Loaded-article-containing container and method for manufacturing same

Abstract

This loaded-article-containing container comprises a container, a plurality of flexible containers, and one or more cushioning materials. Each of the plurality of flexible containers is provided with a body part having a bottom surface part and a side surface part continuous with the bottom surface part, and contents accommodated within the body part. At least a first row and a second row arranged in parallel are formed. The one or more cushioning materials are disposed between the first row and the second row. The relationship 5 ≤ (y1 / x1) × 100 ≤ 80 is satisfied, where x1 is the area of a shape obtained by projecting the body parts of all the flexible containers constituting the first row onto a virtual surface parallel to a pair of side wall parts of the container, and y1 is the total area within which the one or more cushioning materials overlap the aforementioned shape on the virtual surface.

Description

Container with cargo and its manufacturing method

[0001] The present disclosure relates to a loaded container and a method for manufacturing the same.

[0002] Patent Document 1 discloses a transport system for bagged products. This transport system uses a cage cart with casters that accommodates existing flexible containers (also called "container bags"). The cage cart is configured to be able to load and unload items from the flexible container while the flexible container is loaded. According to Patent Document 1, the storage, manual movement, truck transport, and unloading of the filled flexible container are all performed in a state where the cage cart is integrated. This reduces the workload of workers who move the flexible container and enables a large amount of items to be packed into the flexible container.

[0003] Japanese Patent Application Publication No. 6-087513

[0004] According to Patent Document 1, the dimensions and number of the car dollies are preset according to the loading platform of the truck on which the flexible containers are to be loaded. This allows a predetermined number of flexible containers to be loaded in an orderly manner together with the car dollies inside the loading platform or other container (see FIGS. 3 and 4). However, in reality, the number of flexible containers to be loaded into a container does not always reach the predetermined number. In such cases, measures are required to restrict the movement of each car dolly inside the container during transport. These measures may require new equipment or may actually increase the workload of workers.

[0005] Therefore, it is conceivable to restrict the movement of flexible containers within a container by filling the space within the container with cushioning material, rather than using a cart as in Patent Document 1. However, if one tries to fill as much space within the container as possible with cushioning material, a large amount of cushioning material would be required, which could lead to reduced work efficiency and a waste of resources, and is therefore not desirable.

[0006] The present disclosure aims to provide a loaded container that can restrict the movement of a flexible container while reducing the amount of cushioning material used, and a method for manufacturing the same.

[0007] A loaded container according to a first aspect of the present disclosure includes a container, a plurality of flexible containers arranged within the container, and one or more cushioning materials. The container includes a rectangular bottom wall portion having opposing first and second sides and opposing third and fourth sides, a first wall portion rising from the first side, a second wall portion rising from the second side, and a pair of side walls rising from the third and fourth sides. Each of the flexible containers includes a main body portion having a bottom portion and a side portion continuous with the bottom portion, and contents housed within the main body portion. The flexible containers are arranged in at least a first row and a second row, with the flexible container closest to the first wall portion at the front and the flexible container closest to the second wall portion at the rear. One or more cushioning materials are arranged between the first row and the second row. The one or more cushioning materials are arranged so as to contact at least the rear flexible container in the first row and the rear flexible container in the second row. If the area of ​​the shape of the main body portions of all the flexible containers constituting the first row projected onto an imaginary plane parallel to the pair of side wall portions is defined as x1, and the total area of ​​the one or more cushioning materials overlapping with the shape on the imaginary plane is defined as y1, then 5≦(y1 / x1)×100≦80.

[0008] A loaded container according to a second aspect of the present disclosure is the loaded container according to the first aspect, wherein the plurality of flexible containers further form third and fourth rows arranged side by side, with the flexible container closest to the first wall portion at the front and the flexible container closest to the second wall portion at the rear, the third row being formed above the first row, and the fourth row being formed above the second row. The loaded container according to the second aspect further includes one or more cushioning materials arranged between the third and fourth rows. The one or more cushioning materials arranged between the third and fourth rows are arranged so as to contact at least the rearmost flexible container in the third row and the rearmost flexible container in the fourth row. Where x2 is the area of ​​a shape formed by projecting the main bodies of all flexible containers constituting the third row onto the imaginary plane, and y2 is the total area of ​​the one or more cushioning materials arranged between the third and fourth rows that overlap with the shape on the imaginary plane, the relationship is: 5≦(y2 / x2)×100≦80.

[0009] A loaded container according to a third aspect of the present disclosure is a loaded container according to the first or second aspect, wherein the rear flexible container in the third row is positioned closer to the first wall portion than the rear flexible container in the first row, and the rear flexible container in the fourth row is positioned closer to the first wall portion than the rear flexible container in the second row.

[0010] A loaded container according to a fourth aspect of the present disclosure is a loaded container according to any one of the first to third aspects, wherein the one or more cushioning materials arranged between the third row and the fourth row include one or more cushioning materials arranged between the first row and the second row, and between the third row and the fourth row so as to contact at least four flexible containers constituting each of the first row to the fourth row.

[0011] A loaded container according to a fifth aspect of the present disclosure is the loaded container according to any one of the first to fourth aspects, further comprising a top surface portion facing the bottom wall portion. The loaded container according to the fifth aspect further comprises one or more cushioning materials disposed between the top surface portion and the rear flexible containers in the third and fourth rows.

