Packing box

Abstract

This packaging box enables unloading using casters, even for heavy products, without the need to prepare a separate ramp. [Solution] The packaging box comprises a pallet that forms the bottom of the storage area in which the target product is stored, a first panel that forms the top of the storage area, and a second, third, fourth, and fifth panel that surround the storage area from all four sides. One or more panels belonging to the panel group consisting of the first, second, third, fourth, and fifth panels are called slope panels, and each has legs that protrude toward the storage area, formed at one or more locations on the back side, which is the main surface facing the storage area. When unpacked, the slope panel is connected to the pallet with the legs in contact with the mounting surface, so that the slope surface, which is the main surface of the slope panel opposite to the back side, forms a downward sloping surface.

Description

Technical Field

[0001] The present invention relates to a packaging box, and particularly to a packaging box for accommodating a target product equipped with casters.

Background Art

[0002] Conventionally, a foldable slope that can be housed in a case together with a product is known (see Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] According to the above Patent Document 1, a corrugated fiberboard packaging case is formed by using a corrugated fiberboard pallet as the bottom portion and providing side portions so as to cover from above the bottom portion. A product and a foldable slope made of a pulp material are accommodated in this packaging case. The product is placed on the upper surface of the corrugated fiberboard pallet. The foldable slope is fixed to the front portion of the pallet via a hinge. When unpacking, after the side portions are removed, the foldable slope is opened horizontally with the hinge portion as a fulcrum. Thereby, a slope surface extending from the front portion of the pallet is formed.

[0005] However, the above structure is intended for extremely lightweight products to be accommodated, and is not suitable for accommodating heavy objects. This point can also be understood from the fact that the pallet and the case are made of corrugated fiberboard, and the foldable slope is made of pulp. That is, when a heavy object is unloaded from the pallet through this slope, the possibility that the slope may be damaged cannot be ruled out.

[0006] Furthermore, as in Patent Document 1, from the viewpoint of housing the slope in a folded state together with the product inside the case, the slope needs to be made of a material that is foldable and can be easily opened by rotational movement with the hinge as the pivot point. For these reasons, it is difficult to realize a slope suitable for transporting heavy objects with the structure of Patent Document 1.

[0007] In view of the above problems, the present invention aims to realize a packaging box that enables unloading using casters, even when the product to be transported is heavy, without the need to prepare a separate ramp. [Means for solving the problem]

[0008] The packaging box according to the present invention is a packaging box for housing a target product equipped with casters, A pallet placed on a mounting surface and forming the bottom of the storage area in which the target product is stored, A first panel that faces the pallet in a vertical direction and forms the upper part of the storage area, The structure comprises a second panel, a third panel, a fourth panel, and a fifth panel that surround the aforementioned accommodation area from all four sides, each forming the sides of the accommodation area. A slope panel, which is one or more panels belonging to the panel group consisting of the first panel, the second panel, the third panel, the fourth panel, and the fifth panel, has legs that protrude toward the accommodation area, formed at one or more locations on the back side, which is the main surface facing the accommodation area. In an unpacked state in which each panel belonging to the panel group is removed, the ramp panel is connected to the pallet directly or via other members in a manner in which the legs of the ramp panel abut the aforementioned mounting surface, thereby forming a downward sloping surface on the main surface of the ramp panel opposite to the back surface, which extends from the height of the upper surface of the pallet on which the target product is placed to the height of the aforementioned mounting surface.

[0009] According to the above configuration, one or more panels belonging to the panel group, namely the slope panels, have legs formed on their back surface that protrude toward the storage area. Therefore, by connecting these slope panels to the pallet in a direction that the legs abut against the mounting surface, one or more surfaces that formed the top or side of the packaging box form a slope surface.

[0010] In other words, with the above configuration, there is no need to store a foldable ramp within the storage area, so there is no need to make the ramp itself out of a foldable material, and a ramp that can be used even when unloading heavy objects can be formed.

[0011] From the viewpoint of increasing the load-bearing capacity of the pallet and the slope panel, it is preferable that the pallet and each panel belonging to the panel group be made of wood.

[0012] In this case, the panels belonging to the panel group that do not correspond to the slope panels may be wooden members with perforated panels that connect the outside and inside of the storage area. This makes it possible to create a packaging box suitable for transporting heavy objects while suppressing an excessive increase in the weight of the packaging box itself.

[0013] Multiple panels belonging to the aforementioned panel group correspond to the slope panels, Each of the aforementioned slope panels has a different protruding length of the leg portion formed on the back side of the slope panel. Under the aforementioned unpacked state, The slope panel having the longest protruding leg portion is directly connected to the pallet in a manner that the leg portion abuts against the aforementioned surface. Furthermore, the slope panels other than the specified slope panel may be connected to each other in such a way that their legs abut the aforementioned surface, and the slope panels with relatively longer protruding legs are positioned closer to the pallet, thereby connecting the slope surfaces of each of the multiple slope panels, including the specified slope panel, and forming the downward sloping surface.

[0014] According to the above configuration, by connecting two or more slope panels, it is possible to make the downward slope angle of the slope surface gentler, even when the height of the pallet is high. This slope angle is preferably set to 5° or less, more preferably to 4° or less, and particularly preferably to 3° or less.

[0015] As an example, the slope panel is composed of one panel belonging to the side panel group consisting of the second panel, the third panel, the fourth panel, and the fifth panel, and the first panel. Among the slope panels, the panels belonging to the side panel group may constitute the specific slope panel.

[0016] Of the multiple slope panels, at least the specific slope panel has multiple legs with different protruding lengths on its back side, In the unpacked state, the ramp panel having multiple legs may be connected to the pallet in such an orientation that the legs with relatively longer protruding lengths are positioned closer to the pallet.

