Method for packaging foamed sheet assembly, and packaged product of foamed sheet assembly

Abstract

To provide a method for efficiently packaging a large number of small pieces of foamed sheet, and a packaged product in which a large number of small pieces of foamed sheet are packed in a state suitable for transportation and storage.SOLUTION: A method for packaging a foamed sheet assembly includes: a foamed sheet assembly forming step of forming a foamed sheet assembly in which foam layers divided into a plurality of small pieces are laminated in multiple stages; a containing step of containing the foam sheet assembly obtained by the foam sheet assembly forming step in an air-impermeable bag having an opening while maintaining the foam sheet assembly in its assembled state; and a compression sealing step of compressing the bag containing the foam sheet assembly obtained by the containing step in the thickness direction of the foam layers and sealing the opening.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a packaging method for packaging an assembly of small pieces of foam sheet, and to a package containing an assembly of small pieces of foam sheet. [Background technology]

[0002] Conventionally, large foam sheets used for mattresses, automobile interior materials, etc. have sometimes been compressed and packed in consideration of space efficiency during storage and transportation efficiency.

[0003] For example, Patent Document 1 discloses a compression packaging method in which a sheet of cushion material made of synthetic resin foam, such as that used in mattresses, is compressed to form a compressed body, and the compressed body is then wound up in a spiral shape and compressed and packaged. Patent Document 2 also discloses a package and a packaging method in which soft perforated plates used as interior materials for automobiles are stacked one by one in the thickness direction, a stack is placed in an air-impermeable bag, and the bag is evacuated and pressed to compress the thickness of the soft perforated plates. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-105513 [Patent Document 2] Japanese Patent Application Publication No. 7-52978 Summary of the Invention [Problem to be solved by the invention]

[0005] Incidentally, foam sheets are used for a variety of purposes, including but not limited to the above-mentioned mattresses and automotive interior materials. For example, fresh foods such as meat and fish that are displayed in stores are sometimes placed on trays and packaged. In such cases, it is known that small pieces of foam sheets are placed between the fresh foods such as meat and fish and the tray as cushioning material. It is not practical to pack such small pieces of foamed sheet by wrapping them one by one or stacking them one by one in the thickness direction as in the conventional packing method described above, and it is difficult to efficiently pack a large number of small pieces of foamed sheet. Therefore, there has been a demand for a packing method and a package that take into consideration the storage and transportation of small pieces of foamed sheet.

[0006] The present invention has been made in consideration of the above problems, and provides a method for efficiently packing a large number of small pieces of foamed sheet and a package in which a large number of small pieces of foamed sheet are packed in a state suitable for transportation and storage. [Means for solving the problem]

[0007] The method for packaging a foam sheet assembly of the present invention is characterized by comprising: a foam sheet assembly forming step of forming a foam sheet assembly in which foam layers divided into a plurality of small pieces are laminated in multiple stages; a containing step of containing the foam sheet assembly obtained in the foam sheet assembly forming step in an air-impermeable bag having an opening while maintaining the foam sheet assembly in an assembled state; and a compression sealing step of compressing the bag containing the foam sheet assembly obtained in the containing step in the thickness direction of the foam layers and sealing the opening.

[0008] The present invention also provides a foam sheet assembly package comprising a foam sheet assembly formed by laminating foam layers divided into a plurality of small pieces in multiple stages, and a non-breathable bag containing the foam sheet assembly, wherein the opening of the bag is sealed with the inside of the bag decompressed. This product is characterized by comprising a foam sheet assembly formed by laminating foam layers divided into small pieces in multiple stages, and a non-air-permeable bag containing the foam sheet assembly, the inside of which is decompressed and sealed. [Effects of the Invention]

