Cushioning member for packed object

Abstract

To provide a cushioning member that can achieve an excellent cushioning effect despite a small form, as a cushioning member for protecting a packed object, and advantageously reduce industrial waste.SOLUTION: A cushioning member includes: a first cushioning member made of a foam material with a front face disposed adjacent to a packed object and a back side extending, with a first width, in a longitudinal direction on a side opposite to the front face; and a second cushioning member constituted of a corrugated board assembly. The second cushioning member has: a bottom wall extending in the longitudinal direction so as to form a channel extending, with a second width wider than the first width, in the longitudinal direction; a pair of side walls continued on both sides of the bottom wall; and a plurality of bridge portions that extend between engagement portions so as to bridge the pair of side walls and extend in a direction perpendicular to the bottom wall. The first cushioning member is fixed onto the second cushioning member in a state in which the back side is in contact with upper ends of the bridge portions.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present invention relates to a cushioning member for protecting an object to be packaged. [Background technology]

[0002] When industrial products and the like are transported to distant destinations (e.g., overseas) using shipping containers, a packaging structure is adopted in which the product is fixed inside a packaging frame to protect the product from vibrations and shocks during transport.

[0003] For example, Patent Document 1 discloses a packaging structure in which an outboard motor is placed horizontally between polystyrene foam pads and secured to a wooden skid with square posts and angled cardboard tubes. This packaging structure is intended for lightweight, small outboard motors and cannot be used for medium- to large-sized outboard motors. Furthermore, despite its flat packaging, it lacks the strength to withstand multiple stacks, resulting in poor loading efficiency. Furthermore, the structure requires a wide-area pad to support the load in order to distribute it, resulting in the use of a large amount of polystyrene foam, which becomes industrial waste.

[0004] In the case of outboard motors, particularly medium-sized or larger outboard motors, a packaging method is adopted in which the outboard motor is stored upright with its propulsion direction facing downwards using stern brackets, which are structures for fixing the outboard motor to the hull, and is bolted to a stand installed on the inner bottom of the packaging frame.

[0005] In this packaging configuration, there is essentially no support structure for the packing frame other than the stern brackets, and the outboard motor is supported inside the packing frame in an overhanging state on both sides of the frame.In addition, the center of gravity is high relative to the support position and biased toward the engine.If an external impact occurs during loading and unloading or transport, there is a risk that the outboard motor, which is the item to be packed, will swing against the packing frame and come into contact with it.Therefore, to prevent damage from contact, cushioning materials such as polystyrene foam are also used.

[0006] Incidentally, final products such as outboard motors are transported to their destinations in a packaged state. Therefore, packing crates are essentially one-way packaging materials, and to reduce additional costs, they are designed to have the minimum strength and rigidity required for normal loading and unloading operations and transportation. Therefore, if a large impact is applied due to an external factor, particularly if the packing crate falls over, there is a risk that the cushioning material, such as polystyrene foam, will not be able to absorb the impact and will break, causing damage to the outboard motor that is being packaged. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 10-250768 Summary of the Invention [Problem to be solved by the invention]

[0008] The present invention has been made in consideration of the above-mentioned circumstances, and its object is to provide a cushioning material that is small in size but provides good cushioning effect as a cushioning material for protecting packaged items, and that is also advantageous in reducing industrial waste. [Means for solving the problem]

[0009] In order to solve the above problems, the present invention provides: A cushioning member disposed on the inside of a side portion of a packing frame surrounding an object to be packed in order to protect the object fixed to the inner bottom portion of the packing frame, a first cushioning member made of a foam material, the first cushioning member having a surface disposed adjacent to the object to be packed, a back surface extending in a longitudinal direction with a first width on the opposite side of the surface, a side surface extending between a side edge of the back surface and the surface, and an end surface extending between an end edge of the back surface in the longitudinal direction and the surface; a second buffer member formed of an assembly of cardboard, the second buffer member having a bottom wall portion extending in the longitudinal direction so as to form a groove having a second width greater than the first width and extending in the longitudinal direction, a pair of side wall portions continuing on both sides of the bottom wall portion via bent portions, and a plurality of bridging portions extending between the engaging portions so as to bridge the pair of side wall portions and extending in a direction perpendicular to the bottom wall portion; The first buffer member is a buffer member that is fixed to the second buffer member with the back surface thereof abutting against the upper end of the bridge portion within the groove. [Effects of the Invention]

