cushioning material

Abstract

To provide a cushioning material allowing for improving the protection function of an indoor unit by not allowing, when fit to an end of the indoor unit, a gap to occur with the end and the cushioning material to deform.SOLUTION: A cushioning material 2 is to be fit to lengthwise both ends of an indoor unit of a separation-type air conditioner. The cushioning material comprises a bottom-cushioning portion 10 on which a bottom of an indoor unit is rested, a side-cushioning portion 11 that continues to one side of the bottom-cushioning portion 10 and a side surface of the indoor unit is to contact, an outer periphery-cushioning portion 12, 13, 14 that cylindrically extends from an edge of the side-cushioning portion together with the bottom-cushioning portion and an outer periphery excepting a bottom of the indoor unit is to contact. The internal angle defined by the bottom-cushioning portion and the side-cushioning portion is set at 90° and the internal angle defined by the outer periphery-cushioning portion and the side-cushioning portion is set to a blunt angle.SELECTED DRAWING: Figure 3

Description

Technical Field

[0001] The present invention relates to a buffer material attached to both longitudinal ends of a rectangular parallelepiped-shaped indoor unit of a split air conditioner, a mold for manufacturing the buffer material, and a method for manufacturing the buffer material using this mold.

Background Art

[0002] When storing or transporting a rectangular parallelepiped-shaped indoor unit, buffer materials made of foamed materials such as foamed polystyrene are attached to both ends of the indoor unit, and the entire indoor unit and the buffer materials are packed with packaging materials such as cardboard sheets and then tightened with bands to protect the indoor unit. As a buffer material, for example, as shown in Patent Document 1, an insertion portion is provided that forms an internal space along the outer peripheral shape of the end portion in the longitudinal direction of the indoor unit, and the inner surface of this insertion portion contacts the outer periphery of the end portion of the indoor unit to protect the indoor unit.

[0003] The buffer material of Patent Document 1 includes a side buffer portion formed in accordance with the shape of the side surface of the housing of the indoor unit, and a cylindrical outer peripheral buffer portion that rises from all peripheral edges of the side buffer portion and is formed in a shape along the upper surface, front surface, back surface, and bottom surface of the housing of the indoor unit (hereinafter referred to as the conventional buffer material). This conventional buffer material protects the indoor unit by the side buffer portion contacting the side surface of the indoor unit and the outer peripheral buffer portion contacting the outer periphery of the end portion of the indoor unit. This conventional buffer material is molded with a molding die (male die, female die), and a draft angle is provided on the molded product so that the molded product can be smoothly removed from the molding die. Therefore, the conventional buffer material is formed with an obtuse angle at the inner corner formed by the side buffer portion and the outer peripheral buffer portion.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

[0005] Incidentally, when conventional cushioning material is attached to the ends of an indoor unit, if a part of the indoor unit's casing is placed on the outer cushioning portion, a gap is created between the side cushioning portion, which has an obtuse angle between it and the outer cushioning portion, and the side of the outdoor unit. If the unit is then packed with packaging material and tightened with bands, the gap between the cushioning material and the side of the indoor unit narrows, causing the cushioning material to deform. As a result, the cushioning material may be damaged, or it may not make sufficient contact with the ends of the indoor unit, potentially reducing the protective function of the indoor unit. Therefore, the present invention has been made to solve these problems, and aims to provide a cushioning material, a mold for manufacturing the cushioning material, and a method for manufacturing the cushioning material using this mold, which can improve the protective function of the indoor unit by preventing gaps from forming between the cushioning material and the ends of the indoor unit and preventing deformation of the cushioning material. [Means for solving the problem]

[0006] To achieve the above objective, a cushioning material according to one aspect of the present invention is a cushioning material attached to both ends in the longitudinal direction of a rectangular parallelepiped indoor unit, comprising: a bottom cushioning portion on which the bottom of the indoor unit (the part that becomes the back of the indoor unit when in use) is placed; a side cushioning portion continuous with one side of the bottom cushioning portion and in contact with the side of the indoor unit; and an outer cushioning portion extending from the edge of the side cushioning portion together with the bottom cushioning portion and in contact with the outer circumference of the indoor unit other than the bottom, wherein the internal angle between the bottom cushioning portion and the side cushioning portion is set to 90° or less, and the internal angle between the outer cushioning portion and the side cushioning portion is set to an obtuse angle.