[0009] The method for packaging a foamed sheet assembly of the present invention includes placing a foamed sheet assembly, which is formed by laminating foamed layers divided into small pieces in multiple stages, in a bag, compressing and sealing the bag, and therefore, it is possible to efficiently package a large number of small pieces of foamed sheets. Furthermore, in the foam sheet assembly package of the present invention, many foam sheets are packed in a reduced bulk state, which improves the efficiency of transporting and storing many small pieces of foam sheets. [Brief explanation of the drawings]

[0010] [Figure 1] 1A to 1C are explanatory views illustrating one embodiment of a foam sheet assembly forming step in the foam sheet assembly packaging method of the present invention. [Figure 2] 2A and 2B are explanatory views illustrating different embodiments of the foam sheet assembly forming step in the foam sheet assembly packaging method of the present invention. [Figure 3] FIG. 2 is an explanatory view illustrating one embodiment of the accommodation step in the method for packing a foam sheet assembly of the present invention, and also shows an enlarged plan view of one small piece. [Figure 4] 4A and 4B are process explanatory diagrams illustrating one embodiment of the compression sealing step in the method for packaging a foam sheet assembly of the present invention. [Figure 5] 1 is a perspective view showing one embodiment of a foam sheet assembly package of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0011] <Foam sheet assembly packaging method> In the present invention, instead of packaging many small pieces of foamed sheets one by one, foam layers made of a plurality of small pieces of foamed sheets are laminated as if one large piece of foamed sheet were laminated in the thickness direction to form a foamed sheet assembly, which is then compressed and packaged. That is, the method for packaging a foam sheet assembly of the present invention (hereinafter, sometimes simply referred to as the packaging method of the present invention) includes a foam sheet assembly forming step of forming a foam sheet assembly in which foam layers divided into a plurality of small pieces are stacked in multiple layers, a containing step of containing the foam sheet assembly obtained by the foam sheet assembly forming step in an air-impermeable bag having an opening while maintaining the foam sheet assembly in its assembled state, and a compression sealing step of compressing the bag containing the foam sheet assembly obtained by the containing step in the thickness direction of the foam layers and sealing the opening.

[0012] According to the packaging method of the present invention having such a configuration, small pieces of foamed resin sheets can be efficiently packed together in a reduced bulk state. The foamed sheet aggregate package produced by the packaging method of the present invention makes it easy to carry and handle a large number of small pieces of foamed sheet, thereby improving the efficiency of transportation and storage.

[0013] In the present invention, the vertical direction refers to the top-bottom direction based on an arbitrary position. An embodiment of the packaging method of the present invention will be described below with reference to FIGS. Figures 1A to 1C are process diagrams illustrating one embodiment of the foam sheet aggregate forming step in the packaging method of the present invention, Figure 3 is an explanatory diagram illustrating one embodiment of the accommodation step in the packaging method of the present invention and also shows an enlarged plan view of one small piece, and Figures 4A and 4B are process diagrams illustrating one embodiment of the compression sealing step in the packaging method of the present invention. Also, Figure 2 shows another embodiment of the foam sheet aggregate forming step in the packaging method of the present invention.

[0014] [Foam sheet assembly forming process] The foam sheet assembly forming step is a step of forming a foam sheet assembly (30) in which foam layers (20) divided into a plurality of small pieces (10) are laminated in multiple stages. The resin constituting the foam layer 20 may be any resin capable of forming a foam, such as urethane resin, or polyolefin resin such as polypropylene resin or polyethylene resin.

[0015] As shown in Fig. 1A, in the foam sheet assembly forming step of this embodiment, a foam resin block (32) which is a mass of foam resin is used as the foam sheet assembly (30). The shape of the foam resin block (32) is not particularly limited, but is preferably a rectangular parallelepiped or cubic shape from the viewpoint of being able to easily pack the small pieces (10) while maintaining a good assembly state in the compression sealing step described below. The apparent density of the foam resin block (32) is not particularly limited, but is, for example, 14 kg / m 3 More than 20kg / m 3 It is also possible to use a foamed resin block (32) having a relatively low apparent density in the range of 20 kg / m 3 Exceeding 35kg / m 3 It is also possible to use a foamed resin block (32) having a relatively high apparent density within the following range: The apparent density can be measured in accordance with JIS K 7222:2005.

