Packaging unit and packaging method

Abstract

To provide a packaging unit prevented in jumping-up of a packaged object and allowing for stable carriage of multiple packaged objects.SOLUTION: In a packaging unit, multiple holding recesses (14) for holding the end part of a packaged object (P) are formed on each of holding members (12) in a prescribed direction with intervals, discontinuous grooves (16) are formed on each of the holding members (12) so as to longitudinally cross the multiple holding recesses (14) along the prescribed direction, and a pair of regulating members (24) are arranged so as to be engaged with the discontinuous grooves (16) of the pair of holding members (12).SELECTED DRAWING: Figure 2

Description

Technical Field

[0005] , ,

[0001] The present invention relates to a packaging unit and a packaging method for packaging a plurality of packages in an arranged state along a predetermined direction.

Background Art

[0002] In order to package a plurality of packages in an arranged state along a predetermined direction, for example, a packaging unit (referred to as a packaging material in Patent Document 1) as shown in Patent Document 1 is used. The packaging unit according to the prior art includes a pair of support members (referred to as a packaging material main body in Patent Document 1) for packaging a plurality of packages, and the pair of support members face each other in a direction orthogonal to the predetermined direction. Each support member extends in the predetermined direction, and a plurality of holding recesses (referred to as grooves in Patent Document 1) for holding the end portions of the packages are formed at intervals in the predetermined direction on each support member.

[0003] Therefore, one end portion of each package is held from above in a plurality of holding recesses of one of the pair of support members. The other end portion of each package is held from above in a plurality of holding recesses of the other of the pair of support members. Thereby, a plurality of packages can be packaged between the pair of support members in a state where movement in the predetermined direction, the orthogonal direction, and the downward direction of the plurality of packages is restricted.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] [[ID=CO8]] Incidentally, the upper side of each retaining recess of each support member is open in order to hold one end of the packaged item from above in each retaining recess of each support member. Therefore, when transporting multiple packages packed by the packaging unit, if vibration or shock is applied to the multiple packages, the ends of the packages may come out of the retaining recess of the support member, causing the packages to bounce up. As a result, the packages may be damaged, making it difficult to transport (carry) multiple packages stably.

[0006] Therefore, one aspect of the present invention aims to prevent packaged items from bouncing up and to stably transport multiple packaged items. [Means for solving the problem]

[0007] To solve the aforementioned problems, a packaging unit according to one aspect of the present invention is a packaging unit for packaging a plurality of items to be packaged in an arranged state in a predetermined direction, comprising: a pair of support members for packaging a plurality of items to be packaged, which are opposite to each other in a direction perpendicular to the predetermined direction and extend in the predetermined direction; and a pair of restricting members for restricting the upward movement of the items to be packaged, wherein each of the pair of support members is formed at intervals in the predetermined direction and has a plurality of holding recesses for holding the ends of the items to be packaged, and a discontinuous groove formed so as to longitudinally intersect the plurality of holding recesses along the predetermined direction, and each of the pair of restricting members is arranged to engage with the discontinuous groove of the pair of support members, respectively, and extends in the predetermined direction.

[0008] In a unit according to one aspect of the present invention, a plurality of pairs of support members are provided, and an engaging projection is formed on one of the upper edge and lower edge of each support member, and an engaging recess is formed on the other of the upper edge and lower edge of each support member, and when the plurality of pairs of support members are stacked, the engaging projection or engaging recess of the lower pair of support members engages with the engaging recess or engaging projection of the upper pair of support members.

[0009] In a packaging unit according to one aspect of the present invention, the pair of restricting members may be arranged to engage with the discontinuous grooves of the uppermost pair of support members, respectively.

[0010] In a packaging unit according to one aspect of the present invention, the pair of support members may be detachably connected before being used for packaging the items to be packaged.

[0011] In a packaging unit according to one aspect of the present invention, when multiple sets of the pair of support members in a connected state are stacked, the pair of restricting members may be arranged so as to engage with the discontinuous grooves of the second pair of support members from the top, and the discontinuous grooves of the topmost pair of support members, which are inverted vertically, may engage with the pair of restricting members.

[0012] In a packaging unit according to one aspect of the present invention, at least one of each support member and each restricting member may be made of polystyrene foam or polyolefin foam.

