Lead-acid battery packaging structure

Abstract

A buffer 5 for a lead-acid battery 1 having two terminals 12, wherein the buffer 5 for a lead-acid battery 1 is pulp-molded, and has a second wall part 50 and and a first recess 53A. Of the wall parts of a enclosure box 2 in which the lead-acid battery 1 is enclosed, the second wall part 50 faces a first wall part 22 in a state in which the buffer 5 is arranged on the outer side of the first wall part 22, which faces the two terminals 12. The first recess 53A is formed at a position in the second wall part 50 facing the terminals 12, the first recess 53A being recessed heading away from the first wall part 22.

Description

[Technical Field]

[0001] The technology disclosed in this specification relates to a buffer for a lead-acid battery and a packaging structure for a lead-acid battery. [Background technology]

[0002] BACKGROUND ART Conventionally, when an object to be transported is transported, a buffer is placed around the object to protect it from shocks during transportation (see, for example, Patent Document 1). Specifically, the packaging structure described in Patent Document 1 consists of a bottom box made of cardboard, lower cushioning bodies made of pulp mold that are stored on both sides of the bottom box and support both lower ends of the main body of the packaged item (corresponding to the item to be transported), upper cushioning bodies made of pulp mold that are placed against both upper ends of the main body of the packaged item supported by the lower cushioning bodies, and a main box made of cardboard with an open bottom that covers all of these. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-313942 Summary of the Invention [Problem to be solved by the invention]

[0004] However, conventionally, no consideration has been given to the issues specific to the transport of lead-acid batteries as transport objects. This specification discloses a technique for improving the problems specific to the transport of lead-acid batteries. [Means for solving the problem]

[0005] A buffer for a lead-acid battery having two terminals, the buffer being made of pulp mold, and having a second wall portion facing the first wall portion when the buffer is arranged on the outside of a first wall portion of a box in which the lead-acid battery is packed, the first wall portion facing the first terminal portion, and a first recess formed on the second wall portion at a position facing the terminals and recessed in a direction away from the first wall portion. [Effects of the Invention]

[0006] This can improve the issues that are specific to transporting lead-acid batteries. [Brief explanation of the drawings]

[0007] [Figure 1] 1 is a perspective view of a lead-acid battery according to a first embodiment; [Figure 2] A perspective view of the box in which the lead-acid battery is packed [Figure 3] Perspective view of the outer box [Figure 4] Cross-sectional view of lead-acid battery packaging structure [Figure 5] Schematic diagram showing the shape of the outer box when it falls [Figure 6] A perspective view of the upper buffer body seen from diagonally below [Figure 7] A bottom view showing the position of the recess formed in the upper buffer body. [Figure 8] Cross-sectional view of the packaging structure of a lead-acid battery (cross-sectional view corresponding to line AA in Figure 7) [Figure 9A] Schematic diagram showing the upper buffer placed on top of the box [Figure 9B] 9B is a schematic diagram showing the state in which the upper buffer body shown in FIG. 9A is rotated 180 degrees around a line perpendicular to the first wall of the box; [Figure 10] A perspective view of the upper buffer body seen from diagonally above [Figure 11A] Side view of the short side of the upper buffer [Figure 11B] Side view of the long side of the upper buffer [Figure 12] Schematic diagram showing how the outer box is turned sideways to accommodate the lower cushioning body [Figure 13] A top view showing the state in which granular absorbent material is placed in the recess of the lower buffer body. DETAILED DESCRIPTION OF THE INVENTION

[0008] (Outline of this embodiment) (1) A cushioning body for a lead-acid battery having two terminals, the cushioning body being made of pulp mold, and when the cushioning body is arranged on the outside of a first wall portion of a box in which the lead-acid battery is packed, the first wall portion facing the two terminals, and the cushioning body has a second wall portion facing the first wall portion, and a first recess formed on the second wall portion at a position facing the terminals and recessed in a direction away from the first wall portion.

[0009] For example, when transporting lead-acid batteries to replace lead-acid batteries installed in automobiles by air freight or other means, the boxes in which the lead-acid batteries are packed are each housed in a separate outer box for transport. When transporting the outer boxes housing the boxes, there is a risk that the stacked outer boxes may fall due to a collapse of the load. When the outer box falls, the lead-acid batteries may fall with their terminals facing downwards. If the box falls with the terminals facing downwards, the impact from the floor is concentrated on the terminals, and the shock absorber may not be able to fully absorb the impact, resulting in damage to the lead-acid batteries. If the lead-acid battery is damaged, the electrolyte contained inside may leak, potentially affecting the surrounding area. This issue has not been sufficiently considered in the past.

[0010] When the buffer is disposed outside the first wall of the box, it has a second wall facing the first wall and a first recess formed on the second wall facing the terminal and recessed in a direction away from the first wall. Because the lead-acid battery is packed in the box, when it is dropped terminal-side down, the first wall of the box is pressed downward by the terminal. Because the second wall of the buffer has a first recess formed in a position facing the terminal, the first wall pressed downward by the terminal bends downward using the space in the first recess, thereby functioning as a cushion. This buffers the impact on the terminal and distributes the impact throughout the entire first wall of the box. This reduces the possibility of the impact concentrating on the terminal and damaging the lead-acid battery.

