Packing structure of vehicular seat

Abstract

To provide a packing structure of a vehicular seat that enables the seat to be packed and unpacked with good workability, is lightweight and is advantageous in reducing material costs and transportation costs.SOLUTION: A packing structure 100 of a vehicular seat includes a fixing base 50 for fixing vehicular seats S onto a loading surface of a transportation member (a returnable rack R). The fixing base 50 is formed of corrugated boards. The fixing base 50 includes a base main body 10 arranged on the loading surface and tether flaps T extending from the base main body 10. The base main body 10 has forward-tilting support parts 10a that support the seats S in a forward / downward tilted attitude from below. The tether flap T is inserted through a gap G between a seat cushion S1 and a seat back S2 in the seat S to anchor a rear part of the seat S.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a packaging structure for transporting a vehicle seat. [Background technology]

[0002] Vehicle seats may be transported to remote locations (e.g. overseas) using a transport container or the like. In this case, the seats are fixed to a returnable rack via a dedicated mounting frame, loaded into the transport container, and packed. This type of packaging structure prevents the load from collapsing due to vibrations and shocks during transport.

[0003] The mounting frame is generally made of steel and is large and heavy in itself. Therefore, the mounting frame is delivered to the packaging site in a divided state and assembled before the packaging of the seats. The seats are fixed to the mounting frame with bolts using the bolt holes for mounting to the vehicle body. Since the bolt holes are provided in two places, one at the front and one at the back, on the left and right slide rails of the seat, for example, the worker fixes the seat using the front bolt hole, and then slides the seat forward so that the worker can access the rear bolt hole hidden by the seat. The worker must repeat this sliding operation and bolt fastening operation for each seat, and in addition, at the destination, the worker must unpack the seat in the reverse order, which is very time-consuming.

[0004] Moreover, it is preferable that returnable racks be used to transport other items rather than being sent empty. In that case, it is desirable to collect the mounting frames as well, but due to time constraints and transportation costs, in practice, the mounting frames are often not collected and instead become one-way (disposable) packaging materials.

[0005] In Patent Document 1, a packaging structure is adopted in which half of the sheets are stored in an upside-down position in order to improve the spatial storage capacity inside the packaging box. However, as mentioned above, various factors other than storage efficiency are related to the transportation cost, and problems such as the ease of packing and unpacking, the manufacturing cost of the dedicated mounting frame, and the collection cost may remain. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Patent No. 3863863 Summary of the Invention [Problem to be solved by the invention]

[0007] The present invention has been made in consideration of the above-mentioned circumstances, and its object is to provide a packaging structure for a vehicle seat that is easy to pack and unpack, lightweight, and advantageous in reducing material costs and transportation costs. [Means for solving the problem]

[0008] In order to achieve the above object, according to one aspect of the present invention, there is provided a packaging structure for a vehicle seat including a fixing base for fixing a vehicle seat on a loading surface of a transport member. In this packaging structure for a vehicle seat, the fixing base is made of corrugated cardboard, and includes a base body arranged on the loading surface, the base body having a forward tilt support part that supports the seat from below in a posture in which the seat is tilted forward and downward, and a tether flap extending from the base body and inserted into a gap between a seat cushion and a seat back in the seat to anchor the rear part of the seat. Effect of the Invention

[0009] According to the present invention, it is possible to provide a packaging structure for a vehicle seat which is easy to pack and unpack, lightweight, and advantageous in terms of reducing material costs and transportation costs. [Brief description of the drawings]

[0010] [Figure 1] 1 is a perspective view showing a packaging structure for a vehicle seat according to an embodiment of the present invention; [Diagram 2] FIG. 13 is a perspective view showing a state in which a fixing base is placed on a pallet. [Diagram 3] FIG. 2 is a perspective view of the fixing base. [Figure 4] FIG. [Diagram 5] FIG. 4 is a side view of the fixing base with the seat fixed thereto; [Figure 6] FIG. 2 is a perspective view of a vertical member of the fastening base and its blank; [Figure 7] FIG. 2 is a perspective view of a vertical member of the fastening base and its blank; [Figure 8] FIG. 4 is a perspective view of a first horizontal member of the fixing base. [Figure 9] FIG. 4 is a perspective view of a second horizontal member of the fixing base. [Figure 10] 5A to 5C are perspective views illustrating an assembly procedure of the fixing base. [Figure 11] 6 is a perspective view showing a process of assembling the first horizontal member and the vertical member; FIG. [Figure 12] 13 is a side view illustrating a modified example of the fixing base. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, an embodiment of the present invention will be described in detail with reference to the drawings. Fig. 1 is a perspective view of a packaging structure 100 for a vehicle seat according to one embodiment of the present invention. In the drawing, the direction of the arrow F indicates the front in the seat front-rear direction, the direction of the arrow B indicates the rear in the seat front-rear direction, and the direction of the arrow U indicates the vehicle upper side in the seat up-down direction. In the description of the embodiment, the "front part (front end) and the rear part (rear end)" correspond to the front part and the rear part in the seat front-rear direction.

[0012] 1, in this embodiment, a packaging structure 100 for a vehicle seat includes a returnable rack R as a transport member for transporting a vehicle seat S, and a fixing base 50 for fixing the seat S on the loading surface of the returnable rack R. In other words, the packaging structure 100 may be called a packaging unit or package for a vehicle seat, or may be called a transport fixing structure for a vehicle seat. FIG. 1 shows a state in which a vehicle seat S is fixed and arranged in the returnable rack R via the fixing base 50 (fixing base assembly).

[0013] The seat S has a seat cushion S1, a seat back S2 provided at the rear of the seat cushion S1, and a pair of left and right seat rails S3 attached to the bottom of the seat cushion S1. As shown in Fig. 5 described later, a gap G is provided between the rear of the seat surface (upper surface) of the seat cushion S1 and the lower end of the seat back S2. The seat rails S3 are members that form the legs of the seat S, and are attached to both sides in the seat width direction at the bottom of the seat cushion S1.

[0014] Although not particularly limited, the seat S has a seat structure in which the heights of the left and right seat rails S3 are different from each other, specifically, the seat rail closer to the center of the vehicle is attached to a floor tunnel of the vehicle body, and the seat rails closer to the left and right doors are attached to the vehicle floor. When installed in the vehicle, in the left seat S, the right seat rail S3 is located at a higher position than the left seat rail S3, and in the right seat S, the left seat rail S3 is located at a higher position than the right seat rail S3.