[0016] As shown in FIG. 1B , the foamed resin block 32 is sliced ​​in one direction into multiple layers to form multiple foam layers 20. In this embodiment, the foamed resin block 32 is sliced ​​into 10 foam layers 20, but the number of layers is not particularly limited. The thickness of the foamed resin block 20 is not particularly limited, but it can be sliced ​​to a relatively thin thickness, for example, in the range of 2 mm to 50 mm, more preferably 2 mm to 15 mm. A thickness within this range is suitable, for example, for use as a buffer sheet placed between food and a tray in a package for fresh food. In this embodiment, the foamed resin block 32 is sliced ​​into multiple layers of the same thickness. However, the present invention also encompasses an embodiment in which the thickness of one foam layer 20 is different from the thickness of another foam layer 20 within a single foamed resin block 32.

[0017] Next, as shown in Fig. 1C, the multi-sliced ​​foamed resin block (32) is cut in a direction intersecting the one direction, thereby dividing each foamed layer (20) into a plurality of small pieces (10). In this embodiment, the foamed resin block (32) having a plurality of foamed layers (20) is cut in a direction perpendicular to the slicing direction. In this embodiment, the foamed resin block (32) is cut so that, in a plan view, the foamed layers (20) are arranged in an orderly fashion, three in the longitudinal direction and three in the lateral direction, for a total of nine rectangular small pieces (10) of the same shape. More specifically, in the foamed sheet aggregate forming process of this embodiment, when the slicing direction is horizontal, each foamed layer (20) is divided into small pieces (10) by cutting predetermined locations of the foamed resin block (32) in a vertical direction perpendicular to the horizontal direction, and small pieces (10) that are rectangular in plan view and arranged in a similar orderly manner are formed in all foamed layers (20).

[0018] The foam sheet assembly forming process of this embodiment can easily form a foam sheet assembly (30) comprising a large number of foam sheets, each of which is a small piece (10). Furthermore, the foam sheet assembly forming process of this embodiment allows the cut surface of one small piece (10) to be tightly adhered to the cut surface of another adjacent small piece (10). Furthermore, as described above, appropriate pressure is applied to the foam sheet during slicing and cutting, which facilitates tight adhesion between adjacent foam sheets. This tight adhesion in the left-right and up-down directions in the foam sheet assembly (30) allows the foam sheet assembly (30) removed from the bag (40) after opening the package (100) of the present invention (described below) while maintaining the individual small pieces (10) in a mutually assembled state, and the foam sheet assembly (30) can be easily restored to its original shape. Furthermore, the foam sheet assembly (30) that has regained its shape can be moved while maintaining its assembled state, which is preferable in terms of ease of handling after opening.

[0019] However, the foam sheet assembly forming step in the packaging method of the present invention is not limited to the above description. For example, the shape of the small pieces (10) is not limited to a rectangular shape in plan view and may be any shape. For example, as shown in FIG. 2A, the foam resin block (32) may be cut so that triangular small pieces (10) are arranged in an orderly fashion in plan view. Alternatively, although not shown, the foam resin block (32) may be cut so that multiple small pieces (10) of a shape other than a rectangle, such as a square, circle, or ellipse, are arranged in an orderly fashion. As shown in FIGS. 1C and 2B, an embodiment in which the foam resin block (32) is divided into small pieces (10) of a predetermined shape so as to prevent waste material from being generated in the foam layer (20) is preferred from the viewpoint of avoiding waste generation.

