Packaging structure for vehicle seats

Abstract

To provide a packaging structure for vehicle seats that is stable during transportation, lightweight and advantageous in reducing material and transportation costs.SOLUTION: Packaging structure 100 for vehicle seats includes a fixing base 50 for fixing vehicle seats S on the loading surface of a transport component (returnable rack R). The fixing base 50 is formed of corrugated cardboard material. The fixing base 50 includes a base body 10 that is arranged on the loading surface. The base body 10 has a forward inclined support portion 10a that supports the sheets S from below in a forward inclined posture. The forward inclined support portion 10a has an inclined surface (1s, 2s) on which the seat rail S3 is placed. The inclined surfaces (1s, 2s) are more inclined toward the front end side of the base body 10 so as to be closer to the loading surface.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 seats are stored in an inverted position in order to improve the spatial storage capacity in the packaging box. However, as described above, various factors other than storage efficiency are related to the transportation cost, and problems such as the manufacturing cost and collection cost of a dedicated mounting frame may remain. In addition, since the center of gravity of a seat is generally offset toward the rear, there may be a need to improve the stability of the seat S during transportation. [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 vehicle seats that is stable during transportation, 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, the fixing base being made of corrugated cardboard, the fixing base being a base body arranged on the loading surface and having a forward tilt support part for supporting the seat from below in a posture inclined forward and downward, the forward tilt support part having 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 on which a seat rail attached to a bottom of a seat cushion of the seat is placed. Effect of the Invention

[0009] According to the present invention, it is possible to provide a packaging structure for a vehicle seat which provides good stability of the seat during transportation, is lightweight, and is 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. [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] FIG. 4 is an enlarged perspective view of a main portion of the vertical member. [Figure 11] FIG. 4 is a cross-sectional view of a main portion of the vertical member. [Figure 12] FIG. 13 is a top view of a fixing base for explaining the width of the vertical member. [Figure 13] 5A to 5C are perspective views illustrating an assembly procedure of the fixing base. [Figure 14] 6 is a perspective view showing a process of assembling the first horizontal member and the vertical member; FIG. [Figure 15] 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 base body 10 (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 in a predominantly 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] In this embodiment, as shown in Fig. 5, the seat rail S3 has an upper rail S3U attached to the bottom of the seat cushion S1, and a lower rail S3L engaged with the upper rail S3U from below so as to be movable in the front-rear direction relative to the upper rail S3U. The center of gravity C of the seat S is offset rearward. Specifically, the center of gravity C of the seat S is located at the rear of the seat, at the seat back S2 in the figure, and is located approximately at the center of the seat in the up-down direction, at the lower part of the seat back S2 in the figure. The lower rail S3L has a rail width that is, for example, wider than the rail width of the upper rail S3U. Further, as shown in Fig. 6 and Fig. 7, the inclined surfaces (1s, 2s) of the vertical members (1, 2) each have a lower inclined surface portion (1sL, 2sL) against which the lower surface of the lower rail S3L abuts, and an upper inclined surface portion (1sU, 2sU) against which a part of the lower surface of the upper rail S3U slid backward relative to the lower rail S3L abuts. Note that a more detailed structure of each vertical member (1, 2) including the width of each inclined portion (1sL, 1sU, 2sL, 2sU) will be described later.

[0046] (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.

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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).

[0052] 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.

[0053] (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.

[0054] 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.

[0055] 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.

[0056] 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.

[0057] (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.

[0058] 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.

[0059] (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.

[0060] (Detailed structure of vertical members) Next, the structure of the vertical members (1, 2) will be described in more detail. 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 itself. 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 FIG. 3 and FIG. 4. The seat front-rear position setting portion (1p, 2p) determines the front-rear position of the seat S so 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.

[0061] In this embodiment, as described above, the inclined surfaces (1s, 2s) of each vertical member (1, 2) each have a lower inclined surface portion (1sL, 2sL) that contacts the lower surface of the lower rail S3L and an upper inclined surface portion (1sU, 2sU) that contacts the lower surface of the upper rail S3U. The upper inclined surface portion (1sU, 2sU) is located higher than the lower inclined surface portion (1sL, 2sL), and in each of the front seat inclined surface (1s1, 2s1) and the rear seat inclined surface (1s2, 2s2), a vertical step is provided at the boundary between the lower inclined surface portion (1sL, 2sL) and the upper inclined surface portion (1sU, 2sU) in a side view.