[0017] The specific slope panel is installed in the position closest to the pallet among the slope panels, and therefore constitutes the slope surface with the highest height relative to the mounting surface. Therefore, by providing multiple legs on the back side of this specific slope panel and installing it so that each leg contacts the mounting surface, the slope surface can be stabilized.

[0018] The packaging box includes a connecting member arranged in the accommodation area, Under the unpacked state, the pair of slope panels may be connected via the connecting member on the back surface side of the position where the pair of slope panels are connected to each other.

[0019] According to the above configuration, the connection portion between the plurality of slope panels can be stabilized. The surface of the connecting member on the side opposite to the slope panel may be in contact with the placement surface.

[0020] The target product is provided with an adjuster that protrudes downward from the surface on the side where the casters are mounted and allows the protrusion length to be adjusted, The packaging box is installed on the pallet, and includes an adjuster base plate against which the adjuster abuts when the target product is accommodated in the accommodation area, and a caster base plate arranged in the accommodation area, The pallet has a recessed region into which the caster base plate can be inserted, Under the unpacked state, with the caster base plate inserted into the recessed region, the protrusion length of the adjuster is reduced, so that the casters abut against the caster base plate, and the upper surface of the caster base plate and the upper surface of the pallet may be configured to allow the target product to be transported by the casters.

[0021] The packaging box includes a plurality of guide members arranged in the accommodation area, Under the unpacked state, the guide members may be fixed along at least the outer edge of the upper surface of the pallet that extends parallel to the direction in which the slope panels are connected.

[0022] According to the above configuration, when the target product is transported from the pallet via the slope surface under the unpacked state, the target product can be prevented from falling off the outer side of the pallet.

[0023] Within the aforementioned storage area, an accessory storage box is provided located on the outside of the target product, The aforementioned accessory storage box houses the connecting member, the caster base plate, and the guide member. The accessory storage box may be removable to the outside of the storage area when one or more panels belonging to the panel group are removed.

[0024] The slope panel has a slope guide that extends outward along a pair of opposing outer edges on the slope surface, The ramp guide may extend in a direction that connects to the pallet in the unpacked state.

[0025] According to the above configuration, when transporting the product by moving its casters along the slope surface while it is unpacked, it is possible to prevent the product from detaching from the outside of the slope panel.

[0026] The aforementioned slope guide may also be composed of another plate-like member provided on the slope surface. [Effects of the Invention]

[0027] According to the packaging box of the present invention, even if the product to be transported is heavy, it can be unloaded using casters without the need to prepare a separate ramp. [Brief explanation of the drawing]

[0028] [Figure 1] This is a schematic perspective view showing the structure of one embodiment of the packaging box according to the present invention. [Figure 2] This is a schematic perspective view showing the structure of one embodiment of the packaging box according to the present invention, and the viewing direction is different from that of Figure 1. [Figure 3] Figure 1 is a schematic perspective view showing the components of the packaging box 1 disassembled. [Figure 4]Figure 3 is a schematic perspective view showing an example of the accessories stored in the accessory storage box 7. [Figure 5A] This is a schematic perspective view showing the first panel 11 extracted from Figure 3. [Figure 5B] This is a schematic perspective view of the first panel 11 shown in Figure 3, and the viewing direction is different from that of Figure 5A. [Figure 6A] This is a schematic perspective view showing the second panel 12 extracted from Figure 3. [Figure 6B] This is a schematic perspective view of the second panel 12 shown in Figure 3, and the viewing direction is different from that of Figure 6A. [Figure 7] These are schematic side views of the first panel 11 shown in Figures 5A to 5B and the second panel 12 shown in Figures 6A to 6B. [Figure 8] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 9] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 10] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 11] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 12] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 13] Figures 1 and 2 are schematic, partially enlarged cross-sectional views illustrating one procedure for unpacking the packaging box 1. [Figure 14] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 15] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 16] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 17]Figures 1 and 2 are schematic, partially enlarged cross-sectional views illustrating one procedure for unpacking the packaging box 1. [Figure 18] Figures 1 and 2 are schematic, partially enlarged cross-sectional views illustrating one procedure for unpacking the packaging box 1. [Figure 19] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 20] This is a schematic perspective view showing the structure of the cushioning member 23. [Figure 21] Figures 1 and 2 are schematic, partially enlarged cross-sectional views illustrating one procedure for unpacking the packaging box 1. [Figure 22] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 23] Figures 1 and 2 are schematic, partially enlarged cross-sectional views illustrating one procedure for unpacking the packaging box 1. [Figure 24] Figures 1 and 2 are schematic perspective views illustrating one procedure for unpacking the packaging box 1 shown in Figures 1 and 2. [Figure 25A] This is a schematic perspective view showing pallet 5 with a ramp attached. [Figure 25B] This is a schematic perspective view showing the pallet 5 with the ramp attached, and the viewing direction is different from that of Figure 25A. [Figure 26] This diagram schematically illustrates how product 3 is unloaded from pallet 5 via a ramp. [Modes for carrying out the invention]

[0029] Embodiments of the packaging box according to the present invention will be described with reference to Figures 1 to 26 below. Note that the following figures are schematic representations, and the dimensional ratios and number of elements shown in the figures do not necessarily correspond to the actual dimensional ratios and number of elements.

[0030] Figures 1 and 2 are schematic perspective views of the packaging box of this embodiment, but they are viewed from different directions. Figure 3 is a schematic perspective view showing the components of the packaging box 1 shown in Figure 1 disassembled.

[0031] Packing box 1 is a hollow box-shaped member used to house and transport the target product 3. The target product 3 is the product to be housed in the internal space (storage area) of packaging box 1, and is not particularly limited, but is, for example, a heavy object weighing more than 100 kg. If the target product 3 is a heavy object, it generally has casters 52 that can be used during transport and adjusters 51 for height adjustment (see Figure 13 described later).

