CUSHIONING MATERIAL AND PACKAGING BOX

CROSS-REFERENCE TO RELATED APPLICATION

This patent application is based on and claims priority pursuant to 35 U.S.C. § 119 (a) to Japanese Patent Application No. 2023-158132, filed on Sep. 22, 2023, in the Japan Patent Office, the entire disclosure of which is hereby incorporated by reference herein.

BACKGROUND
Technical Field

Embodiments of the present disclosure relate to a cushioning material contained in a packaging box in which a packaging object such as an image forming apparatus is packaged, and a packaging box including the cushioning material.

Background Art

Various typical techniques of holding a packaging object are known that employ a cushioning material in a packaging box in order to buffer an impact that the packaging object in the packaging box receives, for example, during transportation.

A technique of holding a packaging object known in the related art discloses a cushioning material made of a molded pulp, and the cushioning material has a first support (base) and a second support (bending portion) that is bent to the first support so that two faces of the packaging object can be supported.

In the cushioning material used in the above technique, a projection on the second support is fitted into a thin portion on the first support with the second support bent to the first support.

SUMMARY

Embodiments of the present disclosure described herein provide a novel cushioning material including a base and a bending portion. The base includes a first main face and a first cushioning rib protruding orthogonally to the first main face. The bending portion is bent orthogonally to the base, and includes a second main face, a second cushioning rib, and a protrusion. The second cushioning rib protrudes orthogonally to the second main face. The protrusion protrudes orthogonally to the second main face. The base has an opening and a cut portion. The opening has a rim contacting and engaging with the protrusion of the bending portion bent orthogonally to the base. The cut portion in the rim causes the rim to elastically deform in response to an engagement of the protrusion of the bending portion with the opening.

Further, embodiments of the present disclosure described herein provide a packaging box including the above-described cushioning material to be packaged in contact with at least one packaging object.

Further, embodiments of the present disclosure described herein provide a novel cushioning material including a base and a bending portion. The base includes a first main face, and a cushioning rib protruding from the first main face. The bending portion includes a second main face, a first protrusion, and a second protrusion. The second main face is bent against the base in a bending direction. The first protrusion is fitted to the cushioning rib of the base with the second main face bent against the base. The base further includes a restrictor to restrict a movement of the second protrusion in an opposite direction opposite to the bending direction of the second main face.

Further, embodiments of the present disclosure described herein provide a packaging box including the above-described cushioning material to be packaged in contact with at least one packaging object.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Exemplary embodiments of this disclosure will be described in detail based on the following figures, wherein:

FIG. 1 is a diagram illustrating an overall configuration of an image forming apparatus as a packaging object according to an embodiment of the present disclosure;

FIGS. 2A and 2B are diagrams illustrating the image forming apparatus held in a packaging box with cushioning materials;

FIG. 3A is a perspective view of a cushioning material after assembly;

FIG. 3B is a perspective views of the cushioning material before assembly;

FIG. 4 is a cross-sectional view of a part of the cushioning material;

FIG. 5 is a perspective view of the cushioning material before a bending portion is bent to a base;

FIG. 6 is a perspective sectional view of the cushioning material in a state where a projection of the bending portion is fitted to an opening of the base;

FIG. 7 is a perspective sectional view of the cushioning material in a state where a rim of the opening is elastically deformed when the projection of the bending portion is fitted to the opening of the base;

FIGS. 8A and 8B are cross-sectional views of the cushioning material in a state where the projection of the bending portion is fitted to the opening of the base;

FIG. 9 is a perspective view of the area near the opening of the base of the cushioning material;

FIG. 10 is a perspective view of the cushioning material indicating the relation in the width direction between the opening of the base and the projection of the bending portion;

FIG. 11 is a perspective view of the cushioning material schematically indicating the main face and a cushioning rib;

FIG. 12 is a perspective view of the cushioning material schematically indicating the main face and the cushioning rib;

FIG. 13 is a perspective view of a cushioning material as a first comparative example;

FIG. 14 is a cross sectional view of a part of the cushioning material in FIG. 13;

FIG. 15 is a perspective view of a cushioning material of a second comparative example;

FIG. 16 is a cross sectional view of the cushioning material in FIG. 15 in a state where the cushioning material holds a packaging object;

FIG. 17 is a cross sectional view of the cushioning material in FIG. 15 indicating a failure state when the cushioning material is set into a packaging box together with a packaging object;

FIG. 18 is a diagram illustrating a failure of assembly of a cushioning material as a third comparative example;

FIG. 19 is a perspective view of the cushioning material as the third comparative example indicating a state before a bending portion is bent to a base;

FIG. 20 is a perspective sectional view of the cushioning material as Modification 1 indicating a state before a bending portion is bent to a base;

FIG. 21 is a perspective view of the cushioning material as Modification 2 indicating a state before a bending portion is bent to a base; and

FIGS. 22A and 22B are perspective views of a cushioning material as Modification 3 near the opening of the base.