[0062] In this embodiment, the lower inclined surface portions (1sL, 2sL) are formed wider than the upper inclined surface portions (1sU, 2sU) in the rail width direction. Specifically, most of the portions including the lower inclined surface portions (1sL, 2sL) of each vertical member (1, 2) are formed in a rectangular tubular shape as shown in Figs. 10 and 11 described later, and the portions including the upper inclined surface portions (1sU, 2sU) of each vertical member (1, 2) are formed in a generally trapezoidally flattened tubular shape (i.e., a hexagonal tubular shape) as shown in the lower diagrams of Figs. 10 and 11 described later. As a result, the lower inclined surface portions (1sL, 2sL) are formed wider than the upper inclined surface portions (1sU, 2sU). In other words, in a state where the blanks (1', 2') are simply folded at each folding line (K1-K6), the portion including the upper inclined surface portions (1sU, 2sU) of each vertical member (1, 2) is formed into a rectangular tubular shape as shown in the upper views of Fig. 10 and 11 described later. After that, the portion including the upper inclined surface portions (1sU, 2sU) is folded flat as shown in the lower views of Fig. 10 and 11 described later, so that only the portion including the upper inclined surface portions (1sU, 2sU) is formed into a tubular shape that is flattened into a roughly trapezoidal shape.

[0063] 10 to 12 are diagrams for explaining the width of the vertical members (1, 2), FIG. 10 is an enlarged perspective view of the main parts of the vertical members (1, 2), FIG. 11 is a cross-sectional view of the main parts of the vertical members (1, 2), and FIG. 12 is a top view of the fixing base 50 for explaining the width of the vertical members (1, 2). FIG. 11 is a cross-sectional view of a portion including the upper inclined surface portion (1sU, 2sU). In each of FIG. 10 and FIG. 11, the upper view shows the state before flattening and bending into a trapezoidal shape, and the lower view shows the state after flattening and bending into a trapezoidal shape. FIG. 12 mainly shows the width of each vertical member (1, 2) after flattening and bending. Note that FIG. 4 shows the state before flattening and bending. As described above, the vertical member 1 near the center and the vertical member 2 on the outside have the same structure except for the difference in height, and FIG. 10 is an enlarged perspective view of the main parts of the vertical member 1 and also an enlarged perspective view of the main parts of the vertical member 2. In each vertical member (1, 2), the portion including the front seat inclined surface (1s1, 2s1) has the same cross-sectional shape as the portion including the rear seat inclined surface (1s2, 2s2). Therefore, Fig. 11 is a cross-sectional view of the portion including the front seat inclined surface (1s1, 2s1) as well as the portion including the rear seat inclined surface (1s2, 2s2).

[0064] Referring to FIG. 10, the cut portions (1g5, 2g5) are formed in the portions of the side portions (first side portions (13, 23), second side portions (14, 24)) in the rail width direction of each vertical member (1, 2) corresponding to the boundaries between the lower inclined surface portions (1sL, 2sL) and the upper inclined surface portions (1sU, 2sU). The cut portions (1g5, 2g5) extend from above to below, and are then cut so as to curve toward one side in the front-rear direction, dividing the lower inclined surface portions (1sL, 2sL) and the upper inclined surface portions (1sU, 2sU). The cut portions (1g5, 2g5) are cut lines (division lines) that penetrate each blank (1', 2') in its thickness direction. In this embodiment, the cut portions (1g5, 2g5) extend from above to below, and then curve smoothly toward the front in an arc shape.

[0065] Here, as shown in Figures 6 and 7, in each blank (1', 2'), the width of the fold lines (K1, K2) in the outer upper wall (11a, 21a) corresponding to the lower inclined surface portion (1sL, 2sL) is wider than the width of the fold lines (K1, K2) in the outer upper wall (11a, 21a) corresponding to the upper inclined surface portion (1sU, 2sU). Similarly, the width of the fold lines (K5, K6) in the inner upper wall (11b, 21b) corresponding to the lower inclined surface portion (1sL, 2sL) is wider than the width of the fold lines (K5, K6) in the inner upper wall (11b, 21b) corresponding to the upper inclined surface portion (1sU, 2sU). The aforementioned cut portions (1g5, 2g5) are also formed in each blank (1', 2'). In addition, in the portion corresponding to the upper inclined surface portion (1sU, 2sU), a slit (K1', K6') of a predetermined width is formed in the portion corresponding to the fold line (K1, K2) and the outer fold line (K1, K6) of the fold lines (K5, K6), and the blank (1', 2') is not folded in this portion.