[0020] The above description of the foam sheet assembly forming process of this embodiment describes an embodiment in which the foam resin block 32 is sliced ​​into multiple layers and then each foam layer 20 is cut to divide it into multiple small pieces 10. According to this embodiment, the foam resin block 32 is first sliced ​​into multiple layers with smaller thicknesses, and then cut in a direction perpendicular to the slicing direction to divide it. This facilitates the formation of multiple small pieces 10 in an orderly arrangement. However, the foam sheet assembly forming process of the present invention is not limited to this embodiment. As a variation, the foam resin block 32 may first be cut into the desired shapes of the small pieces 10 and then sliced ​​into multiple layers. For example, in FIG. 1A, the foam resin block 32 may be divided into predetermined shapes in the vertical direction of the drawing, and then the divided foam resin blocks 32 may be sliced ​​horizontally in the drawing.

[0021] The foamed sheet assembly forming step of the present invention is not limited to the above-described slicing and cutting of the foamed resin block 32 described in this embodiment. For example, a foamed sheet consisting of a plurality of small pieces 10 may be prepared in advance, and these small pieces 10 may be stacked to form a predetermined assembly as shown in Fig. 2B to form a foamed sheet assembly 30 as shown in Fig. 1C. Specifically, as shown in FIG. 2B , nine small pieces (10a) are first arranged in a 3×3 pattern to form a foam layer (20a). Then, to laminate foam layer (20b) on foam layer (20a), small pieces (10b) are stacked on top of foam layer (10a) in the same arrangement as foam layer (10a). In this manner, foam layers (20c), (20d), etc. (not shown) can be stacked until the desired number of layers is reached to form a foam sheet assembly (30). This foam sheet assembly forming process eliminates the need for a slicer to slice the foam resin block (30). For example, a large foam sheet can be cut into multiple small pieces (10) of the desired shape, and these small pieces (10) can be mechanically or manually stacked to easily obtain a foam sheet assembly (30) in which multiple layers of foam layer (20) divided into multiple small pieces (10) are stacked.

[0022] [Storage process] The foam sheet assembly 30 obtained in the foam sheet assembly forming step described above is placed in a non-breathable bag 40 having an opening 42 while maintaining the foam sheet assembly 30 in an assembled state in a containing step. The bag 40 may be made of a material having a strength sufficient to withstand the compression sealing step described below when the foam sheet assembly 30 is placed therein, and a bag 40 made of a general resin sheet may be used. The size of the bag (40) may be any size that can accommodate the foam sheet assembly (30), but from the viewpoint of maintaining a good assembly state of the accommodated foam sheet assembly (30), the circumferential dimension of the bag (40) is preferably 90% to 110% of the circumferential dimension of the foam sheet assembly (30). When the circumferential dimension of the bag (40) is 90% to 100% of the circumferential dimension of the foam sheet assembly (30), it is preferable to slightly compress the foam sheet assembly (30) when accommodating it in the bag (40). Here, the circumferential dimension of the bag (40) refers to the dimension of the bag (40) in a direction perpendicular to the depth direction (d1) of the bag (40), and the circumferential dimension of the foamed sheet assembly (30) refers to the dimension of the foamed sheet assembly (30) in the same direction as the circumferential direction of the bag (40) when the foamed sheet assembly (30) is oriented so as to be contained in the bag (40). In addition, when the circumferential dimension of the bag (40) is smaller than the circumferential dimension of the foamed sheet assembly (30), for example, it is preferable to cover the opposing sides of the foamed sheet assembly (30) with plates and press the two plates close to each other to temporarily compress the foamed sheet assembly (30) and store it in the bag (40), and then remove the plates while taking care not to disrupt the assembly state of the foamed sheet assembly (30).

[0023] In addition, the storing step is not particularly limited to the storing method or storing form as long as the compression sealing step described below can be carried out with the foam sheet assembly (30) stored in the bag (40). In this embodiment, however, the following preferred form is specifically carried out.