[0012] A method for manufacturing a loaded container according to a sixth aspect of the present disclosure includes the following steps: preparing a container having a rectangular bottom wall portion having opposing first and second sides and opposing third and fourth sides, a first wall portion rising from the first side, a second wall portion rising from the second side, and a pair of side wall portions rising from the third and fourth sides; preparing a plurality of flexible containers, each having a main body portion having a bottom portion and a side portion continuous with the bottom portion, and contents contained within the main body portion; preparing one or more cushioning materials; arranging the plurality of flexible containers on the bottom wall portion to form at least first and second rows in parallel, with the flexible container closest to the first wall portion at the front and the flexible container closest to the second wall portion at the rear; and arranging the one or more cushioning materials between the first row and the second row. Arranging the one or more cushioning materials includes arranging the one or more cushioning materials so that they are in contact with at least the rearmost flexible container in the first row and the rearmost flexible container in the second row, and arranging the one or more cushioning materials so that 5≦(y1 / x1)×100≦80 is satisfied, where x1 is the area of ​​the shape of the main body portions of all flexible containers constituting the first row projected onto an imaginary plane parallel to the pair of side wall portions, and y1 is the total area on the imaginary plane where the one or more cushioning materials overlap with the shape.

[0013] According to the present disclosure, a loaded container and a manufacturing method thereof are provided that can restrict the movement of a flexible container while reducing the amount of cushioning material used.

[0014] 1 is a perspective view showing the overall configuration of a loaded container according to one embodiment. FIG. 2 is a perspective view showing an example configuration of a flexible container. FIG. 3 is a perspective view of the loaded container of FIG. 1 from the side and top. FIG. 4 is a perspective view of the loaded container of FIG. 1 from another side. FIG. 5 is a plan view showing an example configuration of a cushioning material. FIG. 6 is a view explaining a method for calculating an area where a cushioning material overlaps a flexible container. FIG. 7 is a view explaining a method for calculating an area where a cushioning material overlaps a flexible container. A flowchart showing the flow of a method for manufacturing a loaded container according to one embodiment. FIG. 8 is a view showing the configuration of a loaded container according to a modified example. FIG. 9 is a view showing the configuration of a loaded container according to another modified example. FIG. 10 is a view showing the configuration of a loaded container according to an embodiment.

[0015] Hereinafter, a loaded container and a method for manufacturing a loaded container according to one embodiment of the present disclosure will be described with reference to the drawings.

[0016] <1. Overall Structure> Fig. 1 is a perspective view showing the overall structure of a container 1 containing a load (hereinafter also referred to as "loaded container 1"). As shown in Fig. 1, the loaded container 1 includes a container 2, a plurality of flexible containers 3 (hereinafter also referred to as "FIBCs 3") containing contents, and cushioning material 4. In this manner, the loaded container 1 is configured to transport a plurality of FIBCs 3. The method of transporting the loaded container 1 is not particularly limited, and may be, for example, land transport by vehicle or rail, sea transport by ship, or air transport by aircraft. As described below, the loaded container 1 of the present disclosure can restrict the movement of the FIBCs 3 during transport while suppressing the amount of cushioning material 4 used, even if space remains within the container 2.

[0017] 2. Container The container 2 is a robust container configured to be able to load and transport a plurality of flexible containers 3. The container 2 according to this embodiment has a substantially rectangular parallelepiped outer shape and includes a bottom wall 20, a first wall 21, a second wall 22, a pair of side walls 23 and 24, and a top surface 25 facing the bottom wall 20. These sections 20 to 25 define an internal space V of the substantially rectangular parallelepiped. The bottom wall 20 is rectangular and has a first side 201 and a second side 202 facing each other, and a third side 203 and a fourth side 204 facing each other. In this embodiment, the first side 201 and the second side 202 are short sides, and the third side 203 and the fourth side 204 are long sides. The top surface 25 has the same shape as the bottom wall 20. Hereinafter, the direction along the first edge 201 and the second edge 202 will be referred to as the "width direction" of the container 2, the direction along the third edge 203 and the fourth edge 204 will be referred to as the "depth direction" of the container 2, and the first edge 201 side (first wall portion 21 side) will be referred to as the rear side, and the second edge 202 side (second wall portion 22 side) will be referred to as the front side.

[0018] The first wall portion 21 rises upward from the first edge 201. The lower end of the first wall portion 21 is fixed to the bottom wall portion 20 and the upper end of the first wall portion 21 is fixed to the top surface portion 25 so as not to move. In other words, in this embodiment, the back side of the internal space V is always closed by the first wall portion 21.

[0019] The pair of side walls 23 and 24 rise upward from the third edge 203 and the fourth edge 204, respectively. The pair of side walls 23 and 24 are continuous at their upper ends with the top surface 25. In this embodiment, the pair of side walls 23 and 24 are fixed so that their lower ends are immovable to the bottom wall 20 and their upper ends are immovable to the top surface 25. The bottom wall 20, the pair of side walls 23 and 24, and the front end of the top surface 25 define an access port for the container 2.

[0020] The second wall portion 22 has a first door 22a rotatably connected to the front end of the side wall portion 23, and a second door 22b rotatably connected to the front end of the side wall portion 24. The first door 22a and the second door 22b function as an opening / closing mechanism that opens and closes the loading / unloading opening of the container 2 by rotating relative to the side wall portion 23 and the side wall portion 24, respectively. Fig. 1 shows the first door 22a and the second door 22b opening the loading / unloading opening. The first door 22a and the second door 22b close to each other at the center of the loading / unloading opening to close the loading / unloading opening, and constitute the second wall portion 22 that rises from the second side 202.