[0011] Furthermore, as a result of extensive research, the inventors of the present invention have found that if the buffer is made of molded pulp, even if the lead-acid battery is damaged and electrolyte leaks out, the leaked electrolyte can be absorbed to a certain extent by the buffer. The buffer reduces the possibility of electrolyte leakage due to damage to the lead-acid battery, and even if electrolyte does leak, the pulp molded buffer can absorb it to some extent. This alleviates a problem specific to the transport of lead-acid batteries (the risk that the lead-acid battery may be damaged during transport, causing electrolyte leakage and affecting the surrounding area).

[0012] Although the description here has been given using a lead-acid battery mounted on an automobile as an example, the lead-acid battery is not limited to being mounted on an automobile. For example, the lead-acid battery may be mounted on a motorcycle or may be used for other purposes.

[0013] (2) The two terminals are arranged on either side of the center of the box in a direction perpendicular to an imaginary line connecting the two terminals when viewed from a direction perpendicular to the first wall portion of the box, and the first recess is formed on both sides of the center of the box in the direction perpendicular to the imaginary line connecting the two terminals, and the buffer body may be rotated 180 degrees around the line perpendicular to the first wall portion, so that the first recess faces the terminal.

[0014] For example, if the first recess is formed on only one side of the box in the direction perpendicular to the imaginary line connecting the two terminals, the buffer body must be carefully oriented so that the first recess faces the terminals, which reduces workability. With the above-described buffer, the first recesses are formed on both sides of the box in a direction perpendicular to the imaginary line, and the first recesses face the terminals even when the buffer is rotated 180 degrees around a line perpendicular to the first wall of the box, so the worker does not need to pay attention to the orientation of the buffer when placing it, which improves workability.

[0015] (3) The second wall portion has a hollow protruding portion that protrudes in a direction away from the first wall portion, and the tip of the protruding portion may be at the same position as the tip of the first recess or may be further away from the first wall portion than the tip of the first recess.

[0016] With the above-mentioned buffer, the tip of the overhang is at the same position as the tip of the first recess or is further away from the first wall of the box than the tip of the first recess, so when the terminal falls on its bottom, the overhang (or the first recess and overhang) absorbs the impact from the floor. Because the hollow overhang collapses when it receives an impact, the overhang collapses and absorbs the impact, thereby absorbing the impact when the terminal falls on its bottom.

[0017] (4) The box may have a frame-shaped third wall portion that is connected to the outer peripheral edge of the second wall portion and surrounds the box, and a frame-shaped fourth wall portion that is connected to the third wall portion and surrounds the third wall portion, and a space may be secured between the third wall portion and the fourth wall portion.

[0018] The box has a wall portion that is perpendicular to the first wall portion. When the box is dropped, the box may fall with the perpendicular wall portion facing downwards. With the buffer, a space is secured between the third wall portion and the fourth wall portion. Therefore, when the box is dropped with the perpendicular wall portion facing downwards, the fourth wall portion flexes using the space between the third wall portion and the first wall portion (or the third wall portion flexes using the space between the third wall portion and the fourth wall portion), thereby functioning as a cushion to absorb the impact applied to the lead-acid battery. Therefore, the impact can be absorbed when the box is dropped with the perpendicular wall portion facing downwards.

[0019] (5) The fourth wall portion may be inclined so as to approach the box as it moves away from the second wall portion, and a rib having a surface parallel to a wall portion of the box that is connected to the first wall portion at right angles may be formed on the outer surface of the fourth wall portion.

[0020] When workers place a box in an outer box, they may place the buffer in an upright position (with the outer surface of the fourth wall facing downwards) to make the work easier. In this case, if the fourth wall is tilted, the buffer will easily tip over, reducing workability. According to the above-mentioned buffer, a rib is formed on the outer surface of the fourth wall portion, the rib having a surface parallel to a wall portion that is perpendicular to the first wall portion of the box. Since the perpendicular wall portion and the wall portion of the outer box are parallel, when the buffer is stored in an upright position, the parallel surface of the rib comes into contact with the wall portion of the outer box, making it difficult for the buffer to tip over. This improves workability.

[0021] (6) The second wall portion and the third wall portion may be formed with a second recess that is recessed so as to be spaced apart from the corner portion of the box.

[0022] When a box is dropped, it may land on a corner. If the box falls on a corner, the impact is concentrated at the corner, and the shock absorber may not be able to fully absorb the impact, potentially damaging the lead-acid battery. This issue has not been adequately considered in the past. According to the above-mentioned buffer, the second wall and the third wall are formed with second recesses that are recessed away from the corners of the box, so that if the lead-acid battery is dropped on its corners, the concentration of impact on the corners of the lead-acid battery can be suppressed, thereby reducing the possibility of damage to the lead-acid battery due to the impact being concentrated on the corners.

[0023] (7) The box and the cushioning material are transported in a bag, and a flat surface may be formed on the surface of the second wall portion facing away from the first wall portion to press the adhesive tape against when sealing the opening of the bag with the adhesive tape.

