B) is a cross-sectional view illustrating the state of the packaging structure 8 after housing the motor 4. The reducer section 45 is inserted from above into the lower opening 11A and is stably held by the lower first protrusion 13 and the middle first protrusion 23. At this time, the lower first protrusion 13 and the middle first protrusion 23 divide... Figure 6The housing space for the right motor 4 and the housing space for the left motor 4 shown in (B) function in such a way that they prevent contact between the left and right motors 4 (for example, contact between the reducer part 45 of the left motor 4 and the motor part 41 of the right motor 4).

[0107] The motor section 41 is inserted into the lower opening 11B from above and supported by the lower second protrusion 14. At this time, the protrusion 44 of the motor 4 is inserted into the lower holding hole 15 and stably held by the lower longitudinal portion 16 of the lower second protrusion 14. In addition, the cover portion 50 of the reducer section 45 is inserted relative to the cover clearance hole 25 in a non-contact manner, ensuring a certain degree of clearance between the cover clearance hole 25 and the cover portion 50. Furthermore, the middle second protrusion 24, like the lower first protrusion 13 and the middle first protrusion 23, functions to divide the left and right receiving spaces. This prevents contact between the left and right motors 4 (for example, contact between the reducer section 45 of the left motor 4 and the connector section 43 of the right motor 4).

[0108] Figure 7 This is a top view illustrating the packaging structure 8 housing the motor 4. The front end of the output shaft 47 of the motor 4 abuts against the upper abutment portion 32 located at the edge of the upper opening 31. This suppresses the extension direction of the motor 4 towards the output shaft 47. Figure 7 The motor 4 is stabilized by preventing wobbling and movement in the vertical direction. Furthermore, the middle opening 21 and the upper opening 31 are not in contact with the shims 49 present around the output shaft 47, ensuring a certain clearance size. This suppresses wear and deformation of the shims 49, improving the maintainability of the motor 4.

[0109] [3. Effect]

[0110] (1) The packaging structure 8 of the above embodiment includes: a middle box 5 that houses the motor 4; a lower tray 1 formed of corrugated cardboard and disposed inside the middle box 5; and a middle tray 2 formed of corrugated cardboard and disposed inside the middle box 5 at a position above the lower tray 1. The lower tray 1 has: a lower opening 11 for inserting and securing the motor 4; and a lower first tab 13 disposed at the edge of the lower opening 11 and folded downward. The middle tray 2 has: a middle opening 21 for inserting and securing the motor 4; and a middle first tab 23 disposed at the edge of the middle opening 21, folded downward, and engaged with the lower opening 11 in a state of overlapping with the lower first tab 13.

[0111] With the aforementioned structure, the lower pallet 1 and the middle pallet 2 can be securely joined, improving the rigidity and strength of the packaging structure 8 with a simple structure, and ensuring protection for the motor 4 housed in the middle box 5. Furthermore, the operation of joining the lower pallet 1 and the middle pallet 2 is easy, improving workability related to packaging. In particular, compared to conventional longitudinal partition structures such as those described in Patent Document 1, it is not necessary to interlock the cuts of multiple corrugated cardboard pieces to form a grid pattern, significantly improving workability related to the packaging of the motor 4 and the assembly of the packaging structure 8. Additionally, compared to conventional longitudinal partition structures, the amount of corrugated cardboard used can be reduced, resulting in significant cost reduction.

[0112] Furthermore, by overlapping the middle first protrusion 23 with the lower first protrusion 13, they can function as robust walls supporting the mounting feet 48 of the motor 4. Therefore, it is possible to reliably suppress, for example, [the following conditions]. Figure 6 In (B), the motor 4 can be swayed or moved left and right, and the motor 4 can be stably fixed. Additionally, the lower first protrusion 13 and the middle first protrusion 23 are used to divide... Figure 6 The housing space for the right motor 4 and the housing space for the left motor 4 shown in (B) function in this way. As a result, contact between the left and right motors 4 can be prevented (for example, contact between the reducer part 45 of the left motor 4 and the motor part 41 of the right motor 4), thus preventing deformation and damage.

[0113] Furthermore, by contacting, for example, the lower first protrusion 13 and the middle first protrusion 23 with the bottom surface 6 of the middle box 5, the lower tray 1 and the middle tray 2 can be supported relative to the bottom surface 6 by the lower first protrusion 13. This improves the surface rigidity of the lower tray 1 and the middle tray 2, and suppresses downward bending deformation. For example, in Figure 6 In the lower tray 1 and middle tray 2 shown in (A) and (B), the lower tray 1 and middle tray 2 are designed to prevent the central portion in the left-right direction from loosening downwards. Therefore, the stability and protection of the motor 4 can be improved.