[0021] 3. Flexible Container FIG. 2 is a perspective view showing an example of a flexible container 3. The flexible container 3 is a foldable bag-like container made of synthetic resin, natural fiber, paper, or the like. The flexible container 3 has a main body 30 for containing contents. The main body 30 has a bottom 300 and side surfaces 301 continuous with the bottom 300. The planar shape of the bottom 300 is square in this embodiment, but may also be circular. The bottom 300 may be provided with a discharge port for discharging the contents. The side surfaces 301 are configured to rise from the periphery of the bottom 300, and when contents are contained in the main body 30, the main body 30 forms a substantially rectangular outer shape in a side view.

[0022] The flexible container 3 may further include a hanging belt 302 attached to the main body 30 and an upper panel 303 for at least partially covering the contents from above. The flexible container 3 may also include a bag-shaped inner bag that is housed in the main body 30 and directly houses the contents. The contents housed in the flexible container 3 are not particularly limited, but examples include synthetic resin, grains, vegetables, soil and sand, stones, fertilizer, industrial chemicals, etc. In this embodiment, the contents are particles of a water-absorbent resin.

[0023] Fig. 3 is a perspective view of the loaded container 1 of Fig. 1 from the top and from the side on the side wall 23 side, and Fig. 4 is a perspective view of the loaded container 1 from the side on the side wall 24 side. As shown in Figs. 3 and 4 , a plurality of FIBCs 3 containing contents are arranged from the back to the front of the container 2 to form a FIBC row extending in the depth direction of the loaded container 1. The FIBC row includes a first row 31 and a second row 32 arranged side by side on the bottom wall 20, as well as a third row 33 formed above the first row 31 and a fourth row 34 formed above the second row 32. The third row 33 and the fourth row 34 are arranged side by side. The rear FIBC 33h of the third row is positioned closer to the first wall 21 (toward the back) than the rear FIBC 31j of the first row, and the rear FIBC 34h of the fourth row is positioned closer to the first wall 21 (toward the back) than the rear FIBC 32j of the second row. Here, "arranged in parallel" two or more rows of flexible container containers means that the frontmost flexible container container 3 (e.g., 31j) constituting a certain row of flexible container containers (e.g., first row 31) and the frontmost flexible container container 3 (e.g., 32j) constituting a row of flexible container containers (e.g., second row 32) arranged adjacent to the row of flexible container containers in question are arranged adjacent to each other in the width direction of the container 2. In this embodiment, each row of flexible container containers is made up of the same number of flexible container containers 3, and the flexible container containers 3 in the same order, counting from the leading flexible container container 3 in each row of flexible container containers, are arranged so that they are completely adjacent to each other in the width direction of the container 2 (when viewed from the side on the side of the side wall portion 23 (or side wall portion 24) side, the second row 32 (or first row 31) located opposite the first row 31 (or second row 32) is not visible). However, as long as the two or more rows of flexible container containers satisfy the above-mentioned condition of being "arranged in parallel," they do not necessarily have to be made up of the same number of flexible container containers 3, and may be made up of, for example, flexible container containers 3 of different sizes. All of the rows of flexible container containers making up the loading container 1 of the present disclosure may be arranged so that the maximum gap between two adjacent flexible container containers 3 in the depth direction of the loading container 1 is 10 cm or less, 5 cm or less, 3 cm or less, or 1 cm or less.

[0024] The first row 31 and the second row 32 each consist of ten FIBCs 3, and the third row 33 and the fourth row 34 each consist of eight FIBCs 3. In this specification, the FIBCs 3 that make up the first row 31 to the fourth row 34 may be distinguished by being referred to as 31a to 31j, 32a to 32j, 33a to 33h, and 34a to 34h, respectively. FIBCs 31a, 32a, 33a, and 34a are the leading (rearmost) FIBCs closest to the first wall section 21, and FIBCs 31j, 32j, 33h, and 34h are the trailing (frontmost) FIBCs closest to the second wall section 22 in the row to which they belong.

[0025] The flexible containers 3 of this embodiment are placed on pallets 5 having an upper surface that is the same as or slightly wider than the bottom surface 300, constituting a first row 31 to a fourth row 34. The pallets 5 in each row are arranged in the internal space V so as to minimize gaps in the depth direction and so as not to overlap each other. The pallets 5 on which the flexible containers 31a, 32a, 33a, and 34a are placed are arranged so as to be in contact with the first wall 21 or with a gap of approximately 1 cm to 2 cm from the first wall 21. Similarly, the pallets 5 on which the FIBCs 31a-31j and 33a-33h are placed are arranged either in contact with the side wall 23 or with a gap of approximately 1 cm to 2 cm from the side wall 23, respectively. The pallets 5 on which the FIBCs 32a-32j and 34a-34h are placed are arranged either in contact with the side wall 24 or with a gap of approximately 1 cm to 2 cm from the side wall 24, respectively. The pallets 5 are also arranged so that the gaps between the first row 31 and the second row 32, and between the third row 33 and the fourth row 34, are approximately 10 cm to 20 cm. As a result, although each FIBC 3 may come into contact with other adjacent FIBCs 3 or the inner wall of the container 2, the FIBCs are arranged within the internal space V so that the contact areas are not subject to strong friction. By arranging the FIBCs 3 in this manner, it is possible to prevent the FIBCs 3 from breaking during transport of the loaded container 1.

[0026] On the other hand, as described above, if the flexible containers 3 are arranged so as to avoid friction between the flexible containers 3 and the inner wall of the container 2 or other flexible containers 3 as much as possible, the flexible containers 3 will be more likely to move during transportation of the loaded container 1. The flexible containers 3 will also be more likely to move if gaps are left between the rear flexible containers 31j, 32j, 33h, and 34h and the second wall portion 22. The movement of the flexible containers 3 here includes not only cases in which the flexible containers 3 move from the initial position together with the pallet 5, but also cases in which the flexible containers 3 become displaced relative to the pallet 5 (a state in which at least a portion of the bottom portion 300 protrudes from the top surface of the pallet 5). The loaded container 1 is provided with buffer material 4 to restrict such movement of the flexible containers 3.

