Paper container deformation preventing and retaining structure of packaging box

Abstract

To provide paper container deformation preventing and retaining structure of a packaging box capable of reducing the risk of liquid leakage by preventing deformation of a mouth part.SOLUTION: In paper container deformation preventing and retaining structure of a packaging box 1 for storing a plurality of paper containers (paper cups C1) to convey, end surfaces of all inner flaps 2a, 2b (inner flaps 3c, 3d) of a top surface 2 and a bottom surface 3 are brought into contact with each other, and at least flaps extending from a long side 4 being a longitudinal direction to the top surface 2 side are the inner flaps 2a, 2b.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a holding structure for preventing deformation of paper containers in a packaging box. [Background technology]

[0002] In recent years, there has been a noticeable trend among convenience stores and other retailers to switch from plastic to paper containers for coffee and other beverages in order to address environmental destruction such as marine microplastic pollution and to achieve the SDGs. However, compared to plastic containers, paper containers have a weaker resilience to deformation caused by external forces, raising concerns that the mouths of paper cups may become deformed during the distribution process in which they are loaded into cardboard boxes with their contents filled and then transported to each store.

[0003] Specifically, it has been pointed out that the mouth of a paper container can become deformed during a case (cardboard box) drop test in which the container is filled with ice and top-sealed, simulating the distribution process.If the mouth of the paper container becomes deformed in this way and the deformed part of the mouth coincides with the drinking opening of the lid, there is a risk of liquid leakage from the lid fitting.

[0004] The packaging box described in Patent Document 1 has a folded and stacked backing sheet that is suspended in the space between the bottom and top of the inside of the outer box, without contacting the outer box except where it touches the support posts. The stacked backing sheets sandwich and secure the items to be contained in the box through a window, thereby reducing the effects of external shocks and vibrations and preventing friction and collisions between the inside surface of the packaging box and the items. However, the packaging box described in Patent Document 1 has limitations on the number and amount of items that can be contained within the box, making it unsuitable for use as a cardboard box for transporting paper containers such as paper cups. Therefore, there is a strong demand for a packaging box that prevents deformation of paper containers, preventing the openings of the paper containers contained therein from deforming even when subjected to a drop test. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Publication No. 2023-68905 Summary of the Invention [Problem to be solved by the invention]

[0006] The present invention was devised in consideration of the above-mentioned background, and its purpose is to provide a paper container deformation prevention holding structure for packaging boxes that can prevent deformation of the mouth and reduce the risk of liquid leakage. [Means for solving the problem]

[0007] The paper container deformation prevention holding structure of the first invention is a paper container deformation prevention holding structure of a packaging box for storing and transporting multiple paper containers, characterized in that the end faces of the inner flaps on both the top and bottom surfaces abut against each other, and the flaps extending from at least the long side in the longitudinal direction toward the top surface are inner flaps.

[0008] The second invention relates to a paper container deformation prevention holding structure for a packaging box, which is characterized in that, in the first invention, a perforated pad is attached that holds the multiple paper containers by fitting them into holes, and the paper containers are supported at two or more points separated in the vertical direction on the bottom and sides of the paper containers by fitting them into holes formed in the perforated pad and in one of the inner flaps on the bottom surface.

[0009] The paper container deformation prevention holding structure for a packaging box according to the third invention is characterized in that, in the first invention, the inner flaps on the top surface have staggered, stepped end faces, the end faces abutting each other in two or more parallel, stepped straight lines, the protruding lengths of the inner flaps on the top surface and the protruding lengths of the outer flaps on the top surface are the same, and the outermost end faces of the inner and outer flaps on the top surface are on the same straight line.

[0010] The fourth invention relates to a paper container deformation prevention holding structure for a packaging box, which is characterized in that in the third invention, the inner flaps on the top and bottom surfaces are both staggered and stepped, and are symmetrical in a plan view.

[0011] The paper container deformation prevention holding structure for a packaging box according to the fifth invention is characterized in that, in the second invention, the multiple holes into which the multiple paper containers are fitted and held are all formed in the perforated pad, and the holes that support the bottoms of the paper containers are located at a height spaced apart from the bottom surface. [Effects of the Invention]

[0012] According to the first to fifth inventions, even if the packaging box is dropped, the end faces of the inner flaps will come into contact and be stretched, thereby suppressing deformation of the packaging box, preventing deformation of the mouth of the paper container contained therein, and eliminating the risk of liquid leakage from the lid fitting portion. [Brief explanation of the drawings]