[0024] When sealing the opening of the bag with adhesive tape, the worker presses the tape against the second wall to ensure that it adheres securely. If the surface of the second wall facing away from the first wall is uneven, it becomes difficult to apply the adhesive tape, reducing workability. According to the above-mentioned buffer, a flat surface is formed on the surface of the second wall portion facing away from the first wall portion, so that the worker can easily apply the adhesive tape by pressing the adhesive tape against the flat surface, thereby improving workability.

[0025] (8) A packaging structure for a lead-acid battery having two terminals, comprising: a box in which the lead-acid battery is packed; an outer box in which the box is housed; and the buffer for the lead-acid battery according to any one of claims 1 to 7, which is disposed inside the outer box and on the outside of the first wall portion of the box.

[0026] The above-described packaging structure can alleviate the problems specific to the transport of lead-acid batteries.

[0027] <Embodiment 1> The first embodiment will be described with reference to Figures 1 to 13. In the following description, the vertical direction is based on the vertical direction shown in Figure 4. In the following description, the reference numerals in the drawings may be omitted for the same components, with some exceptions.

[0028] (1)Lead acid battery A lead-acid battery 1 according to embodiment 1 will be described with reference to Fig. 1. The lead-acid battery 1 is an engine starting lead-acid battery that is mounted on an automobile and supplies power to an engine starting device (cell motor). The lead-acid battery 1 is rectangular when viewed from above and includes a synthetic resin battery case 10 that is open at the top, and a synthetic resin lid member 11 that closes the opening of the battery case 10. An electrode plate group and an electrolyte are contained inside the battery case 10. Two terminals 12 (a positive electrode external terminal 12P and a negative electrode external terminal 12N) that protrude upward are provided on the top surface of the lid member 11. The positive electrode external terminal 12P is connected to the positive electrode of the electrode plate group, and the negative electrode of the electrode plate group is connected to the negative electrode external terminal 12N.

[0029] The two terminals 12 are arranged spaced apart from each other in the long-side direction of the lead-acid battery 1 in a top view, and are arranged on one side (the front side in the example shown in FIG. 1 ) of the center of the short-side direction of the lead-acid battery 1 (the direction perpendicular to the imaginary line 13 connecting the two terminals 12 when viewed from a direction perpendicular to the first wall portion). A gas vent hole (not shown) is formed in the lid member 11.

[0030] (2) Packaging structure of lead-acid batteries As shown in FIG. 2, a lead-acid battery 1 used as a replacement for a lead-acid battery installed in an automobile is sold packaged in a packaging box 2 (an example of a box). The packaging box 2 is made of cardboard and is formed in the shape of a rectangular parallelepiped having four side walls 20, a bottom wall 21 (see FIG. 4), and an upper wall 22. The upper wall 22 is an example of a first wall that faces the two terminals 12 of the lead-acid battery 1. In the following description, the upper wall 22 will be referred to as the first wall 22. The four side walls 20 are an example of walls that are connected to the first wall 22 at right angles. The direction of the short sides of the first wall 22 in a top view is an example of a direction that is perpendicular to the imaginary line 13 when viewed from a direction perpendicular to the first wall 22 of the packaging box 2.

[0031] As shown in Fig. 3, when transporting replacement lead-acid batteries 1 by air freight or the like, the packaging boxes 2 in which the lead-acid batteries 1 are packed are each housed in an individual transport box 3 (an example of an outer box) and transported. The transport box 3 is also made of cardboard and is formed in the shape of a rectangular parallelepiped having four side walls 30, a bottom wall 31 (see Fig. 4), and an upper wall 32.

[0032] As shown in FIG. 4, the packaging structure of the lead-acid battery 1 includes a packaging box 2 in which the lead-acid battery 1 is packed, a vinyl inner bag 4, two buffers 5 for the lead-acid battery 1, granular absorbent material 6, a vinyl outer bag 7 (an example of a bag), and a shipping box 3. The packaging box 2 is placed inside the inner bag 4 and then housed in the transport box 3. The inner bag 4 is designed to prevent the electrolyte from leaking outside the transport box 3 in the event that the lead-acid battery 1 falls over during transport and the electrolyte leaks from the gas vent hole, or if the transport box 3 is dropped and the impact causes the electrolyte to leak during transport.

[0033] The two buffers 5 are intended to absorb shock if the shipping box 3 falls due to a collapse of the cargo during transportation, etc. The two buffers 5 have the same shape. One of the two buffers 5 is arranged on the lower side of the packaging box 2 placed in the inner bag 4. The other buffer 5 is arranged on the upper side of the packaging box 2 placed in the inner bag 4. The upper side is an example of the outer side of the first wall portion 22. In the following explanation, the buffer 5 arranged on the upper side will be referred to as upper buffer 5A, and the buffer 5 arranged on the lower side will be referred to as lower buffer 5B. The specific configuration of the buffers 5 will be described later.

[0034] The granular absorbent material 6 is for absorbing the leaked electrolyte when the electrolyte leaks from the lead-acid battery 1 and leaks out of the inner bag 4. The granular absorbent material 6 is, for example, mica crushed into granules. The absorbent material 6 is not limited to mica and can be selected as appropriate. The outer bag 7 is provided to prevent the leaked electrolyte from leaking to the outside if the electrolyte leaks from the inner bag 4.