[0015] The returnable rack R is a general-purpose transport member that surrounds the sheet S to protect the sheet S during transport. The returnable rack R includes a pallet R1 that is rectangular in shape and long in a plane view, and two first outer frames R2 and two second outer frames R3 that are detachable from the pallet R1. The returnable rack R is assembled by erecting each outer frame (R2, R3) on the edge of the pallet R1. During transport, multiple returnable racks R are stored in a single box-shaped transport container (not shown). Each returnable rack R is configured so that another returnable rack R can be stacked above it. In FIG. 1, the first outer frame R2 on the first side (long side) on the front side of the pallet R1 is removed.

[0016] The pallet R1 and each of the outer frames (R2, R3) are made of steel. An opening for inserting the forks of a forklift is provided at the bottom of the first side of the pallet R1. A protruding edge R1a is provided along the top of the first side of the pallet R1, and first engagement portions R1b that engage with the lower edge of the first outer frame R2 are provided at approximately the center and both ends in the longitudinal direction on the protruding edge R1a.

[0017] Second engagement parts R1c that engage with the lower edge of the second outer frame R3 are provided at approximately the center and both ends in the longitudinal direction of the upper part of the second side (short side) of the pallet R1. These second engagement parts R1c have a structure that allows the lower edge of the second outer frame R3 to slide in a direction along the second side (short side) of the pallet R1 and engage with it.

[0018] With the lower edge of the second outer frame R3 engaged with the second engagement portion R1c, the first outer frame R2 is placed in a predetermined position by the first engagement portion R1b. In this state, the sliding movement of the second outer frame R3 is prevented by the first outer frame R2, and the second outer frame R3 is fixed to the pallet R1. Then, the first outer frame R2 is connected to the second outer frame R3 by a lock mechanism R4 provided on the upper portion of the second outer frame R3, and the first outer frame R2 is fixed to the pallet R1.

[0019] The returnable rack R having the above-mentioned configuration is a general-purpose transport member, and the loading surface of the pallet R1 is not provided with a fixing structure for a specific item. For this reason, vehicle seats have conventionally been fixed with bolts using a steel mounting frame. However, as mentioned above, conventionally, a space was required within the transport member (returnable rack) to allow the seats to slide back and forth. For this reason, for example, six seats (three sets) were fixed horizontally in three rows of two seats to the returnable rack R shown in FIG. 1.

[0020] In contrast, in the packaging structure 100 shown in FIG. 1, two fixing bases 50 made of cardboard are used to fix eight sheets S (four sets) in two rows of four sheets each. Each fixing base 50 is made of cardboard material. The cardboard material (cardboard sheet) constituting the fixing base 50 is a paper-made cardboard (double-sided cardboard) in which liners are attached to both sides of a corrugated core. As described later, each member of the fixing base 50 is formed by folding a single cardboard blank (a sheet-shaped cardboard material after punching) that has been subjected to punching or other processing. The fixing base 50 is also integrally formed with a fixing means for the sheet S, and the fixing base 50 is configured to support the sheet S in a posture inclined downward toward the front, so that the sheets can be arranged close to each other in the front and rear. Below, the fixing base 50 according to this embodiment will be mainly described.

[0021] Figure 2 is an oblique view showing the situation in which the fixing base 50 is placed on the pallet R1, Figure 3 is an oblique view of the fixing base 50, Figure 4 is a top view of the fixing base 50, and Figure 5 is a side view of the fixing base 50 with the sheet S fixed thereto.

[0022] 2 to 5, the fixing base 50 includes a base body 10 that is placed on the loading surface of the pallet R1, and a tether flap T that anchors the rear portion of the sheet S.

[0023] The base body 10 is a base that supports the seat S from below. In this embodiment, the base body 10 is formed in a lattice shape as a whole. Specifically, the base body 10 has a plurality of vertical members (1, 2) and a plurality of horizontal members (3, 4), and the vertical members (1, 2) and the horizontal members (3, 4) are combined with each other at their intersections to form a lattice shape as a whole. In other words, the base body 10 has a lattice structure as its basic structure.

[0024] The vertical members (1, 2) extend in a first direction D1 on the loading surface of the pallet R1 and are spaced apart from each other in a second direction D2 perpendicular to the first direction D1. The horizontal members (3, 4) extend in the second direction D2 on the loading surface of the pallet R1 and are spaced apart from each other in the first direction D1. When loaded on the pallet R1, the first direction D1 is aligned with the direction in which the short side (second side) of the pallet R1 extends, and the second direction D2 is aligned with the direction in which the long side (first side) of the pallet R1 extends, with each vertical member (1, 2) extending parallel to the short side of the pallet R1 and each horizontal member (3, 4) extending parallel to the long side of the pallet R1.

[0025] In this embodiment, the base body 10 includes at least one set of vertical members (1, 2) and at least two sets of horizontal members (3, 4), and each set of horizontal members (3, 4) is composed of one first horizontal member 3 and one second horizontal member 4 arranged behind the first horizontal member 3. The fixing base 50 is configured so that at least two sheets S can be fixed in a state in which they are placed side by side in the front and rear direction by disposing the second set of horizontal members (3, 4) behind the first set of horizontal members (3, 4). Here, the base body 10 of the fixing base 50 has two sets (four) of vertical members (1, 2) and two sets (four) of horizontal members (3, 4), and one fixing base 50 can fix four sheets S in two rows of two sheets. The packaging structure 100 has two fixing bases 50, and the fixing bases 50 for four sheets are arranged side by side on the loading surface of the pallet R1. As a result, eight sheets (four sets) of seats S are fixed by the packaging structure 100.

[0026] Basically, each pair of vertical members (1, 2) is disposed in correspondence with the left and right seat rails S3 of the seat S, and serves as a structural element that supports the weight of the seat S. Meanwhile, each pair of horizontal members (3, 4) has the function of defining the spacing between the vertical members (1, 2), and of holding each of the vertical members (1, 2), which have a vertically long rectangular cross section, in an upright position.