[0114] (2) In the above-described packaging structure 8, the lower tray 1 has a lower foot 12 formed by folding the outer periphery of the lower tray 1 downward and contacting the bottom surface 6, and the middle tray 2 has a middle foot 22 formed by folding the outer periphery of the middle tray 2 downward and contacting the lower tray 1.

[0115] The structure described above ensures the separation distance between the bottom surface 6 and the lower tray 1, and also ensures the separation distance between the lower tray 1 and the middle tray 2. In other words, as... Figure 6 As shown in (A), the motor 4 can be fixed at two different positions in the height direction, which can improve the stability and protection of the motor 4.

[0116] (3) The motor 4 mentioned above is a motor 4 with a protrusion 44. In addition, in the packaging structure 8 mentioned above, the lower tray 1 has: a lower second protrusion 14, which is folded downward and contacts the bottom surface 6 of the middle box 5; and a lower retaining hole 15, which is opened on the surface of the lower second protrusion 14 for the protrusion 44 to be inserted.

[0117] Through the structure described above, for example, Figure 5 , Figure 6 As shown in (B), the motor section 41, which has a relatively large weight, can be supported from all four sides (front, back, left, and right from the motor 4 in a top view), thereby improving the stability and protection of the motor 4. Furthermore, the protrusion 44 can be firmly supported on the lower second protrusion 14, suppressing the shaking and movement of the motor section 41. Moreover, by having the lower second protrusion 14 contact the bottom surface 6 of the middle box 5, the surface rigidity of the lower tray 1 can be further improved. Therefore, the stability and protection of the motor 4 can be improved.

[0118] (4) For example, Figure 5 , Figure 6 As shown in (A), the lower second tab 14 is formed in a crank-like shape that is folded downwards. This allows for adjustment of the holding height of the motor housing 42, improving the stability and protection of the motor 4.

[0119] (5) The motor 4 mentioned above is a motor 4 having an output shaft 47. In addition, the packaging structure 8 mentioned above also includes an upper tray 3, which is formed of corrugated cardboard and is disposed inside the middle box 5 on the upper surface of the middle tray 2. The upper tray 3 has: an upper opening 31 for inserting and fixing the motor 4; and an upper abutment 32, which is disposed at the edge of the upper opening 31 and abuts against the front end of the output shaft 47.

[0120] By combining the lower tray 1, middle tray 2, and upper tray 3 in this way, a three-dimensional packaging structure 8 that supports the motor 4 in the vertical, horizontal, and front-back directions can be achieved, improving the stability and protection of the motor 4. Furthermore, during motor 4 handling, movement of the output shaft 47 caused by vibration, contact between adjacent motors 4, and swaying of the motor 4 in the direction extending from the output shaft 47 can be suppressed, improving the maintainability of the motor 4. Additionally, the upper tray 3 reinforces the middle tray 2. Therefore, the stability and protection of the motor 4 are further enhanced.

[0121] (6) In the above-described packaging structure 8, the upper tray 3 has an upper locking part 33 that is wedge-shaped at the edge of the upper opening 31, and the middle tray 2 has a middle second protrusion 24 that is disposed at the edge of the middle opening 21, folded upward and engaged with the upper locking part 33.

[0122] The structure described above allows for a secure connection between the upper pallet 3 and the middle pallet 2. This simple structure enhances the rigidity and strength of the packaging structure 8, ensuring protection for the motor 4 housed within the middle box 5. Furthermore, as... Figure 6 As shown in (B), the middle layer second protrusion 24, like the lower layer first protrusion 13 and the middle layer first protrusion 23, functions to divide the left and right receiving spaces. This prevents contact between the left and right motors 4 (e.g., contact between the reducer portion 45 of the left motor 4 and the connector portion 43 of the right motor 4), thus preventing deformation and damage.

[0123] (7) In the above-described packaging structure 8, such as Figure 3 , Figure 4 As shown, the upper opening 31 and the middle opening 21 are arranged in multiple rows (e.g., two rows) in a top view. Furthermore, the upper locking part 33 and the middle second protrusion 24 are disposed between the multiple rows (e.g., the central side of two rows) in a top view. For example, for Figure 3 In the odd-numbered rows from the top, a second protrusion 24 is provided only at the right end of the left middle layer opening 21 in the two columns. In the even-numbered rows, a second protrusion 24 is provided only at the left end of the right middle layer opening 21 in the two columns.

[0124] Similarly, for Figure 4 In the odd-numbered rows from the top, an upper locking part 33 is provided only at the right end of the upper opening 31 on the left side of the upper opening 31 in the two columns. In the even-numbered rows, an upper locking part 33 is provided only at the left end of the upper opening 31 on the right side of the upper opening 31 in the two columns.