[0035] (3) Dropping of the shipping box The manner in which the transport box 3 falls will be described with reference to Figure 5. As mentioned above, the transport box 3 may fall due to a collapse of the load during transport. The manner in which the transport box 3 falls can be divided into a top fall, a bottom fall, a side fall, and a corner fall. The top-side drop is a form in which the transport box 3 is dropped with its top side facing downwards. The bottom drop is a form in which the bottom of the transport box 3 falls downwards. Side drop occurs when the box 3 falls on its side. The box 3 has two sides: short sides, which are narrower in the horizontal direction, and long sides, which are wider in the horizontal direction. Side drop occurs when the box falls on its short side or when the box falls on its long side. Corner drops occur when the transport box 3 falls at an angle so that it hits the floor from a corner of the transport box 3. Corner drops can occur when the transport box 3 falls from a lower corner or an upper corner.

[0036] If the transport box 3 falls, the lead-acid battery 1 may be damaged by the impact of touching the ground, and the electrolyte contained therein may leak. Drop test standards are set for marine equipment transported by aircraft or ship to ensure the safety of aircraft and ships. These standards require that the lead-acid battery 1 will not be damaged even if the transport box 3 containing the lead-acid battery 1 is dropped from a height of approximately 1.3 m to 1.6 m.

[0037] (4) Structure of buffer for lead-acid battery The buffer 5 for the lead-acid battery 1 will be described with reference to Figs. 6 to 11. Here, the upper buffer 5A will be described as an example. For convenience, Figs. 6 and 11 show the upper buffer 5A upside down. The shape of the upper buffer 5A is symmetrical both front to back and left to right.

[0038] As shown in FIG. 6 , the upper buffer body 5A has a wall portion 50 whose outer peripheral shape substantially matches the outer peripheral shape of the first wall portion 22 of the packaging box 2, a third wall portion 51 that is continuous with the outer peripheral edge of the wall portion 50, and a fourth wall portion 52 that is connected to the third wall portion 51. The wall portion 50 is an example of a second wall portion. In the following description, the wall portion 50 will be referred to as the second wall portion 50. The third wall portion 51 extends downward from the outer peripheral edge of the second wall portion 50 all the way around, and is formed in a frame shape that surrounds the upper end of the packaging box 2. The lower side of the fourth wall portion 52 is connected to the third wall portion 51, and is formed in a frame shape that surrounds the third wall portion 51.

[0039] When the upper cushioning body 5A is placed on the packaging box 2, the second wall 50 faces the first wall 22 of the packaging box 2 with the inner bag 4 sandwiched therebetween. The second wall 50 has a plurality of recesses 53 formed therein that are recessed upward (an example of a direction away from the first wall 22 of the packaging box 2). The area of the second wall 50 other than the recesses 53 (in other words, the area of the second wall 50 that contacts the first wall 22 of the packaging box 2) is between 50% and 80% of the area of the second wall 50.

[0040] The recesses 53 will be described in detail with reference to Figure 7. For convenience, the position of each recess 53 is indicated by a dashed line in Figure 7. The recesses 53 include two first recesses 53A, four second recesses 53B, a cross-shaped third recess 53C, four fourth recesses 53D, two fifth recesses 53E, and four sixth recesses 53F. These recesses 53 may intersect with each other or may partially overlap each other.

[0041] The two first recesses 53A extend parallel to the short side direction and are spaced apart from each other in the long side direction of the second wall portion 50. The first recesses 53A are intended to cushion the impact applied to the two terminals 12 when the transport box 3 is dropped on its top side. The first recess 53A extends on both sides in the short side direction with the center of the short side direction of the second wall 50 (corresponding to the center of the short side direction of the packaging box 2) as the reference point. In other words, the first recess 53A is formed on both sides in the short side direction with the center of the short side direction of the packaging box 2 as the reference point.

[0042] Fig. 8 is a partial cross-sectional view of the transport box 3 when it has fallen face up. Fig. 8 shows the transport box 3 upside down, but when the transport box 3 is not upside down, the left first recess 53A of the two first recesses 53A is formed in a position directly above the left terminal 12 (positive external terminal 12P) of the lead-acid battery 1. The right first recess 53A is formed in a position directly above the right terminal 12 (negative external terminal 12N) of the lead-acid battery 1.

[0043] 8, the width of the first recess 53A in the long-side direction of the second wall 50 is wider than the width of the terminals 12 in the long-side direction. Specifically, for example, the width of the first recess 53A in the long-side direction is 1.3 times or more the width of the terminals 12 in the long-side direction. If the width of the first recess 53A in the long-side direction is narrow, when the shipping box 3 falls face-down and the first wall 22 of the packaging box 2 is pressed downward by the terminals 12, the first wall 22 is less likely to bend, and cushioning properties are impaired. For this reason, it is desirable that the width of the first recess 53A in the long-side direction be somewhat wide.

[0044] The length of the short side of the first recess 53A will be described with reference to FIGS. 9A and 9B. For convenience, in FIG. 9A, one of the two long sides of the upper buffer body 5A is designated as long side A, and the other is designated as long side B. The length of the short side of the first recess 53A is a length that allows the first recess 53A to face the terminal 12 even when the upper buffer body 5A is rotated 180 degrees around a straight line (around a line perpendicular to the first wall portion 22 of the packaging box 2). Specifically, FIG. 9B shows a state in which the upper buffer body 5A is rotated 180 degrees around a straight line so that the long side A and the long side B are interchanged. As shown in FIG. 9B, the first recess 53A is located directly above the terminal 12 even when the upper buffer body 5A is rotated 180 degrees.