[0027] Each of the vertical members (1, 2) and horizontal members (3, 4) is formed into a hollow cylinder by bending a single cardboard blank (cardboard material), as described below. The fitting portions at the intersections of the vertical members (1, 2) and horizontal members (3, 4) are formed as upper and lower fitting grooves (1g1, 1g2, 2g1, 2g2, 3g1, 3g2, 4g1, 4g2) that are open upward or downward. The vertical members (1, 2) and horizontal members (3, 4) are fitted together to maintain their respective cross-sectional shapes.

[0028] The upper surface (1u, 2u) of each vertical member (1, 2) provides a placement surface on which the seat rail S3 of the seat S is placed. In the packaging structure 100, a seat layout structure is adopted in which the left seat S is placed on the left side on the fixing base 50, and the right seat S is placed on the right side on the fixing base 50. As a result, a pair of left and right seats S are placed on the base main body 10 in the same layout as when mounted on the vehicle. Specifically, in this seat layout structure, the two vertical members 1 near the center in the base width direction (second direction D2) are higher than the two vertical members 2 on the outside in the base width direction, and each horizontal member (3, 4) has a different height of the upper surface (3u, 4u) near the center in the base width direction and outside in the base width direction, and has a high surface near the center.

[0029] The lower surfaces (3b, 4b) of the horizontal members (3, 4) are disposed on the same plane as the lower surfaces (1b, 2b) of the vertical members (1, 2). In this embodiment, the first horizontal member 3 is fitted to the vertical members (1, 2) from above, and the second horizontal member 4 is fitted to the vertical members (1, 2) from below.

[0030] In this embodiment, the base body 10 has a front tilt support portion 10a that supports the seat S from below in a posture in which the seat S is tilted downward toward the front, and a rail front end restriction portion 10b that restricts movement of the front end portion of the seat rail S3.

[0031] The forward tilt support portion 10a is provided on each of the vertical members (1, 2). That is, each vertical member (1, 2) has a forward tilt support portion 10a. The forward tilt support portion 10a has an inclined surface (1s, 2s) that is inclined so as to approach the loading surface (in other words, the lower surface (1b, 2b)) of the pallet R1 toward the front end side of the vertical member (1, 2), and has an inclined surface (1s, 2s) on which the seat rail S3 is placed. The upper surface (1u, 2u) of each vertical member (1, 2) includes an inclined surface (1s, 2s).

[0032] In this embodiment, in order to accommodate a two-row seat arrangement, the upper surface (1u, 2u) has upper and lower step portions at approximately the center in the longitudinal direction (first direction D1). The inclined surfaces (1s, 2s) are divided into a front seat inclined surface (1s1, 2s1) on which the seat rail S3 of the front seat S is placed, and a rear seat inclined surface (1s2, 2s2) on which the seat rail S3 of the rear seat S is placed. The height h1 from the lower surface (1b, 2b) of the vertical member (1, 2) to the rear end of the front seat inclined surface (1s1, 2s1) is higher than the height h2 from the lower surface (1b, 2b) of the vertical member (1, 2) to the front end of the rear seat inclined surface (1s2, 2s2), thereby forming the step portion.

[0033] The rail front end restricting portion 10b has a rail insertion hole 10b1 into which the front end of the seat rail S3 is inserted. The rail front end restricting portion 10b is provided on the first horizontal member 3.

[0034] The tether flap T extends from the base body 10 and is inserted into the gap G between the seat cushion S1 and the seat back S2 of the seat S to anchor the rear part of the seat S. The tether flap T extends from the second horizontal member 4. In other words, the tether flap T is formed integrally with the second horizontal member 4. Below, specific configurations of the vertical members (1, 2), the horizontal members (3, 4), the forward tilt support portion 10a, the rail front end regulation portion 10b, and the tether flap T will be mainly described.

[0035] (Vertical member) Figures 6 and 7 show the vertical members (1, 2) and their respective corrugated board blanks (1', 2'). With reference to Figures 6 and 7, the vertical member 1 arranged near the center in the width direction of the base and the vertical member 2 arranged outside in the width direction of the base basically have the same structure, except that they are different in height.

[0036] Each vertical member (1, 2) has an upper wall (11, 21) having an upper surface (1u, 2u) of the vertical member (1, 2), a lower wall (12, 22) located below the upper wall (11, 21), and a first side wall (13, 23) and a second side wall (14, 24) extending in the vertical direction from the lower wall (12, 22) to the upper wall (11, 21).

[0037] Each vertical member (1, 2) is formed into a roughly rectangular tube extending in the longitudinal direction by folding a single cardboard blank (1', 2') along fold lines (creases, scores) whose flute direction FL is a direction (second direction D2) that intersects (is perpendicular to) the longitudinal direction (first direction D1) of the blank.

[0038] As described above, each vertical member (1, 2) has a forward tilt support portion 10a. The forward downward inclined surface (1s, 2s) of the forward tilt support portion 10a constitutes the upper surface (1u, 2u) of the upper wall (11, 21) of each vertical member (1, 2). In other words, the upper wall (11, 21) has the inclined surface (1s, 2s) of the forward tilt support portion 10a.

[0039] In the vertical members (1, 2), the upper and lower fitting grooves (1g1, 2g1) as fitting portions for the first horizontal member 3 are formed across the upper walls (11, 21), the first side walls (13, 23), and the second side walls (14, 24) so ​​as to be open upward. On the other hand, the upper and lower fitting grooves (1g2, 2g2) as fitting portions for the second horizontal member 4 are formed across the lower walls (12, 22), the first side walls (13, 23), and the second side walls (14, 24) so ​​as to be open downward.

[0040] 6 and 7, in the state of the blank (1', 2'), the bottom wall (12, 22) is located at the center of the blank width direction (second direction D2) perpendicular to the longitudinal direction (first direction D1). A first outer wall (13a, 23a) constituting the first side wall (13, 23), an outer upper wall (11a, 21a) constituting the upper wall (11, 21), and a second outer wall (14a, 24a) constituting the second side wall (14, 24) on the opposite side are continuous with the bottom wall (12, 22) on one side in the width direction. On the other widthwise side of the lower wall (12, 22), a second inner wall (14b, 24b) constituting the second side wall (14, 24), an inner upper wall (11b, 21b) constituting the upper wall (11, 21), and a first inner wall (13b, 23b) constituting the first side wall (13, 23) are continuous.