[0010] With the above-described configuration, when a large impact is applied to the cushioning member according to the present invention due to an external factor, the impact load acting on the cushioning member from the packaged item is alleviated by the elastic deformation of the first cushioning member made of foam material, and is absorbed by the plastic deformation of the second cushioning member made of a corrugated cardboard assembly, thereby suppressing breakage of the first cushioning member, especially in the early stages, thereby achieving good cushioning effects. Furthermore, compared to cushioning members made entirely of foam material, the amount of foam material used, which becomes industrial waste after use, can be reduced. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 2 is a front view showing the packaging structure for the outboard motor. [Figure 2] FIG. 2 is a side view showing the packaging structure for the outboard motor. [Figure 3] 1A is a front view showing a mounting structure of a buffer member, and FIG. 1B is a side view showing the mounting structure of a buffer member. [Figure 4] FIG. [Figure 5] FIG. 4 is a side view showing the shock absorbing member in an exploded state. [Figure 6] 1A is a plan view showing a second buffer member, and FIG. 1B is a development view thereof. [Figure 7] FIG. 4 is a front cross-sectional view of a main part showing an exploded state of the buffer member. [Figure 8] FIG. 10 is a front cross-sectional view of a main part showing a deformed state of the buffer member. [Figure 9] 1A is a side view of a main part showing a buffer member, and FIG. 1B is a side view of a main part showing a deformed state of the buffer member. DETAILED DESCRIPTION OF THE INVENTION

[0012] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.

[0013] 1 and 2 show a packaging structure in which an outboard motor 60, which is the object to be packaged, is fixed and housed inside a packaging frame 50. The packaging frame 50 comprises a bottom frame 51 that forms a skid, and side frames 52 and end frames 53 that form a crate portion around the bottom frame 51. A stand 54 is erected approximately in the center of the bottom frame 51.

[0014] The outboard motor 60 is fixed to the mount 54 by placing the stern bracket 64 on the mount 54 in an upright position with its propulsion direction facing downwards and fastening it with bolts. The propeller (not shown) is removed from the propeller shaft 63 and is wrapped in a sheet 65 (such as a vinyl sheet) in this state.

[0015] Next, the lower parts (521) of the side frames 52 are fixed to each long side of the bottom frame 51 with bolts, the lower ends of the end frames 53 are fixed to each short side with bolts, the side frames 52 and the end frames 53 are joined to each other with bolts, and the upper parts of the opposing side frames 52 are connected with a reinforcing frame (not shown) to form a crate section that surrounds the outboard motor 60. After that, a cardboard box (not shown) is placed over the packaging frame 50, and the outboard motor is shipped in this state.

[0016] The bottom frame 51 is configured as a skid by joining five base frames 511 arranged parallel to the short side direction and four vertical frames 512 arranged parallel to the long side direction and crossing the five base frames 511 above them, together with a bottom plate (not shown). The base frames 511 and vertical frames 512 are made of structural materials such as channel steel. The platform 54 has legs erected adjacent to the joints between the two base frames 511 and the two vertical frames 512 near the center, and an upper surface that fits onto the stern bracket 64 and has the same slope as the transom board of the boat so that the engine crankshaft is horizontal when the outboard motor 60 is fixed.

[0017] 1, the side frame 52 is configured such that the lower frame 521, which serves as the fixed portion to the bottom frame 51, and the upper frame 522 are bolted to the lower and upper ends of multiple vertical frames 523, respectively, and are welded to the ends of a pair of braces 525, which are welded to each other at their central intersection, and are rigidly connected by fastening braces 524 to prevent distortion. The lower frame 521, upper frame 522, and braces 524 are configured as L-angle structural materials, and the vertical frame 523 is configured as a hat-shaped structural material.

[0018] As shown in Figure 2, the end frame 53 is constructed by connecting the upper parts of a pair of vertical frames 531 with an upper frame 532, and by welding a pair of braces 533 welded to each other at the central intersection, creating a rigid connection that prevents distortion. The vertical frames 531 and the upper frames 532 are constructed from L-angle structural materials. A reinforcing frame 535 is installed between the side frames 52, providing a support structure for the upper buffer member 45.