[0027] <4. Cushioning Material> FIG. 5 is a plan view showing an example of the configuration of the cushioning material 4. The cushioning material 4 is not particularly limited, and any material can be used. The cushioning material 4 of this embodiment is a bag-shaped gas bag used during container transport. It includes a main body 40 with a vent (not shown) and a valve device 41 for opening and closing the vent. The main body 40 is made of a sheet-like material with gas barrier properties, such as synthetic resin, paper, metal, or a composite material thereof, and has a generally rectangular outer shape. The surface of the main body 40 shown in FIG. 5 is the surface that faces the flexible container 3 and has the largest area within the main body 40. The valve device 41 is configured to open the vent to fill the main body 40 with gas, open the vent to discharge gas from the main body 40 to the outside, and close the vent to maintain the internal pressure within the main body 40. Filling the main body 40 with gas is performed using a dedicated gas filling device or the like.

[0028] In this embodiment, the gas to be filled is air, but is not particularly limited to this. The internal pressure of the buffer material 4 can be adjusted appropriately depending on the size of the space in which the buffer material 4 is placed (the width of the gap to be filled by the buffer material 4), the weight of the flexible container 3 that suppresses movement, etc. A more specific internal pressure of the buffer material 4 is, for example, 0.001 kgf / cm 2 ~0.50Kgf / cm 2 ,0.01Kgf / cm 2 ~0.30Kgf / cm 2 ,0.05Kgf / cm2 ~0.20Kgf / cm 2 If the internal pressure of the buffer material 4 is within the above range, it is possible to further restrict the movement of the flexible container container 3 while further reducing the amount of buffer material 4 used. Note that the internal pressure of the buffer material 4 is a gauge pressure based on the pressure around the buffer material 4 (atmospheric pressure), and means the force that actually pushes the cargo that the buffer material 4 is in contact with.

[0029] After extensive research, the inventors have found that the movement of FIBCs 3 can be efficiently restricted by arranging the buffer material 4 between the FIBCs 3 at least in contact with the rearmost FIBCs 3 in a row of FIBCs arranged side by side in the container 2. Based on this finding, in the loaded container 1, buffer material 4A is arranged between FIBCs 31j and 32j, and buffer material 4B is arranged between FIBCs 33h and 34h. The internal pressure of buffer material 4A is adjusted so that it contacts both FIBCs 31j and 32j, and the air in the main body 40 presses against them. The internal pressure of buffer material 4B is adjusted so that it contacts both FIBCs 33h and 34h, and the air in the main body 40 presses against them. As shown in Figures 3 and 4, the buffer material 4 may extend not only between the FIBCs 3, but also into the gaps in the pallet 5 on which they are placed.

[0030] In order for the buffer material 4A to restrict the movement of the FIBCs 31a-31j and 32a-32j, it is necessary for the buffer material 4A to be able to contact the FIBCs 31a-31j and 32a-32j over a certain area or more. The inventors have further studied the matter and discovered the following. FIG. 6 is a diagram illustrating this. Let us now assume that the area of ​​the shape of the main body 30 of all the FIBCs 31a-31j constituting the first row 31 projected onto an imaginary plane P0 parallel to the pair of side walls 23 and 24 is x1. Also, let us assume that the area of ​​the buffer material 4A overlapping with this shape on the imaginary plane P0 is y1. If the loaded container 1 satisfies 5≦(y1 / x1)×100, then the placement of the buffer material 4A can restrict the movement of the FIBCs 31a-31j and 32a-32j. On the other hand, if the loaded container 1 satisfies (y1 / x1)×100≦80, then the amount of buffer material 4 used can be reduced. The value of (y1 / x1) x 100 may be 5 to 70, 5 to 60, 5 to 50, 5 to 40, 5 to 30, 5 to 20, 5 to 15, 10 to 70, 10 to 60, 10 to 50, 10 to 40, 10 to 30, 10 to 20, 10 to 15, 15 to 70, 15 to 60, 15 to 50, 15 to 40, 15 to 30, 15 to 20, 20 to 70, 20 to 60, 20 to 50, 20 to 40, or 20 to 30. The same applies to the value of (y2 / x2) x 100 described below.

[0031] When the main body 30 of the FIBC 3 expands while containing contents (i.e., when a portion of the side surface 301 of the FIBC 3 protrudes outward), the shape of the main body 30 of the FIBC 31a-31j is approximated on the imaginary plane P0 by a circumscribing rectangle P1 of the entire main body 30 of the FIBC 31a-31j, and the area x1 is therefore considered to be the area of ​​the circumscribing rectangle P1. The length W1 of the circumscribing rectangle P1 corresponds to the maximum length (the longest vertical length of the main body 30) of the FIBC 31a-31j filled with contents. The width W1 of the circumscribing rectangle P1 corresponds to the maximum length from the rear end of the main body 30 of the FIBC 31a to the front end of the main body 30 of the FIBC 31j at a certain height relative to the bottom wall 20. From the above, the area x1 of the circumscribing rectangle P1 can be calculated according to the following formula (1). x1=L1×W1 (1)

[0032] On the other hand, if the bottom surface 300 of the FIBC 3 is circular or square in shape and the main body 30 does not expand even when contents are placed inside (i.e., if the side surface 301 of the FIBC 3 containing contents forms a substantially vertical line when viewed from the side), the area x1 is calculated by (the area of ​​the shape obtained by projecting the main body 30 of any one of the FIBCs 3 constituting the first row 31 onto the imaginary plane P0) x (the number of FIBCs 3 constituting the first row). The area of ​​the projected shape of any one FIBC 3 is calculated by (the diameter or length of one side of the bottom surface 300) x (the vertical length of the side surface 301). In other words, if the FIBC 3 meets the above-mentioned conditions, the area x1 can also be calculated from a FIBC 3 that does not contain contents.