[0013] In a packaging unit according to one aspect of the present invention, at least one of each support member and each restricting member may be made of (i) a polystyrene-based resin foam having an expansion ratio of 20 to 60 times, or (ii) a polypropylene-based resin foam having an expansion ratio of 10 to 50 times.

[0014] Furthermore, in order to solve the aforementioned problems, a packaging method according to one aspect of the present invention is a packaging method for packaging a plurality of items to be packaged in a predetermined direction using a packaging unit according to one aspect of the present invention, comprising: an installation step of installing the pair of support members at intervals corresponding to the length of the items to be packaged; a holding step, after the completion of the installation step, of holding one end of the items to be packaged in the plurality of holding recesses of one of the pair of support members, and holding the other end of the items to be packaged in the plurality of holding recesses of the other support member; and an arrangement step, after the completion of the holding step, of arranging the pair of regulating members to engage with the discontinuous grooves of the pair of support members, respectively.

[0015] A packaging method according to one aspect of the present invention is a packaging method for packaging a plurality of items to be packaged in a predetermined direction using a packaging unit according to one aspect of the present invention, comprising: an installation step of installing a pair of support members at intervals corresponding to the length of the items to be packaged; a first holding step, after the completion of the installation step, of holding one end of the items to be packaged in the plurality of holding recesses of one of the pair of support members and holding the other end of the items to be packaged in the plurality of holding recesses of the other support member of the pair of support members; a stacking step, after the completion of the first holding step, of stacking another pair of support members on top of the lower pair of support members; a second holding step, after the completion of the stacking step, of holding one end of the items to be packaged in the plurality of holding recesses of one of the other pair of support members and holding the other end of the items to be packaged in the plurality of holding recesses of the other support member of the other pair of support members; and an arrangement step, after the completion of the second holding step, of arranging the pair of regulating members to engage with the discontinuous grooves of the uppermost pair of support members.

[0016] In one aspect of the present invention, a repetitive step may be included in which the stacking step and the second holding step are alternately repeated before the arrangement step is started. [Effects of the Invention]

[0017] According to one aspect of the present invention, one aspect of the present invention can prevent the packaged objects from bouncing up and stably transport a plurality of packaged objects.

Brief Description of the Drawings

[0018] [Figure 1] It is a schematic perspective view showing a state in which a plurality of packaged objects are packaged in three or more stages by the packaging unit according to the present embodiment. [Figure 2] It is a schematic perspective view showing a pair of support members and a pair of regulating members in the packaging unit according to the present embodiment. [Figure 3] It is a schematic partially enlarged perspective view showing a pair of support members in the packaging unit according to the present embodiment. [Figure 4] It is a schematic plan view showing a pair of support members in a connected state. [Figure 5] It is a schematic side view showing a pair of support members in a connected state. [Figure 6] It is a schematic perspective view showing a state in which a plurality of pairs of support members in a connected state are stacked, showing the state before the pair of support members in the uppermost stage is inverted up and down. [Figure 7] It is a schematic perspective view showing a state in which a plurality of pairs of support members in a connected state are stacked, showing the state after the pair of support members in the uppermost stage is inverted up and down. [Figure 8] It is a schematic perspective view for explaining the installation process in the packaging method according to the present embodiment. [Figure 9] It is a schematic perspective view for explaining the first holding process in the packaging method according to the present embodiment. [Figure 10] It is a schematic perspective view for explaining the stacking process in the packaging method according to the present embodiment. [Figure 11] It is a schematic perspective view for explaining the second holding process in the packaging method according to the present embodiment. [Figure 12] It is a schematic perspective view for explaining the repeating process and the arranging process in the packaging method according to the present embodiment.

Best Mode for Carrying Out the Invention

[0019] Hereinafter, embodiments of the present invention will be described with reference to the drawings. This embodiment will be described with reference to the drawings. As shown in the drawings, the horizontal direction, which is the longitudinal direction of the support member, is referred to as the X direction. The water direction, which is the direction orthogonal to the longitudinal direction of the support member (the short side direction), is referred to as the Y direction. The vertical direction, which is the direction orthogonal to the X direction and the Y direction, is referred to as the Z direction. The upper side is referred to as one side in the Z direction, and the lower side is referred to as the other side in the Z-axis direction, respectively.