[0066] In this embodiment, the lower inclined surface portions (1sL, 2sL) are formed wider than the upper inclined surface portions (1sU, 2sU) in the rail width direction (see the lower diagrams of Figs. 10 and 11). That is, a first width W1, which is the width of the lower inclined surface portions (1sL, 2sL), is larger than a second width W2, which is the width of the upper inclined surface portions (1sU, 2sU) (W1>W2). The first width W1 is set to be approximately the same dimension as the rail width WL of the lower rail S3L, and the second width W2 is set to be approximately the same dimension as the rail width WU of the upper rail S3U.

[0067] In this embodiment, the first lower surface (1bL, 2bL) located below the lower inclined surface portion (1sL, 2sL) of the lower surface (1b, 2b) of each vertical member (1, 2) is continuous with the second lower surface (1bU, 2bU) located below the upper inclined surface portion (1sU, 2sU) of the lower surface (1b, 2b) of each vertical member (1, 2) and is in surface contact with the loading surface of the pallet R1. The second lower surface (1bU, 2bU) is formed wider than the upper inclined surface portion (1sU, 2sU) in the rail width direction. In this embodiment, the lower inclined surface portion (1sL, 2sL), the first lower surface (1bL, 2bL), and the second lower surface (1bU, 2bU) are formed to have the same width in the rail width direction. In other words, when the width of the first lower surface (1bL, 2bL) is the third width W3 and the width of the second lower surface (1bU, 2bU) is the fourth width W4, the width (fourth width W4) of the second lower surface (1bU, 2bU) is larger than the width (second width W2) of the upper inclined surface portion (1sU, 2sU) (W4>W2), and the first width W1, the third width W3, and the fourth width W4 are set to the same dimension (W1=W3=W4>W2). With the above dimensional relationship, each vertical member (1, 2) is formed in a rectangular tube shape in the portion including the lower inclined surface portion (1sL, 2sL), and is formed in a tube shape with its upper portion flattened into a trapezoid shape in the portion including the upper inclined surface portion (1sU, 2sU). In each of the vertical members (1, 2), a rectangular cylindrical portion and a trapezoidal flat cylindrical portion are separated by a cut portion (1g5, 2g5).

[0068] (Assembly of the fixing base) Next, the assembly procedure of the fixing base 50 will be described with reference to Figures 13 and 14. Figure 13 is a conceptual diagram for explaining the assembly procedure of the fixing base 50, and Figure 14 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.

[0069] (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).

[0070] In this embodiment, as shown in FIG. 14, 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 above displacement.

[0071] 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. Then, as shown in the lower view of FIG. 10, the lower view of FIG. 11, and FIG. 12, in the portion including the upper inclined surface portion (1sU, 2sU) of each vertical member (1, 2), the upper portion is folded parallel to the folding line (K1, K2, K5, K6) starting from the lower portion of the notch portion (1g5, 2g5). As a result, the portion including the lower inclined surface portion (1sL, 2sL) is formed into a rectangular tube expanded in the width direction relative to the upper inclined surface portion (1sU, 2sU), and only the portion including the upper inclined surface portion (1sU, 2sU) is formed into a tube that is flattened into a roughly trapezoidal shape. As a result, the lower inclined surface portion (1sL, 2sL) is formed wider than the upper inclined surface portion (1sU, 2sU). The assembly of the fixing base 50 is completed by the above assembly procedure.

[0072] (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.

[0073] (Major components and effects) The packaging structure 100 for a vehicle seat according to the present invention has the following features and advantages.