[0032] As shown in Figures 1 to 3, the packaging box 1 includes a pallet 5 that forms the bottom of the storage area. During packaging, the product 3 is placed on top of the pallet 5. The pallet 5 is preferably made of wood. The bottom of the pallet 5 is in contact with the floor surface 90. The floor surface 90 forms the mounting surface.

[0033] The packaging box 1 has a first panel 11 that faces the pallet 5 vertically and forms the upper part of the storage area. The first panel 11 constitutes the upper panel.

[0034] The packaging box 1 comprises a second panel 12, a third panel 13, a fourth panel 14, and a fifth panel 15, which are arranged to surround the storage area from all four sides. The second panel 12 and the third panel 13 face each other, and the fourth panel 14 and the fifth panel 15 face each other. In the packaging box 1 of this embodiment shown in Figures 1 to 3, when viewing the pallet 5 from the side of the first panel 11, the panels are arranged in the order of second panel 12, fifth panel 15, third panel 13, and fourth panel 14 in a counterclockwise direction. The second panel 12, third panel 13, fourth panel 14, and fifth panel 15 all constitute side panels.

[0035] In the following, an XYZ coordinate system will be referenced as appropriate, where the direction in which the second panel 12 and the third panel 13 face each other is the X-axis, the direction in which the fourth panel 14 and the fifth panel 15 face each other is the Y-axis, and the direction in which the first panel 11 and the palette 5 face each other is the Z-axis.

[0036] In the following descriptions, when expressing direction, positive and negative directions are distinguished, and these are indicated with a sign, such as "+X direction" and "-X direction". When expressing direction without distinguishing between positive and negative directions, it is simply written as "X direction". In other words, in this specification, when simply written as "X direction", both "+X direction" and "-X direction" are included. The same applies to the Y direction and Z direction.

[0037] According to this definition, the direction from the third panel 13 to the second panel 12 is the +X direction, the direction from the fourth panel 14 to the fifth panel 15 is the +Y direction, and the direction from pallet 5 to the first panel 11 is the +Z direction. If pallet 5 is placed on a horizontal plane, the +Z direction corresponds to the vertically upward direction.

[0038] In the packaging box 1 of this embodiment shown in Figures 1 to 3, the third panel 13 is made of a wooden member with a perforated paneling. In other words, when the packaging box 1 is viewed facing the third panel 13, that is, from the -X side to the +X direction of the packaging box 1, a part of the storage area, which is the internal space of the packaging box 1, can be seen.

[0039] Similarly, in the packaging box 1 of this embodiment, the fourth panel 14 and the fifth panel 15 are made of wooden members with a perforated paneling. In other words, when the packaging box 1 is viewed from the -Y side in the +Y direction, and when viewed from the +Y side in the -Y direction, a part of the storage area, which is the internal space of the packaging box 1, can be seen.

[0040] On the other hand, in the packaging box 1 of this embodiment, the first panel 11 and the second panel 12 are made of wooden members, not perforated panels. In other words, when the packaging box 1 is viewed from the +Z side in the -Z direction, and when viewed from the +X side in the -X direction, the internal space of the packaging box 1, which is the storage area, is not visible.

[0041] As will be described later, in the packaging box 1 of this embodiment, the first panel 11 and the second panel 12, which are not perforated panels, are used as ramps when unloading the target product 3 from the pallet 5, among the panel group consisting of the first panel 11, the second panel 12, the third panel 13, the fourth panel 14, and the fifth panel 15. In this specification, the panels that are used as ramps among the panels belonging to the panel group in this way are referred to as "ramp panels".

[0042] However, the present invention does not exclude cases where one or more of the third panel 13, fourth panel 14, and fifth panel 15, which are panels that do not fall under the category of slope panels, are made of wooden members that are not in a perforated panel configuration.

[0043] In this embodiment, as shown in Figure 3, the accessory storage box 7, corner member 21, upper pressing member 22, and cushioning member 23 are arranged within the storage area of ​​the packaging box 1, which is surrounded by each panel (11, 12, 13, 14, 15) and the pallet 5.

[0044] The corner members 21 and upper restraining members 22 are both positioned to prevent the target product 3 from moving within the storage area of ​​the packaging box 1 and colliding with each panel (11, 12, 13, 14, 15) during transport. However, depending on the shape, size, and material of the target product 3, it is possible to omit the placement of one or both of the corner members 21 and upper restraining members 22.

[0045] In detail, the corner members 21 are positioned to cover the outside of each corner of the target product 3 for the purpose of preventing the target product 3 from directly contacting the side panels (12, 13, 14, 15), and are made of a cushioning material such as foamed resin or rubber. The upper retaining member 22 is positioned to cover a part of the upper (+Z side) of the target product 3 for the purpose of preventing the target product 3 from directly contacting the first panel 11 that constitutes the upper panel, and is made of a cushioning material such as foamed resin or rubber.

[0046] The cushioning member 23 is positioned between a portion of the bottom of the target product 3 and the top surface of the pallet 5, and is arranged for the purpose of stably placing the target product 3 on the top surface of the pallet 5. An example of the detailed structure of the cushioning member 23 will be described later with reference to Figure 20.

[0047] As will be described later, in this embodiment, when the packaging box 1 has each panel (11, 12, 13, 14, 15) belonging to the panel group removed (hereinafter referred to as the "unpacked state"), the aforementioned slope panel is connected to the pallet 5, making it possible to install a slope with a downward incline from the pallet 5 to the surface (floor surface 90) on which the packaging box 1 is placed. The accessory storage box 7 stores accessories used when transitioning from the state of the packaging box 1 shown in Figures 1 and 2 (hereinafter referred to as the "packed state") to the state in which the slope is connected to the pallet 5. The material of the accessory storage box 7 is not limited, but for example, it may be formed by combining multiple wooden members.

[0048] Figure 4 is a schematic perspective view showing an example of the accessories stored in the accessory storage box 7. In the example shown in Figure 4, the accessory storage box 7 contains an adjuster base plate 41, a caster base plate 42, a guide member 43, a connecting member 44, and a step plate 45. Details of these accessories will be described later.