[0013] [Figure 1] FIG. 1 is a development view showing a blank sheet for a packaging box according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a development view showing a blank sheet of a perforated pad that is loaded into the packaging box and holds paper containers. [Figure 3] FIG. 3 is a perspective view showing the packaging box. [Figure 4] FIG. 4 is a perspective view showing the packaging box with the inner top flap closed and the outer flap 2 open. [Figure 5] FIG. 5 is a perspective view showing the perforated pad. [Figure 6] Figure 6 is a photograph showing the results of a drop test in which a current cardboard packaging box containing a filled and sealed paper cup was dropped with its short side, which is its weak point, facing downwards. [Figure 7] FIG. 7 is a vertical cross-sectional view showing the paper container deformation prevention holding structure of the packing box 1 according to the first embodiment. [Figure 8] Figure 8 is a photograph showing a paper container loaded into a current packaging box during a drop test. [Figure 9] FIG. 9 is a schematic diagram mainly showing the drop direction in the drop test of the current packaging box. [Figure 10] Figure 10 is a photograph showing the inside of a current packaging box. [Figure 11] FIG. 11 is a photograph showing the damage to the rear surface of the packaging box after the drop test. [Figure 12] FIG. 12 is a photograph mainly showing the damage to the inner flap on the top surface of the packaging box after the drop test. [Figure 13] FIG. 13 is a photograph mainly showing the damage to the paper container after the drop test of the packaging box. [Figure 14] FIG. 14 is a development view showing a blank sheet for a packing box according to the second embodiment of the present invention. [Figure 15] FIG. 15 is a development view showing a blank sheet of a perforated pad that is loaded into the packaging box and holds paper containers. [Figure 16] FIG. 16 is a development view showing the top pad to be loaded into the packaging box. [Figure 17] FIG. 17 is a perspective view showing the packaging box. [Figure 18] FIG. 18 is a perspective view showing the packaging box with the inner flaps on the top surface closed and the outer flaps open. [Figure 19] FIG. 19 is a photograph showing a paper cup attached to a perforated pad. [Figure 20] FIG. 20(a) is a process explanatory diagram showing the top surface sealing step in the procedure for loading a perforated pad and a top pad, and FIG. 20(b) is a process explanatory diagram showing the top pad insertion step in the same loading procedure. [Figure 21] FIG. 21(a) is a process explanatory diagram showing the paper cup loading step of the loading procedure, and FIG. 21(b) is a process explanatory diagram showing the perforated pad insertion step of the loading procedure. [Figure 22] FIG. 22 is a photograph showing the damage to the top pad of the packaging box after the drop test. [Figure 23] FIG. 23 is a photograph showing the damage to the inner flap on the top surface of the packaging box after the drop test. [Figure 24] FIG. 24 is a photograph showing the damage to the paper cup on the drop surface side of the packaging box after the drop test. [Figure 25] FIG. 25 is a photograph showing the damage to the paper cup on the back side of the packaging box after the drop test. [Figure 26] FIG. 26 is a photograph showing the damage to the perforated pad after the drop test of the packaging box. DETAILED DESCRIPTION OF THE INVENTION

[0014] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, exemplary embodiments of the present invention will be described with reference to the accompanying drawings.

[0015] [First embodiment] First, a packaging box 1 having a paper container deformation prevention holding structure according to a first embodiment of the present invention will be described using Figs. 1 to 4. A case will be described in which a plurality of paper cups C1, which are inverted truncated cone-shaped paper containers, are stored as merchandise in the packaging box 1 and transported to various stores. Fig. 1 is a development view showing a blank sheet 10 for the packaging box 1 according to the first embodiment of the present invention, and Fig. 2 is a development view showing a blank sheet 20 for a perforated pad 9 that holds the paper cups C1 loaded in the packaging box 1. Fig. 3 is a perspective view showing the packaging box 1, and Fig. 4 is a perspective view of the packaging box 1 with the inner flaps 2a and 2b of the top surface 2 closed and the outer flaps 2c and 2d open. Fig. 5 is a perspective view showing the perforated pad 9.

[0016] The packaging box 1 according to the first embodiment of the present invention is a cardboard box for packaging multiple paper cups C1, which are paper containers, and transporting them to a store such as a convenience store. The box has a paper container deformation prevention holding structure that prevents the paper cups C1, which are the product, from deforming and leaking liquid from the lid fitting, even if the box is dropped during transport.

[0017] The packaging box 1 is made by folding a blank sheet 10 shown in FIG. 1 made of cardboard (C160×S120×C160 A flute in this embodiment) in a mountain fold along the crease lines indicated by dotted lines in the figure, and assembling it to form a rectangular box body consisting of a hexahedron with a top surface 2 and a bottom surface 3, a long side surface 5 on the long side 4 side, and a short side surface 7 on the short side 6 side, as shown in FIG. 3.

[0018] As shown in Figures 1 and 4, in this packaging box 1, the flaps extending from the long side 4 of the long side 5 toward the top surface 2 are inner flaps 2a and 2b, and the flaps extending from the short side 6 of the short side 7 toward the top surface 2 are outer flaps 2c and 2d.

[0019] In current cardboard packaging boxes, the end faces of the inner flaps that face each other when folded do not abut against each other, but in the packaging box 1 having the paper container deformation prevention holding structure according to this embodiment, the length of the inner flaps 2a, 2b protruding from the long side 4 is set to about half of the short side 6, and in the assembled state, the end faces of the inner flaps 2a, 2b abut against each other at end faces on a straight line parallel to the long side 4. Therefore, even if the packaging box 1 is dropped, not only do the end faces of the outer flaps 2c, 2d abut against each other, but the end faces of the inner flaps 2a, 2b abut against each other and are stretched, which has the effect of suppressing deformation of the packaging box 1 when dropped.

[0020] In contrast, current cardboard packaging boxes have a problem in that the edges of the inner flaps do not abut against each other, so when they are dropped on their short sides, they become weak points, and the areas where the edges of the outer flaps abut against each other rise upward in an arched shape, preventing them from bracing, causing the short sides to cave inward and deforming the paper cups that serve as the products. Figure 6 is a photograph showing the results of a drop test in which a current cardboard packaging box containing a paper cup that has been filled with the contents and sealed as a product was dropped on its short side, which is the weak point, (see <Drop test for packaging boxes> below).