[0020] 〔Configuration of Packing Unit 10〕 Referring to FIGS. 1 to 7, the configuration of the packing unit 10 according to this embodiment will be described. FIG. 1 is a schematic perspective view showing a state in which a plurality of objects to be packed P are packed in three or more stages by the packing unit 10 according to this embodiment. FIG. 2 is a schematic perspective view showing a pair of support members 12 and a pair of regulating members 24 in the packing unit 10 according to this embodiment. FIG. 3 is a schematic partial enlarged perspective view showing a pair of support members 12 in the packing unit 10 according to this embodiment. FIG. 4 is a schematic plan view showing a pair of support members 12 in a connected state. FIG. 5 is a schematic side view showing a pair of support members 12 in a connected state. FIGS. 6 and 7 are schematic perspective views showing a state in which a plurality of pairs of support members 12 in a connected state are stacked in stages. FIG. 6 shows a state before the pair of support members 12 in the uppermost stage is inverted vertically. FIG. 7 shows a state after the pair of support members in the uppermost stage is inverted vertically.

[0021] (Overview of Packing Unit 10) As shown in FIGS. 1 and 2, the packing unit 10 according to this embodiment is a unit for packing a plurality of objects to be packed P in a state arranged along the X direction, which is a predetermined direction. In this embodiment, the object to be packed P as the packing target of the packing unit 10 is, for example, a long automotive part, but it is not limited to automotive parts, nor is it limited to long parts or objects.

[0022] (Support member 12) As shown in Figures 1 to 3, the packaging unit 10 is equipped with multiple sets of elongated block-shaped support members 12 for packaging the items to be packaged P. Each set of support members 12 is arranged facing each other in the Y direction, which is perpendicular to a predetermined direction. Each support member 12 is made of a foamed resin and extends in the X direction, which is a predetermined direction. Multiple sets of support members 12 are configured to be stackable. Although each support member 12 is formed in an elongated block shape, the shape of each support member 12 may be appropriately changed depending on the shape and number of items to be packaged P.

[0023] (Retaining recess 14) As shown in Figures 2 and 3, each support member 12 has a plurality of retaining recesses 14 formed at intervals in the X direction to hold the end of the packaged item P. One side (opposing side) in the Y direction and one side (upper side) in the Z direction of each retaining recess 14 of each support member 12 are open. Each retaining recess 14 of each support member 12 can receive the end of the packaged item P from below.

[0024] Each retaining recess 14 of each support member 12 has a bottom surface 14a, a pair of side surfaces 14b facing each other in the X direction, and a back surface 14c. The bottom surface 14a of each retaining recess 14 of each support member 12 supports the packaged object P from below and restricts the downward movement of the packaged object P (to the other side in the Z direction). The pair of side surfaces 14b of each retaining recess 14 of each support member 12 can contact the end of the packaged object P from both sides in the X direction and restrict the movement of the packaged object P in the X direction. The back surface 14c of each retaining recess 14 of each support member 12 can contact the end of the packaged object P from one side in the Y direction and restricts the movement of the packaged object P in the Y direction.

[0025] (Discontinuous groove 16, divided recess 18) As shown in Figures 2 and 3, a discontinuous groove 16 is formed on the upper part of each support member 12 so as to longitudinally intersect the plurality of retaining recesses 14 along the X direction. The discontinuous groove 16 of each support member 12 has a plurality of divided recesses 18 formed at intervals in the X direction on the upper part of each support member 12, and both sides in the X direction and one side (upper side) in the Z direction of each divided recess 18 are open. The arrangement line of the plurality of divided recesses 18 of each support member 12 is such that it longitudinally intersects the plurality of retaining recesses 14 along the X direction.

[0026] (Engaging projection 20, engaging recess 22) As shown in Figures 1 to 3, the upper edge of each support member 12 has multiple engaging protrusions 20 that protrude upward, spaced apart in the X direction. The lower edge of each support member 12 has multiple engaging recesses 22 that are recessed upward, spaced apart in the X direction, and each engaging recess 22 is located directly below each engaging protrusion 20. The packaging unit 10 is configured such that when multiple pairs of support members 12 are stacked, the engaging protrusions 20 of the lower pair of support members 12 engage with the engaging recesses 22 of the upper pair of support members 12. Preferably, the engaging protrusions 20 and the engaging recesses 22 fit together.

[0027] Alternatively, multiple engaging protrusions 20 may be formed on the lower edge of each support member 12, and multiple engaging recesses 22 may be formed on the upper edge of each support member 12. In this case, each engaging protrusion 20 is located directly below each engaging recess 22. The packaging unit 10 is configured such that when multiple pairs of support members 12 are stacked, the engaging recesses 22 of the lower pair of support members 12 engage with the engaging protrusions 20 of the upper pair of support members 12.