[0074] (1) In the vehicle seat packaging structure 100 according to the present embodiment, the fixing base 50 is made of cardboard, so that the material cost and manufacturing cost are significantly reduced compared to conventional steel fixing materials. The fixing base 50 has an inclined surface (1s, 2s) that inclines so as to approach the loading surface of the returnable rack R toward the front end side of the base body 10, and the seat rail S3 is placed on the inclined surface (1s, 2s) of the forward tilt support part 10a, which supports the seat S from below in a forward-downward position. Therefore, even if the center of gravity C of the seat S is offset to the rear side as in the present embodiment and a local seat load can act directly below the center of gravity C of the seat S in the base body 10 (each vertical member (1, 2)), the seat S is supported in a forward tilted position, so that the seat load on the base body 10 directly below the center of gravity C of the seat S is reduced by the load amount corresponding to the inclination angle θ of the seat S, and the load of the seat load on the base body 10 is effectively distributed to the front side. Therefore, the local load on the base body 10 (each vertical member (1, 2)) is reduced, and the occurrence of deformation or crushing of the base body 10 (each vertical member (1, 2)) due to the local load is effectively suppressed or prevented. As a result, the sheet S is stably supported, and the stability during transportation can be easily improved. In addition, the weight is significantly reduced compared to steel fixing materials, and the transportation cost, especially the transportation cost during sea 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. Furthermore, compared to steel fixing materials, it has moderate cushioning properties, and has the advantage that external forces and vibrations acting on the sheet through the fixing materials during transportation are mitigated. In addition, since the sheet S is supported in a forward-leaning position, the distance in the front-back direction of the sheet occupation space in the returnable rack R is shorter than in the case of a horizontal position. Therefore, the degree of freedom of sheet arrangement in the returnable rack R is improved, and the working space is expanded.

[0075] As described above, the packaging structure 100 for a vehicle seat of this embodiment is a packaging structure that has good stability during transportation, is lightweight, and is advantageous in terms of reducing material costs and transportation costs.

[0076] (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 upper surfaces (1u, 2u) of the vertical members (1, 2) have the inclined surfaces (1s, 2s) of the forward tilt support parts 10a. 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 lattice-like basic structure that is lightweight yet easily equipped with sufficient strength and durability for practical use is formed. Therefore, material costs and manufacturing costs are significantly reduced compared to conventional steel fixing materials.

[0077] (3) The inclined surface (1s, 2s) of the forward tilt support portion 10a has a lower inclined surface portion (1sL, 2sL) that the lower surface of the lower rail S3L abuts against, and an upper inclined surface portion (1sU, 2sU) that a part of the lower surface of the upper rail S3U that has been slid backward relative to the lower rail S3L abuts against. Therefore, the forward tilt support portion 10a can support not only the lower rail S3L but also a part of the upper rail S3U from below, so that the forward tilt support portion 10a can expand the area of ​​the inclined surface (1s, 2s) that receives the load of the seat S backward and increase the contact area with the seat rail S3, thereby more stably supporting and fixing the seat S. In addition, since the area of ​​the inclined surface (1s, 2s) that receives the load of the seat S is expanded and widened backward, the load of the seat load on each vertical member (1, 2) is effectively distributed to the rear side as well. As a result, deformation or crushing of each vertical member (1, 2) due to a local load can be more effectively suppressed or prevented, and the stability of the seat S during transportation can be more effectively improved. Although not particularly limited, it is preferable that the front-rear length of the upper inclined surface portion (1sU, 2sU) is set so that the upper rail S3U is slid rearward to the maximum extent relative to the lower rail S3L and the entire portion of the upper rail S3U protruding rearward from the rear end of the lower rail S3L can contact the upper inclined surface portion (1sU, 2sU).

[0078] (4) The lower inclined surface portions (1sL, 2sL) are formed wider than the upper inclined surface portions (1sU, 2sU), so that the width of the portion of the inclined surface (1s, 2s) that contacts the lower rail S3L is wider than the width of the portion that contacts the upper rail S3U. As a result, even if a force is generated in a direction that tilts the seat S forward during transportation, the force (load) is received by the wider lower inclined surface portions (1sL, 2sL). Therefore, the seat S is effectively prevented from tilting forward during transportation, and the seat S is more reliably supported stably.

[0079] (5) The first lower surface (1bL, 2bL) below the lower inclined surface portion (1sL, 2sL) is continuous with the second lower surface (1bU, 2bU) below the upper inclined surface portion (1sU, 2sU) and is in surface contact with the loading surface of the pallet R1, so that the load of the sheet S is stably received by the loading surface of the pallet R1 through the entire first lower surface (1bL, 2bL) and second lower surface (1bU, 2bU). In addition, since the second lower surface (1bU, 2bU) is formed wider than the upper inclined surface portion (1sU, 2sU), the sheet S is more reliably supported stably even on the upper inclined surface portion (1sU, 2sU) side.