[0041] Each blank (1', 2') is folded around the bottom wall (12, 22) so that the second outer wall (14a, 24a), the outer upper wall (11a, 21a) and the first outer wall (13a, 23a) overlap with the outer surface side of the second inner wall (14b, 24b), the inner upper wall (11b, 21b) and the first inner wall (13b, 23b). As a result, a vertical member 1 formed in a roughly rectangular tube shape extending in the first direction D1 is formed, and each of the top wall 11, the first side wall 13 and the second side wall 14 is configured as a multiple wall (here, a double wall) with multiple (here, two) walls (11a-11b, 13a-13b, 14a-14b) that overlap each other. Similarly, a vertical member 2 is formed in a generally rectangular tubular shape extending in the first direction D1, and each of the top wall 21, the first side wall 23, and the second side wall 24 is configured as a multiple wall (here, a double wall) with a plurality of (here, two) walls (21a-21b, 23a-23b, 24a-24b) that overlap each other. That is, in this embodiment, each of the top wall (11, 21), the first side wall (13, 23), and the second side wall (14, 24) is configured as a multiple wall (double wall) with a plurality of walls that overlap each other.

[0042] Each blank (1', 2') has a fold line (crease) K1 between the second outer wall (14a, 24a) and the outer upper wall (11a, 21a), a fold line K2 between the outer upper wall (11a, 21a) and the first outer wall (13a, 23a), a fold line K3 between the first outer wall (13a, 23a) and the lower wall (12, 22), a fold line K4 between the lower wall (12, 22) and the second inner wall (14b, 24b), a fold line K5 between the second inner wall (14b, 24b) and the inner upper wall (11b, 21b), and a fold line K6 between the inner upper wall (11b, 21b) and the first inner wall (13b, 23b). The fold lines K3 and K4 near the center are parallel to each other and extend in the first direction D1. The fold lines K1 and K2 extend parallel to each other, but are inclined at a predetermined inclination angle θ with respect to the fold lines (K3, K4) closer to the center so as to approach the front end. Similarly, the fold lines K5 and K6 extend parallel to each other, but are inclined to approach the fold lines (K3, K4) closer to the center so as to approach the front end. In the blank (1', 2') state, the flute direction FL intersects with the fold lines K3 and K4 at an angle of 90°, but intersects with the other fold lines (K1, K2, K5, K6) at an angle deviated from 90° by an angle corresponding to the inclination angle θ. The inclination angle θ is set to an angle corresponding to the inclination angle of the inclined surfaces (1s, 2s) inclined downward toward the front of the upper wall (11, 21).

[0043] By folding each blank (1', 2') constructed as described above along each folding line, an inclined surface (1s, 2s) with an inclination angle θ is formed on the upper wall (11, 21). In each vertical member (1, 2), in the first outer wall (13a, 23a) and the second inner wall (14b, 24b), the flute direction FL extends in a normal direction to the lower surface (1b, 2b) of the lower wall (12, 22). On the other hand, in the second outer wall (14a, 24a) and the first inner wall (13b, 23b), the flute direction FL is inclined by an angle corresponding to the inclination angle θ so as to approach the front end as it approaches the upper wall (11, 21). As a result, when focusing on each of the first side wall (13, 23) and the second side wall (14, 24), in the multiple walls constituting the multiple walls, the flute directions FL are oriented predominantly in the vertical direction and intersect with each other.

[0044] Each blank (1', 2') is punched out from a cardboard sheet. At that time, the upper and lower fitting grooves (1g1, 1g2, 2g1, 2g2) constituting the fitting portion, the front and rear fitting grooves (1g3, 2g3) for fitting with the rear end member 5 described later, the notches (1g4, 2g4) for fitting with the front end member 5 described later, the division lines (notches) for dividing the inclined surfaces (1s, 2s) into the front sheet inclined surfaces (1s1, 2s1) and the rear sheet inclined surfaces (1s2, 2s2), and the respective fold lines (K1, K2, K3, K4, K5, K6) are formed.

[0045] (1st horizontal member) 8 shows the first horizontal member 3. The first horizontal member 3 has a first upper wall 31 having an upper surface 3u of the first horizontal member 3, a first lower wall 32 located below the first upper wall 31, and a first front wall 33 and a first rear wall 34 extending in the vertical direction from the first lower wall 32 to the first upper wall 31.

[0046] The first horizontal member 3 is formed into a rectangular tube shape extending in the longitudinal direction by folding a single corrugated board blank (not shown) whose flute direction FL is a direction intersecting (perpendicular to) its longitudinal direction (second direction D2) along fold lines (creases, scores) parallel to the longitudinal direction. However, the first horizontal member 3 has two cross-sectional shape parts with different heights, separated by steps, near the center and on both sides in the longitudinal direction.

[0047] The first horizontal member 3 has a multiple-wall structure, similar to each of the vertical members (1, 2). That is, in the first horizontal member 3, the first upper wall 31, the first front wall 33, and the first rear wall 34 are each configured as a plurality of walls that overlap each other, that is, multiple walls (here, double walls). Focusing on each of the first front wall 33 and the first rear wall 34, the flute directions FL of each of the multiple walls that make up the multiple walls extend in the vertical direction.

[0048] The upper and lower fitting grooves (3g1, 3g2) of the first horizontal member 3 as fitting portions for the vertical members (1, 2) are formed across the first lower wall 32, the first front wall 33, and the first rear wall 34 so as to be open downward. The upper and lower fitting grooves 3g1 near the center in the longitudinal direction are formed to a higher position than the outer upper and lower fitting grooves 3g2.

[0049] As described above, the first horizontal member 3 is provided with the rail front end regulating portion 10b having the rail insertion hole 10b1. The rail front end regulating portion 10b is provided above the fitting portion (upper and lower fitting grooves (3g1, 3g2)) of the first horizontal member 3 with respect to the vertical members (1, 2). The rail insertion hole 10b1 opens above the upper and lower fitting grooves (3g1, 3g2) of the first rear wall 34 of the first horizontal member 3.

[0050] In this embodiment, the upper and lower fitting grooves (3g1, 3g2) are formed as inverted L-shaped fitting grooves when viewed in a plan view toward the rail insertion hole 10b1 (in other words, when viewed in a plan view toward the first rear wall 34 or in a plan view in the rail insertion direction), and are configured to prevent upward movement of the first horizontal member 3 relative to the vertical members (1, 2).