[0049] Figures 5A and 5B are schematic perspective views of the first panel 11, which is one of the panels constituting the slope panel among the panel group in the packaging box 1 of this embodiment, and the two figures are viewed from different directions.

[0050] As shown in Figures 5A and 5B, the first panel 11 has a main surface (first slope surface 11a) that is exposed to the outside of the containment area when packaged, and a main surface (first back surface 11b) that is opposite to the first slope surface 11a and faces the containment area when packaged. The first slope surface 11a corresponds to the "slope surface," and the first back surface 11b corresponds to the "back surface."

[0051] As shown in Figure 5A, the first panel 11 has a first slope guide 31 that extends along the X direction near a pair of outer edges spaced apart in the Y direction on the first slope surface 11a side. In this embodiment, the first slope guide 31 extends in the X direction between the -X side end 11p of the first panel 11 and the +X side end 11q of the first panel 11. The first slope guide 31 corresponds to the "slope guide".

[0052] The first slope guide 31 is a structure whose height (length in the Z direction) is greater than that of the first slope surface 11a, and is formed, for example, by bonding a plate material extending in the X direction onto the first slope surface 11a. As a detailed example, the first panel 11 is formed by bonding a plate material with a thickness of about 3 mm to the vicinity of the outer edges on both sides in the Y direction of the first slope surface 11a, which is made of a plate material with a thickness of about 25 mm. The width (length in the Y direction) of the first slope guide 31 is not limited, but is for example about 50 mm to 150 mm.

[0053] The width (length in the Y direction) and length (length in the X direction) of the first panel 11 are set according to the dimensions of the product 3 to be packaged. For example, the width of the first panel 11 is 600 mm to 800 mm, and the length of the first panel 11 is 1,100 mm to 1,500 mm. Also, the width of the area on the first slope surface 11a where the first slope guide 31 is not formed is, for example, 350 mm to 750 mm.

[0054] As shown in Figure 5B, the first panel 11 has a first leg portion 32 on the first back surface 11b side that protrudes outward from the first back surface 11b. This first leg portion 32 protrudes toward the storage area (inward) when the packaging box 1 is in its packaged state. The first leg portion 32 corresponds to the "leg portion".

[0055] Figures 6A and 6B are schematic perspective views of the second panel 12, which is one of the panels constituting the slope panel among the panel group in the packaging box 1 of this embodiment, and the two figures are viewed from different directions.

[0056] As shown in Figures 6A and 6B, the second panel 12 has a main surface (second slope surface 12a) that is exposed to the outside of the containment area when packaged, and a main surface (second back surface 12b) that is opposite to the second slope surface 12a and faces the containment area when packaged. The second slope surface 12a corresponds to the "slope surface," and the second back surface 12b corresponds to the "back surface."

[0057] As shown in Figure 6A, the second panel 12 has a second slope guide 33 that extends along the Z direction near a pair of outer edges spaced apart in the Y direction on the second slope surface 12a side. In this embodiment, the second slope guide 33 extends in the Z direction between the -Z side end 12p of the second panel 12 and the +Z side end 12q of the second panel 12. The second slope guide 33 corresponds to the "slope guide".

[0058] The second slope guide 33 is a structure whose height (length in the X direction) is greater than that of the second slope surface 12a, and is formed, for example, by bonding a plate material extending in the Z direction onto the second slope surface 12a. As a detailed example, the second panel 12 is made of a plate material with a thickness of about 25 mm, and is formed by bonding a plate material with a thickness of about 3 mm to the vicinity of both outer edges in the Y direction on the second slope surface 12a side. The width (length in the Y direction) of the second slope guide 33 is not limited, but is for example about 50 mm to 150 mm.

[0059] The width (length in the Y direction) and length (length in the Z direction) of the second panel 12 are set according to the dimensions of the product 3 to be packaged. As is clear from the configuration of the packaging box 1 shown in Figures 1 and 2, the width of the first panel 11 and the width of the second panel 12 are substantially the same. Here, "substantially the same" means that manufacturing tolerances are allowed, and may include, for example, an error of 2% or less.

[0060] For example, the width of the second panel 12 is 600mm to 800mm, and the length of the second panel 12 is 1,100mm to 1,500mm. Also, the width of the area on the second slope surface 12a where the second slope guide 33 is not formed is, for example, 350mm to 750mm.

[0061] As shown in Figure 6B, the second panel 12 has second legs 34 on the second back surface 12b side that protrude outward from the second back surface 12b. These second legs 34 protrude toward the storage area (inward) when the packaging box 1 is in its packaging state. The second legs 34 correspond to "legs". In this embodiment, the second legs 34 (34a, 34b, 34c) are formed at three locations spaced apart in the Z direction on the second back surface 12b side of the second panel 12.

[0062] Figure 7 is a schematic side view of the first panel 11 and the second panel 12, illustrating the state in which their respective legs (32, 34) are in contact with the floor surface 90. For explanatory purposes, Figure 7 shows a UVW coordinate system, separate from the XYZ coordinate system referenced in Figures 1 and 2, where the floor surface 90 is a plane parallel to the UV plane and the direction perpendicular to the UV plane is the W axis. As shown in Figure 5A, the first slope surface 11a of the first panel 11 is composed of the XY plane under the packaging box 1 in the packaging state shown in Figures 1 and 2. Also, as shown in Figure 6A, the second slope surface 12a of the second panel 12 is composed of the YZ plane under the packaging box 1 in the packaging state shown in Figures 1 and 2.