[0080] (6) The lower inclined surface portion (1sL, 2sL), the first lower surface (1bL, 2bL), and the second lower surface (1bU, 2bU) are formed with the same width, so that the portion including the lower inclined surface portion (1sL, 2sL) of each vertical member (1, 2) is formed with a rectangular tube shape (vertically elongated rectangular tube shape in the figure) with the same width as the second lower surface (1bU, 2bU). Therefore, each vertical member (1, 2) can effectively bear the increased load of the seat load due to the forward tilt support by each side wall (13, 14, 23, 24) with a rectangular tube-like cross section. As a result, the occurrence of deformation or crushing of the front portion of each vertical member (1, 2) due to local load load is more reliably suppressed or prevented, and the stability of the seat S during transportation can be more reliably improved.

[0081] (7) At the portion of the side portion (first side wall (13, 23), second side wall (14, 24)) in the rail width direction of each vertical member (1, 2) corresponding to the boundary between the lower inclined surface portion (1sL, 2sL) and the upper inclined surface portion (1sU, 2sU), a notch portion (1g5, 2g5) is formed, which extends from above to below and then curves to one side in the front-rear direction. This effectively prevents vertical tearing starting from the boundary between the lower inclined surface portion (1sL, 2sL) and the upper inclined surface portion (1sU, 2sU) in the corrugated cardboard material of each vertical member (1, 2). In other words, when the flute direction FL of each side wall (13, 14, 23, 24) of the vertical member (1, 2) extends in an orientation that is predominantly vertical, as in this embodiment, the strength against the load in the vertical direction is improved, but the material has a tendency to be easily torn in the vertical direction. In contrast, in this embodiment, the cuts (1g5, 2g5) are provided in advance in the portions that are likely to become the starting points of upper and lower tears, and the cuts (1g5, 2g5) extend from above to below, and then are cut so as to curve to one side in the front-rear direction intersecting with the flute direction FL. As a result, the terminal side portions of the cuts (1g5, 2g5) extend in a direction roughly perpendicular to the flute direction FL, which has high strength against the breaking force, so that tearing (breakage) after the terminals of the cuts (1g5, 2g5) is effectively suppressed. In this way, by suppressing tearing of the cardboard material, the shape of each vertical member (1, 2) can be more reliably maintained, and the stability of the sheet S can be further reliably improved.

[0082] (8) 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') whose flute direction FL is a direction intersecting 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.

[0083] In this embodiment, 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 position 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, so there is no need to repeat the bolt fastening operation and the seat sliding operation for that purpose, and there is an advantage that the workability during packaging is significantly improved and the workability during unpacking at the transport destination is also significantly improved. 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 port of the tether flap T, from the rear of the seat is improved, and it becomes easier for the worker to visually check the insertion port (gap G), and the workability of the insertion operation of the tether flap T is improved.

[0084] 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.

[0085] 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.

[0086] For example, in this embodiment, as shown in Fig. 5, when the seat S is supported in a forward-downward posture at an inclination angle θ by the forward-tilting support portion 10a, 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. 15, 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, and the line of sight of the gap G from the rear may be 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.

[0087] In addition, when setting the inclination angle θ, as shown in Fig. 15, the inclination angle θ of the front seat inclined surface (1s1, 2s1) is set so that the imaginary line X passing through the center of gravity C of the seat S placed on the front seat inclined surface (1s1, 2s1) and extending in the normal direction of the front seat inclined surface (1s1, 2s1) intersects the second horizontal member 4 of the front set (first set). Similarly, for the rear seat S, the inclination angle θ of the rear seat inclined surface (1s2, 2s2) is set so that the imaginary line X' passing through the center of gravity C of the seat S and extending in the normal direction of the rear seat inclined surface (1s2, 2s2) intersects the second horizontal member 4 of the rear set (second set). With this geometrical arrangement, the load of the seat S is effectively received by the second horizontal member 4, and the front and rear seats S are supported more stably. In addition, since the front second horizontal member 4 is reliably pressed downward by the load of the front seat S, the upward movement of the rear first horizontal member 3 adjacent to the front second horizontal member 4 is also suppressed. Furthermore, since the rear first horizontal member 3 is pressed diagonally downward toward the front by the rear seat S supported in a forward leaning position, the upward movement of the rear first horizontal member 3 is also suppressed. Therefore, even if two seats S are arranged closely to each other in two rows in the front and rear, the two seats are stably supported on one fixing base 50.