[0051] In addition, in the first front wall 33 of the first horizontal member 3, three openings 33a are formed for inserting the clamped portions 5a of the end members 5 described later in the first horizontal member 3 located at the forefront (see FIG. 5). Although such openings 33a are not necessary in the first horizontal members 3 other than the forefront one, all the first horizontal members 3 are formed in the same shape in order to reduce costs by standardizing parts.

[0052] (2nd horizontal member) 9 shows the second horizontal member 4. The second horizontal member 4 has a second upper wall 41 having an upper surface 4u of the second horizontal member 4, a second lower wall 42 located below the second upper wall 41, and a second front wall 43 and a second rear wall 44 extending in the vertical direction from the second lower wall 42 to the second upper wall 41.

[0053] The second horizontal member 4 is formed into a rectangular tube shape extending in the longitudinal direction by folding a single cardboard blank (not shown) with a flute direction FL that intersects (is perpendicular to) the longitudinal direction (second direction D2) of the second horizontal member 4 along fold lines (rules, scores) parallel to the longitudinal direction. However, the second horizontal member 4 has two cross-sectional shapes with different heights, separated by steps, near the center and on both sides in the longitudinal direction of the second horizontal member 4.

[0054] The second horizontal member 4 has a multiple-wall structure, similar to each of the vertical members (1, 2). That is, in the second horizontal member 4, the second upper wall 41, the second front wall 43, and the second rear wall 44 are each configured as a plurality of walls that overlap each other, that is, multiple walls (here, double walls). Focusing on each of the second front wall 43 and the second rear wall 44, the flute directions FL of each of the multiple walls that constitute the multiple walls extend in the vertical direction.

[0055] The upper and lower fitting grooves (4g1, 4g2) of the second horizontal member 4 as fitting portions for the vertical members (1, 2) are formed across the second upper wall 41, the second front wall 43, and the second rear wall 44 so as to be open upward. The upper and lower fitting grooves 4g1 near the center in the longitudinal direction are formed to a higher position than the outer upper and lower fitting grooves 4g2.

[0056] (Tether flap for seat anchoring) As described above, the tether flap T extends from the second horizontal member 4. Specifically, the tether flap T is integrally formed with one cardboard blank forming the second horizontal member 4. The tether flap T has a base portion T1 (root portion) that is continuous with the second rear wall 44 of the second horizontal member 4 via a fold line (crease, score), a middle portion T2, and a tip portion T3. The tip portion T3 has four portions divided by the fold lines, that is, a first portion T31, a second portion T32, a third portion T33, and a fourth portion T34. A lock piece T31a is formed by a pair of division lines (notches) on both sides of the first portion T31, and a notch portion T34a is formed in the fourth portion T34.

[0057] The tether flap T is inserted from the rear into the gap G between the rear of the seat cushion S1 and the lower part of the seat back S2 in order to anchor the rear of the seat S supported in a forward-downward position on the inclined surface (1s, 2s) via the forward-tilting support portion 10a. Then, the tip portion T3 of the inserted tether flap T is folded along each folding line on the front side of the seat back S2. At this time, the fourth portion T34 is overlapped on the upper surface of the first portion T31, the lock piece T31a is folded and locked in the notch portion T34a, and the first portion T31 (fourth portion T34), the second portion T32, and the third portion T33 form a triangular tubular sleeve (enlarged cross-sectional portion Ta). In this state, the tether flap T has a function of anchoring the rear of the seat S to the second horizontal member 4.

[0058] (End member for fixing the base) In this embodiment, the fixing base 50 is provided with end members 5 having clamped portions 5a at the front end and rear end of the base for fixing the fixing base 50 to the pallet R1. The end members 5 are common parts at the front and rear ends of the fixing base 50 for the purpose of reducing costs by commonalizing parts. The end members 5 extend parallel to the horizontal members (3, 4), that is, in the second direction D2. The end members 5 are formed into a multi-layer structure in which a single cardboard blank having a flute direction FL intersecting the longitudinal direction (second direction D2) is folded at fold lines extending parallel to the longitudinal direction. The clamped portions 5a protrude from one edge extending in the longitudinal direction of the end member 5 and are provided at three places on the edge. In addition, on the edge of the end member 5 opposite the clamped portion 5a, front and rear fitting grooves 5b that fit with the notch portion 1g4 of the vertical member 1 and a notch portion 5c that fits with the notch portion 2g4 of the vertical member 2 are formed.

[0059] In this embodiment, each of the vertical members (1, 2) has a seat front-rear position setting portion (1p, 2p) on the upper wall (11, 21) that determines the front-rear position of the seat S along the upper wall (11, 21) of the vertical member (1, 2). Here, for example, a positioning pin S4 protrudes from the bottom of the seat rail S3 as shown in FIG. 5. The seat front-rear position setting portion (1p, 2p) is opened in the upper wall (11, 21) as a hole into which the positioning pin S4 fits as shown in FIGS. 3 and 4. The seat front-rear position setting portion (1p, 2p) determines the front-rear position of the seat S such that the base T1 (root portion) of the tether flap T is located rearward in the front-rear direction with respect to the gap G of the seat S to be moored.

[0060] (Assembly of the fixing base) Next, the assembly procedure of the fixing base 50 will be described with reference to Figures 10 and 11. Figure 10 is a conceptual diagram for explaining the assembly procedure of the fixing base 50, and Figure 11 is a conceptual diagram showing the process of combining the first horizontal members 3 and the vertical members (1, 2). In the following example, the one first horizontal member 3 at the forefront is not folded in advance, but is finally folded while being fitted into the vertical members (1, 2) as described later.