[0028] (Regulating member 24) As shown in Figures 1 and 2, the packaging unit 10 is equipped with a pair of rod-shaped restricting members 24 that restrict the upward movement of the packaged object P relative to the support member 12. Each restricting member 24 is made of a foamed resin and extends in the X direction. The pair of restricting members 24 are arranged to engage with the discontinuous grooves 16 of the pair of support members 12, respectively. When multiple sets of pairs of support members 12 are stacked, the pair of restricting members 24 are arranged to engage with the discontinuous grooves 16 of the uppermost pair of support members 12. Although each restricting member 24 is formed in a rod shape, the shape of each restricting member 24 may be appropriately changed as long as each restricting member 24 has a portion that engages with the discontinuous grooves 16 of the pair of support members 12. Furthermore, the pair of restricting members 24 are not particularly limited as long as they restrict the upward movement of the packaged object P relative to the support member 12, but preferably they are inserted and fitted into the discontinuous grooves 16 of the support member 12.

[0029] (A pair of support members 12 in a connected state) As shown in Figures 1, 4, and 5, each pair of support members 12 is connected by a plurality of joints 26 before being used to pack the goods P. The plurality of joints 26 are spaced apart in the X direction between the lower parts of each pair of support members 12. The plurality of joints 26 are configured to break when a force is applied to the upper parts of each pair of support members 12 in a direction that separates them from each other (opening direction). In other words, each pair of support members 12 is detachably connected before being used to pack the goods P. When packing the goods P, the joints 26 are broken and the pair of support members 12 are used.

[0030] In a pair of support members 12 connected by a joint 26 before use, the gap between the upper parts of the pair of support members 12 can be appropriately set so that the pair of support members 12 break. The gap is preferably 3 mm to 20 mm, more preferably 5 mm to 15 mm, and even more preferably 8 mm to 10 mm.

[0031] Furthermore, in the height direction (Z direction), the joint portion 26 is provided in a region that is preferably 20% or less, more preferably 15% or less, and even more preferably 10% or less, of the height of the pair of support members 12 from the lower surface of the support members 12. When a force is applied to the upper parts of each pair of support members 12 in a direction that separates them from each other (opening direction), causing the joint portion 26 to break and allowing them to be used as a pair of support members 12, the joint portion 26 is preferably located at a distance of 4 mm to 15 mm, more preferably 5 mm to 12 mm, and even more preferably 7 mm to 10 mm from the lower surface of the pair of support members 12, in order to balance the connection strength between the pair of support members 12 before separation and the ease with which the joint portion 26 breaks.

[0032] Furthermore, the cross-sectional shape of the upper end of the joint portion 26 can be appropriately set so that the pair of support members 12 break. Preferably, the cross-sectional shape of the upper end of the joint portion 26 is V-shaped so that the pair of support members 12 break easily. Furthermore, it is preferable that the angle of the V-shape is 90° or less.

[0033] As shown in Figures 6 and 7, the packaging unit 10 is configured such that when multiple pairs of connected support members 12 are stacked, the engaging protrusions 20 of the lower pair of support members 12 engage with the engaging recesses 22 of the upper pair of support members 12. When multiple engaging protrusions 20 are formed on the lower edge of each support member 12 and multiple engaging recesses 22 are formed on the upper edge of each support member 12, the packaging unit 10 is configured such that the engaging recesses 22 of the lower pair of support members 12 engage with the engaging protrusions 20 of the upper pair of support members 12.

[0034] As shown in Figure 6, when multiple pairs of connected support members 12 are stacked, the discontinuous grooves 16 of the second pair of support members 12 from the top are positioned to engage with the pair of restricting members 24. Also, as shown in Figure 7, when multiple pairs of connected support members 12 are stacked, the discontinuous grooves 16 of the topmost pair of support members 12, when inverted vertically, are positioned to engage with the pair of restricting members 24.