[0033] Because the shape of the cushioning material 4A on the imaginary plane P0 is similar to the circumscribing rectangle P2 of the main body 40 of the cushioning material 4A, the area y1 is considered to be the area of ​​the portion where the circumscribing rectangle P2 and the circumscribing rectangle P1 overlap. The length L2 of the circumscribing rectangle P2 corresponds to the maximum length of the main body 40 in the longitudinal direction, and the width W2 corresponds to the maximum length of the main body 40 in the width direction (see FIG. 5 ). The area y1 is calculated by subtracting the area z1 of the portion of the circumscribing rectangle P2 that protrudes outside the circumscribing rectangle P1 from the area of ​​the circumscribing rectangle P2 (L2 × W2). Specifically, as shown in FIG. 7 , if the vertical length of the circumscribing rectangle P2 that protrudes from the circumscribing rectangle P1 is dL and the horizontal length of the circumscribing rectangle P2 that protrudes from the circumscribing rectangle P1 is dW, the area y1 can be calculated according to the following formula (2): y1=(L2-dL)×(W2-dW) (2)

[0034] The length dL can be determined based on, for example, the measured distance from the bottom wall 20 to the lower end or upper end of the cushioning material 4A, the height of the pallet 5, and the length L1. The length dW can be determined based on the measured distance from the front end of the main body 30 of the flexible container 31j to the front end of the cushioning material 4A.

[0035] The above description is based on an example in which one cushioning material 4A is placed between the first row 31 and the second row 32. However, in addition to the cushioning material 4A, one or more cushioning materials 4 may be placed between the first row 31 and the second row 32. In this case, the area y1 is the total area of ​​the cushioning materials 4 (including the cushioning material 4A) placed between the first row 31 and the second row 32 overlapping with the circumscribed rectangle P1. Note that the depth direction position at which one or more cushioning materials 4 other than the cushioning material 4A are placed is not particularly limited. Furthermore, the above description is based on an example in which the relationship between the FIBCs 31a to 31j that constitute the first row 31 and the cushioning materials 4 is used, but the same applies to the relationship between the FIBCs 32a to 32j that constitute the second row 32 and the cushioning materials 4. Therefore, in the loaded container 1, it is sufficient that at least one of the first column 31 and the second column 32 satisfies 5≦(y1 / x1)×100≦80, but it is preferable that both the first column 31 and the second column 32 satisfy 5≦(y1 / x1)×100≦80.

[0036] Additionally, in the loaded container 1, it is preferable that either the third row 33 or the fourth row 34 (preferably both the third row 33 and the fourth row 34) satisfies 5≦(y2 / x2)×100≦80 in relation to the buffer material 4B. x2 is the area of ​​the shape of the body 30 of the FIBC 33a-33h or the FIBC 34a-34h projected onto the imaginary plane P0. Area x2 can be calculated in the same manner as area x1. y2 is the area of ​​the buffer material 4B overlapping the shape on the imaginary plane P0. Area y2 can be calculated in the same manner as area y1. Furthermore, the loaded container 1 may further include one or more buffer materials 4 arranged between the third row 33 and the fourth row 34 in addition to the buffer material 4B. In this case, area y2 is the sum of the areas of the buffer materials 4 (including the buffer material 4B) arranged between the third row 33 and the fourth row 34 overlapping the shape. The position in the depth direction where one or more buffer materials 4 other than the buffer material 4B are arranged is not particularly limited.

[0037] 8 is a flowchart showing the flow of a method for manufacturing a loading container 1 according to this embodiment. This manufacturing method is carried out when transporting a plurality of flexible containers 3 filled with contents. The manufactured loading container 1 is loaded onto a vehicle, ship, or aircraft and transported to its destination. Each of the following steps S1 to S13 can be performed by a person or by a machine such as a robot.

[0038] First, a container 2, a plurality of FIBCs 3 containing contents, and a plurality of buffer materials 4 are prepared (step S1). In step S1, the container 2 is empty. Each FIBC 3 has contents stored in its main body 30. Each buffer material 4 is not filled with gas. The number of buffer materials 4 and their positions are determined in advance according to the number of FIBCs 3 and their arrangement method so that 5≦(y / x)×100≦80 is satisfied. The container 2 may be loaded on a transport vehicle. Note that the orientation of the loaded container 1 when transported is not particularly limited, and the loaded container 1 may be loaded on a transport vehicle or the like so that either the first wall portion 21 or the second wall portion 22 faces the direction of travel during transport.

[0039] Next, the flexible containers 3 are sequentially carried into the internal space V of the container 2 through the loading / unloading opening (step S2). The flexible containers 3 may be carried in together with the pallets 5. Step S2 may be performed continuously in parallel with the following steps S3 to S13, or may be performed with appropriate pauses.

[0040] Next, of the FIBCs 3 carried in at step S2, two consecutive FIBCs 3 are placed on the bottom wall 20 to form a first row 31 and a second row 32 (step S3). For example, the two FIBCs 3 carried in first at step S2 are placed on the bottom wall 20 so as to face the first wall 21. In this case, the two FIBCs 3 become the leading FIBC 31a of the first row 31 and the leading FIBC 32a of the second row 32, respectively. On the other hand, when step S3 is carried out again after step S6, which will be described later, the two consecutive FIBCs 3 are placed adjacent to and in front of the FIBCs 3 placed in the previous step S3. That is, step S3 is a step of sequentially arranging the FIBCs 3 that make up the first row 31 and the second row 32 from the back side to the front side.