[0019] As described above, the side frames 52 and end frames 53 surrounding the outboard motor 60 fixed to the mount 54 on the bottom frame 51 each have a truss structure, which not only protects the outboard motor 60 but also provides the strength and rigidity to enable it to be stacked when loaded into a container or stored.

[0020] However, medium to large outboard motors have an overall height of 1.5 to 2 m and a weight of 100 to 350 kg, and in addition to being supported in a state where they overhang significantly from the frame 54, their center of gravity is high relative to the support position and is biased toward the engine, which is on the left side in Figure 1. Moreover, as already mentioned, the packing frame 50 is basically a one-way packing material, and is designed to have the minimum strength and rigidity required for normal loading and unloading operations and transportation.

[0021] Therefore, if an excessive impact is applied to the packing crate 50 due to an external factor during loading and unloading operations or transportation, for example, if a transport vehicle passes over a bump in the road surface such as a speed breaker without slowing down during land transportation, the outboard motor 60 may swing inside the packing crate 50 and come into contact with the packing crate 50. In particular, if the packing crate 50 were to tip over, it would be difficult for the stand 54 to cantilever the outboard motor 60, and the outboard motor 60 would fall onto the inside surface of the packing crate 50.

[0022] Therefore, in order to prevent damage to the outboard motor 60 due to contact with the packing frame 50, shock absorbing members 41, 45, 46 are provided adjacent to the outboard motor 60 inside the packing frame 50.

[0023] Of these, the buffer members 45, 46 are buffer member 45 against upward movement near the cavitation plate and buffer member 46 against downward movement of the top cowling 62 when a counterclockwise moment in Figure 1 is generated due to the offset in the center of gravity of the outboard motor 60 mentioned above, and buffer member 46 is fixed onto the bottom plate of the bottom frame 51.

[0024] On the other hand, the buffer members 41 are disposed adjacent to the sides of the outboard motor 60 and inside the side frames 52 for the purpose of absorbing shock when the outboard motor 60 swings left and right in Figure 2 or when the outboard motor 60 is dropped due to tipping over of the packing frame 50. The buffer members 41 and their mounting structure will be described below with reference to the drawings.

[0025] (Mounting structure of cushioning member 41) As shown in Figures 2 and 3, the cushioning member 41 is made up of a first cushioning member 10 having a surface that is curved two-dimensionally or three-dimensionally along the shape of the side surface near the bottom cowl 61 of the outboard motor 60, and a second cushioning member 20 that supports the first cushioning member 10 while abutting against the back surface of the first cushioning member 10, with the first cushioning member 10 being made up of a foam material and the second cushioning member 20 being made up of a cardboard assembly.

[0026] As shown in FIG. 1 , the buffer member 41 is oriented to match the shape of the bottom cowl 61 of the outboard motor 60, and is joined to the surface of the base portion 42 at the bottom of the second buffer member 20. The base portion 42 is made of a cardboard sheet, and a block-shaped anchor portion 43 is joined to the back surface of the base portion 42. The anchor portion 43 is made of a laminate of multiple cardboard sheets, and therefore the base portion 42 and the anchor portion 43 also have a buffer function in their thickness direction, and together with the buffer member 41, they constitute the buffer member assembly 40.

[0027] The buffer member 41 (buffer member assembly 40) having the above-described mounting structure is positioned adjacent to the side of the outboard motor 60 inside the side frame 52 by fitting the anchor portion 43 between the two vertical frames 523 so that the side edge portion 423 of the base portion 42 overlaps the inside of each part (flange portion) of the two adjacent vertical frames 523 of the side frame 52, and by sandwiching the side edge portion 433 of the anchor portion 43 between the two vertical frames 523.

[0028] The base portion 42 has a vertical length corresponding to the length from the top to the bottom of the vertical frame 523, and the lower end 422 of the base portion 42 is supported on the inner bottom of the packing frame 50, and in this state, the upper end 421 of the base portion 42 abuts or is adjacent to the upper frame 522.This configuration prevents the cushioning member 41 from shifting position during transportation.