[0021] On the other hand, unlike the top surface 2, the packaging box 1 has long sides 4 of the bottom surface 3 that form outer flaps 3a and 3b, and short sides 6 that form inner flaps 3c and 3d.

[0022] As described above, in current cardboard packaging boxes, the end faces of the inner flaps do not abut against each other even at the bottom, but in the packaging box 1, the protruding length of the inner flaps 3c, 3d is set to about half of the long side 4, and in the assembled state, the end faces of the inner flaps 3c, 3d abut against each other at end faces on a straight line parallel to the short side 6. Therefore, even if the packaging box 1 is dropped, not only the end faces of the outer flaps 3a, 3b abut against each other, but also the end faces of the inner flaps 3c, 3d abut against each other and are stretched, so that deformation of the packaging box 1 can be suppressed even at the bottom 3 when dropped.

[0023] Additionally, six cup insertion holes 3e are drilled in the inner flaps 3c, 3d of the bottom surface 3 to hold the bottom of the paper cup C1 in place. These cup insertion holes 3e are circular holes corresponding to the diameter of the bottom of the paper cup C1. However, for convenience of the sealing procedure, it is preferable that the cup insertion holes 3e be elliptical holes with a long radius along the short side 6 so that they do not get caught when the inner flaps 3c, 3d of the bottom surface 3 are swung around the short side 6 as a central axis to close the packaging box 1 after the paper cup C1 is loaded into the packaging box 1 upside down.

[0024] As shown in Figure 1, an adhesive piece 8 is formed on the blank sheet 10 of the packaging box 1, and adhesive is applied to the surface of this adhesive piece 8 (the surface in Figure 1) and the adhesive piece 8 is adhered to the inside of the long side 5 (the back surface in Figure 1), which is the other end of the blank sheet 10, thereby forming a box body.

[0025] (Perforated pad) Furthermore, the packaging box 1 is fitted with a perforated pad 9 shown in FIGS. 2 and 5 for holding the paper cups C1.

[0026] This perforated pad 9 is a component consisting of a single blank sheet 20 of cardboard material (in this embodiment, C160 x S120 x C160 B flute) as shown in Figure 2, and is composed of a rectangular pad body 21, a pair of short side fold pieces 22 formed on the short sides of this pad body 21, and a pair of long side fold pieces 23 formed on the long sides of the pad body 21.

[0027] Furthermore, the pad body 21 is provided with a plurality of (12 in the illustrated embodiment) cup holding holes 24 that hold the side of the paper cup C1 in place. Unlike the cup insertion holes 3e formed in the inner flaps 3c, 3d, these cup holding holes 24 can be circular holes that correspond to the holding height of the side of the paper cup C1, because the perforated pad 9 can be inserted into the paper cup C1 after the paper cup C1 has been loaded into the packaging box 1.

[0028] 2, at the boundaries between the rectangular pad body 21 and each of the short-side folded pieces 22 and long-side folded pieces 23, there are formed ruled lines 25 shown by dotted lines, and also formed with a plurality of slits 26 shown by solid lines. Therefore, the short-side folded pieces 22 and long-side folded pieces 23 can be folded neatly along the ruled lines 25 and can be prevented from returning to their original shape.

[0029] Fig. 7 is a vertical cross-sectional view showing the paper container deformation prevention holding structure of the packaging box 1 according to the first embodiment. As shown in Fig. 7, the perforated pad 9 cooperates with the cup insertion holes 3e formed in the inner flaps 3c, 3d described above to prevent the paper cups C1 from shifting and moving when an impact load acts on the packaging box 1, such as when the packaging box 1 is dropped, and prevents heavy paper cups C1 filled with contents from colliding with each other and deforming the paper cups C1.

[0030] As shown in Figure 7, in the paper container deformation-preventing holding structure of the packaging box 1, the cup insertion hole 3e in the inner flaps 3c, 3d holds the bottom of the paper cup C1 in place, and the cup holding hole 24 in the perforated pad 9 holds the side of the paper cup C1 in place. Therefore, when an impact load acts on the packaging box 1, the paper container deformation-preventing holding structure of the packaging box 1 can support the paper cup C1 against the impact load at two points separated in the height direction: the end face of the cup insertion hole 3e and the end face of the cup holding hole 24, preventing stress from concentrating at one point on the paper cup C1 and preventing deformation of the paper cup C1. Furthermore, the bottom of the paper cup C1 is the strongest part because the paper is folded multiple times, which also helps prevent deformation of the paper cup C1. Although the example given of the holding structure for preventing deformation of the paper container of the packaging box 1 is one in which the container is supported at two points spaced apart in the vertical direction, it is of course acceptable to have a configuration in which the container is supported at three or more points as long as the support is at two or more points so that stress is not concentrated at one point (the same applies below).