[0007] Furthermore, a mold for manufacturing a cushioning material according to one aspect of the present invention comprises a female mold with a recess and a male mold having a protrusion that fits into the recess of the female mold and is movable relative to the female mold in the opening and closing direction of the mold. The male mold and the female mold form a space for molding the cushioning material. The molding space consists of a bottom forming space for molding the bottom cushioning portion, a side forming space for molding the side cushioning portion, and an outer periphery forming space for molding the outer periphery cushioning portion. In addition, a supply passage is provided for supplying molding material to the bottom forming space, the side forming space, and the outer periphery forming space, and the molding surface of the bottom forming space and the molding surface of the side forming space extend at a 90° angle to each other, and the molding surface of the side forming space and the molding surface of the outer periphery forming space extend at an obtuse angle to each other, and the male mold is movable in the demolding direction.

[0008] Furthermore, in a method for manufacturing a cushioning material using a mold for manufacturing cushioning material according to one aspect of the present invention, a molding material is supplied from a supply channel to the bottom forming space, the side forming space, and the outer peripheral forming space, and after the molding material has solidified, the male mold is moved in the demolding direction. [Effects of the Invention]

[0009] According to the present invention, the cushioning material prevents gaps from forming between the cushioning material and the end of the indoor unit when it is attached to the end of the indoor unit, and prevents deformation of the cushioning material, thereby improving the protective function of the indoor unit. Furthermore, according to the mold for manufacturing cushioning material and the method for manufacturing cushioning material using this mold, it is possible to manufacture cushioning material that improves the protective function of indoor units. [Brief explanation of the drawing]

[0010] [Figure 1] This diagram shows the indoor unit and the cushioning materials attached to both ends of the indoor unit in the longitudinal direction. [Figure 2] This is a perspective view showing the exterior of the indoor unit. [Figure 3] This is a cross-sectional view showing the shape of the cushioning material. [Figure 4]This is a cross-sectional view of the main part of the indoor unit, showing the indoor unit wrapped in a cardboard sheet along with the cushioning material, and then secured with a band from the longitudinal direction of the indoor unit. [Figure 5] (a) is a diagram showing the structure of the molding die used to form the cushioning material, and (b) is a diagram showing the state after the male die has been moved after the cushioning material has been formed. [Modes for carrying out the invention]

[0011] Next, embodiments of the present invention will be described with reference to the drawings. The embodiments shown below illustrate devices and methods for realizing the technical idea of ​​the present invention, and the technical idea of ​​the present invention is not limited to the materials, shapes, structures, arrangements, etc. of the components described below. Various modifications can be made to the technical idea of ​​the present invention within the technical scope defined by the claims described in the patent claims. Please note that the directional terms such as "up," "down," "front," "back," "left," and "right" used in the following explanation are based on the assumption that the indoor unit of the air conditioner is mounted on a wall inside the room.

[0012] Figure 1 shows one embodiment of a rectangular parallelepiped indoor unit 1 and a cushioning material 2 that is attached to both ends of the indoor unit 1 in the longitudinal direction when storing or transporting the indoor unit 1. The indoor unit 1 is a wall-mounted indoor unit and includes a housing 3 that houses a drain pan assembly with a blower fan, heat exchanger, electrical components, etc. (not shown) installed inside. As shown in Figure 2, the housing 3 of the indoor unit 1 includes a top panel 4 extending from the top surface of the indoor unit 1, a front panel 5 positioned at the front of the indoor unit 1 and having a curved surface with a large curvature, a bottom panel 6 positioned on one side in the width direction of the front panel 5, a back panel 7 made of a metal plate positioned on the back side of the front panel 5 and fixed to the wall of the room, and a pair of side panels 8 positioned at both ends in the longitudinal direction of the top panel 4, front panel 5, bottom panel 6, and back panel 7. The top panel 4 is provided with an intake port (not shown), and a rotatable air deflector 9 is positioned between the front panel 5 and the bottom panel 6, with an outlet port (not shown) provided inside the air deflector 9.

[0013] When storing or transporting the indoor unit 1, the cushioning material 2 is attached with the highly rigid back panel 7 facing downwards, as shown in Figure 2. The cushioning material 2 is a component molded from a foamed material such as expanded polystyrene, and as shown in Figure 3, it comprises a flat bottom cushioning portion 10 on which the back plate 7 of the indoor unit 1 rests, a side cushioning portion 11 rising from one side of the bottom cushioning portion 10 and facing the side panel 8 of the indoor unit 1, and outer peripheral cushioning portions 12, 13, 14 extending from the periphery of the side cushioning portion 11 and in contact with the outer periphery of the indoor unit 1 other than the back plate 7 (top panel 4, front panel 5, and bottom panel 6). The side cushioning portion 11 is formed in a shape that follows the outer periphery of the side panel 8, and the bottom cushioning portion 10 and the outer peripheral cushioning portions 12, 13, 14 rise from the periphery of the side cushioning portion 11, forming a cylindrical shape with a bottom (side cushioning portion 11).