[0061] (1) First, the upper and lower fitting grooves (3g1, 3g2) of the first rear horizontal member 3 are fitted from above into the upper and lower fitting grooves (1g1, 2g1) of the vertical members (1, 2), and the upper and lower fitting grooves (4g1, 4g2) of each second horizontal member 4 are fitted from below into the upper and lower fitting grooves (1g2, 2g2) of the vertical members (1, 2). This allows the horizontal members (3, 4) to be assembled to the vertical members (1, 2). (2) Next, the front and rear fitting grooves 5b and the notch portion 5c of the front end member 5 are fitted into the notch portion (1g4, 2g4) of the vertical members (1, 2), and the front and rear fitting grooves 5b and the notch portion 5c of the rear end member 5 are fitted into the front and rear fitting grooves (1g3, 2g3) of the vertical members (1, 2) from behind. As a result, the front and rear end members 5 are assembled to the vertical members (1, 2). (3) Finally, the blank constituting the first horizontal member 3 at the foremost end is folded in a rolling manner while the upper and lower fitting grooves (3g1, 3g2) are fitted from above into the upper and lower fitting grooves (1g1, 2g1) of the vertical members (1, 2). At this time, the clamped portion 5a of the front end member 5 is inserted from inside into the opening 33a of the first front wall 33 of the first horizontal member 3. As a result, the first horizontal member 3 at the foremost end is assembled to the vertical members (1, 2).

[0062] In this embodiment, as shown in FIG. 11, the upper and lower fitting grooves (3g1, 3g2) of the first horizontal member 3 are fitted from above into the upper and lower fitting grooves (1g1, 2g1) of the vertical members (1, 2), and the first front wall 33 and the first rear wall 34 on the upper side of the upper and lower fitting grooves (3g1, 3g2) are fitted into the upper and lower fitting grooves (1g1, 2g1) of the vertical members (1, 2). After that, the first horizontal member 3 is displaced (slid) in the lateral direction (second direction), and the protrusions (3g11, 3g21) for forming the inverted L-shaped upper and lower fitting grooves (3g1, 3g2) engage with the lock grooves (1r, 2r) opened across the first side walls (13, 23) and the lower walls (12, 22) of the vertical members (1, 2). As a result, the first horizontal member 3 is prevented from moving upward unless it is displaced in the direction opposite to the displacement.

[0063] A cardboard key member 6 is used as a means for restricting the reverse displacement of the rear first horizontal member 3. Specifically, the key member 6 is inserted into a gap that is generated between the second side wall (14, 24) of the vertical member (1, 2) and the first horizontal member 3 in the upper and lower fitting grooves (3g1, 3g2) due to the displacement of the first horizontal member 3. This restricts the reverse displacement of the rear first horizontal member 3. On the other hand, a clamped portion 5a is used as a means for restricting the reverse displacement of the front first horizontal member 3. In other words, the clamped portion 5a is inserted into an opening 33a opened in the first front wall 33 of the first horizontal member 3, thereby restricting the reverse displacement of the front first horizontal member 3. The assembly of the fixing base 50 is completed by the above assembly procedure.

[0064] (Installation of the fixing base on the pallet and loading of the sheets) (1) At the packaging location of the seat S, two fixing bases 50 are placed side by side on the loading surface of the pallet R1. In this state, the clamped portions 5a protruding from the front and rear ends of the vertical members (1, 2) of each fixing base 50 extend to the protruding edge R1a of the first side (long side) of the pallet R1 as shown in Figs. 1 and 5. (2) Next, the seat S is lifted up using a hanger (not shown) or the like and loaded at the corresponding position on the fixing base 50. Specifically, the left and right seat rails S3 of the seat S are placed on the inclined surfaces (1s, 2s) of the forward tilt support parts 10a of the vertical members (1, 2), and the front ends of the seat rails S3 are inserted into the rail insertion holes 10b1 of the rail front end regulating parts 10b, so that the movement of the front ends of the seat rails S3 is regulated, and the left and right seat rails S3 are positioned at predetermined positions on the inclined surfaces (1s, 2s). When the seat rail S3 is inserted into the rail insertion hole 10b1, a cushioning material such as a cushion sheet may be wrapped around the front end of the seat rail S3. (3) In this state, the tether flap T is inserted from the rear into the gap G between the seat cushion S1 and the seat back S2. Then, the tip portion T3 of the tether flap T is folded to form a triangular tubular sleeve (enlarged cross-sectional portion Ta) in front of the gap G. This operation prevents the enlarged cross-sectional portion Ta of the tether flap T from slipping rearward through the gap G. As a result, the rear portion of the seat S is anchored to the second horizontal member 4 by the tether flap T. (4) In a state in which the seat S is supported from below in a forward-downward posture at an inclination angle θ by the forward tilt support portion 10a, the movement of the front end of the seat rail S3 is restricted by the rail front end restriction portion 10b. In this state, the rear portion of the sheet S is tethered to the second horizontal member 4 by the tether flap T, thereby preventing the sheet S from moving upward, i.e., "floating," and the sheet S is fixed onto the fixing base 50. (5) The above work is repeated, and eight sheets S (four sets) of sheets S in two rows of four sheets are fixed to the fixing base 50, and further, a resin sheet is placed over the entire eight sheets S. (6) After that, as shown in Fig. 1, the first outer frame R2 and the second outer frame R3 are attached to the pallet R1. At this time, each clamped portion 5a of the end member 5 is clamped between the lower edge portion of the first outer frame R2 and the protruding edge R1a of the pallet R1.In this state, the second outer frame R3 is connected to the first outer frame R2 by the lock mechanism R4. As a result, the eight sheets S are fixed and arranged on the two fixing bases 50. (7) Through the above operation, the clamped portion 5a is finally clamped between the protruding edge R1a of the pallet R1 and the lower edge of the first outer frame R2, restricting the upward movement of the fixing bases 50, restricting the movement of the fixing bases 50 in the front-rear direction on the pallet R1, and restricting the lateral movement of each fixing base 50 by the second outer frame R3, thereby forming a packaging structure 100 in which the eight sheets S fixed to the two fixing bases 50 are fixedly loaded at predetermined positions in the returnable rack R.

[0065] (Major components and effects) The packaging structure 100 for a vehicle seat according to the present invention has the following features and advantages.