[0031] 5 and 7, in the paper container deformation-preventing holding structure for the packaging box 1 according to the illustrated embodiment, the height from the bottom of the perforated pad 9 when the short-side folded pieces 22 and the long-side folded pieces 23 are folded is set to 45 mm. Adding a 5 mm thickness to the inner flaps 3c and 3d, the end faces of the cup holding holes 24 hold the side portions of the paper cup C1 at a height of 50 to 55 mm from the bottom, and the end faces of the cup insertion holes 3e hold the bottom portions of the paper cup C1 at a height of 5 to 10 mm from the bottom. Here, the height of the paper cup C1 in the illustrated embodiment is assumed to be 119 mm. In this way, by holding the paper cup C1 at two points on the lower part, which are relatively strong, rather than near the mouth, which is weak, deformation of the paper cup C1 can be prevented, and the cardboard portion of the perforated pad 9 can be reduced, thereby reducing material costs.

[0032] <Drop test for packaging boxes> (Current packaging box) Next, we will explain the drop test of the packaging box. A current packaging box was made of C120 x S120 x C120 B-flute corrugated cardboard, and 170 g of acrylic resin blocks, simulating ice, was loaded into the box. As shown in Figure 8, 12 large-size paper cups C1, each 119 mm high and with their openings sealed with a resin film, were then placed inside. The box was then dropped from a height of 80 cm with its short side facing downwards, a condition that causes the most deformation, and the extent of damage was visually confirmed (see Figure 9). Figure 8 is a photograph showing the current packaging box loaded with paper cups C1 during the drop test.

[0033] As shown in Figures 9 and 10, the current packaging box has inner flaps extending from the short sides of the side of the packaging box to the top and from the short sides of the side of the packaging box to the bottom, and the protruding length of the inner flaps is set to less than half the long sides of the side of the packaging box, so that the end faces of the inner flaps do not abut against each other when assembled. Also, as shown in Figure 10, the inner flaps on the bottom of the current packaging box have holes formed in them to hold the bottom of a paper cup C1 in place. Figure 9 is a schematic diagram mainly showing the drop direction of the current packaging box in a drop test, and Figure 10 is a photograph showing the interior of the current packaging box.

[0034] (Test results) As a result of the test, it was found that in the current packaging box, the contents of the paper cup C1 were significantly deformed at the opening, as shown in Figure 6, and there was a risk of liquid leaking from the lid fitting.

[0035] (Packaging box 1 of the first embodiment) As a packaging box according to the first embodiment, a cardboard box made of C160 x S120 x C160 A-flute cardboard material of the aforementioned packaging box 1 was filled with 170 g of acrylic resin blocks simulating ice, in the same way as the current packaging box, and 12 L-size paper cups C1 with a height of 119 mm and a mouth sealed with a resin film were placed inside. The box was then dropped from a height of 80 cm with the short side 7 facing downwards, which is the condition for dropping that causes the most deformation, and the extent of damage was visually confirmed.

[0036] (Test results) As a result of the test, as shown in Figure 11, the appearance of the cardboard box showed that the short side, which is the top surface at the time of dropping, was dug into at the bottom due to the impact of the drop. However, as shown in Figure 12, the inner flaps 2a and 2b on the top surface 2 were only slightly crushed at the edge. This is thought to be because the impact of the drop was absorbed by the dug-in bottom of the short side, which is the top surface at the time of dropping. Figure 11 is a photograph showing the damage to the back side of the packaging box 1 after the drop test. Also, Figure 12 is a photograph mainly showing the damage to the inner flaps 2a and 2b on the top surface 2 of the packaging box 1 after the drop test.

[0037] Furthermore, as shown in Figure 13, the paper cup C1 contained in the container only had visible wrinkles in the resin film that sealed the mouth, and since the deformation was limited to within the elastic deformation range of the mouth of the paper cup C1, there was no problem with the lid fitting, and it is believed that there was no risk of liquid leakage. Figure 13 is a photograph that mainly shows the damage to the paper cup C1 after the drop test of the packaging box 1.

[0038] The packaging box 1 having the paper container deformation prevention holding structure according to the first embodiment described above has a structure in which, when assembled from the blank sheet 10 into a box body, the end faces of the inner flaps 2a, 2b on the top surface 2 that face each other when folded and the end faces of the inner flaps 3c, 3d on the bottom surface 3 that face each other when folded abut each other. Therefore, even if the packaging box 1 is dropped, not only do the end faces of the outer flaps 2c, 2d and the outer flaps 3a, 3b abut each other, but the end faces of the inner flaps 2a, 2b and the inner flaps 3c, 3d abut each other and are tensioned, so that longitudinal deformation of the packaging box 1 can be suppressed on both the top surface 2 and the bottom surface 3 when dropped.

[0039] Furthermore, according to the packaging box 1, the flaps extending from the long side 4 in the longitudinal direction toward the top surface 2 are the inner flaps 2a, 2b, so even if the packaging box 1 is dropped with its short side 7 facing down, the end faces of the inner flaps 2a, 2b of the top surface 2 that face each other when folded will abut against each other, so even if a force applied to the top surface during the drop acts in the longitudinal direction, the inner flaps will be stretched against each other. Therefore, compared to conventional cases where the inner flaps do not abut against each other, the impact during the drop is not countered by the bending rigidity of the cardboard sheet material of the side surface 5, but by the rigidity of the inner flaps 2a, 2b against the compressive force in the material axis direction of the cardboard sheet material, so compressive deformation of the top surface 2, which is the weaker mouth side of the paper cup C1 to be placed inside, can be suppressed, and as a result, deformation of the mouth of the paper cup C1 can be prevented and the problem of liquid leakage can be solved.