[0024] That is, in this embodiment, among the plurality of small pieces (10) dividing the foam layer (20), at least the small pieces (10) adjacent to the opening (42) are regularly arranged with a long axis (12) and a short axis (14) in a plan view, and in the storing step, the foam sheet assembly (30) is stored in the bag (40) with the long axis (12) oriented along the depth direction (d1) of the bag (40). 3, the foam sheet assembly 30 includes multiple foam layers 20 stacked vertically on the paper, and all of the small pieces 10 in each foam layer 20 are arranged in an orderly fashion with a major axis 12 and a minor axis 14 in a plan view. The major axes 12 of the small pieces 10 constituting the foam sheet assembly 30 are parallel to each other. In the storing step of this embodiment, the foamed sheet assembly 30 is stored in the bag 40 with the long axis 12 oriented along the depth direction d1 of the bag 40. In the present invention, the depth direction d1 of the bag 40 refers to the direction from the opening 32 of the bag 40 toward the bottom 46 of the bag 40 opposite the opening 42. By carrying out the accommodation step in this manner, when the foam sheet assembly (30) is compressed in the compression sealing step described below, pressure is firmly applied even to the small pieces (10) in the row closest to the opening (42), making it difficult for them to jump out of the opening (42). This is preferable. Although not shown, the present invention also encompasses an embodiment in which the major axes 12 of the small pieces 10 in the row closest to the opening 42 are oriented along the depth direction d1, and the major axes of the remaining small pieces 10 are partially or entirely not oriented along the depth direction d1. The small pieces 10 not adjacent to the opening 42 can be firmly held between the fixed compression surfaces 52 during compression, thereby preventing them from jumping out of the opening 42.

[0025] [Compression sealing process] The compression sealing step is a step of compressing the bag (40) containing the foamed sheet assembly (30) obtained in the containing step in the thickness direction of the foam layer (20) and sealing the opening (42). That is, in the compression sealing step, the bag (40) containing the foamed sheet assembly (30) is sealed in a compressed state, thereby producing a foamed sheet package (100) in which the inside of the bag (40) is kept decompressed.

[0026] The position of the bag (40) during compression is not particularly limited, but from the viewpoint of taking care to prevent small pieces (10) from flying out of the opening (42) during compression, it is preferable that the compression sealing step be carried out with the bag (40) positioned so that the opening (42) faces upward, as shown in FIG. 4A. At this time, it is preferable that the bottom (46) of the bag (40) and the small piece (10) at the bottom layer are in a state of being in contact with the work surface 50. By positioning the bag (40) so that the opening (42) faces upward and supporting the bottom (46) and the small piece (10) at the bottom layer by the work surface 50 in this manner, it is preferable that the assembled state of the foam sheet assembly (30) is less likely to be broken during the compression and sealing operations.

[0027] The means for compressing the bag (40) containing the foam sheet assembly (30) is not particularly limited, but for example, in the compression sealing step of this embodiment, as shown in Fig. 4A, the bag (40) containing the foam sheet assembly (30) is placed between a fixed compression surface (52) fixed at a predetermined location and a movable compression surface (54) that faces each other and whose distance from the fixed compression surface (52) is adjustable, and in this state, the movable compression surface (54) is moved toward the fixed compression surface (52), thereby sandwiching and compressing the bag (40) between the two surfaces. At this time, the surface directions of the fixed compression surface (52) and the movable compression surface (54) are parallel to the surface direction of the foam layer (20), so that the foam sheet assembly (30) is compressed in the thickness direction of the foam layer (20). With the bag 40 compressed as described above, the vicinity of the opening 42 is sealed to form the sealed portion 44. The means for sealing the bag 40 is not particularly limited, and can be selected appropriately from known means such as heat sealing or other thermal fusion, or adhesion with an adhesive. The foam sheet package (100) can be produced by the method for packaging a foam sheet assembly described above. The packaging method of the present invention is referred to as an example of a method for producing a foam sheet package of the present invention. However, the method for producing a foam sheet package of the present invention is not limited to the packaging method described above. The following describes the foam sheet package of the present invention using a foam sheet package (100) produced by the packaging method of the present invention. Figure 5 is used for the description, and Figures 1 to 4 are also referenced as appropriate for understanding the foam sheet package (100). Figure 5 is a perspective view of a foam sheet assembly package (100) according to one embodiment of the present invention.