[0041] Next, based on the predetermined arrangement, it is determined whether or not a cushioning material 4 should be placed between the two flexible containers 3 placed in the previous step S3 (step S4). If it is determined in step S4 that a cushioning material 4 should be placed (YES), step S5 is then executed. If it is determined in step S4 that a cushioning material 4 should not be placed (NO), step S5 is skipped and step S6 is executed next.

[0042] In step S5, the buffer material 4 is placed between the two flexible containers 3 arranged in the previous step S3, and then gas is filled into the main body 40 using a dedicated gas filling device. As described above, the amount of gas filled is adjusted appropriately according to the size of the gaps between the flexible containers 3 and / or the weight of the flexible containers 3 so that the buffer material 4 applies an appropriate pressing force to the flexible containers 3. After step S5 is completed, step S6 is executed.

[0043] In step S6, the two consecutive FIBCs 3 carried in in step S2 are placed on top of the two FIBCs 3 arranged in the immediately preceding step S3, while aligning them with the two FIBCs 3. For example, if FIBCs 31a and 32a were arranged in the immediately preceding step S3, two new FIBCs 3 are placed on top of FIBCs 31a and FIBCs 32a, respectively. That is, the two new FIBCs 3 become the leading FIBC 33a of the third row 33 and the leading FIBC 34a of the fourth row 34, respectively. In other words, step S6 is a step in which the third row 33 is formed on top of the first row 31, and the fourth row 34 is formed on top of the second row 32.

[0044] Next, based on the predetermined arrangement, it is determined whether or not a cushioning material 4 should be placed between the two flexible containers 3 placed in the previous step S6 (step S7). If it is determined in step S6 that a cushioning material 4 should be placed (YES), step S8 is then executed. If it is determined in step S7 that a cushioning material 4 should not be placed (NO), step S3 is executed again.

[0045] In step S8, in the same manner as in step S5, the buffer material 4 is placed between the two flexible containers 3 arranged in the immediately preceding step S6, and then gas is filled into the main body 40 using a dedicated gas filling device. After step S8 is completed, step S9 is executed.

[0046] In step S9, it is determined whether the third row 33 and the fourth row 34 are complete. In other words, it is determined whether the FIBCs 3 arranged in the immediately preceding step S6 correspond to the rear FIBCs 3 (FIBCs 33h and 34h) of the third row 33 and the fourth row 34, respectively. If it is determined that the third row 33 and the fourth row 34 are not complete (NO), the process returns to step S3 and the processes up to step S9 are executed again. If it is determined that the third row 33 and the fourth row 34 are complete (YES), step S10 is executed.

[0047] In step S10, the first row 31 and the second row 32 are arranged in the portion located in front of the third row 33 and the fourth row 34. Specifically, two consecutively carried-in flexible containers 3 are arranged adjacent to the flexible containers 3 arranged in the immediately preceding step S3 or the immediately preceding step S10, on the front side thereof.

[0048] In step S11, it is determined based on a predetermined arrangement whether or not a cushioning material 4 should be placed between the two flexible containers 3 placed in the previous step S10. If it is determined in step S11 that a cushioning material 4 should be placed (YES), step S12 is then executed. If it is determined in step S11 that a cushioning material 4 should not be placed (NO), step S10 is executed again.

[0049] In step S12, similar to step S5, cushioning material 4 is placed between the two flexible containers 3 arranged in the previous step S10, and then gas is filled into the main body 40 using a dedicated gas filling device. After step S12 is completed, step S13 is executed.

[0050] In step S13, it is determined whether the first row 31 and the second row 32 are complete. In other words, it is determined whether the FIBCs 3 arranged in the immediately preceding step S10 are the rear FIBCs 3 (FIBCs 31j and 32j) of the first row 31 and the second row 32, respectively. If it is determined that the first row 31 and the second row 32 are not complete (NO), the process returns to step S10 again, and steps up to step S13 are executed. If it is determined that the first row 31 and the second row 32 are complete (YES), the loading container 1 is manufactured by closing the loading / unloading opening of the container 2 with the first door 22a and the second door 22b. Note that if the determination in step S13 is YES, it is determined in the immediately preceding step S11 that cushioning material 4 should be placed, and the placement of the cushioning material 4 and filling with gas are carried out in the subsequent step S12. That is, in step S12, the buffer material 4 is placed between the first row 31 and the second row 32 so as to come into contact with at least the flexible containers 31j and 32j.

[0051] <6. Features> According to the loaded container 1 of the above embodiment, even when gaps remain between rows of flexible containers arranged in the container 2, it is possible to restrict the movement of the flexible containers 3 while suppressing the amount of buffer material 4 used. In particular, when multiple flexible containers 3 are loaded into the container 2, in order to avoid breakage of the flexible containers 3, it is necessary to arrange the flexible containers 3 so that each flexible container 3 is not subjected to strong friction from other flexible containers 3 or the inner wall of the container 2. For this reason, it is thought that the flexible containers 3 are more likely to move during transportation, but the loaded container 1 can achieve the effect of restricting the movement of the flexible containers 3 while avoiding breakage of the flexible containers 3. In particular, in the present embodiment, when the rear FIBC 33h of the third row 33 is positioned further back than the rear FIBC 31j of the first row 31, and the rear FIBC 34h of the fourth row 34 is positioned further back than the rear FIBC 32j of the second row 32, a large gap is created between the rear FIBC 33h of the third row 33 and the rear FIBC 34h of the fourth row 34 and the second wall portion 22 (i.e., an environment in which the FIBCs 33a to 33h and the FIBCs 34a to 33h are likely to move), but by arranging the buffer material 4B as described above, it is possible to achieve the effect of restricting the movement of the FIBCs 33a to 33h and the FIBCs 34a to 34h.