[0045] As shown in FIG. 7 , four second recesses 53B are formed at corners defined by the second wall 50 and the third wall 51. The second recesses 53B are intended to protect the lead-acid batteries 1 from impact if the transport box 3 falls from the corner. Specifically, in top view, the square of the second wall 50 is recessed upward and extends obliquely toward the center of the second wall 50. The third wall 51 is formed in a frame shape by two parallel side walls 51A extending in the long-side direction and two parallel side walls 51B extending in the short-side direction, and the longitudinal ends of each side wall 51A, 51B are recessed outward. As a result, the second recesses 53B are recessed so as to be spaced apart from the upper corners of the packaging box 2.

[0046] The cross-shaped third recess 53C extends cross-shaped from the center of the second wall 50 in the long-side and short-side directions in a top view. A step is provided between the center of the third recess 53C and the other parts of the third recess 53C to improve the strength of the buffer 5, and the center part is located lower than the other parts. As shown in FIG. 10 , the third recess 53C has a flat surface 70 on the surface facing away from the first wall 22 of the packaging box 2 (the surface facing upward). When sealing the opening of the outer bag 7 with adhesive tape, the worker presses the adhesive tape toward the flat surface 70. Since the adhesive tape has a certain width, the third recess 53C also has a certain width to match the width of the adhesive tape.

[0047] 7, the four fourth recesses 53D extend parallel to the short side direction and are spaced apart from each other in the long side direction of the second wall portion 50 between two first recesses 53A. Specifically, two fourth recesses 53D are formed on the right side and two on the left side with respect to the center of the buffer body 5 in the long side direction. The two fifth recesses 53E extend parallel to the long side direction and are spaced apart in the short side direction of the second wall portion 50. Specifically, one fifth recess 53E is formed on the rear side and one on the front side with respect to the center of the short side direction of the buffer body 5. The fifth recess 53E has a deeper bottom than the first recess 53A but is shallower than the recesses other than the first recess 53A. The fifth recess 53E is provided mainly to improve the strength of the second wall portion 50. The four sixth recesses 53F extend from the ends of the fifth recesses 53E in the long side direction.

[0048] While Figure 8 shows the transport box 3 in an upside-down state, when the transport box 3 is not upside-down, the upper ends of the third recess 53C and the fourth recess 53D are located higher than the upper end of the first recess 53A and are at the same position as the upper end of the fourth wall portion 52. Although not shown in Figure 8, the upper ends of the second recess 53B and the sixth recess 53F are also located at the same positions as the upper ends of the third recess 53C and the fourth recess 53D. These recesses form hollow protruding portions that protrude upward from the second wall portion 50. The hollow protruding portions are intended to protect the lead-acid batteries 1 from impact when the transport box 3 falls topside (or falls bottomside when the buffer 5 is used as the lower buffer 5B).

[0049] When the buffer 5 is used as the lower buffer 5B, the recesses 53 also serve as recesses in which the granular absorbent material 6 is placed (see FIGS. 4 and 13).

[0050] The third wall portion 51 and the fourth wall portion 52 will be described with reference to Figures 4 and 6. As shown in Figure 4, a space 65 is provided between the third wall portion 51 and the fourth wall portion 52. In the following description, the portion consisting of the third wall portion 51 and the fourth wall portion 52 will be referred to as a frame portion 60. As shown in Figure 6, a recessed portion 61 recessed upward at the center of the long side direction is formed in the frame portion 60, in a portion extending in the long side direction of the second wall portion 50. A recessed portion 61 recessed upward at the center of the short side direction is also formed in a portion extending in the short side direction of the frame portion 60. These recessed portions 61 are intended to improve the strength of the frame portion 60.

[0051] A plurality of inverted triangular recesses 62 are formed on the inward-facing surface of the third wall portion 51. These recesses 62 are intended to improve the strength of the third wall portion 51. Specifically, the portion of the third wall portion 51 extending in the long-side direction has two recesses 62 formed on one side and two recesses 62 formed on the other side of the center of the long-side direction. The vertices of these recesses 62 are connected to the fourth recess 53D. The portion of the third wall portion 51 extending in the short-side direction has one recess 62 formed on one side and one recess 62 on the other side of the center of the short-side direction. The vertices of these recesses 62 are connected to the sixth recess 53F.

[0052] 11A and 11B, the fourth wall portion 52 is inclined downward so as to approach the packaging box 2. In other words, the fourth wall portion 52 is inclined so as to approach the packaging box 2 as it moves away from the second wall portion 50. As shown in FIG. 11A, recesses 63 recessed from top to bottom are formed on both sides of the recess 61 in the portion extending in the short side direction of the fourth wall portion 52. As shown in FIG. 11B, recesses 63 recessed from top to bottom are formed on both sides of the recess 61 in the portion extending in the long side direction of the fourth wall portion 52. These recesses 63 are intended to improve the strength of the fourth wall portion 52.