[0014] Furthermore, the bottom of the indoor unit 1 described in the present invention corresponds to the rear panel 7, and the parts of the indoor unit other than the bottom of the indoor unit described in the present invention correspond to the outer perimeter other than the rear panel 7 (top panel 4, front panel 5, and bottom panel 6). Furthermore, the end 10a of the bottom cushioning portion 10, which rises from the side cushioning portion 11, may be provided with an R-shape to allow the cushioning material 2 to be smoothly attached to the indoor unit 1. Also, an R shape may be provided at the end of the end portion 12a of the outer peripheral buffer portion 12 rising from the side buffer portion 11.

[0015] And, for the buffer material 2 of the present embodiment, the inner angle θ1 formed by the bottom buffer portion 10 and the side buffer portion 11 is set to 90°, and the inner angle θ2 formed by the side buffer portion 11 and the outer peripheral buffer portions 12, 13, 14 is set to 92°. FIG. 4 shows a state where the buffer material 2 is attached to the longitudinal end of the indoor unit 1, the outer periphery of the indoor unit 1 and the bottom buffer portion 10 and the outer peripheral buffer portions 12, 13, 14 of the buffer material 2 are wrapped with a square cardboard sheet 15, and then tightened with a band 16 so as to surround the indoor unit 1 in the longitudinal direction.

[0016] The buffer material 2 of the present embodiment is arranged such that the bottom buffer portion 10 is on the lower side. When the buffer material 2 is attached to the longitudinal end of the indoor unit 1, the back panel 7 of the indoor unit 1 is placed on the bottom buffer portion 10 of the buffer material 2, and the side panel 8 orthogonal to the back panel 7 faces the side buffer portion 11 of the buffer material 2. At this time, since the inner angle θ1 formed by the bottom buffer portion 10 and the side buffer portion 11 is set to 90°, no gap occurs between the side panel 8 and the side buffer portion 11. Here, the inner angle θ1 formed by the bottom buffer portion 10 and the side buffer portion 11 may be appropriately set according to the angle formed by the back panel 7 and the side panel 8.

[0017] Here, the inner angle θ1 formed by the bottom buffer portion 10 and the side buffer portion 11 may be set to (90 - β)° within a range where no problem such as damage to the side panel 8 occurs due to friction generated between the side panel 8 and the side buffer portion 11 when the back panel 7 of the indoor unit 1 is placed on the bottom buffer portion 10 of the buffer material 2. In that case, the inner angle θ2 formed by the side buffer portion 11 and the outer peripheral buffer portions 12, 13, 14 may be set to 90 + (2 + β)° or more. Thus, when the cushioning material 2 is attached to the longitudinal end of the indoor unit 1, no gap is generated between the side panel 8 and the side cushioning portion 11. Therefore, even when the band 16 is tightened after wrapping with the cardboard sheet 15, there are no locally deformed portions in the bottom cushioning portion 10 and the side cushioning portion 11 of the cushioning material 2. Accordingly, the cushioning material 2 does not crack, and thus the protection function of the indoor unit 1 can be improved.

[0018] Also, the end portions 10a of the bottom cushioning portion 10 and the end portions 12a of the outer peripheral cushioning portion 12 of the cushioning material 2 are formed in a shape where the end face side has the thinnest thickness and the thickness gradually increases toward the side cushioning portion 11. Therefore, when wrapping with the cardboard sheet 15, the edge of the cardboard sheet 15 is less likely to be caught by the end portions 10a of the bottom cushioning portion 10 and the end portions 12a of the outer peripheral cushioning portion 12, and the packaging operation of the cardboard sheet 15 can be easily performed.

[0019] Next, FIGS. 5(a) and (b) show a manufacturing method of an embodiment of the cushioning material 2 using the molding die 20. Note that the molding die for manufacturing the cushioning material described in the present invention corresponds to the molding die 20. As shown in FIG. 5(a), the molding die 20 includes a female die 22 provided with a concave portion, and a male die 21 provided with a convex portion that enters the concave portion of the female die 22 and is movable in the mold opening and closing direction with respect to the female die 22. A line R indicated by a two-dot chain line in FIG. 5(a) is parallel to the moving direction of the male die 21.

[0020] When the male die 21 and the female die 22 are combined, a bottom forming space 23 for forming the bottom cushioning portion 10 of the cushioning material 2 extends in the mold release direction R between the male die 21 and the female die 22, a side forming space 24 for forming the side cushioning portion 11 extends in a direction intersecting the mold release direction R, and an outer peripheral forming space 25 for forming the outer peripheral cushioning portion 12 extends in the mold release direction R. Although not shown, the outer peripheral forming space 25 for forming the outer peripheral cushioning portions 13 and 14 is also formed with the same structure as the outer peripheral forming space 25 for the outer peripheral cushioning portion 12.