[0029] (Assembly structure of the buffer member 41) Next, an embodiment of the first buffer member 10 and the second buffer member 20 that constitute the buffer member 41 will be described with reference to the drawings.

[0030] 4, the first cushioning member 10 has a front surface 11 formed of a curved surface that curves along the shape of the side surface of the outboard motor 60, and a back surface 12 having a flat basic shape, and is configured as an elongated block having a first width w1 and extending in the longitudinal direction. The foam material that forms the first cushioning member 10 is not particularly limited, but a synthetic resin foam material such as expanded polystyrene can be suitably used.

[0031] 6(B), the second cushioning member 20 is formed from a single corrugated cardboard blank, with the bottom wall 21, a pair of side walls 22, and a pair of end flaps 23 having a flute direction in the width direction perpendicular to the longitudinal direction. That is, fold lines 221, 231 (rules, scores) are formed on both sides and both ends of the bottom wall 21, respectively, and are continuous with the side walls 22 and end flaps 23 via these fold lines. Slits 25 that engage with the engaging pieces 33 of the bridging portions 30 are formed on the edges of each side wall 22.

[0032] The multiple bridging portions 30 are each formed from a corrugated cardboard blank of the same shape, with the flute direction extending from the upper end 32 toward the lower end 31. At positions corresponding to the engaging pieces 33 on both sides of the lower end 31, engaging grooves 35 are provided toward the engaging piece 33 on the upper end 32 side to engage with the lower portions of the slits 25 in the side wall portions 22, and as shown in Figure 7, expanded portions 34 are formed extending laterally via the engaging piece 33. In addition, an expanded portion is formed at the introduction portion at the lower end of each engaging groove 35 to facilitate engagement with the slit 25.

[0033] Then, the fold lines 221 on both sides of the bottom wall portion 21 are bent, and the bottom wall portion 21 and the pair of side wall portions 22 on either side thereof form a groove shape extending in the longitudinal direction with a second width w2. By engaging the engagement grooves 35 of the bridging portions 30 with each slit 25 and engaging the engagement piece portions 33, as shown in Figure 6(A), the side wall portions 22 are bridged by each bridging portion 30, and three box-shaped portions 24 are formed by three adjacent pairs of bridging portions 30 and side wall portions 22.

[0034] 5 and 7, when the engaging piece 33 of the bridging part 30 is engaged with the slit 25 of the side wall part 22, a gap is formed between the lower end 31 of the bridging part 30 and the bottom wall part 21. In other words, the height from the upper end 32 to the lower end 31 of the bridging part 30 and the depth of the engaging groove 35 (the length of the engaging piece 33 in the engaging direction) are determined so that a gap is formed between the bridging part 30 and the bottom wall part 21 in the engaged state.

[0035] 5, the first cushioning member 10 is placed on the second cushioning member 20 so that the back surface 12 of the first cushioning member 10 abuts against the upper ends of each bridging portion 30 of the second cushioning member 20, and the end flaps 23 of the second cushioning member 20 are joined to the end faces 13 of the first cushioning member 10, thereby integrating the first cushioning member 10 and the second cushioning member 20. As shown in FIGS. 9(A) and 9(B), the flute direction of the end flaps 23 is oriented in the width direction, and therefore the non-jointed portions can deform in the height direction while maintaining the joints 15 with the end portions 13, and this does not hinder the displacement of the first cushioning member 10 or the plastic deformation of the second cushioning member 20 (bridging portions 30).

[0036] (Impact absorption effect of buffer member 41) As described above, the cushioning members 41 (cushioning member assemblies 40), each made of the first cushioning member 10 made of foam and the second cushioning member 20 made of a cardboard assembly, are arranged inside the side frames 52 of the packing crate 50, adjacent to the side of the outboard motor 60. If the packing crate 50 falls over due to an external factor during transportation or loading / unloading of the outboard motor 60 (packing crate 50), causing the outboard motor 60 to fall sideways inside the packing crate 50, as shown in Figures 8 and 9(B), the first cushioning member 10 and the second cushioning member 20 are interposed below the outboard motor 60', and the impact load from the outboard motor 60' acts on the surface 11' of the first cushioning member 10'. This causes the first cushioning member 10' to be pressed downward while partially elastically deforming, and to enter between the side wall portions 22 of the second cushioning member 20', and the bridging portion 30' begins to plastically deform from the upper end 32' (first stage).