[0028] <Foam sheet assembly packaging> As shown in FIG. 5, the foam sheet assembly package (100) of this embodiment includes a foam sheet assembly (30) formed by stacking foam layers (20) divided into a plurality of small pieces (10) in multiple layers, and a non-breathable bag (40) containing the foam sheet assembly (30), and the opening (42) of the bag (40) is sealed with the pressure inside the bag (40) reduced. The foam sheet assembly package (100) having such a configuration has a significantly reduced volume compared to the foam sheet assembly (30) (see FIG. 1C) before compression, making it suitable for transportation and storage. When the foam sheet assembly package (100) is opened and the pressure inside the bag (40) is returned to atmospheric pressure, each of the compressed pieces (10) can easily restore its original shape.

[0029] Because the foam sheet assembly 30 removed from the opened bag 40 can maintain its assembled state, subsequent operations (such as packaging fresh food) using the small pieces 10 are more efficient than using individual pieces 10. Alternatively, multiple small pieces 10 can be used for various subsequent operations while the foam sheet assembly 30 remains inside the opened bag 40. In this case, the small pieces 10 can be removed from the bag 40 according to the operation. As described in the foam sheet assembly forming process described above, a foam sheet assembly package 100 using a foam sheet assembly 30 having multiple foam layers 20 formed by slicing a foam resin block 32 in one direction and the foam layers 20 divided into small pieces 10 is preferable because the foam sheet assembly 30 maintains its assembled state well after opening.

[0030] In the foam sheet assembly package (100) of this embodiment, the foam layer (20) is divided into small pieces (10) that are regularly arranged and have long axes (12) and short axes (14) in a plan view. The foam sheet assembly (30) is contained in the bag (40) so that all of the long axes (12) are oriented along the depth direction (d1) of the bag (40). In other words, the short axes (14) of the small pieces (10) face the opening (42). Therefore, when the sealed portion (44) is cut to open the foam sheet assembly package (100), the small pieces (10) that have recovered their original shape are unlikely to fall out of the cutting opening. Although not shown, the present invention also encompasses a foam sheet assembly package in which the long axes (12) of the small pieces (10) in the row closest to the opening (42) are oriented along the depth direction (d1), and part or all of the long axes of the other small pieces (10) are not oriented along the depth direction (d1).

[0031] To facilitate easy insertion of scissors into the boundary between the first edge 60 and the sealing portion 44 when opening the bag, the foam sheet assembly package 100 of this embodiment is configured such that the dimension 60a of the first edge 60 on the sealing portion 44 side is longer than the dimension 62a of the second edge 62 on the bottom 46 side of the bag 40. This configuration also shortens the time it takes for the multiple small pieces 10 contained in the bag 40 to return to their original state. Specifically, in the row of small pieces 10 facing the sealing portion 44, the small pieces 10 located at both ends of the row are stored in a less compressed state than the small pieces 10 near the center, allowing for quicker recovery when the bag is opened. Furthermore, improved air flow through the small pieces 10 that quickly return to their original state upon opening can accelerate the recovery of the other small pieces 10 located below them. 4A, such a configuration can be achieved by adjusting the positions of the upper end 52a of the fixed compression surface 52 and the upper end 54a of the moving compression surface 54, which are the compression means, so that they coincide with or are close to the upper end 30a of the foam sheet assembly 30. In other words, by positioning the upper end 52a of the fixed compression surface 52 and the upper end 54a of the moving compression surface 54 significantly higher than the upper end 30a of the foam sheet assembly 30, it is possible to adjust the dimension 60a of the first side 60 and the dimension 62a of the second side 62 to be approximately the same length.