[0125] With the structure described above, compared to the case where upper locking parts 33 and middle second protrusions 24 are provided in all upper openings 31 and middle openings 21, the structure can be simplified, and interference between the motors 4 arranged in multiple rows when viewed from above can be reliably prevented. Therefore, with a simple structure, protection for the motors 4 can be ensured and the workability of the packaging operation can be improved.

[0126] (8) In the above-described packaging structure 8, the middle pallet 2 and the lower pallet 1 are laid inside the middle box 5 in a manner in which the corrugation directions of the middle pallet 2 and the lower pallet 1 are parallel. In contrast, the upper pallet 3 is laid inside the middle box 5 in a manner in which the corrugation direction of the upper pallet 3 is orthogonal to the corrugation directions of the middle pallet 2 and the lower pallet 1.

[0127] In this way, by aligning the corrugation directions of the middle tray 2 and the lower tray 1, the deformation of the middle tray 2 and the lower tray 1 relative to external forces can be aligned, thereby improving the tracking performance of the motor 4 in response to such deformation. Therefore, the protection of the motor 4 can be improved. Furthermore, by making the corrugation directions of the middle tray 2 and the lower tray 1 orthogonal to the corrugation direction of the upper tray 3, the overall rigidity of the middle tray 2 and the lower tray 1 can be improved, thereby enhancing the stability and protection of the motor 4.

[0128] [4. Other]

[0129] The above embodiments are merely illustrative and are not intended to exclude various modifications and techniques not explicitly shown in these embodiments. The structures of these embodiments can be implemented through various modifications without departing from their main principles. Furthermore, the structures of these embodiments can be selected and omitted as needed, or appropriately combined with various structures included in the known art.

[0130] In the above embodiment, a packaging structure 8 comprising a lower tray 1, a middle tray 2, an upper tray 3, and a middle box 5 is illustrated, but the upper tray 3 may be omitted. Additionally, the lower foot 12 and lower second protrusion 14 of the lower tray 1, and the middle foot 22 and middle second protrusion 24 of the middle tray 2 may also be omitted. At least, by forming a lower opening 11 and a lower first protrusion 13 on the lower tray 1, and a middle opening 21 and a middle first protrusion 23 on the middle tray 2, and by having the middle first protrusion 23 engage with the lower opening 11 in a state of overlap with the lower first protrusion 13, a packaging structure 8 achieving the same effect as the embodiment described above can be achieved.

[0131] Figure 8 This is a sectional view used to illustrate the packaging structure 8′ as a variation. Figure 8 In this drawing, elements corresponding to the above embodiments are labeled with the same reference numerals. In this packaging structure 8′, a lower first protrusion 13′ is provided at the edge of the lower opening 11 of the lower tray 1. The lower first protrusion 13′ is a portion that is folded downward and contacts the bottom surface 6 of the middle box 5. The lower end (front end side) of the lower first protrusion 13′ is bent in a manner similar to the lower horizontal portion 17 of the lower second protrusion 14, extending almost horizontally along the bottom surface 6.

[0132] The structure described above increases the contact area between the lower first protrusion 13' and the bottom surface 6. Therefore, the load acting on the lower tray 1 is reliably transferred to the bottom surface 6 via the lower first protrusion 13', improving the shape stability and surface rigidity of the lower tray 1. Furthermore, if the lower end (front end) of the middle insertion portion 27 contacts the curved portion of the lower first protrusion 13', the shape stability and surface rigidity of the middle tray 2 can also be improved.

[0133] It should be noted that openings and tabs can also be added to each of the trays 1 to 3 in the above embodiments and variations. For example, an additional tab can be added to the edge of the upper opening 31. This upper tab is formed to be folded downwards and engages with the middle opening 21 and the lower opening 11. With such a structure, the robustness of the packaging structure 8 can be improved, and the stability and protection of the motor 4 can be further improved with a simple structure.

[0134] The lower pallet 1 described above can also be configured to serve as the bottom surface 6 of the middle box 5. That is, instead of the lower pallet 1 which is to be separated from the middle box 5, a lower opening 11, a lower retaining hole 15, etc., can be provided on the bottom surface 6 of the middle box 5. By giving the bottom surface 6 of the middle box 5 the function of a lower pallet 1, the overall weight of the packaging and the amount of corrugated cardboard used can be reduced, the efficiency of handling operations can be improved, and further cost reductions can be achieved.

[0135] Industrial applicability

[0136] This application can be used in the manufacturing industry of components and the manufacturing industry of packaging materials for packaging components.