[0052] 7. Modifications Although the embodiments of the present disclosure have been described above, the present disclosure is not limited to the above embodiments, and various modifications are possible without departing from the spirit of the present disclosure. For example, the following modifications are possible. Furthermore, the gist of the following modifications can be combined as appropriate.

[0053] (1) The number of multiple FIBCs 3 is not limited to the number in the above embodiment and can be changed as appropriate. For example, in the loaded container 1, the third row 33 and the fourth row 34 may be omitted. That is, the multiple FIBCs 3 do not have to be stacked vertically. Therefore, the buffer material 4B may also be omitted, and the loaded container 1 may be provided with one buffer material 4A. On the other hand, in the loaded container 1, the multiple FIBCs 3 may be stacked vertically in three or more rows. Furthermore, the multiple FIBCs 3 may be arranged in three or more rows on the bottom wall portion 20. Furthermore, the first row 31 and the second row 32 may be defined in the opposite way to the above embodiment. Similarly, the third row 33 and the fourth row 34 may be defined in the opposite way to the above embodiment.

[0054] (2) The top surface 25 of the container 2 may be omitted. Also, multiple flexible containers 3 may be loaded into the container 2 without using pallets 5.

[0055] (3) When the container 2 has a top surface 25, the loaded container 1 may further include one or more buffer materials 4 arranged between the top surface 25 and the third and fourth rows of FIBCs 3, as shown in Fig. 9. In this case, it is preferable that the one or more buffer materials 4 be arranged between the top surface 25 and the rearmost FIBCs 3 (FIBCs 33h and 34h) of the third and fourth rows.

[0056] (4) As shown in Fig. 10, the cushioning materials 4 including the cushioning material 4B may be arranged not only between the third row 33 and the fourth row 34 but also between the first row 31 and the second row 32. In other words, the loaded container 1 may be provided with one or more cushioning materials 4 arranged between the first row 31 and the second row 32 and between the third row 33 and the fourth row 34 so as to come into contact with at least four FIBCs 3 constituting each of the first row 31 to the fourth row 34. Furthermore, the cushioning material 4 may come into contact with two or more FIBCs 3 that belong to the same FIBC row and are consecutive in the depth direction.

[0057] (5) The cushioning material 4 is not limited to a gas bag, and any known packaging material may be used as appropriate. For example, the cushioning material 4 may be a bag-shaped main body filled with bead-shaped foam cushioning material.

[0058] Examples of the present disclosure will be described in detail below, but the present disclosure is not limited to these examples.

[0059] A container 2X, 32 flexible containers 3X, and three cushioning materials 4X were prepared. The container 2X was a known transport container (25.6 tons) and had the same configuration as the container 2 according to the above embodiment. Each flexible container 3X contained water-absorbent resin particles. The bottom of each flexible container 3X was square, with a side length of 0.9 m. The vertical length of the side of each flexible container 3X was 1.3 m. The cushioning materials 4X were airbags, each with an internal pressure of 0.06 kgf / cm. 2 ~0.10Kgf / cm 2 The length of the circumscribing rectangle of the main body of the buffer material 4X was 1.1 m and the width was 0.8 m.

[0060] A loaded container 1X according to the example was manufactured using a container 2X, a flexible container 3X, and a cushioning material 4X according to the manufacturing method of the above embodiment. Specifically, as shown in FIG. 11 , 20 flexible containers 3X ​​were arranged in parallel to form first and second rows (10 in each row), and 12 flexible containers 3X ​​were arranged in parallel to form third and fourth rows (6 in each row). Each flexible container 3X was placed on a pallet. The height of each pallet was 0.12 m. Furthermore, each flexible container 3X barely expanded when filled with contents. Note that in FIG. 11 , the first wall side of the container 2X is shown on the left, and the second wall side of the container 2X is shown on the right.

[0061] One cushioning material 4X was placed between the rear FIBCs 3X of the first and second rows. This cushioning material 4X was placed so that its upper end coincided with the upper end of the main body of the rear FIBC 3X of the first and second rows. Another cushioning material 4X was placed between the rear FIBCs 3X of the third and fourth rows, between the FIBCs 3X (in the first and second rows) below that FIBC 3X. The remaining cushioning material 4X was placed between the FIBCs 3X one row behind the rear FIBC 3X of the third and fourth rows, between the FIBCs 3X (in the first and second rows) below that FIBC 3X. The two cushioning materials 4X placed between the third and fourth rows were placed so that the height from the bottom wall 20 to their upper ends was 2.1 m each (i.e., the height from the bottom wall 20 to their lower ends was 1 m).

[0062] In the loaded container 1X, the area x1 is calculated based on the length of one side of the bottom surface of the flexible container 3X, the length of the side surface in the vertical direction, and the number of flexible containers 3X ​​that make up the first and second rows, and is calculated as 0.9 x 1.3 x 10 = 11.7 (m 2 The area y1 was calculated as 0.8 × 1.1 + 2 × 0.8 × (1.3 + 0.12 − 1) = 1.552 (m) based on the area of ​​the circumscribed rectangle of one cushioning material 4X, the positions of the two cushioning materials 4X in the vertical direction, and the height of the pallet. 2 ) was calculated. As a result, (y1 / x1) × 100 ≈ 13.26, which confirmed that the range of 5≦(y1 / x1) × 100 ≦ 80 was satisfied.