[0063] As shown in Figure 7, the protruding length of the first leg portion 32 of the first panel 11 is different from the protruding length of the second leg portion 34 of the second panel 12, with the former being smaller than the latter. Furthermore, in this embodiment, as described above with reference to Figure 6B, the second panel 12 has second leg portions 34 (34a, 34b, 34c) formed at three positions spaced apart in the Z direction. In this embodiment, the protruding lengths h34a of the second leg portion 34a, h34b of the second leg portion 34b, and h34c of the second leg portion 34c show the relationship h34a > h34b > h34c, respectively. Furthermore, comparing the protruding length h34c of the second leg portion 34c with the protruding length h32 of the first leg portion 32, the relationship h34c > h32 is shown.

[0064] In this way, by designing the protruding length of the second legs 34 (34a, 34b, 34c), when the second legs 34 (34a, 34b, 34c) are brought into contact with the floor surface 90, the side of the second panel 12 on which the second legs 34 are not formed, i.e., the second slope surface 12a, forms a slope that slopes downward from the second leg 34a side, i.e., the +Z side end 12q of the second panel 12, toward the second leg 34c side, i.e., the -Z side end 12p of the second panel 12.

[0065] Furthermore, the protruding length h32 of the first leg portion 32 of the first panel 11 is designed such that when the first leg portion 32 is brought into contact with the floor surface 90, the vicinity of the -X side end 11p of the first panel 11 also comes into contact with the floor surface 90. At this time, when the first leg portion 32 is brought into contact with the floor surface 90, the side of the first panel 11 on which the first leg portion 32 is not formed, i.e., the first slope surface 11a, forms a slope that shows a downward incline from the +X side end 11q of the first panel 11 toward the -X side end 11p of the first panel 11.

[0066] Furthermore, the inclination angle θ11a of the first slope surface 11a when the first leg portion 32 is in contact with the floor surface 90, and the inclination angle θ12a of the second slope surface 12a when the second leg portion 34 is in contact with the floor surface 90, are both preferably set to 5° or less, more preferably to 4° or less, and particularly preferably to 3° or less. The inclination angle θ11a corresponds to the angle between the first slope surface 11a, which is composed of the XY plane, and the floor surface 90, which is composed of the UV plane. Similarly, the inclination angle θ12a corresponds to the angle between the second slope surface 12a, which is composed of the YZ plane, and the floor surface 90, which is composed of the UV plane. The inclination angles θ11a and θ12a are designed to show substantially the same value, including a manufacturing tolerance of ±10%.

[0067] For example, the protruding length h34a of the second leg 34a is 116 mm, the protruding length h34b of the second leg 34b is 96 mm, the protruding length h34c of the second leg 34c is 75 mm, and the protruding length h32 of the first leg 32 is 40 mm. In other words, this shows the relationship h34a > h34b > h34c > h32.

[0068] As an example, the width of the first leg portion 32, the second leg portion 34a, the second leg portion 34b, and the second leg portion 34c in the U direction is 60 mm. As mentioned above, when the inclination angle θ11a and the inclination angle θ12a are both 5° or less, cos(θ11a) and cos(θ12a) are both approximately 1.0, so the width of the first leg portion 32 in the X direction, and the width of the second leg portion 34a, the second leg portion 34b, and the second leg portion 34c in the Z direction can also be considered to be approximately 60 mm.

[0069] As an example, in the second panel 12, the distance in the U direction between the end portion 12q of the second panel 12 and the second leg portion 34a is 100 mm, the distance in the U direction between the second leg portion 34a and the second leg portion 34b is 350 mm, the distance in the U direction between the second leg portion 34b and the second leg portion 34c is 350 mm, and the distance in the U direction between the second leg portion 34c and the end portion 12p of the second panel 12 is 255 mm.

[0070] As an example, in the first panel 11, the distance in the U direction between the end portion 11q of the first panel 11 and the first leg portion 32 is 400 mm, and the distance in the U direction between the first leg portion 32 and the end portion 11p of the first panel 11 is 732 mm.

[0071] The following describes the procedure for moving from the packaging box 1 shown in Figures 1 and 2 to the unpacked state and then attaching the ramp panel to the pallet 5, referring to Figures 8 to 26.

[0072] (Procedure S1) First, as shown in Figure 8, the third panel 13 is removed. In the packaging box 1 shown in Figures 1 and 2, the third panel 13 is connected to the adjacent panels (11, 14, 15) and the pallet 5 via mounting members (not shown), such as bolts and screws. When removing the third panel 13, these mounting members are removed first, and then the third panel 13 is removed.

[0073] (Procedure S2) Next, as shown in Figure 9, the second panel 12 is removed. In the packaging box 1 in its packed state, the second panel 12, like the third panel 13, is connected to the adjacent panels (11, 14, 15) and the pallet 5 via mounting members (not shown), such as bolts and screws. When removing the second panel 12, as with the third panel 13, the mounting members (not shown) are removed first, and then the second panel 12 is removed.

[0074] Once the second panel 12 and the third panel 13 are removed, the packing box 1 is opened on both the -X side and the +X side. Note that the order of steps S1 and S2 may be reversed.

[0075] (Procedure S3) Next, as shown in Figure 10, the corner member 21 is removed through the open surfaces on the -X and +X sides. Then, as shown in Figure 11, the accessory storage box 7 is removed through the open surface on either the -X or +X side. The order in which the corner member 21 and the accessory storage box 7 are removed can be reversed.

[0076] (Procedure S4) Next, as shown in Figure 12, the adjuster base plates 41 (see Figure 4) removed from the accessory storage box 7 are placed on the top surface of the pallet 5. In this embodiment, four adjuster base plates 41 are stored in the accessory storage box 7, and the adjuster base plates 41 are placed on each of the four locations on the top surface of the pallet 5 that correspond to the positions directly below the four adjusters 51 installed at the bottom of the target product 3. Then, as shown in Figure 13, each adjuster 51 of the target product 3 is lowered and brought into full contact with the adjuster base plate 41. Figure 13 is a schematic cross-sectional view showing a magnified view of the vicinity of one of the adjusters 51 provided on the target product 3.