[0053] 6, a rib 64 is formed on the outer surface of the fourth wall portion 52 along the edge of the recess 61. As shown in FIGS. 11A and 11B, the rib 64 has a surface 64A that is parallel to the side wall portion 20 of the packaging box 2.

[0054] (5) Placing lead-acid batteries in the shipping box 4, 12, and 13, the placement of the lead-acid battery 1 in the transport box 3 will be described. As shown in FIG. 4, when placing the lead-acid battery 1 in the transport box 3, the outer bag 7 is first placed inside the transport box 3, and the lower cushioning body 5B is placed inside the outer bag 7. As shown in FIG. 12, when placing the lower cushioning body 5B, the worker may lay the transport box 3 on its side to make the work easier, and place the lower cushioning body 5B in an upright position (with the outer surface of the fourth wall portion 52 facing downward). Because the side wall portions 20 of the packaging box 2 and the side wall portions 30 of the transport box 3 are parallel, when the lower cushioning body 5B is placed in an upright position, the parallel surfaces 64A of the ribs 64 come into contact with the side wall portions 30 of the transport box 3, making it difficult for the cushioning body 5 to tip over.

[0055] Next, the transport box 3 is returned to its original position (a position with the top open). After the transport box 3 is returned to its original position, granular absorbent material 6 is placed in the recesses 53 of the lower cushioning body 5B, as shown in FIG. 13. Although FIG. 13 shows a case where absorbent material 6 is placed in only some of the recesses 53, absorbent material 6 is placed in all of the recesses 53. After the absorbent material 6 is placed in the recesses 53, the packaging box 2 placed in the inner bag 4 is placed on top of the lower cushioning body 5B, as shown in FIG. 4. Next, further granular absorbent material 6 is placed between the side wall portion 30 of the transport box 3 and the side wall portion 20 of the packaging box 2 (specifically, between the outer bag 7 and the inner bag 4). After the absorbent material 6 is placed, the upper cushioning body 5A is placed on top of the packaging box 2 placed in the inner bag 4.

[0056] Next, the upper end of the outer bag 7 is folded over on the upper cushioning body 5A. After the upper end of the outer bag 7 is folded over, adhesive tape is applied to the folded portion of the outer bag 7 to seal the outer bag 7. At this time, the worker presses the adhesive tape against the upward-facing surface 70 of the third recess 53C (the surface facing away from the first wall portion 22). Thereafter, the upper opening of the transport box 3 is closed and sealed with adhesive tape or the like.

[0057] (6) Shock absorption by buffers As shown in Figure 8, when the transport box 3 falls face-up, the first wall portion 22 of the packaging box 2 is pressed downward by the terminals 12 of the lead-acid battery 1. The pressed first wall portion 22 functions as a cushion by bending downward using the space in the first recess 53A of the upper buffer body 5A. This buffers the impact on the terminals 12 and distributes the impact over the entire first wall portion 22 of the packaging box 2. Furthermore, if the transport box 3 falls face-up, the hollow protruding portions (the second recess 53B, the third recess 53C, the fourth recess 53D, and the sixth recess 53F) protruding upward (the downwards because the top and bottom are inverted in FIG. 8) from the second wall portion 50 will receive the impact from the floor. Since the hollow protruding portions will collapse when subjected to an impact, the hollow protruding portions will collapse and absorb the impact, thereby further cushioning the impact on the lead-acid batteries 1.

[0058] As shown in FIG. 5, even if the transport box 3 falls on its bottom, the hollow protruding portion of the lower buffer body 5B collapses, thereby absorbing the impact. When the transport box 3 falls on its side, the fourth wall 52 bends toward the third wall 51, or the third wall 51 bends toward the fourth wall 52, thereby cushioning the impact of the side fall. If the transport box 3 falls on a corner, the presence of the second recess 53B prevents the impact from being concentrated on the corner of the lead-acid battery 1.

[0059] (7) Effects of the embodiment According to the buffer 5 of the first embodiment, when the transport box 3 is dropped face-up, the first wall 22 pressed downward by the terminals 12 bends downward using the space in the first recess 53A, thereby functioning as a cushion. This buffers the impact on the terminals 12 and distributes the impact across the entire first wall 22 of the packaging box 2. This reduces the possibility of the impact concentrating on the terminals 12 and damaging the lead-acid battery 1. Furthermore, because the buffer 5 is made of pulp mold, even if the lead-acid battery 1 is damaged and electrolyte leaks, the leaked electrolyte can be absorbed to some extent by the buffer 5. Therefore, the buffer 5 can alleviate a problem specific to transporting the lead-acid battery 1 (the problem that the lead-acid battery 1 may be damaged during transport, causing electrolyte to leak and affect the surrounding area).

[0060] For example, it is possible to form the buffer 5 by stacking corrugated cardboard plates, but the smooth surface of corrugated cardboard poses the problem that the packaging box 2 may slip inside the shipping box 3 during transportation, making it difficult to stabilize its position. In contrast, the surface of pulp mold is rough, which has the advantage that the packaging box 2 is less likely to slip. Generally, corrugated cardboard has sharp corners, which can injure workers when placing the buffer material 5 in the outer bag 7, or tear the outer bag 7 with the corners of the cardboard. Pulp molded materials have fewer sharp corners than corrugated pole materials, which can reduce the possibility of workers being injured or the outer bag 7 being torn.