[0063] Similarly, the area x2 is 0.9 x 1.3 x 6 = 7.02 (m 2 ) and the area y2 was calculated as 2 × 0.8 × (2.1 − 0.12 − 1.3 − 0.12) = 0.896 (m 2 This resulted in (y2 / x2) × 100 ≈ 12.76, and it was confirmed that the relationship between the third and fourth rows and the buffer material also satisfied the range of 5≦(y2 / x2) × 100≦80.

[0064] The loaded container 1X was transported from Japan to an overseas destination. The transportation route was land transport, sea transport, and land transport in that order. During land transport, the loaded container 1X was positioned so that the first wall side of the loaded container 1X faced the direction of travel. The loading / unloading entrance of the loaded container 1X that arrived at the destination was opened, and the movement of each FIBC 3X was confirmed by comparing it with a photograph of the interior of the loaded container 1X at the time of manufacture. As a result, no movement of the FIBC 3X was confirmed. The FIBC 3X was also checked for bag breakage, but no breakage was found. This confirms that the present disclosure makes it possible to restrict the movement of FIBCs while reducing the amount of buffer material used.

[0065] 1, 1X Loading container 2, 2X Container 3, 31a~31j, 32a~32j, 33a~33h, 34a~34h, 3X Flexible container 4, 4A, 4B, 4X Cushioning material 31 1st row 32 2nd row 33 3rd row 34 4th row

Claims

1. A container comprising: a rectangular bottom wall portion having opposing first and second sides and opposing third and fourth sides, a first wall portion rising from the first side, a second wall portion rising from the second side, and a pair of side wall portions rising from the third and fourth sides; a plurality of flexible containers arranged within the container, each of which comprises a main body portion having a bottom portion and a side portion continuous with the bottom portion, and contents contained within the main body portion, forming at least a first row and a second row in which the flexible container closest to the first wall portion is arranged at the front and the flexible container closest to the second wall portion is arranged at the rear; and one or more cushioning materials arranged between the first row and the second row, the one or more cushioning materials being arranged so as to be in contact with at least the rear flexible container of the first row and the rear flexible container of the second row, A loaded container, wherein x1 is the area of ​​the shape of the main body portions of all the flexible containers constituting the first row projected onto an imaginary plane parallel to the pair of side wall portions, and y1 is the total area on the imaginary plane that the one or more cushioning materials overlap with the shape, and 5≦(y1 / x1)×100≦80.

2. The loaded container according to claim 1, wherein the multiple flexible containers further form third and fourth rows arranged side by side with the flexible container closest to the first wall portion at the front and the flexible container closest to the second wall portion at the rear, the third row being formed above the first row and the fourth row being formed above the second row, the loaded container further comprises one or more cushioning materials arranged between the third row and the fourth row, the one or more cushioning materials arranged between the third row and the fourth row being arranged so as to contact at least the rear flexible container of the third row and the rear flexible container of the fourth row, and wherein, where x2 is the area of ​​a shape of the main bodies of all flexible containers constituting the third row projected onto the imaginary plane and y2 is the total area of ​​the one or more cushioning materials arranged between the third row and the fourth row that overlap with said shape on the imaginary plane, then 5≦(y2 / x2)×100≦80.

3. A loaded container as described in claim 2, wherein the rearmost flexible container in the third row is positioned closer to the first wall portion than the rearmost flexible container in the first row, and the rearmost flexible container in the fourth row is positioned closer to the first wall portion than the rearmost flexible container in the second row.

4. A loaded container as described in claim 2, wherein the one or more cushioning materials arranged between the third row and the fourth row include one or more cushioning materials arranged between the first row and the second row and between the third row and the fourth row so as to contact at least four flexible containers constituting each of the first row to the fourth row.

5. A loaded container as described in claim 3, wherein the one or more cushioning materials arranged between the third row and the fourth row include one or more cushioning materials arranged between the first row and the second row and between the third row and the fourth row so as to contact at least four flexible containers constituting each of the first row to the fourth row.

6. A container filled with cargo as described in claim 2, wherein the container further comprises a top surface portion facing the bottom wall portion, and further comprises one or more cushioning materials disposed between the top surface portion and the rearmost flexible containers in the third and fourth rows.

7. A container filled with cargo as described in claim 3, wherein the container further comprises a top surface portion facing the bottom wall portion, and further comprises one or more cushioning materials disposed between the top surface portion and the rearmost flexible containers in the third and fourth rows.

8. A method for manufacturing a container containing a load, comprising: preparing a container having a rectangular bottom wall portion having opposing first and second sides and opposing third and fourth sides, a first wall portion rising from the first side, a second wall portion rising from the second side, and a pair of side wall portions rising from the third and fourth sides; preparing a plurality of flexible containers, each of which has a main body portion having a bottom portion and a side portion continuous with the bottom portion, and contents contained within the main body portion; preparing one or more cushioning materials; arranging the plurality of flexible containers on the bottom wall portion to form at least a first row and a second row in which the flexible container closest to the first wall portion is at the front and the flexible container closest to the second wall portion is at the rear; and arranging the one or more cushioning materials between the first row and the second row, wherein arranging the one or more cushioning materials is a first flexible container having a first width and a second width, the first row including a first side wall portion and a second side wall portion, the first row including a second side wall portion and a third side wall portion, the second row including a first side wall portion and a fourth side wall portion, the first row including a second side wall portion and a fourth side wall portion, the second row including a first side wall portion and a fourth side wall portion, the second row including a first side wall portion and a fourth side wall portion, the third side wall portion and the fourth ...

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