[0077] (Procedure S5) Next, as shown in Figure 14, the first panel 11 is removed. When removing the first panel 11, it is also possible to assume that mounting members (not shown) are removed before the first panel 11 is removed.

[0078] (Step S6) Once the first panel 11 is removed, the packaging box 1 opens on the +Z side. Subsequently, the upper retaining member 22 is removed through the open surface on the +Z side.

[0079] (Procedure S7) Next, as shown in Figure 15, the fourth panel 14 and the fifth panel 15 are removed from the pallet 5. When removing the fourth panel 14 and the fifth panel 15, mounting members (not shown) may be removed first, and then the fourth panel 14 and the fifth panel 15 may be removed.

[0080] Once step S7 has been completed, the packaging box 1 will be in an unpacked state, with the first panel 11, second panel 12, third panel 13, fourth panel 14, and fifth panel 15 removed.

[0081] (Procedure S8) Next, as shown in Figures 16 and 17, the caster base plate 42 (see Figure 4) removed from the accessory storage box 7 is placed on the top surface of the pallet 5. As shown in Figure 13, the pallet 5 has a recessed area 42p in a portion of its top surface, and the caster base plate 42 is installed by fitting it into this recessed area 42p. This recessed area 42p corresponds to a position that includes the area facing the caster 52 installed on the target product 3 in the Z direction. Figure 17 is a schematic cross-sectional view showing the vicinity of one adjuster 51 provided on the target product 3, enlarged following Figure 13.

[0082] (Procedure S9) Next, as shown in Figure 18, the tip of the adjuster 51 is gradually extended in the -Z direction. At a point prior to this step S9, the adjuster 51 is in complete contact with the adjuster base plate 41. By slightly extending the position of the adjuster 51 in the -Z direction, the height position of the bottom of the target product 3 can be slightly moved in the +Z direction while maintaining the contact between the adjuster 51 and the adjuster base plate 41. As a result, the close contact between the cushioning member 23 and the target product 3 is relaxed compared to the close contact state between the cushioning member 23 and the target product 3 at the point shown in Figure 16, and a gap is formed between them.

[0083] (Procedure S10) After step S9, the cushioning member 23 is pulled out to the outside of the target product 3, as shown in Figure 19.

[0084] Figure 20 is a schematic perspective view showing the structure of the cushioning member 23. The cushioning member 23 includes a base material 23a, a cushioning body 23b formed on the upper surface of the base material 23a, and tape material 23c that fixes the entire structure including the base material 23a and the cushioning body 23b. For example, the base material 23a is a plate material, and the cushioning body 23b is made of a cushioning resin such as urethane. As a result of performing procedure S9, the close contact between the cushioning member 23 and the target product 3 is alleviated.

[0085] More specifically, after the execution of step S9, the tape material 23c is cut. This allows the base material 23a and the buffer material 23b to move independently of the tape material 23c. Therefore, the base material 23a and the buffer material 23b can be easily removed from the separation portion in the Z direction between the target product 3 and the pallet 5.

[0086] Note that the structure of the cushioning member 23 shown in Figure 20 is merely an example. As another example, the upper surface of the cushioning body 23b may have a cover made of a material with lower cushioning properties than the cushioning body 23b, and the tape material 23c may fix the laminate including the base material 23a, the cushioning body 23b, and the cover.

[0087] (Procedure S11) Next, as shown in Figure 21, the tip of the adjuster 51 is gradually moved back in the +Z direction, shifting the height of the bottom of the target product 3 in the -Z direction. As a result, the height of the caster 52 installed on the bottom of the target product 3 also moves (decreases) in the -Z direction. The position adjustment of the adjuster 51 is completed when the caster 52 comes into contact with the caster base plate 42.

[0088] (Procedure S12) When step S11 is performed, the casters 52 of the target product 3 come into contact with the upper surface of the pallet 5 through the caster base plate 42. Therefore, as shown in Figure 22, the adjuster base plate 41 can be removed from the pallet 5. More specifically, as shown in Figure 23, the tip of the adjuster 51 is retracted in the +Z direction, so that the tip of the adjuster 51 is separated from the adjuster base plate 41 in the Z direction, and then the adjuster base plate 41 is removed.

[0089] (Procedure S13) Next, as shown in Figure 24, the guide members 43 removed from the accessory storage box 7 (see Figure 4) are placed on the top surface of the pallet 5. In this embodiment, the guide members 43 are arranged along a pair of outer edges of the pallet 5 that extend in the X direction and face each other in the Y direction. Note that Figure 4 shows an example in which four guide members 43 are stored in the accessory storage box 7. In this case, two guide members 43 are arranged side by side in the X direction along the -Y side outer edge of the top surface of the pallet 5, and the remaining two guide members 43 are arranged side by side in the X direction along the +Y side outer edge of the top surface of the pallet 5. However, the number of guide members 43 is not limited.

[0090] Furthermore, when attaching the guide member 43 to the pallet 5, the mounting members 61 such as bolts and screws that were removed in a step prior to this S13 procedure may be used.

[0091] By performing this procedure S13, when the target product 3 is moved, the fall of the target product 3 from the pallet 5 in the Y direction is suppressed. However, the present invention does not exclude cases where there is no guide member 43 inside the packaging box 1.

[0092] (Procedure S14) Next, as shown in Figures 25A to 25B, the second panel 12 is attached to the pallet 5 with the second slope surface 12a facing the +Z side. At this time, the mounting members 61 such as bolts and screws that were removed when the steps prior to step S13 were performed may be used.

[0093] As described above with reference to Figure 7, the second panel 12 has second legs 34 (34a, 34b, 34c) that protrude outward on the second back surface 12b side. By installing these second legs 34 in a direction that abuts the floor surface 90, the second slope surface 12a of the second panel 12 forms a slope that slopes downward from the end 12q of the second panel 12 toward the end 12p of the second panel 12.