[0037] Furthermore, as the first buffer member 10' descends between the side wall portions 22, plastic deformation of the upper end 32' and the engaging piece portion 33' of the bridging portion 30' of the second buffer member 20' progresses, causing the lower end 31 to abut against the bottom wall portion 21, and overall plastic deformation of the bridging portion 30' and plastic deformation of the slit 25' and slit bottom portion 253 of the side wall portion 22 progresses, causing the bridging portion 30' to collapse before the first buffer member 10' reaches its elastic limit (second stage).

[0038] Thereafter, the first buffer member 10', whose underside (rear surface 12) is seated on the bottom wall portion 21, is elastically and partially plastically compressed by the load of the outboard motor 60', and the fall of the outboard motor 60' ends while it is subjected to the static load of the outboard motor 60' (third stage).

[0039] The above process is actually completed almost instantly, but the difference in deformation patterns between the elastic deformation of the first cushioning member 10 made of foam material and the plastic deformation of the second cushioning member 20 made of a cardboard assembly, in particular the synergistic effect of the plastic deformation of the second cushioning member 20 delaying the elastic compression of the first cushioning member 10 and slowing down the plastic deformation of the second cushioning member 20, prevents the first cushioning member 10 from breaking and maximizes the shock absorption effect achieved by the elastic deformation of the first cushioning member 10 and the plastic deformation of the second cushioning member 20, which is advantageous in preventing damage to the outboard motor 60.

[0040] Furthermore, in the above process, the first buffer member 10 enters the groove defined between the side wall portions 22, 22 of the second buffer member 20, and the side surface of the first buffer member 10 is guided by the side wall portion 22. In addition, the end flap 23 of the second buffer member 20 is joined 15 to the end face 13 of the first buffer member 10, thereby preventing misalignment of the first buffer member 10 and the second buffer member 20, ensuring that the first buffer member 10 is guided reliably between the side wall portions 22, 22 of the second buffer member 20, and ensuring that the impact load acting on the first buffer member 10 is input reliably to the bridging portion 30 of the second buffer member 20, thereby achieving the designed impact absorption effect.

[0041] Although the embodiments of the present invention have been described above, the present invention is not limited to the above-described embodiments, and various modifications and changes are possible within the scope of the present invention.

[0042] For example, in the above embodiment, the first cushioning member 10 is held by the second cushioning member 20 by joining 15 the end flap 23 of the second cushioning member 20 to the end surface 13 of the first cushioning member 10. However, an engagement portion that interconnects the end surface 13 of the first cushioning member 10 and the end flap 23 of the second cushioning member 20 may be provided to hold the first cushioning member 10 by the second cushioning member 20. For example, an engagement portion can be formed without impairing the formability of the first cushioning member 10 by configuring an opening formed in the end flap 23 of the second cushioning member 20 to engage with a protrusion protruding from the end surface 13 of the first cushioning member 10, or by inserting a narrow tongue-shaped piece formed on the end flap 23 of the second cushioning member 20 into a slit that vertically penetrates the extending portion of the end surface 13 of the first cushioning member 10 and engaging the opening. In addition, the back surface 12 of the first buffer member 10 can be adhered to the upper end 32 of the bridging portion 30 of the second buffer member 20, so that the first buffer member 10 is held by the second buffer member 20.

[0043] Furthermore, in the above embodiment, a configuration has been shown in which the back surface 12 of the first buffer member 10 is formed flat, but a protrusion that protrudes between the pair of side wall portions 22 of the second buffer member 20 may also be provided on the back surface 12 of the first buffer member 10, or a groove (recess) that extends in the width direction may be formed on the back surface 12 of the first buffer member 10 so as to engage with the upper end 32 of the bridging portion 30 of the second buffer member 20. These configurations have the advantage of being able to more reliably prevent misalignment between the first buffer member 10 and the second buffer member 20.