[0066] (1) In the packaging structure 100 for a vehicle seat according to this embodiment, the fixing base 50 is formed from a corrugated cardboard material, and therefore the material cost and manufacturing cost are significantly reduced compared to conventional steel fixing materials. The fixing base 50 can anchor the seat S from the rear to the fixing base 50 by the tether flap T while supporting the seat S in a forward-downward posture by the forward-tilting support portion 10a. Therefore, the fixing base 50 can fix the seat S by utilizing the structure of the fixing base itself, and there is no need to repeatedly perform bolt tightening work or slide the seat for that purpose. This has the advantage of significantly improving the workability during packaging and significantly improving the workability during unpacking at the transport destination. In addition, when the tether flap T is inserted into the gap G between the seat cushion S1 and the seat back S2 from the rear of the seat, the seat S is supported in a forward-downward position, so that the visibility of the gap G, which is the insertion opening of the tether flap T, from the rear of the seat is improved, so that the worker can easily visually check the insertion opening (gap G), and the workability of the insertion work of the tether flap T is improved. In addition, the weight is significantly reduced compared to steel fixing materials, and the transportation cost, especially the transportation cost during marine transportation, is significantly reduced. Moreover, even if it is used as a one-way (disposable) packaging material, it has the advantage that it can be recycled as a paper resource. In addition, compared to steel fixing materials, it has an appropriate cushioning property, and has the advantage that the external force and vibration acting on the seat through the fixing materials during transportation are mitigated. In addition, since the seat S is supported in a forward-leaning position, the distance in the front-to-rear direction of the seat occupied space in the returnable rack R is shorter than in the case of a horizontal position. This improves the freedom of sheet arrangement within the returnable rack R and expands the working space.

[0067] As described above, the packaging structure 100 for a vehicle seat of this embodiment is a packaging structure that provides good workability in packaging and unpacking, is lightweight, and is advantageous in terms of reducing material costs and transportation costs.

[0068] (2) The base body 10 has a plurality of vertical members (1, 2) and a plurality of horizontal members (3, 4), and the vertical members (1, 2) and the horizontal members (3, 4) are combined with each other at their intersections to form a lattice-like structure as a whole, and the forward tilt support portion 10a is provided on each of the vertical members (1, 2). As a result, by simply combining the members (1, 2, 3, 4) with each other, the seat S can be supported in a forward tilted position, and a basic lattice-like structure is formed that is lightweight yet easily provides sufficient strength and durability for practical use. Therefore, material costs and manufacturing costs are significantly reduced compared to conventional steel fixing materials.

[0069] (3) The forward tilt support portion 10a has an inclined surface (1s, 2s) that is inclined so as to approach the loading surface of the pallet R1 toward the front end side of the vertical members (1, 2), and has an inclined surface (1s, 2s) on which the seat rail S3 is placed. Therefore, the support of the seat S can be easily stabilized.

[0070] (4) The fixing base 50 has at least a first set of horizontal members (3, 4) and a second set of horizontal members (3, 4), and is configured to be able to fix at least two seats S in a state where they are placed in a line in the front-rear direction, and the tether flap T extends from the second horizontal member 4. The height h1 from the lower surface (1b, 2b) of the vertical member (1, 2) to the rear end of the front seat inclined surface (1s1, 2s1) is higher than the height h2 from the lower surface (1b, 2b) of the vertical member (1, 2) to the front end of the rear seat inclined surface (1s2, 2s2). Therefore, even if the two seats S are arranged in positions close to each other in the front-rear direction, a sufficient working space in the vertical direction according to the difference between h1 and h2 is easily secured between the front seat S and the rear seat S below the gap G (insertion opening) of the front seat S. As a result, the workability of the tether flap T is further improved.

[0071] (5) Each of the multiple vertical members (1, 2) has a seat front-rear position setting portion (1p, 2p) that determines the front-rear position of the seat S, and the seat front-rear position setting portion (1p, 2p) determines the front-rear position of the seat S so that the base T1 of the tether flap T is located rearward of the gap G of the seat S. Therefore, between the front seat S and the rear seat S, a sufficient working space in the front-rear direction is easily secured rearward of the gap G (insertion opening) of the front seat S. As a result, the workability of inserting the tether flap T is significantly improved.

[0072] In this embodiment, each vertical member (1, 2) has an upper wall (11, 21) having an inclined surface (1s, 2s), a lower wall (12, 22) located below the upper wall (11, 21), and a first side wall (13, 23) and a second side wall (14, 24) extending in the up-down direction from the lower wall (12, 22) to the upper wall (11, 21), and is formed into a cylindrical shape extending in the first direction D1 by bending a single cardboard blank (1', 2') having a flute direction FL that intersects with the first direction D1, and the flute direction FL of each side wall (13, 14, 23, 24) of the vertical member (1, 2) extends with an orientation that is predominantly vertical. Therefore, the compressive strength against the load of the sheet S is easily ensured.

[0073] In this embodiment, the fixing base 50 includes a rail front end regulating portion 10b that regulates the movement of the front end of the seat rail S3 of the seat S, the rail front end regulating portion 10b having a rail insertion hole 10b1 into which the front end of the seat rail S3 is inserted. Therefore, the fixing base 50 can regulate the lateral and vertical movement of the front end of the seat rail S3, for example, by simply inserting the front end of the seat rail S3 into the rail insertion hole 10b1. Therefore, it is not necessary to fix the front end of the seat rail S3 using a separate cable tie or bolt, and a through groove for the cable tie is not required.

[0074] Although the embodiment of the present invention has been described above, the present invention is not limited to the above-mentioned embodiment, and various modifications and changes are possible within the scope of the present invention.

[0075] For example, in this embodiment, as shown in Fig. 5, when the seat S is supported by the forward tilt support part 10a in a forward-downward posture at an inclination angle θ, the gap G of the seat S is seen from the rear in a generally horizontal direction, but the line of sight of the gap G from the rear is not limited to this. For example, as shown in Fig. 12, which is a conceptual diagram for explaining a modified example, the inclination angle θ may be set to be larger than the angle in Fig. 5, so that the line of sight of the gap G from the rear is set to look diagonally downward from the rear to the front. In this case, the height h1 from the lower surface (1b, 2b) to the rear end of the front seat inclined surface (1s1, 2s1) and the height h2 from the lower surface (1b, 2b) to the front end of the rear seat inclined surface (1s2, 2s2) may be set so that the front part of the seat cushion S1 of the rear seat S is located lower than the rear region of the gap G of the front seat S. This further improves visibility of the gap G, which is the insertion port for the tether flap T, from the rear of the seat, making it easier for workers to visually check the insertion port (gap G), further improving the ease of inserting the tether flap T.