[0040] Furthermore, according to the packaging box 1, the paper cup C1 is supported not near the mouth where the strength is weak, but at two points on the lower part where the strength is relatively high, at two points on the end face of the cup insertion hole 3e and the end face of the cup holding hole 24. Therefore, even if the packaging box 1 is dropped, the impact load is not concentrated at one point on the paper cup C1, and deformation of the mouth of the paper cup C1 can be suppressed.

[0041] [Second embodiment] Next, a packaging box 1' having a paper container deformation prevention holding structure according to a second embodiment of the present invention will be described with reference to FIGS. 14 to 19. Similar to the packaging box 1 described above, a case will be described in which a plurality of paper cups C1, which are inverted truncated cone-shaped paper containers, are stored in the packaging box 1' as merchandise and transported to various stores. FIG. 14 is a development view showing a blank sheet 10' for the packaging box 1' according to the second embodiment of the present invention. FIG. 15 is a development view showing a blank sheet 20' for a perforated pad 9' that holds the paper cups C1 loaded in the packaging box 1'. FIG. 18 is a plan view showing a top pad 31 loaded in the packaging box 1'. FIG. 17 is a perspective view showing the packaging box 1, and FIG. 18 is a perspective view of the packaging box 1 with the inner flaps 2a' and 2b' of the top surface 2 closed and the outer flaps 2c' and 2d' open. FIG. 19 is a photograph showing a paper cup C1 attached to the perforated pad 9'.

[0042] The packaging box 1' according to the second embodiment of the present invention is, like the packaging box 1 described above, a cardboard box for packaging the aforementioned multiple paper cups C1 and transporting them to a store such as a convenience store, and has a paper container deformation prevention holding structure that holds the paper cups C1 (products) in place so that they do not deform and leak liquid from the lid fitting portion even if the box is dropped during transport.

[0043] Like the packaging box 1, the packaging box 1' is also assembled by folding a blank sheet 10' shown in FIG. 14 made of cardboard (in this embodiment, C160×S120×C160 A flute) in a mountain fold along the dotted lines in the figure, to form a rectangular box body consisting of a hexahedron with a top surface 2' and a bottom surface 3', a long side surface 5' on the long side 4' side, and a short side surface 7' on the short side 6' side, as shown in FIG. 17.

[0044] As shown in Figures 14 and 18, in this packaging box 1', the flaps extending from the long side 4' of the long side 5' toward the top surface 2' are inner flaps 2a', 2b', and the flaps extending from the short side 6' of the short side 7' toward the top surface 2' are outer flaps 2c', 2d'.

[0045] In the packaging box 1' having the paper container deformation prevention holding structure according to this embodiment, the end faces of the inner flaps 2a', 2b' on the top surface 2' that face each other when folded form stair-like end faces that are staggered, and these end faces abut each other along two or more parallel, step-like straight lines. Note that both of these step-like straight end faces of the inner flaps 2a', 2b' are parallel to the long side 4' when folded. For this reason, even if the packaging box 1' is dropped, not only do the end faces of the outer flaps 2c', 2d' come into contact with each other, but the end faces between the two stepped straight end faces of the inner flaps 2a', 2b' also come into contact with each other, so even if a force is applied to the top surface in the longitudinal direction when the box is dropped, the inner flaps will be braced against each other, and the impact when dropped can be countered by the rigidity of the inner flaps 2a, 2b, which have higher rigidity than the bending rigidity of the cardboard plate material, against the compressive force in the material axis direction of the cardboard plate material, thereby having the effect of suppressing deformation of the packaging box 1' when dropped.

[0046] 14, the length of protrusion of the inner flaps 2a', 2b' from the long side 4' to the end face that is the outermost end in the upward direction is the same as the length of protrusion of the outer flaps 2c', 2d' to the end face, and is set to about half of the long side 4' to match the outer flaps 2c', 2d'. In other words, the outermost end face of the inner flaps 2a', 2b' and the outermost end face of the outer flaps 2c', 2d' are on the same straight line.

[0047] As shown in Figure 14, the blank sheet 10' of the packaging box 1' has an adhesive piece 8' formed on it, similar to the blank sheet 10 described above, and adhesive is applied to the surface of this adhesive piece 8' (surface of Figure 14) and the adhesive piece 8' is adhered to the inside of the long side surface 5' (back surface of Figure 14), which is the other end of the blank sheet 10', thereby forming the packaging box 1' as a box body.

[0048] Here, when forming the packaging box 1' into a box body by adhering adhesive pieces 8' from the blank sheet 10', a ruler can be placed on the outermost ends of the inner flaps 2a', 2b' and the outermost ends of the outer flaps 2c', 2d' of the top surface 2', which are on the same straight line, to correct the alignment while adhering, which reduces the chance of accidentally adhering them out of alignment, improves the yield when forming the packaging box 1' neatly, and reduces manufacturing costs.

[0049] On the other hand, unlike packaging box 1, packaging box 1' has inner flaps 3a' and 3b' extending from the long side 4' of long side 5' to the bottom 3' side, as with top surface 2', and outer flaps 3c' and 3d' extending from the short side 6' of short side 7' to the bottom 3' side, on the bottom 3' side, as with top surface 2'.