[0061] When forming the cushioning material 5 by stacking cardboard sheets, adhesive is required, but with pulp mold, no adhesive is required and there is no need for the process of stacking cardboard sheets, so it has the advantage of being cheaper to manufacture than cardboard sheets. Pulp molding is easier to mold into complex shapes than corrugated cardboard, so it has the advantage of being easier to design the shape to cushion impacts.

[0062] For example, it is possible to use a polystyrene foam cushioning 5 as the cushioning 5, but the combustion temperature of polystyrene foam becomes so high when incinerated that it quickly damages the incinerator and generates harmful gases. In contrast, a pulp mold cushioning 5 has the advantage of being able to overcome these problems.

[0063] According to the buffer body 5, the first recessed portion 53A faces the terminal 12 even when the buffer body 5 is rotated 180 degrees around a straight line perpendicular to the first wall portion 22 of the packaging box 2, so the worker does not need to pay attention to the orientation of the buffer body 5 when placing the buffer body 5. This improves workability.

[0064] According to the buffer 5, the tip of the hollow protruding portion is farther from the first wall portion 22 of the packaging box 2 than the tip of the first recess 53A, so that when the packaging box is dropped on its top side, the hollow protruding portion absorbs the impact from the floor. The hollow protruding portion collapses when it receives an impact, and the collapse of the protruding portion absorbs the impact, thereby further absorbing the impact when the packaging box is dropped on its top side. When the buffer 5 is used as the lower buffer 5B, the hollow protruding portion absorbs the impact when the packaging box is dropped on its bottom side.

[0065] The buffer 5 ensures a space 65 between the third wall 51 and the fourth wall 52 that constitute the frame 60, so that when the transport box 3 falls sideways, the fourth wall 52 or the third wall 51 bends using the space 65, thereby functioning as a cushion to absorb the impact on the lead-acid batteries 1. This makes it possible to absorb the impact when the transport box 3 falls sideways.

[0066] According to the buffer 5, a rib 64 having a surface 64A parallel to the side wall 20 (wall continuing perpendicularly to the first wall 22) of the packaging box 2 is formed on the outer surface of the fourth wall 52, so when the buffer 5 is stored in an upright position, the parallel surface 64A of the rib 64 comes into contact with the side wall 30 of the shipping box 3, making it difficult for the buffer 5 to tip over. This improves workability.

[0067] The buffer 5 has a third recess 53C formed therein that is recessed away from the corner of the packaging box 2, which can prevent the lead-acid battery 1 from being damaged by an impact concentrated on the corner when the corner is dropped.

[0068] According to the cushioning body 5, a flat surface 70 is formed on the surface of the second wall portion 50 of the cushioning body 5 that faces away from the packaging box 2, so that the worker can easily apply the adhesive tape by pressing the adhesive tape against the flat surface 70. This improves workability.

[0069] According to the buffer 5, a recess 53 is formed in the lower buffer 5B, so that the granular absorbent material 6 can be placed in the recess 53. Conventionally, after the packaging box 2 is placed in the transport box 3, the absorbent material 6 is placed between the side surface of the transport box 3 and the side surface of the packaging box 2, and the absorbent material 6 is not placed under the packaging box 2. This has resulted in uneven placement of the absorbent material 6 inside the transport box 3. According to the buffer 5, by placing the absorbent material 6 in the recess 53, uneven placement of the absorbent material 6 inside the transport box 3 can be reduced. This makes it possible to more reliably absorb leaked electrolyte.

[0070] According to the buffer 5, the area of the portion of the second wall 50 of the buffer 5 other than the recess 53 is between 50% and 80% of the area of the second wall 50. If the area of the portion of the second wall 50 other than the recess 53 (the portion in contact with the bottom wall 21 of the packaging box 2) is too small, the lower buffer 5B may not be able to sufficiently buffer impact. Conversely, if the area of the portion other than the recess 53 is too large, the amount of absorbent material 6 that can be placed under the packaging box 2 decreases, resulting in a decrease in the absorption of electrolyte. After extensive research, the inventors of the present application found that a good balance between shock buffering and electrolyte absorption can be achieved by setting the area of the portion of the second wall 50 other than the recess 53 to between 50% and 80% of the area of the second wall 50. According to the buffer 5, the area of the portion of the second wall 50 other than the recess 53 is between 50% and 80% of the area of the second wall 50, thereby achieving a good balance between shock buffering and electrolyte absorption.

[0071] According to the buffer 5, the first recess 53A extends in the direction of the short side of the lead-acid battery 1 when viewed from above. Lead-acid batteries 1 come in a variety of sizes, and the position of the terminal 12 in the direction of the short side may vary depending on the size. If the first recess 53A extends in the direction of the short side of the lead-acid battery 1, the first recess 53A will be located directly above the terminal 12 even if the size of the lead-acid battery 1 varies, so the buffer 5 can be commonly used for lead-acid batteries 1 of different sizes. This is more efficient than preparing a buffer 5 for each size.