[0094] At this time, the connecting member 44 (see Figure 4) removed from the accessory storage box 7 is placed directly below the location where the end portion 12p of the second panel 12 is located, and the end portion 12p of the second panel 12 is brought into contact with a part of the upper surface of the connecting member 44. Subsequently, the contact points of the connecting member 44 and the second panel 12 are connected by mounting members 61 such as bolts and screws. The height of the connecting member 44 may be lower than the height (protruding length) of the second leg portion 34c and higher than the height (protruding length) of the first leg portion 32.

[0095] Subsequently, the first panel 11 is attached to the second panel 12 with the first slope surface 11a facing the +Z side. As described above with reference to Figure 7, the first panel 11 has a first leg portion 32 that protrudes outward on the first back surface 11b side, and by installing the first leg portion 32 in a direction that abuts the floor surface 90, the first slope surface 11a of the first panel 11 forms a slope that shows a downward incline from the end portion 11q of the first panel 11 to the end portion 11p of the first panel 11.

[0096] Specifically, the first panel 11 is brought into contact with a portion of the upper surface of the connecting member 44. At this time, the position of the first panel 11 is adjusted so that the end 11q of the first panel 11 and the end 12p of the second panel 12 come into contact with the upper surface of the connecting member 44. Subsequently, the contact points of the connecting member 44 and the first panel 11 are connected by mounting members 61 such as bolts and screws. The end 11p of the first panel 11 comes into contact with the floor surface 90 (see Figure 7).

[0097] At this point, the second slope surface 12a and the first slope surface 11a form a downward-sloping ramp that descends from the top surface of the pallet 5 to the height of the floor surface 90. As described above, the second slope surface 12a is the main surface of the second panel 12 of the packaging box 1, and the second panel 12 is used as a ramp. Similarly, the first slope surface 11a is the main surface of the first panel 11 of the packaging box 1, and the first panel 11 is used as a ramp. In other words, in this embodiment, the first panel 11 and the second panel 12 correspond to "ramp panels".

[0098] Furthermore, in this embodiment, of the first panel 11 and second panel 12 that constitute the slope panel, the second panel 12 is directly connected to the pallet 5, and the first panel 11 is connected to the second panel 12. In other words, in this embodiment, of the first panel 11 and second panel 12 that constitute the slope panel, the second panel 12 corresponds to the "specific slope panel". As described above, the second legs 34 (34a, 34b, 34c) formed on the back surface of the second panel 12 have a longer protruding length than the first legs 32 formed on the back surface of the first panel 11.

[0099] Furthermore, the second panel 12, which corresponds to a specific slope panel, is installed at a higher height from the floor surface 90 compared to the first panel 11, which corresponds to a slope panel that is not a specific slope panel. From this perspective, and in consideration of the stability of the slope, the second legs 34 are formed at three locations on the back side of the second panel 12, which is more than the number of first legs 32 formed on the back side of the first panel 11. However, from the standpoint of stability, it is sufficient for legs to be formed at multiple locations on the back side of the specific slope panel, and legs may also be formed at multiple locations on the back side of a slope panel that is not a specific slope panel.

[0100] Furthermore, the step plate 45 (see Figure 4), which has been removed from the accessory storage box 7, is installed on the outside of the end 11p of the first panel 11 that is farther from the second panel 12, so as to be continuous with the first panel 11. The step plate 45 is provided for the purpose of further lowering the step from the height position of the end 11p of the first panel 11 to the height position of the floor surface 90 in the state shown in Figure 25B. However, the step plate 45 is not necessarily essential in this invention.

[0101] (Procedure S15) Subsequently, as shown in Figure 26, the casters 52 of the target product 3 are moved along the slope formed by the second slope surface 12a and the first slope surface 11a. This allows the target product 3 to be smoothly lowered from the top surface of the pallet 5 to the height of the floor surface 90.

[0102] In this case, as shown in Figures 25A and 25B, the second slope surface 12a is provided with second slope guides 33 on both sides, and the first slope surface 11a is provided with first slope guides 31 on both sides. As described above, the slope guides (31, 33) are constructed by extending structures that are taller than each of the slope surfaces (12a, 11a). Therefore, when the target product 3 is driven along the slope formed by the second slope surface 12a and the first slope surface 11a, the target product 3 is prevented from falling off in a direction perpendicular to the direction of extension of the slope.

[0103] [Alternative Embodiment] The following describes another embodiment.

[0104] <1> In the above embodiment, the first panel 11 and the second panel 12 among the group of panels constituting the packaging box 1 correspond to the slope panel. However, the slope panel may consist of one panel or three or more panels. However, when the slope panel is realized with three or more panels, the packaging box 1 preferably has a cubic shape.

[0105] <2> In the above embodiment, of the first panel 11 and the second panel 12 corresponding to the slope panel, the second panel 12 is directly connected to the pallet 5 and corresponds to a specific slope panel. However, the first panel 11 may be a specific slope panel. In this case, the first panel 11 may have multiple legs of different protruding lengths formed on its back side.

[0106] Furthermore, if multiple panels are slope panels, it is preferable to use the panel with the relatively longer length in the direction in which the target product 3 travels on the slope surface as the designated slope panel.

[0107] <3> In the above embodiment, the first panel 11 and the second panel 12 corresponding to the slope panel are assumed to have slope guides (31, 33) formed on both sides of their respective slope surfaces (11a, 12a). However, the present invention does not exclude cases in which slope guides are not formed on the slope surface side of the panels constituting the pass slope panel.