[0050] Similarly to the inner flaps 2a', 2b', the inner flaps 3a', 3b' on the bottom surface 3' also have staggered, stepped end faces, and the end faces abut each other in two or more parallel, stepped straight lines. Therefore, even if the packaging box 1' is dropped, not only do the end faces of the outer flaps 3c', 3d' abut each other on the bottom surface 3' side, but also the end faces between the two stepped straight line end faces of the inner flaps 3a', 3b' abut each other and are braced, so that the impact at the time of dropping is countered in the material axis direction of the highly rigid corrugated cardboard plate material through the abutting end faces of the inner flaps 3a', 3b', which has the effect of suppressing deformation of the packaging box 1' when dropped.

[0051] Furthermore, as can be seen in Figure 14, the inner flaps 2a', 2b' of the top surface 2' and the inner flaps 3a', 3b' of the bottom surface 3' are symmetrical in a plan view, and the positions where the end faces abut each other are different in plan view, dispersing weak points in strength and improving the rigidity of the packaging box 1' against deformation. Therefore, the packaging box 1' can further suppress deformation when dropped, preventing deformation of the mouths of the paper cups C1 contained therein and eliminating the risk of liquid leaking from the lid fitting portion.

[0052] (Perforated pad) As shown in FIG. 15, a packaging box 1' is fitted with a perforated pad 9' for holding a paper cup C1.

[0053] This perforated pad 9' is a member made of a single blank sheet 20' of cardboard material (in this embodiment, C160 x S120 x C160 B flute), and is composed of a rectangular upper surface portion 21' and a lower surface portion 22', a folded piece 23' that folds outward from the long and short sides of this upper surface portion 21', a folded piece 24' that folds outward from the long side of the lower surface portion 22', and a connecting portion 25' that connects the upper surface portion 21' and the lower surface portion 22'.

[0054] Additionally, the top surface 21' and the bottom surface 22' are each provided with a plurality of (12 in the illustrated embodiment) cup holding holes 26', 27' that hold the sides and bottom of the paper cup C1 in place. Unlike the cup insertion holes 3e described above, these cup holding holes 26', 27' can be circular holes corresponding to the holding height of the sides of the paper cup C1, since the perforated pad 9' can be inserted into the paper cup C1 after the paper cup C1 has been loaded into the packaging box 1'. Note that the paper cup C1 has an inverted truncated cone shape that widens in diameter toward the top opening, so the cup holding hole 26' formed in the top surface 21' has a larger diameter than the cup holding hole 27' formed in the bottom surface 22'.

[0055] 15, at the boundaries between the top surface portion 21' and the folded piece 23' and the connecting portion 25', a line 28' shown by a dotted line is formed, and a plurality of slits 29' shown by a solid line are also formed. At the boundaries between the bottom surface portion 22' and the folded piece 24' and the connecting portion 25', a line 28' shown by a dotted line is formed, and a plurality of notches 30' shown by a solid line are also formed. These notches 30' are trapezoidal notches, and by folding back along the line 28', the trapezoidal notches 30' rise, allowing the bottom surface portion 22' to be raised by about 5 mm from the bottom surface 3' of the packaging box 1'.

[0056] In a packaging box 1' having a paper container deformation-preventing holding structure according to the second embodiment, cup holding holes 27' formed in the bottom surface 22' hold the bottom of a paper cup C1 to prevent it from shifting, and cup holding holes 26' formed in the top surface 21' hold the side of the paper cup C1 to prevent it from shifting. Therefore, when the packaging box 1' is dropped and an impact load is applied, the paper container deformation-preventing holding structure of the packaging box 1' is able to support the paper cup C1 against the impact load at two points spaced apart in the height direction on the end faces of the cup holding holes 26', 27', preventing stress from concentrating on one point on the paper cup C1 and suppressing deformation of the paper cup C1.

[0057] 19, the perforated pad 9' has a 50 mm gap between the top surface of the upper surface 21' and the bottom surface of the lower surface 22' (the vertical width of the connecting portion 25'), and the lower surface 22' of the perforated pad 9' is raised by the notches 30', raising it about 5 mm above the bottom surface 3' of the packaging box 1'. This allows the paper cup C1 to be held by the cup-holding holes 26' in the upper surface 21' near the center of its overall height of 119 mm. Therefore, even though the perforated pad 9' is made of thin, B-flute corrugated cardboard, which reduces material costs, it can firmly hold the paper cup C1.

[0058] (Top Pad) The top pad 31 is a cardboard plate made of cardboard material (C160×S120×C160 B flute in this embodiment) as shown in Fig. 17. This top pad 31 is interposed between the mouth of the paper cup C1 and the top surface 2', and has the function of preventing deformation of the top surface 2' of the packaging box 1' when dropped, and preventing deformation of the mouth of the paper cup C1 contained therein.

[0059] Next, the loading procedure for the perforated pad 9' and top pad 31 in the paper container deformation prevention holding structure according to the second embodiment will be described using Figures 20 and 21. Figure 20(a) is a process explanatory diagram showing the top surface sealing step of the loading procedure for the perforated pad 9' and top pad 31, and Figure 20(b) is a process explanatory diagram showing the top pad insertion step of the same loading procedure. Figure 21(a) is a process explanatory diagram showing the paper cup loading step of the same loading procedure, and Figure 21(b) is a process explanatory diagram showing the perforated pad insertion step of the same loading procedure.