[0035] (The resin foam and its base resin that constitute the support member 12 and the regulating member 24) The material of each support member 12 and each restricting member 24 is not particularly limited as long as it achieves the effects described above. Preferably, each support member 12 and each restricting member 24 is composed of a resin foam made of foamed resin, as described above. The base resin of the resin foam constituting each support member 12 and each restricting member 24 is not particularly limited, but is preferably a thermoplastic resin. Examples of such thermoplastic resins include polystyrene resins, polyolefin resins, polyester resins, and polycarbonate resins. Preferably, the thermoplastic resin is a polystyrene resin or a polyolefin resin. Furthermore, in this embodiment, at least one of each support member 12 and each restricting member 24 may be a resin foam with the above thermoplastic resin as the base resin. That is, it is preferable that at least one of each support member 12 and each restricting member 24 is composed of a polystyrene resin foam or a polyolefin resin foam. Even more preferably, both each support member 12 and each restricting member 24 are composed of a polystyrene resin foam or a polyolefin resin foam.

[0036] Examples of polystyrene resins include resins containing structural units derived from styrene monomers. Suitable examples of styrene monomers include styrene, methylstyrene, ethylstyrene, isopropylstyrene, dimethylstyrene, bromostyrene, chlorostyrene, vinyltoluene, and vinylxylene. Examples of resins containing structural units derived from styrene monomers include homopolymers of styrene monomers obtained by polymerizing one type of styrene monomer, or copolymers of styrene monomers obtained by polymerizing two or more types of styrene monomers. As resins containing structural units derived from styrene monomers, polystyrene resins that are homopolymers and copolymers of styrene monomers, i.e., resins containing only structural units derived from styrene monomers, can be preferably used.

[0037] Polyolefin resins are not particularly limited and include polypropylene resins, polyethylene resins, etc. Specific examples of monomers of polyolefin resins (hereinafter sometimes referred to as olefin monomers) include, for example, α-olefins with 2 to 12 carbon atoms such as ethylene, propylene, butene-1, isobutene, pentene-1, 3-methyl-butene-1, hexene-1, 4-methyl-pentene-1, 3,4-dimethyl-butene-1, heptene-1, 3-methyl-hexene-1, octene-1, and decene-1. These may be used individually or in combination of two or more.

[0038] Other monomers copolymerizable with olefin monomers include, for example, cyclic olefins such as cyclopentene, norbornene, and 1,4,5,8-dimethano-1,2,3,4,4a,8,8a,6-octahydronaphthalene, and dienes such as 5-methylene-2-norbornene, 5-ethylidene-2-norbornene, 1,4-hexadiene, methyl-1,4-hexadiene, and 7-methyl-1,6-octadiene. These may be used individually or in combination of two or more.

[0039] Specific examples of polyolefin resins include polyethylene resins mainly composed of ethylene, such as high-density polyethylene, medium-density polyethylene, low-density polyethylene, and linear low-density polyethylene, and polypropylene resins mainly composed of propylene. These polyolefin resins may be used individually or in combination of two or more types.

[0040] Polyethylene-based resins, particularly those containing ethylene as a copolymer monomer component, are readily available and exhibit excellent processability and moldability.

[0041] The polypropylene resin is not particularly limited as long as it contains propylene as the main component of the monomer. Examples include propylene homopolymer, α-olefin-propylene random copolymer, and α-olefin-propylene block copolymer. These may be used individually or in combination of two or more.

[0042] Examples of polyester resins include aliphatic polyester resins, aromatic polyester resins, and aliphatic aromatic polyester resins. Specific examples of polyester resins include polyhydroxyalkanoates, polybutylene succinates (PBS), poly(butylene adipate-co-butylene terephthalate) (PBAT), and polyethylene terephthalate (PET). Furthermore, polyhydroxyalkanoates are at least one selected from the group consisting of poly(3-hydroxybutyrate-co-3-hydroxyhexanoate) (PHBH), poly(3-hydroxybutyrate) (P3HB), poly(3-hydroxybutyrate-co-3-hydroxyvalate) (PHBV), poly(3-hydroxybutyrate-co-4-hydroxybutyrate) (P3HB4HB), poly(3-hydroxybutyrate-co-3-hydroxyoctanoate), and poly(3-hydroxybutyrate-co-3-hydroxyoctadecanoate).

[0043] Furthermore, aromatic polycarbonate resins can be mentioned as polycarbonate resins. Aromatic polycarbonate resins are polycarbonate esters or mixtures thereof formed from a carbonic acid component and an aromatic diol component containing at least a bisphenol compound or a diol component mainly composed of the same. Among these, aromatic polycarbonate resins having diphenylalkanes in their molecular chains are preferred because they have high crystallinity and a high melting point, as well as excellent heat resistance, weather resistance, and acid resistance.