[0108] (4) The present invention is not limited to the embodiments described above, and includes various modifications. For example, the embodiments described above are described in detail for a better understanding of the present invention and are not necessarily limited to all configurations described. The scope of the present invention is indicated by the claims, and all modifications within the meaning and scope equivalent to the claims are intended to be included. [Explanation of Symbols]

[0109] 1: Packaging box 3: Target Products 5: Palette 7: Accessory storage box 11: First Panel 11a: First slope surface 11b: First back side 11p, 11q: Edge of the first panel 12: Second Panel 12a: Second slope surface 12b: Second back side 12p, 12q: Edge of the second panel 13: Third Panel 14: Fourth Panel 15: Fifth Panel 21: Corner members 22: Upper retaining member 23: Cushioning material 31: First Slope Guide 32: First leg 33: Second Slope Guide 34,34a:34b:34c: Second leg 41: Adjustable base plate 42: Caster base plate 42p: Recessed area 43: Guide member 44: Connecting member 45: Step plate 51: Adjuster 52: Caster 61: Mounting components 90: Floor

Claims

1. A packaging box for housing a product equipped with casters, A pallet placed on a mounting surface and forming the bottom of the storage area in which the target product is stored, A first panel that faces the pallet in a vertical direction and forms the upper part of the storage area, The structure comprises a second panel, a third panel, a fourth panel, and a fifth panel that surround the aforementioned accommodation area from all four sides, each forming the sides of the accommodation area. A slope panel, which is one or more panels belonging to the panel group consisting of the first panel, the second panel, the third panel, the fourth panel, and the fifth panel, has legs that protrude toward the accommodation area, formed at one or more locations on the back side, which is the main surface facing the accommodation area. A packaging box characterized in that, in an unpacked state in which each panel belonging to the panel group is removed, the slope panel is connected to the pallet directly or via other members in a direction in which the legs of the slope panel abut the aforementioned mounting surface, thereby forming a downward sloping surface on the main surface of the slope panel opposite to the back surface, which extends from the height position of the top surface of the pallet on which the target product is placed to the height position of the aforementioned mounting surface.

2. Multiple panels belonging to the aforementioned panel group correspond to the slope panels, Each of the aforementioned slope panels has a different protruding length of the leg portion formed on the back side of the slope panel. Under the aforementioned unpacked state, The slope panel having the longest protruding leg portion is directly connected to the pallet in a manner that the leg portion abuts against the aforementioned surface. Furthermore, the packaging box according to claim 1, characterized in that the slope panels other than the specified slope panel are connected to each other in such a way that the legs abut against the aforementioned surface, and the slope panels with relatively longer protruding legs are positioned closer to the pallet, thereby connecting the respective slope surfaces of the plurality of slope panels, including the specified slope panel, and forming the downward sloping surface.

3. Of the multiple slope panels, at least the specific slope panel has multiple legs with different protruding lengths on its back side, The packaging box according to claim 2, characterized in that, in the unpacked state, the ramp panel having a plurality of legs is connected to the pallet in such an orientation that the legs with relatively longer protruding lengths are positioned closer to the pallet.

4. A connecting member is provided within the aforementioned containment area, The packaging box according to claim 3, characterized in that, in the unpacked state, the pair of slope panels are connected via the connecting member on the back side of the location where the pair of slope panels are connected.

5. The aforementioned product is equipped with an adjuster that protrudes downward from the side on which the caster is mounted, and whose protrusion length can be adjusted. The packaging box is installed on the pallet and comprises an adjuster base plate against which the adjuster abuts when the target product is placed within the storage area, and a caster base plate positioned within the storage area. The pallet has a recessed area into which the caster base plate can be inserted, The packaging box according to claim 1, characterized in that, in the unpacked state, with the caster base plate inserted into the recessed area, the protruding length of the adjuster is reduced so that the caster comes into contact with the caster base plate, and the upper surface of the caster base plate and the upper surface of the pallet are configured to allow the target product to be transported by the caster.

6. The facility comprises a plurality of guide members arranged within the aforementioned containment area, The packaging box according to claim 1, characterized in that, in the unpacked state, the guide member is fixed along at least the outer edge of the upper surface of the pallet that extends parallel to the direction in which the slope panels are connected.

7. The aforementioned product is equipped with an adjuster that protrudes downward from the side on which the caster is mounted, and whose protrusion length can be adjusted. The packaging box is installed on the pallet and comprises an adjuster base plate against which the adjuster abuts when the target product is placed within the storage area, a caster base plate placed within the storage area, and an accessory storage box placed outside the target product within the storage area. The pallet has a recessed area into which the caster base plate can be inserted, In the unpacked state, with the caster base plate inserted into the recessed area, the protruding length of the adjuster is reduced, causing the caster to contact the caster base plate, and the upper surface of the caster base plate and the upper surface of the pallet are configured to allow the target product to be transported by the caster. The aforementioned accessory storage box houses the connecting member and the caster base plate. The packaging box according to claim 4, characterized in that the accessory storage box can be removed from the storage area when one or more panels belonging to the panel group are removed.

8. The accessory storage box contains a plurality of guide members, The packaging box according to claim 7, characterized in that, in the unpacked state, the guide member is fixed along at least the outer edge of the upper surface of the pallet that extends parallel to the direction in which the slope panels are connected.

9. The slope panel has a slope guide that extends outward along a pair of opposing outer edges on the slope surface, The packaging box according to claim 1, characterized in that the ramp guide extends in a direction that connects to the pallet in the unpacked state.

10. The packaging box according to claim 2, characterized in that the downward sloping surface has an inclination angle of 5° or less.

11. The slope panel is composed of one panel belonging to the side panel group consisting of the second panel, the third panel, the fourth panel, and the fifth panel, and the first panel. The packaging box according to any one of claims 2 to 4, 7 to 8, or 10, characterized in that, among the slope panels, the panels belonging to the side panel group constitute the specific slope panel.

12. The packaging box according to any one of claims 1 to 10, characterized in that the pallet and each panel belonging to the panel group are all made of wood.

13. The packaging box according to claim 12, characterized in that, among the panels belonging to the panel group, the panels that do not correspond to the slope panels are wooden members in a perforated paneling configuration, connecting the outside of the storage area and the inside of the storage area.

Images