[0060] (Top seal) First, in the procedure for loading the perforated pad 9' and the top pad 31, a top sealing process is performed as shown in Figure 20(a). In this process, the packaging box 1' is turned upside down, and the end faces of the outer flaps 2c', 2d' of the top face 2' are butted together and sealed by adhering them with adhesive tape or the like, and the inner flaps 2a', 2b' are closed, and the staggered end faces are butted together.

[0061] (Top pad inserted) Next, in the loading procedure, the top pad insertion step is carried out as shown in Figure 21(a). In this step, the top pad 31, which is the aforementioned cardboard plate, is inserted and placed inside the closed inner flaps 2a', 2b'. This step interposes the top pad 31 between the mouth of the paper cup C1 and the top surface 2', preventing deformation of the top surface 2' even if the packaging box 1' should fall, and thus preventing deformation of the mouth of the paper cup C1 contained therein.

[0062] (Paper cup loading) Next, in the loading procedure, a paper cup loading step is carried out as shown in Figure 21(a). In this step, multiple paper cups C1 are placed upside down with their mouths facing downwards on top pad 31 inserted inside top surface 2', and then loaded upside down into packaging box 1'.

[0063] (insert perforated pad) Next, in the loading procedure, a perforated pad insertion step is carried out as shown in Figure 21(b). In this step, the perforated pad 9' is pressed against the bottom of the paper cups C1 loaded into the packaging box 1' in the previous step, and the paper cups C1 are inserted into the cup holding holes 26' and 27'.

[0064] (bottom sealed) Thereafter, the inner flaps 3a' and 3b' of the bottom 3' are closed to bring the staggered stepped end faces into contact, and the outer flaps 3c' and 3d' are closed to bring the faces together and seal them with adhesive tape or the like (not shown). This completes the loading of the paper cups C1, fitted into the top pad 31 and perforated pad 9', into the packaging box 1'.

[0065] <Drop test for packaging boxes> (Packaging box 1' of second embodiment) As a packaging box according to the second embodiment, a cardboard box made of C160 x S120 x C160 A-flute cardboard material of the aforementioned packaging box 1' was filled with 170 g of acrylic resin blocks simulating ice, in the same manner as the current packaging box and packaging box 1, and 12 L-size paper cups C1 with a height of 119 mm and a state in which the openings were sealed with a resin film were packed inside. The box was then dropped from a height of 80 cm with the short side 7' facing downwards, which is the drop condition that causes the most deformation, and the extent of damage was visually confirmed.

[0066] (Test results) As a result of the test, no damage such as crushing was found on the top pad, as shown in Fig. 22. And, no damage such as crushing was found on the end surface of the short side of the inner flap on the top surface, as shown in Fig. 23. Fig. 22 is a photograph showing the damage to the top pad after the drop test of the packaging box 1', and Fig. 23 is a photograph showing the damage to the inner flap on the top surface after the drop test of the packaging box 1'.

[0067] Regarding damage to the contents of the cardboard box, as shown in Figure 24, wrinkles were observed in the plastic film seal of the paper cup C1, a paper container contained on the drop-facing side of the packaging box 1'. However, the flange portion of the opening was perfectly round, and it is presumed that deformation occurred within the elastic range. As shown in Figure 25, the paper cups C1 contained on the drop-facing side of the packaging box 1' were observed to have shifted slightly, with the spacing between the paper cups C1 shrinking by approximately 2 mm since loading. However, the flange portion of the opening was perfectly round, and it is presumed that deformation occurred within the elastic range. Furthermore, as shown in Figure 26, no deformation was observed in the perforated pad. Figure 24 is a photograph showing the damage to the paper cups C1 on the drop-facing side of the packaging box 1' after the drop test. Figure 25 is a photograph showing the damage to the paper cups C1 on the drop-facing side of the packaging box 1' after the drop test. Furthermore, Figure 26 is a photograph showing the damage to the perforated pad of the packaging box 1' after the drop test.

[0068] According to the packaging box 1' having the paper container deformation prevention holding structure according to the second embodiment described above, the inner flaps 2a', 2b' of the top surface 2' have staggered, stepped end faces, and the end faces abut each other along two or more parallel, stepped straight lines. Therefore, even if the packaging box 1' is dropped, not only do the end faces of the outer flaps 2c', 2d' abut each other, but also the end faces between the two stepped straight end faces of the inner flaps 2a', 2b' abut each other. Therefore, even if a force applied to the top surface during the drop acts in the longitudinal direction, the inner flaps are braced against each other. Therefore, the impact during the drop is resisted in the material axis direction of the highly rigid corrugated cardboard plate material of the inner flaps 2a', 2b', which has the effect of suppressing deformation of the packaging box 1' during the drop.

[0069] Furthermore, according to the packaging box 1', the flaps extending from the long side 4' in the longitudinal direction toward the top surface 2' are the inner flaps 2a', 2b', so even if the packaging box 1' is dropped with the short side 7' facing down, the end faces of the inner flaps 2a', 2b' on the top surface 2' abut against each other, so even if the force applied to the top surface when dropped acts in the longitudinal direction, the inner flaps will be stretched against each other, and the impact when dropped is countered in the material axis direction of the highly rigid cardboard plate material through the abutting end faces of the inner flaps 2a', 2b', so that compressive deformation of the top surface 2', which is the weaker mouth side of the paper cup C1 to be placed inside, can be suppressed, and as a result, deformation of the mouth of the paper cup C1 can be prevented and the problem of liquid leakage can be solved.