[0032] The above describes one embodiment of the method for packaging a foam sheet assembly of the present invention and the packaged foam sheet assembly of the present invention. However, the present invention is not limited to the above description and can be modified as appropriate within the scope of the present invention. [Example]

[0033] Examples of the present invention are shown below, but the present invention is not limited to the following examples and various applications are possible within the scope of the technical concept of the present invention.

[0034] A foamed resin block (urethane foam, apparent density 16 kg / m) measuring 420 mm in length, 480 mm in width, and 280 mm in height. 3 ) was prepared. The foamed resin block was sliced ​​at 5 mm intervals in the height direction and divided into 6 rows at 70 mm intervals in the vertical direction and 3 rows at 160 mm intervals in the horizontal direction to form a foamed sheet assembly having 56 foam layers, each divided into 18 rectangular foam sheets of 70 mm x 160 mm. That is, a foamed sheet assembly consisting of 1008 foamed sheet pieces (18 sheets x 56 rows) each measuring 5 mm thick x 160 mm long x 70 mm wide was obtained.

[0035] An airtight bag (made of vinyl chloride resin, 0.05 mm thick, 400 mm deep, 600 mm wide, with a 250 mm bottom gusset) was prepared. Then, while maintaining the assembled state of the foam sheet assembly formed as described above, the foam sheet assembly was placed in the bag with the long axis direction of the foam sheet pieces oriented along the depth direction of the bag. The circumferential length of the bag used was 1280 mm, and the circumferential length of the foam sheet assembly placed in the bag was 1400 mm (420 mm x 2 + 280 mm x 2). The entire top and bottom surfaces of the foam sheet assembly were covered with two plates, and the foam sheet assembly was sandwiched between the two plates and placed in the bag in a moderately compressed state. The plates were then removed, taking care to maintain the assembled state of the foam sheets.

[0036] The bag containing the foam sheet assembly as described above was placed in a compression device equipped with a fixed compression surface and a movable compression surface, each measuring 540 mm high and 700 mm wide, with the opening facing upward and the 420 mm vertical side of the foam sheet assembly in the bag facing up. At this time, the bottom of the bag and the smallest piece of the foam sheet assembly contained in the bag were placed on the work surface. This allowed the top ends of the fixed compression surface and the movable compression surface to be relatively close to the top end of the foam sheet assembly. The moving compression surface was then moved toward the fixed compression surface, compressing the foam sheet assembly until its thickness reached 40 mm. While compressed, the vicinity of the opening of the bag was heat-sealed to form a sealed portion, and the bag was then sealed. This resulted in a foam sheet assembly package with a thickness reduced by 85.7% compared to the pre-compression thickness of 280 mm. The resulting foam sheet assembly package had a first side dimension (see reference numeral 60a in FIG. 5) on the sealed portion side of 630 cm, and a second side dimension (see reference numeral 62a in FIG. 5) opposite the first side dimension was 460 cm.

[0037] The sealed portion of the foam sheet assembly package prepared as described above was cut off with scissors, and the foam sheet assembly package was opened. After opening, the foam sheet assembly recovered to nearly its original dimensions within about one minute. After recovering its dimensions, the foam sheet assembly was able to maintain its assembled state, and the foam sheets could then be removed in their assembled state from the row closest to the opening of the bag.