[0021] Here, the molding surface 31 of the bottom forming space 23 and the molding surface 30 of the side forming space 24 extend perpendicularly to each other. In other words, the first protrusion 21a formed by the molding surface 31 and the molding surface 30 of the male mold 21 is formed protruding at a 90° angle. Also, the molding surface 30 of the side forming space 24 and the molding surface 32 of the outer peripheral forming space 25 extend at obtuse angles to each other, and the second protrusion 21b formed by the molding surface 30 and the molding surface 32 of the male mold 21 is formed protruding at a 92° angle.

[0022] Furthermore, the molding surface 30 of the side forming space 24 is not formed in a direction perpendicular to the demolding direction R. As the side forming space 24 is tilted to the left in Figure 5, the molding surface 31 of the bottom forming space 23 extends with a 1° slope (draft angle) relative to the demolding direction R, and the outer periphery forming space 25 extends with a 1° draft angle relative to the demolding direction R. The predetermined draft angle described in the present invention corresponds to the aforementioned 1° draft angle. By providing this inclination, it becomes possible to mold a cushioning material with an angle of 90° between the bottom cushioning portion 10 and the side cushioning portion 11.

[0023] Furthermore, the female mold 22 has supply passages 26 for supplying the cushioning material (foam) to the bottom forming space 23, the side forming space 24, and the outer peripheral forming space 25 before molding, and a foam supply device 27 is connected to the opening of these supply passages 26. When liquid foam material is supplied from the foam material supply device 27 to the molding die 20 with the above configuration, the liquid foam material passes through the supply passage 26 and fills the bottom forming space 23, the side forming space 24, and the outer peripheral forming space 25. Here, the molding material described in the present invention corresponds to the cushioning material (foam material) before molding.

[0024] Then, once the liquid foam material filled in the bottom forming space 23, the side forming space 24, and the outer peripheral forming space 25 has solidified, the mold is opened as shown in Figure 5(b), and the male mold 21 is separated from the female mold 22, thereby producing a cushioning material 2 with a bottom cushioning portion 10, side cushioning portions 11, and outer peripheral cushioning portions 12 (13, 14) that were released together with the male mold 21. In this way, by configuring the male mold 21 and female mold 22, even a cushioning material with a bottom cushioning portion 10 and side cushioning portions 11 at an angle of 90° can be given a draft angle that allows for smooth release from the female mold 22. Therefore, by using the molding die 20 in the above configuration, it is possible to manufacture a cushioning material 2 that is less prone to damage. [Explanation of symbols]

[0025] 1 Indoor unit 2 Cushioning material 3 cabinets 4. Top panel 5 Front Panel 6. Bottom panel 7 Back plate 8 Side Panels 9 Wind direction board 10 Bottom buffer 10a End of bottom cushioning section 11 Side buffer section 12,13,14 Outer buffer section 12a End of outer periphery buffer θ1 Inner angle between the bottom buffer portion and the side buffer portion 11 θ2 Inner angle between the lateral buffer portion and the outer periphery buffer portion 15 cardboard sheets 16 bands 20 Molding molds 21 Male mold 22 Female mold 23 Bottom forming space 24 Side forming space 25 Peripheral Formation Space 26 Supply route 27 Foaming material supply device 30,31,32 Molding surface

Claims

1. A cushioning material made of foam material, which is attached to both ends in the longitudinal direction of the indoor unit of an air conditioner and fastened with bands to surround the indoor unit from the longitudinal direction, and which is attached to the indoor unit using a mold, has a draft angle applied to the molded product so that it can be smoothly released from the mold, The indoor unit comprises a bottom buffer portion on which the bottom of the indoor unit rests, a side buffer portion continuous with one side of the bottom buffer portion and in contact with the side surface of the indoor unit, and an outer buffer portion extending from the edge of the side buffer portion together with the bottom buffer portion and in contact with the outer circumference of the indoor unit other than the bottom, The inner angle between the bottom cushioning portion and the side cushioning portion is set to 90° or less. The inner angle between the outer peripheral buffer portion and the side buffer portion is set to an obtuse angle, A cushioning material characterized in that, with the outer circumference of the indoor unit, the bottom cushioning portion, and the outer circumference cushioning portion wrapped in a cardboard sheet, the band is attached to surround the outer circumference cushioning portion adjacent to the bottom cushioning portion and the side cushioning portion of the outer circumference cushioning portion, without surrounding the bottom cushioning portion.

2. The cushioning material according to claim 1, characterized in that the outer shape of the ends of the bottom cushioning portion and the outer peripheral cushioning portion, which are spaced apart from the side cushioning portion, is formed with a sloped surface such that the cross-sectional area gradually increases toward the side cushioning portion.

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