[0070] Furthermore, according to the packaging box 1', the protruding length from the long side 4' side of the inner flaps 2a', 2b' to the end face that is the outermost end in the upward direction is the same as the protruding length to the end face of the outer flaps 2c', 2d', and the end faces that are the outermost ends of the inner flaps 2a', 2b' and the end faces that are the outermost ends of the outer flaps 2c', 2d' are on the same straight line. Therefore, when the packaging box 1' is formed into a box body by adhering the adhesive pieces 8' from the blank sheet 10', the outermost ends of the inner flaps 2a', 2b' and the outermost ends of the outer flaps 2c', 2d' on the top surface 2' that are on the same straight line can be corrected with a ruler while bonding, reducing the risk of incorrect bonding, thereby improving the yield when forming the packaging box 1' neatly and reducing the manufacturing cost.

[0071] Furthermore, according to the packaging box 1', a perforated pad 9' is attached, and the cup holding holes 27' formed in the lower surface 22' hold the bottom of the paper cup C1 to prevent it from shifting, and the cup holding holes 26' formed in the upper surface 21' hold the side of the paper cup C1 to prevent it from shifting. Therefore, when the packaging box 1' is dropped and an impact load is applied, the paper container deformation prevention holding structure of the packaging box 1' can support the paper cup C1 at two points separated in the height direction on the end faces of the cup holding holes 26', 27' against the impact load, preventing stress from concentrating at one point on the paper cup C1 and suppressing deformation of the paper cup C1.

[0072] In addition, the perforated pad 9' of the packaging box 1' has a gap of 50 mm between the top surface of the upper surface 21' and the bottom surface of the lower surface 22' (the vertical width of the connecting portion 25'), and is raised by the notches 30', causing the lower surface 22' of the perforated pad 9' to be raised about 5 mm above the bottom surface 3' of the packaging box 1'. As a result, the paper cup C1 can be held by the cup holding holes 26' in the upper surface 21' near the center of its overall height, and the paper cup C1 can be held firmly.

[0073] Furthermore, in the packaging box 1', a top pad 31 is interposed between the mouth of the paper cup C1 and the top surface 2', so that even if the packaging box 1' should fall, the top pad 31 itself braces itself within the packaging box 1', and the impact of the fall is countered in the material axis direction of the highly rigid cardboard board material of the top pad 31, thereby preventing deformation of the top surface 2' and preventing deformation of the mouth of the paper cup C1 contained therein.

[0074] The packaging boxes 1, 1' having a holding structure for preventing deformation of paper containers according to the first and second embodiments of the present invention have been described in detail above, but the above-mentioned and illustrated embodiments are merely specific embodiments for carrying out the present invention, and therefore the technical scope of the present invention should not be interpreted as being limited by them. [Explanation of symbols]

[0075] 1,1': Packaging box (holding structure to prevent deformation of paper containers in packaging boxes) 2,2': Top 2a, 2b, 2a', 2b': inner flaps 2c, 2d, 2c', 2d': outer flaps 3: Bottom 3c, 3d, 3a', 3b': Inner flap 3a,3b,3c',3d':Outer flap 3e: Cup insertion hole 4,4': long side 5,5': Long side 6,6': Short side 7,7': short side 8,8':Adhesive piece 9,9': Perforated pad 10,10': Blank sheet (for packaging boxes) 20,20': Blank sheet (for perforated pad) 21: Pad body 21':Top part 22: Short side folded piece 22': Bottom part 23: Long side folded piece 23': Folded piece 24: Cup holding hole 24': Folded piece 25,28': Ruled 25': Connecting part 26: Break 26', 27': Cup holding hole 29': Break 30': cut 31: Top pad C1: Paper cups (paper containers)

Claims

1. A paper container deformation prevention holding structure for a packaging box for storing and transporting a plurality of paper containers, The end faces of the inner flaps on both the top and bottom surfaces are in contact with each other, At least the flap extending from the long side in the longitudinal direction to the top surface is an inner flap A paper container deformation prevention holding structure for packaging boxes, characterized by the above.

2. A perforated pad is attached to hold the plurality of paper containers by fitting them into holes, and the paper containers are supported at two or more points apart in the height direction of the bottom and side of the paper containers by fitting them into holes formed in the perforated pad or in one of the inner flaps on the bottom surface.

2. The paper container deformation prevention holding structure of a packaging box according to claim 1.

3. The inner flaps of the top surface have step-like edge faces that are staggered, and the edge faces abut on two or more parallel step-like straight lines. The protruding lengths of the inner flaps of the top surface and the outer flaps of the top surface are the same, and the outermost edge faces of the inner flaps and outer flaps of the top surface are on the same straight line.

2. The paper container deformation prevention holding structure of a packaging box according to claim 1.

4. The inner flaps on the top and bottom are both stair-shaped and symmetrical in plan view. The paper container deformation prevention holding structure of a packaging box according to claim 3, characterized in that:

5. The plurality of holes for fitting and holding the plurality of paper containers are all formed in the perforated pad, and the holes for supporting the bottoms of the paper containers are located at a height spaced apart from the bottom surface.

3. The paper container deformation prevention holding structure of a packaging box according to claim 2.

Images