[0044] Examples of such polycarbonate resins include those formed from bisphenol compounds such as 2,2-bis(4-oxyphenyl)propane (also known as bisphenol A), 2,2-bis(4-oxyphenyl)butane, 1,1-bis(4-oxyphenyl)cyclohexane, 1,1-bis(4-oxyphenyl)isobutane, and 1,1-bis(4-oxyphenyl)ethane.

[0045] Furthermore, as blowing agents used for foaming foamed resins, volatile hydrocarbon blowing agents such as propane, isobutane, butane, pentane, and hexane, inorganic gases such as air, nitrogen, and carbon dioxide, and water can be used. When using inorganic gases, carbon dioxide is preferred because it is easier to obtain foamed particles with a relatively high foaming ratio. These blowing agents may be used alone or in combination of two or more types.

[0046] The foaming ratio of the resin foam constituting at least one of each support member 12 and each restricting member 24 is not particularly limited, but for example, if the resin foam is a polystyrene-based resin foam, it is preferably 20 times or more and 60 times or less, more preferably 25 times or more and 50 times or less, and even more preferably 30 times or more and 50 times or less. First, regarding the resin foam constituting the support member 12, if the foaming ratio of the polystyrene-based resin foam is less than 20 times, the cushioning performance and lightness of the support member 12 tend to be inferior. Furthermore, if the foaming ratio of the polystyrene-based resin foam exceeds 60 times, the rigidity of the support member 12 tends to be insufficient with respect to the weight of the packaged item P. Next, regarding the resin foam constituting the restricting member 24, if the foaming ratio of the polystyrene-based resin foam is less than 20 times, it is rigid and there is a risk of scratching the packaged item P when it comes into contact with it during handling, and furthermore, the restricting member 24 tends to chip and crack easily. When the foaming ratio of the polystyrene resin foam exceeds 60 times, deformation due to insufficient rigidity is more likely to occur, making it difficult to ensure the linearity of the regulating member 24.

[0047] When the resin foam constituting at least one of each support member 12 and each restricting member 24 is a polyolefin-based resin foam, the foaming ratio is preferably 10 times or more and 50 times or less, more preferably 20 times or more and 50 times or less, and even more preferably 35 times or more and 45 times or less. First, regarding the resin foam constituting the support member 12, if the foaming ratio of the polyolefin-based foam resin is less than 10 times, the support member 12 tends to be less lightweight. Furthermore, if the polyolefin-based foaming ratio exceeds 50 times, the rigidity of the support member 12 tends to be insufficient with respect to the weight of the packaged item P. Next, regarding the resin foam constituting the restricting member 24, if the foaming ratio of the polyolefin-based foam resin is less than 10 times, it is rigid and may cause damage when it comes into contact with the packaged item P during handling, and furthermore, the restricting member 24 tends to chip and crack easily. If the polyolefin-based foaming ratio exceeds 50 times, deformation due to insufficient rigidity tends to occur easily, and it tends to be difficult to ensure the linearity of the restricting member 24.

[0048] Based on the above, it is preferable that at least one of each support member 12 and each regulating member 24 is made of (i) a polystyrene-based resin foam with an expansion ratio of 20 to 60 times, or (ii) a polypropylene-based resin foam with an expansion ratio of 10 to 50 times.

[0049] [Packaging Method] Next, the packaging method according to this embodiment will be described with reference to Figures 1 and 8 to 12. Figure 8 is a schematic perspective view illustrating the installation process in the packaging method according to this embodiment. Figure 9 is a schematic perspective view illustrating the first holding process in the packaging method according to this embodiment. Figure 10 is a schematic perspective view illustrating the stacking process in the packaging method according to this embodiment. Figure 11 is a schematic perspective view illustrating the second holding process in the packaging method according to this embodiment. Figure 12 is a schematic perspective view illustrating the repetition process and the placement process in the packaging method according to this embodiment.

[0050] As shown in Figures 1, 8 to 12, the packaging method according to this embodiment is a method for packaging multiple items to be packaged P in a predetermined direction, X, using a packaging unit 10. In this embodiment, the items to be packaged by the packaging method according to this embodiment are not limited to automobile parts, nor are they limited to long parts or objects. Furthermore, the packaging method according to this embodiment includes an installation step, a first holding step, a stacking step, a second holding step, a repeating step, and an arrangement step. The specific details of each step in the packaging method according to this embodiment are as follows.