Claims

1. A packaging structure, characterized in that, The packaging structure includes: A box, containing its internal components; The lower tray, formed of corrugated cardboard sheet, is disposed inside the box; and The middle tray, formed of corrugated cardboard, is positioned inside the box above the lower tray. The lower tray has: a lower opening for inserting and securing the component; and a lower first tab disposed at the edge of the lower opening and folded downward. The middle tray has: a middle opening for inserting and securing the component; and a middle first tab disposed at the edge of the middle opening, folded downward, and engaged with the lower opening in a state of overlapping with the lower first tab.

2. The packaging structure according to claim 1, characterized in that, The lower tray has a lower foot, which is formed by folding the outer periphery of the lower tray downwards to contact the bottom surface of the box. The middle tray has a middle foot, which is formed by folding the outer periphery of the middle tray downwards and contacting the lower tray.

3. The packaging structure according to claim 1, characterized in that, The component is a motor with protrusions. The lower tray has: a lower second protrusion that is folded downward and contacts the bottom surface of the box; and a lower retaining hole that is formed on the surface of the lower second protrusion and for the protrusion to be inserted.

4. The packaging structure according to claim 2, characterized in that, The component is a motor with protrusions. The lower tray has: a lower second protrusion that is folded downward and contacts the bottom surface; and a lower retaining hole that is formed on the surface of the lower second protrusion and for the protrusion to be inserted.

5. The packaging structure according to claim 3, characterized in that, The lower second protrusion is folded downwards in a crank-like shape.

6. The packaging structure according to claim 4, characterized in that, The lower second protrusion is folded downwards in a crank-like shape.

7. The packaging structure according to any one of claims 1 to 6, characterized in that, The component is a motor with an output shaft. The packaging structure also includes an upper pallet, which is formed of corrugated cardboard and laid inside the box on top of the middle pallet. The upper tray has: an upper opening for inserting and securing the component; and an upper abutment portion disposed at the edge of the upper opening and abutting against the front end of the output shaft.

8. The packaging structure according to any one of claims 1 to 6, characterized in that, The packaging structure also includes an upper pallet, which is formed of corrugated cardboard and laid inside the box on top of the middle pallet. The upper tray has: an upper opening for inserting and securing the component; and an upper locking portion formed in a wedge shape at the edge of the upper opening. The middle tray has a middle second protrusion, which is disposed at the edge of the middle opening, folded upward, and engaged with the upper locking part.

9. The packaging structure according to claim 7, characterized in that, The upper tray has an upper locking part, which is wedge-shaped at the edge of the upper opening. The middle tray has a middle second protrusion, which is disposed at the edge of the middle opening, folded upward, and engaged with the upper locking part.

10. The packaging structure according to claim 8, characterized in that, The upper opening and the middle opening are arranged in multiple columns when viewed from above. The upper locking part and the middle second protrusion are arranged between the multiple columns when viewed from above.

11. The packaging structure according to claim 9, characterized in that, The upper opening and the middle opening are arranged in multiple columns when viewed from above. The upper locking part and the middle second protrusion are arranged between the multiple columns when viewed from above.

12. The packaging structure according to claim 7, characterized in that, The middle and lower pallets are laid inside the box with their corrugated surfaces parallel to each other. The upper pallet is laid inside the box in such a manner that the corrugation direction of the upper pallet is orthogonal to the corrugation directions of the middle pallet and the lower pallet.

13. The packaging structure according to claim 8, characterized in that, The middle and lower pallets are laid inside the box with their corrugated surfaces parallel to each other. The upper pallet is laid inside the box in such a manner that the corrugation direction of the upper pallet is orthogonal to the corrugation directions of the middle pallet and the lower pallet.

14. The packaging structure according to claim 9, characterized in that, The middle and lower pallets are laid inside the box with their corrugated surfaces parallel to each other. The upper pallet is laid inside the box in such a manner that the corrugation direction of the upper pallet is orthogonal to the corrugation directions of the middle pallet and the lower pallet.

15. The packaging structure according to claim 10, characterized in that, The middle and lower pallets are laid inside the box with their corrugated surfaces parallel to each other. The upper pallet is laid inside the box in such a manner that the corrugation direction of the upper pallet is orthogonal to the corrugation directions of the middle pallet and the lower pallet.

16. The packaging structure according to claim 11, characterized in that, The middle and lower pallets are laid inside the box with their corrugated surfaces parallel to each other. The upper pallet is laid inside the box in such a manner that the corrugation direction of the upper pallet is orthogonal to the corrugation directions of the middle pallet and the lower pallet.

17. The packaging structure according to claim 1, characterized in that, The lower tray is configured to also serve as the bottom of the box.

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