[0038] The present invention described above encompasses the following technical ideas. (1) a foam sheet assembly forming step of forming a foam sheet assembly in which foam layers divided into a plurality of small pieces are laminated in multiple layers; a storing step of storing the foamed sheet assembly obtained in the foamed sheet assembly forming step in an air-impermeable bag having an opening while maintaining the foamed sheet assembly in an assembled state; a compression sealing step of compressing the bag containing the foamed sheet assembly obtained in the containing step in a thickness direction of the foam layer and sealing the opening. (2) In the foam sheet assembly forming step, The method for packing a foamed sheet assembly according to (1) above, wherein a foamed resin block is sliced ​​in multiple stages in one direction to form multiple foam layers, and each foam layer is divided into the small pieces by cutting in a direction intersecting the one direction to form a foamed sheet assembly. (3) Among the plurality of small pieces that divide the foam layer, at least the small pieces that are close to the opening are regularly arranged with a major axis and a minor axis in a plan view, In the containing step, The method for packing an assembly of foamed sheets according to (1) or (2) above, wherein the assembly of foamed sheets is placed in the bag with the long axis oriented along the depth direction of the bag. (4) The method for packing a foam sheet assembly according to (1) or (2) above, wherein the compression sealing step is performed with the bag positioned so that the opening faces upward. (5) A foam sheet assembly formed by laminating foam layers divided into a plurality of small pieces in multiple stages; a non-breathable bag containing the foam sheet assembly, A foam sheet assembly package, characterized in that the opening of the bag is sealed with the inside of the bag being decompressed. (6) The foamed sheet assembly according to (5), wherein the foamed resin block is sliced ​​in one direction into multiple layers, and the multiple layers are formed by dividing the foamed layers into small pieces. The foam sheet assembly package according to claim 1. (7) Among the plurality of small pieces dividing the foam layer, at least the small pieces adjacent to the opening of the bag are regularly arranged with a major axis and a minor axis in a plan view, The foam sheet assembly package according to (5) or (6) above, wherein the foam sheet assembly is contained in the bag with the long axis oriented along the depth direction of the bag. [Explanation of symbols]

[0039] 10...small pieces 12...Long axis 14...Short axis 16...Plane 20. Foam layer 30...Foam sheet assembly 30a...Top end 32...Foam resin block 40 bags 42...Aperture 44 Sealing part 46...bottom 50···Work surface 52 Fixed compression surface 52a...Top end 54....Moving compression surface 54a...Top end 60...First side 60a: Dimension of first side 62...Second side 62a... Second side dimension 100...Foam sheet packaging d1: Bag depth direction d2: Thickness direction of foam layer

Claims

1. a foam sheet assembly forming step of forming a foam sheet assembly in which foam layers divided into a plurality of small pieces are laminated in multiple stages; a storing step of storing the foamed sheet assembly obtained in the foamed sheet assembly forming step in an air-impermeable bag having an opening while maintaining the foamed sheet assembly in an assembled state; a compression sealing step of compressing the bag containing the foamed sheet assembly obtained in the containing step in a thickness direction of the foam layer and sealing the opening.

2. In the foam sheet assembly forming step, 2. The method for packing a foamed sheet assembly according to claim 1, wherein a foamed resin block is sliced ​​in multiple stages in one direction to form multiple foam layers, and then cut in a direction intersecting the one direction to divide each foam layer into the small pieces, thereby forming a foamed sheet assembly.

3. Among the plurality of small pieces that divide the foam layer, at least the small pieces that are close to the opening are regularly arranged with a major axis and a minor axis in a plan view, In the containing step, 3. The method for packing an assembly of foamed sheets according to claim 1, wherein the assembly of foamed sheets is placed in the bag with the major axis oriented along the depth direction of the bag.

4. 3. The method for packing an assembly of foamed sheets according to claim 1, wherein the compression sealing step is performed with the bag positioned so that the opening faces upward.

5. a foam sheet assembly formed by laminating foam layers divided into a plurality of small pieces in multiple stages; a non-breathable bag containing the foam sheet assembly, A foam sheet assembly package, characterized in that the opening of the bag is sealed with the inside of the bag being decompressed.

6. 6. The foam sheet assembly package according to claim 5, wherein the foam sheet assembly has multiple foam layers formed by slicing a foam resin block in one direction into multiple layers, and the foam layers are divided into small pieces.

7. Among the plurality of small pieces that divide the foam layer, at least the small pieces that are close to the opening of the bag are regularly arranged with a major axis and a minor axis in a plan view, 7. The foam sheet assembly package according to claim 5, wherein the foam sheet assembly is contained in the bag with the major axis oriented along the depth direction of the bag.

Images