[0051] (Installation process) As shown in Figure 8, a pair of support members 12 are installed in a predetermined installation area SA at intervals corresponding to the length of the item to be packaged P. This completes the preparation for packaging the item to be packaged P.

[0052] (1st holding step) After the installation process is complete, as shown in Figure 9, one end of the packaged items P is inserted from above into the multiple retaining recesses 14 of one of the pair of support members 12 and held in place. The other end of the packaged items P is inserted from above into the multiple retaining recesses 14 of the other support member 12 and held in place. This allows multiple packaged items P to be packed between the pair of support members 12 while restricting their movement in the X, Y, and downward directions (the other side of the Z direction).

[0053] (Stacking process) After the first holding step is completed, as shown in Figure 10, the engaging recesses 22 of the other pair of support members 12 are engaged with the engaging protrusions 20 of the lower pair of support members 12, thereby stacking the other pair of support members 12 on top of the lower pair of support members 12. This completes the preparation for packaging multiple items P between the other pair of support members 12. Furthermore, the upward movement (one side in the Z direction) of the multiple items P packaged between the lower pair of support members 12 is restricted by the other pair of support members 12.

[0054] (Second holding process) After the stacking process is completed, as shown in Figure 11, one end of the packaged items P is inserted from above into the multiple retaining recesses 14 of one of the other pair of support members 12 and held in place. The other end of the packaged items P is inserted from above into the multiple retaining recesses 14 of the other support member 12 and held in place. This allows multiple packaged items P to be packed between the other pair of support members 12 while restricting their movement in the X, Y, and downward directions.

[0055] (Repeated process) After the completion of the second holding process, the stacking process and the second holding process are repeated alternately, as shown in Figure 12. This allows the packaging unit 10 to package multiple items P in at least three or more layers.

[0056] (Placement process) After the repetitive process is completed, as shown in Figure 12, a pair of restricting members 24 are positioned to engage with the discontinuous grooves 16 of the uppermost pair of support members 12. This restricts the upward movement (to one side in the Z direction) of the multiple packages P packed between the uppermost pair of support members 12 by the pair of restricting members 24.

[0057] (Additional information) After the placement process is completed, the pair of restricting members 24 may be fixed to the support member 12 using cable ties (not shown). When the packaging unit 10 packages multiple items P in two layers, the repetition process may be omitted from the configuration of the packaging method according to this embodiment. When the packaging unit 10 packages multiple items P in one layer, the layering process, the second holding process, and the repetition process may be omitted from the configuration of the packaging method according to this embodiment.

[0058] [Effects] Next, the effects and advantages of this embodiment will be explained.

[0059] By inserting the ends of the items to be packaged P into the multiple holding recesses 14 of the pair of support members 12 from above and holding them, the movement of the multiple items to be packaged P in the X, Y, and downward directions is restricted, and the multiple items to be packaged P are packaged between the pair of support members 12. By arranging the pair of restricting members 24 to engage with the discontinuous grooves 16 of the pair of support members 12, the upward movement of the multiple items to be packaged P packaged between the pair of support members 12 is restricted by the pair of restricting members 24. Therefore, even if the multiple items to be packaged P are subjected to vibration or shock during transport, the bouncing of the items to be packaged P can be suppressed. In other words, according to this embodiment, the bouncing of the items to be packaged P can be prevented, and the multiple items to be packaged P can be transported stably.

[0060] Furthermore, by stacking another pair of support members 12 on top of the lower pair of support members 12, the upward movement of the multiple packages P packed between the lower pair of support members 12 is restricted by the other pair of support members 12. By arranging a pair of restricting members 24 to engage with the discontinuous grooves 16 of the uppermost pair of support members 12, the upward movement of the multiple packages P packed between the uppermost pair of support members 12 is restricted by the pair of restricting members 24. Therefore, when transporting multiple packages P packed in multiple layers by the packaging unit 10, even if the multiple packages P are subjected to vibration or shock, the bouncing of the packages P can be suppressed. In other words, according to this embodiment, the bouncing of the packages P can be prevented, and multiple packages P packed in multiple layers can be transported stably.