[0044] In the above embodiment, the upper end 32 of the bridging portion 30 of the second buffer member 20 coincides with the upper end of the side wall portion 22 in a side view, but the upper end of the side wall portion 22 may extend upward beyond the upper end 32 of the bridging portion 30. While such an extension does not contribute to reducing material costs, it is advantageous in that it ensures that the first buffer member 10 is guided into the groove of the second buffer member 20 and prevents misalignment between the first buffer member 10 and the second buffer member 20, as described above.

[0045] In the above embodiment, the bridging portions 30 of the second cushioning member 20 are shown to be composed of three sets of bridging portions 30 forming three box-shaped portions 24 and two bridging portions 30 adjacent to the end flaps 23, but the arrangement and arrangement density of the bridging portions 30 may be other than those described above.

[0046] In the above embodiment, the shock absorbing member 41 is disposed between the vertical frames 523, 523 at an angle along the bottom cowl 61, which is a high-strength portion of the outboard motor 60, but it may also be disposed inside the vertical frame 523 on the top cowl 62 side, which is the left side in Fig. 1, or may be added. In that case, the shock absorbing member 41 may be fixed directly to the inside of the vertical frame 523 without using the base member 42.

[0047] In the above embodiment, the outboard motor 60 is described as the object to be packed. However, the cushioning member 41 according to the present invention can also be used when packing other items that, like the outboard motor, are not sufficiently self-supporting but are transported fixed in a packing frame in an upright position, such as a motorcycle. [Explanation of symbols]

[0048] 10 First cushioning material (foam material) 11 Surface 12 Bottom 13 End face 20 Second cushioning member (cardboard assembly) 21 Bottom wall 22 Side wall 23 End flap 25 slit 30 Bridge section 31 Bottom end 32 Top 33 Engagement piece 35 Engagement groove 60 Outboard motor (packaged item) 50 packing boxes 51 Bottom frame 52 Side frame 53 End Frame 54 Mounting stand

Claims

1. A cushioning member disposed on the inside of a side portion of a packing frame surrounding an object to be packed in order to protect the object fixed to the inner bottom portion of the packing frame, a first cushioning member made of a foam material, the first cushioning member having a surface disposed adjacent to the object to be packed, a back surface extending in a longitudinal direction with a first width opposite to the surface, a side surface extending between a side edge of the back surface and the surface, and an end surface extending between an end edge of the back surface in the longitudinal direction and the surface; a second buffer member constructed of an assembly of corrugated cardboard, the second buffer member having a bottom wall portion extending in the longitudinal direction so as to form a groove having a second width greater than the first width and extending in the longitudinal direction; a pair of side wall portions continuing on both sides of the bottom wall portion via bent portions; and a plurality of bridging portions extending between the engaging portions so as to bridge the pair of side wall portions and extending in a direction perpendicular to the bottom wall portion; The first buffer member is fixed to the second buffer member with the back surface thereof abutting against the upper end of the bridge portion within the groove.

2. The cushioning member according to claim 1, wherein the second cushioning member has a pair of end flaps that are continuous with each other via a folded portion at both ends of the bottom wall portion, and the first cushioning member is fixed to the second cushioning member by joining or engaging the end flaps to the end surfaces.

3. 3. The cushioning member according to claim 2, wherein the bottom wall portion, the pair of side wall portions, and the pair of end flaps of the second cushioning member are formed from a single first corrugated board blank whose flute direction is the width direction perpendicular to the longitudinal direction, and the plurality of bridging portions are formed from a plurality of second corrugated board blanks whose flute direction is the perpendicular direction.

4. 4. The cushioning member according to claim 3, wherein the engaging portion of the bridge portion includes an engaging piece portion extending laterally to engage with a slit extending from the upper end of the side wall portion toward the bottom wall portion.

5. 5. The cushioning member according to claim 4, wherein the engagement piece of the bridge portion further includes an enlarged portion extending beyond the slit to form an engagement groove that engages with a lower portion of the slit of the side wall portion.

6. The buffer member according to any one of claims 1 to 5, wherein the length from the upper end to the lower end of the bridging portion is shorter than the length from the upper end to the lower end of the side wall portion, and a gap is formed between the lower end of the bridging portion and the bottom wall portion.

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