[0088] 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. 15, 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.

[0089] 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]

[0090] 1, 2... Vertical members; 1', 2'... Cardboard blanks; 1b, 2b...bottom surface, 1bL, 2bL...first lower surface, 1bU,2bU...second lower surface, 1u, 2u...Top surface, 1s, 2s...Slope surface, 1sL, 2sL...Lower slope part, 1sU, 2sU...Upper slope part, 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, 1g5, 2g5...cutting part (cutting line, dividing line), 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, C...center of gravity of sheet, D1...first direction, D2...second direction, FL...flute direction, G…gap, h1…height, h2…height, K1, K2, K3, K4, K5, K6...Bent lines, K1', K6'...Slits, S...seat, S1...seat cushion, S2...seat back, S3…Seat rail, S3L…Lower rail, S3U…Upper 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...tilt angle, X...virtual line, X'...virtual line, W1…1st frame, W2…2nd frame, W3…3rd frame, W4…4th frame

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 that is placed on the loading surface and includes a base body having a forward tilt support portion that supports the sheet from below in a posture in which the sheet is tilted forward and downward, The packaging structure for a vehicle seat, characterized in that the forward tilt support portion has an inclined surface that inclines so as to approach the loading surface toward the front end side of the base body, and has an inclined surface on which a seat rail attached to the bottom of the seat cushion of the seat is placed.

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, Each of the vertical members is formed in a cylindrical shape extending in the first direction, Each of the cross members is formed in a cylindrical shape extending in the second direction, The packaging structure for a vehicle seat according to claim 1 , wherein an upper surface of each of the vertical members includes the inclined surface.

3. the seat rail includes an upper rail attached to a bottom portion of the seat cushion, and a lower rail having a rail width wider than a rail width of the upper rail and engaging with the upper rail from below so as to be movable in a front-rear direction relative to the upper rail, 3. The packaging structure for a vehicle seat according to claim 2, wherein the inclined surface has a lower inclined surface portion against which the lower surface of the lower rail abuts, and an upper inclined surface portion against which a portion of the lower surface of the upper rail that has been slid rearward relative to the lower rail abuts.

4. The packaging structure for a vehicle seat according to claim 3 , wherein the lower inclined surface portion is formed to be wider than the upper inclined surface portion in the rail width direction.

5. a first lower surface of the lower surface of each of the vertical members that is located below the lower inclined surface portion is continuous with a second lower surface of the lower surface of each of the vertical wall portions that is located below the upper inclined surface portion and is in surface contact with the loading surface; The packaging structure for a vehicle seat according to claim 4 , wherein the second lower surface is formed to be wider than the upper inclined surface portion in the rail width direction.

6. The packaging structure for a vehicle seat according to claim 5 , wherein the lower inclined surface portion, the first lower surface, and the second lower surface are formed to have the same width in the rail width direction.

7. 6. The packaging structure for a vehicle seat according to claim 5, wherein a notch is formed in a portion of the side portion of each vertical member in the rail width direction corresponding to a boundary between the lower inclined surface portion and the upper inclined surface portion, the notch extending from above toward below and then curving toward one side in the front-rear direction.

8. Each of the vertical members has an upper wall having the inclined surface, a lower wall located below the upper wall, and a first side wall and a second side wall extending in a vertical direction from the lower wall to the upper wall, and is formed into a cylindrical shape by bending a single corrugated board blank whose flute direction is a direction intersecting with the first direction; 3. The packaging structure for a vehicle seat according to claim 2, wherein each of the first side wall and the second side wall is a plurality of walls that overlap each other, each of the flute directions of which is oriented such that the flute directions are predominantly in the vertical direction and intersect with each other, and are configured as multiple walls.

9. 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 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, 9. A packaging structure for a vehicle seat according to claim 2, wherein the inclination angle of the front seat inclined surface is set so that a virtual line passing through the center of gravity of the seat placed on the front seat inclined surface and extending in a normal direction to the front seat inclined surface intersects with the first set of second horizontal members.

Images