[0061] Each pair of support members 12 is detachably connected before being used to pack the goods P. When multiple pairs of connected support members 12 are stacked, the pair of restricting members 24 are positioned to engage with the discontinuous grooves 16 of the second pair of support members 12 from the top. The discontinuous grooves 16 of the top pair of support members 12, when inverted vertically, engage with the pair of restricting members 24. Therefore, according to this embodiment, before being used to pack the goods P, the packing unit 10 can be stored in a stable state without the multiple pairs of support members 12 being dispersed, while saving storage space for the packing unit 10.

[0062] When the foaming ratio of the polystyrene resin foam constituting each support member 12 is between 20 and 60 times, it is possible to improve the cushioning performance and lightness of the support member 12 while ensuring sufficient rigidity of the support member 12 relative to the weight of the packaged item P.

[0063] When the foaming ratio of the polypropylene resin foam constituting each support member 12 is between 10 and 50 times, it is possible to improve the lightness of the support member 12 while ensuring sufficient rigidity of the support member 12 relative to the weight of the packaged item P.

[0064] [Additional Notes] The present invention is not limited to the embodiments described above, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in each embodiment are also included in the technical scope of the present invention. Furthermore, new technical features can be formed by combining the technical means disclosed in each embodiment. [Explanation of symbols]

[0065] 10 Packaging Units 12 Support members 14 Retaining recess 14a Base 14b Side 14c back side 16 discontinuous grooves 18 divided recesses 20 Engagement protrusion 22 Engagement recess 24 Regulating members 26 Joint section

Claims

1. A packaging unit for packaging multiple items arranged in a predetermined direction, A pair of support members for packaging multiple items, facing each other in a direction perpendicular to the predetermined direction and extending in the predetermined direction, A pair of restricting members that restrict the upward movement of the packaged item, Equipped with, Each of the aforementioned pair of support members is: A plurality of retaining recesses are formed at intervals in the predetermined direction to hold the end of the packaged item, The plurality of retaining recesses are provided with discontinuous grooves formed to traverse them longitudinally along the predetermined direction, Each of the pair of restricting members is positioned to engage with the discontinuous grooves of the pair of support members and is configured to extend in the predetermined direction. The packaging unit comprises a plurality of pairs of support members, each support member having an engaging projection on one of its upper or lower edges and an engaging recess on the other of its upper or lower edges. When multiple pairs of the aforementioned support members are stacked, the engaging projection or engaging recess of the lower pair of support members is configured to engage with the engaging recess or engaging projection of the upper pair of support members. A packaging unit in which the pair of support members are detachably connected before being used for packaging the goods to be packaged, and when multiple sets of the connected pairs of support members are stacked, the pair of restricting members are arranged so that they engage with the discontinuous grooves of the second row of the pair of support members from the top, and the discontinuous grooves of the top row of the pair of support members, when inverted, engage with the pair of restricting members.

2. The packaging unit according to claim 1, characterized in that the pair of restricting members are arranged to engage with the discontinuous grooves of the uppermost pair of support members.

3. The packaging unit according to claim 1 or 2, characterized in that at least one of each support member and each regulating member is made of polystyrene foam or polyolefin foam.

4. The packaging unit according to claim 1 or 2, characterized in that at least one of each support member and each regulating member is made of (i) a polystyrene-based resin foam having an expansion ratio of 20 times or more and 60 times or less, or (ii) a polypropylene-based resin foam having an expansion ratio of 10 times or more and 50 times or less.

5. A packaging method for packaging multiple items to be packaged in a predetermined direction using the packaging unit described in claim 1, Installation process involves setting a pair of support members at intervals corresponding to the length of the packaged item, After the completion of the installation step, a first holding step is performed in which one end of the packaged item is held in the plurality of holding recesses of one of the pair of support members, and the other end of the packaged item is held in the plurality of holding recesses of the other support member of the pair of support members, After the completion of the first holding step, a stacking step is performed in which another pair of support members are stacked on top of the lower pair of support members, After the completion of the stacking step, a second holding step is performed in which one end of the packaged item is held in the plurality of holding recesses of one of the other pair of support members, and the other end of the packaged item is held in the plurality of holding recesses of the other support member of the other pair of support members, A packaging method characterized by comprising, after the completion of the second holding step, an arrangement step of arranging the pair of restricting members so as to engage with the discontinuous grooves of the uppermost pair of support members.

6. The packaging method according to claim 5, characterized in that it includes a repeating step of alternately repeating the stacking step and the second holding step before starting the placement step.

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