[0072] According to the buffer 5, the first recess 53A has a certain width in the long side direction of the lead-acid battery 1 when viewed from above. Lead-acid batteries 1 come in a variety of sizes, and the position of the terminal 12 in the long side direction may vary depending on the size. If the first recess 53A has a certain width in the long side direction of the lead-acid battery 1, the first recess 53A will be located directly above the terminal 12 even if the size of the lead-acid battery 1 varies, so the buffer 5 can be commonly used for lead-acid batteries 1 of different sizes. This is more efficient than preparing a buffer 5 for each size.

[0073] The packaging structure according to the first embodiment can solve the problems specific to transporting the lead-acid battery 1.

[0074] <Other embodiments> The present invention is not limited to the embodiments described above and illustrated in the drawings, and the following embodiments, for example, are also included within the technical scope of the present invention.

[0075] (1) In the above-described first embodiment, the first recesses 53A are formed on both sides of the short side relative to the center of the short side, and the first recesses 53A face the terminals 12 even when the buffer body 5 is rotated 180 degrees around a line perpendicular to the first wall portion 22. However, the first recesses 53A may be formed on only one side of the short side relative to the center of the short side. In this case, however, care must be taken when placing the upper buffer body 5A.

[0076] (2) In the above-described first embodiment, the lower end (tip) of the hollow protruding portion of the upper buffer body 5A is located below the lower end of the first recess 53A. However, the lower end of the hollow protruding portion may be located at the same position as the lower end of the first recess 53A. In this case, when the transport box 3 is dropped top-side or bottom-side, the first recess 53A also absorbs the impact.

[0077] (3) In the above embodiment, the terminals 12 are provided on the top surface of the lead-acid battery 1, but the surface on which the terminals 12 are provided is not limited to the top surface. For example, the terminals 12 may be provided on a side surface of the lead-acid battery 1.

[0078] (4) In the above-described first embodiment, the lead-acid battery 1 is described as being mounted on an automobile, but the lead-acid battery 1 is not limited to being mounted on an automobile. For example, the lead-acid battery 1 may be mounted on a motorcycle or may be used for other purposes. [Explanation of symbols]

[0079] 1 lead acid battery 2 Packaging box (example of a box) 3. Shipping box (example of outer box) 5 Buffer 7 Outer bag (example of bag) 12 terminals 13 Imaginary Line 22 First wall 50 Second wall 51 Third Wall 52 Fourth Wall 53A First recess 53B Second recess (an example of a hollow protruding portion) 53C Third recess (an example of a hollow protruding portion) 53D Fourth recess (an example of a hollow protruding portion) 53F 6th recess (an example of a hollow protrusion) 64 Ribs 64A Parallel Surfaces 65 Space (an example of the space between the third wall and the fourth wall) 70 plane

Claims

1. A packaging structure for a lead-acid battery having two terminals, a box in which the lead-acid battery is packed; an outer box in which the box is housed; a buffer for the lead-acid battery disposed inside the outer box on the outside of a first wall portion of the wall portion of the box that faces the two terminals; Equipped with The buffer body is made of pulp mold, In a state in which the buffer body is disposed on the outside of the first wall portion, a second wall portion facing the first wall portion; a first recess formed in the second wall portion at a position facing the terminal and recessed in a direction away from the first wall portion; A packaging structure for a lead-acid battery.

2. The packaging structure for a lead-acid battery according to claim 1, the two terminals are arranged on the same side in a direction perpendicular to a virtual line connecting the two terminals with respect to a center of the box as a reference, as viewed from a direction perpendicular to the first wall portion of the box; a packaging structure for a lead-acid battery, wherein the first recess is formed on both sides of the box in the orthogonal direction with the center of the box as a reference, and the first recess faces the terminal even when the buffer is rotated 180 degrees around a straight line perpendicular to the first wall portion.

3. The packaging structure for a lead-acid battery according to claim 1 or 2, a packaging structure for a lead-acid battery, wherein the second wall portion has a hollow protruding portion that protrudes in a direction away from the first wall portion, and a tip of the protruding portion is at the same position as a tip of the first recess or is farther away from the first wall portion than the tip of the first recess.

4. The packaging structure for a lead-acid battery according to any one of claims 1 to 3, a frame-shaped third wall portion that is connected to the outer peripheral edge of the second wall portion and surrounds the box; a frame-shaped fourth wall portion connected to the third wall portion and surrounding the third wall portion; and A packaging structure for a lead-acid battery, wherein a space is secured between the third wall portion and the fourth wall portion.

5. The packaging structure for a lead-acid battery according to claim 4, the fourth wall portion is inclined so as to approach the box as it moves away from the second wall portion, a rib having a surface parallel to a wall portion of the box wall that is connected to the first wall portion at a right angle is formed on an outer surface of the fourth wall portion.

6. The packaging structure for a lead-acid battery according to claim 4 or 5, a second recess formed in the second wall portion and the third wall portion so as to be recessed away from a corner portion of the box;

7. The packaging structure for a lead-acid battery according to any one of claims 1 to 6, The box and the cushioning material are transported in a bag, a surface of the second wall portion facing away from the first wall portion, the surface having a flat surface against which an adhesive tape is pressed when the adhesive tape is used to close the opening of the bag.

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