[0076] In this embodiment, the fixing base 50 fixes the seat S having a seat structure in which the heights of the left and right seat rails S3 are different from each other, but the seat structure of the fixed target seat S is not limited to this. For example, as shown in Fig. 12, the fixing base 50 can also fix a seat S having a seat structure in which the heights of the left and right seat rails S3 are the same. In this case, the vertical members 1 near the front ends of the central vertical members 1 and the outer vertical members 2 are made of members having the same shape (height), and the rail front end regulating portions 10b are provided at the same height position.

[0077] In addition, in this embodiment, the base body 10 has two sets (four) of vertical members (1, 2) and two sets (four) of horizontal members (3, 4), but the number of sets of each member is not limited to this, and may be one set of each, or a predetermined number of sets of three or more. Furthermore, the base body 10 of the fixing base 50 is formed in a lattice shape as a whole, but is not limited to this. The base body 10 may have a forward tilt support part 10a that supports the sheet S from below in a posture inclined forward downward, and an appropriate shape may be adopted. In addition, in this embodiment, the end member 5 having the clamped part 5a is provided at the front end and rear end of each vertical member (1, 2) as a fixing means of the fixing base 50 to the pallet R1, but is not limited to this. The clamped part 5a may be formed integrally with each vertical member (1, 2). In addition, a means other than the clamped part, or a material other than cardboard, such as a packing band, may be used as a fixing means of the fixing base 50 to the pallet R1. [Explanation of symbols]

[0078] 1, 2... Vertical members; 1', 2'... Cardboard blanks; 1b,2b...bottom surface, 1u,2u...top surface, 1s,2s...slanted surface, 1s1, 2s1...Front seat inclined surface, 1s2, 2s2...Rear seat inclined surface, 1g1,1g2,2g1,2g2...Top and bottom fitting grooves, 1g3,2g3...front and rear fitting grooves, 1g4,2g4...notch part, 1p, 2p: Seat front / rear position setting part, 1r, 2r: Lock groove, 11, 21...upper wall, 11a, 21a...outer upper wall, 11b, 21b...inner upper wall, 12,22…Lower wall, 13,23...first side wall, 13a,23a...first outer wall, 13b,23b...first inner wall, 14,24...second side wall, 14a,24a...second outer wall, 14b,24b...second inner wall, 3,4... horizontal member, 3... first horizontal member, 4... second horizontal member, 3b,4b...bottom surface, 3u,4u...top surface, 3g1,3g2...Upper and lower fitting groove, 3g11,3g21...Protrusion, 4g1,4g2...Upper and lower fitting grooves, 31,41…First upper wall, 32,42...first lower wall, 33,43...first front wall, 33a...opening, 34,44...first rear wall, 5... End member, 5a... Sandwiched part, 5b... Front and rear fitting groove, 5c... Notch part, 6...Key member, 10…Base body, 10a...forward tilt support portion, 10b...rail front end regulating portion, 10b1...rail insertion hole, 50…Fixing base, 100…Packaging structure, D1...first direction, D2...second direction, FL...flute direction, G…gap, h1…height, h2…height, K1,K2,K3,K4,K5,K6…broken line, S...seat, S1...seat cushion, S2...seat back, S3...seat rail, S4: Positioning pin, R…Returnable rack (transportation material), R1...palette, R2...first outer frame, R3...second outer frame, R1a: protruding edge, R1b: first engagement portion, R1c: second engagement portion, R4: lock mechanism, T: tether flap, Ta: enlarged cross-sectional area, T1...Base, T2...Middle part, T3...Tip part, T31...first part, T32...second part, T33...third part, T34...fourth part, T31a: lock piece, T34a: notch, θ…Inclination angle

Claims

1. A packaging structure for a vehicle seat including a fixing base for fixing a vehicle seat on a loading surface of a transport member, The fixing base is made of corrugated cardboard. The fixing base is a base body disposed on the loading surface and having a forward tilt support portion that supports the sheet from below in a posture inclined forward and downward; A tether flap extends from the base body and is inserted into a gap between a seat cushion and a seat back of the seat to anchor a rear portion of the seat; Including, A packaging structure for a vehicle seat.

2. The base body is A plurality of vertical members extending in a first direction on the loading surface, the vertical members being spaced apart from each other in a second direction perpendicular to the first direction; a plurality of cross members extending in the second direction on the loading surface, the cross members being spaced apart from one another in the first direction; The vertical members and the horizontal members are combined with each other at their intersections to form a lattice shape as a whole, The packaging structure for a vehicle seat according to claim 1 , wherein the forward tilt support portion is provided on each of the plurality of vertical members.

3. 3. The packaging structure for a vehicle seat according to claim 2, wherein the forward tilt support portion has an inclined surface that is inclined so as to approach the loading surface as it approaches the front end side of the vertical member, and has an inclined surface on which a seat rail attached to a bottom of the seat cushion of the seat is placed.

4. the base body has at least one set of the vertical members and at least two sets of the horizontal members, each set of the horizontal members being composed of one first horizontal member and one second horizontal member disposed rearward of the first horizontal member; The fixing base is configured such that a second set of horizontal members is disposed behind the first set of horizontal members, so that at least two of the seats can be fixed in a state in which they are placed in a front-to-rear arrangement, the tether flap extends from the second cross member; The inclined surface is divided into a front seat inclined surface on which the seat rail of the front seat is placed and a rear seat inclined surface on which the seat rail of the rear seat is placed, 4. The packaging structure for a vehicle seat according to claim 3, wherein a height from a lower surface of the vertical member to a rear end of the front seat inclined surface is greater than a height from the lower surface of the vertical member to a front end of the rear seat inclined surface.

5. 5. The packaging structure for a vehicle seat according to claim 4, wherein the height of the front seat inclined surface and the height of the rear seat inclined surface are each set so that a front portion of the seat cushion of the rear seat is positioned lower than a rear region of the gap of the front seat.

6. Each of the plurality of vertical members has a seat front-rear position setting portion on the upper wall thereof that determines a front-rear position of the seat along the upper wall thereof, The packaging structure for a vehicle seat according to claim 4 or 5, wherein the seat front-rear position setting portion determines the front-rear position of the seat such that a base of the tether flap is positioned rearward of the gap of the seat to be moored.

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