The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted.

DETAILED DESCRIPTION

It will be understood that if an element or layer is referred to as being “on,” “against,” “connected to” or “coupled to” another element or layer, then it can be directly on, against, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, if an element is referred to as being “directly on,” “directly connected to” or “directly coupled to” another element or layer, then there are no intervening elements or layers present. As used herein, the term “connected/coupled” includes both direct connections and connections in which there are one or more intermediate connecting elements. Like numbers refer to like elements throughout. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.

Spatially relative terms, such as “beneath,” “below,” “lower,” “above,” “upper” and the like may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the figures. For example, if the device in the figures is turned over, elements describes as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, term such as “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors herein interpreted accordingly.

The terminology used herein is for describing particular embodiments and examples and is not intended to be limiting of exemplary embodiments of this disclosure. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes” and/or “including,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

Embodiments of the present disclosure are described below in detail with reference to the drawings. In the drawings, the same or corresponding parts are denoted by the same reference numerals, and redundant description thereof are simplified or omitted as appropriate.

Embodiments of the present disclosure are described below in detail with reference to the drawings. Identical reference numerals are assigned to identical or equivalent components and a description of those components may be simplified or omitted.

Initially with reference to FIG. 1, a description is given of the overall configuration and operation of an image forming apparatus 1 according to an embodiment of the present disclosure. FIG. 1 is a diagram illustrating the overall configuration of an image forming apparatus 1 as a packaging object according to the present embodiment. In another embodiment of the present disclosure, the image forming apparatus 1 may be, for example, a printer, a facsimile machine, or a multifunction peripheral (MFP) having at least two of copying, printing, scanning, facsimile, and plotter functions.

The image forming apparatus 1 is distributed in the market, and is conveyed from a manufacturing factory to a transportation destination such as a user or a service center in a state of being packaged in a packaging box 50 (see FIGS. 2A and 2B).

In FIG. 1, the image forming apparatus 1, which is a copier in the present embodiment, includes a document reading device 2, an exposure device 3, an image forming device 4, a transfer device 7 serving as an image forming unit, a document feeding device 10, sheet feeding devices 12 and 13, a downstream conveyance roller pair 16, a registration roller pair 17 as a timing roller pair, a fixing device 20, and an ejection tray 25. The document reading device 2 optically reads image data of an original document D. The exposure device 3 irradiates a photoconductor drum 5, which is included in the image forming device 4, with exposure light L according to the image data read by the document reading device 2. The image forming device 4 forms a toner image on the photoconductor drum 5. The transfer device 7 transfers the toner image from the photoconductor 5 onto a sheet P.

The document feeding device 10 is an automatic document feeder (ADF) that conveys the original document D placed on a tray, to the document reading device 2. Each of the sheet feeding devices 12 and 13 feeds the sheet P accommodated in the corresponding sheet tray. The sheet feeding device 12 is an in-body sheet tray placed inside the housing of the image forming apparatus 1. The sheet feeding device 13 is a bypass sheet feeding device projecting on one side of the housing of the image forming apparatus 1.

The downstream conveyance roller pair 16 is disposed downstream from a sheet feeding assembly 45 in the sheet conveyance direction. The registration roller pair 17 as a timing roller pair conveys the sheet P toward the transfer device 7. The fixing device 20 includes a fixing roller 21 and a pressure roller 22 to fix the toner image borne as an unfixed image on the sheet P. The sheet Pis ejected from the housing of the image forming apparatus 1 onto the ejection tray 25. Moreover, the image forming apparatus 1 further includes a toner container 30 that is detachably (replaceably) attached to the housing of the image forming apparatus 1.

Each of the sheet feeding devices 12 and 13 includes a sheet stacker 42 (elevation plate) that is vertically movable, and a sheet feeding assembly 51 serving as a sheet feeding mechanism included in the sheet feeding device 12.

A description is given of regular image forming operations (printing operations) of the image forming apparatus 1 with reference to FIG. 1.

The original document D is conveyed (fed) by conveyance rollers of the document feeding device 10 from the document loading table in a direction indicated by arrow in FIG. 1, and then passes over the document reading device 2. At this time, the document reading device 2 optically reads image data of the original document D passing over the document reading device 2.

The image data optically read by the document reading device 2 is converted into electrical signals. The electrical signals are transmitted to the exposure device 3 serving as a writer. The exposure device 3 then emits the exposure light L such as laser light according to the electrical signals (i.e., the image data) toward the surface of the photoconductor drum 5 of the image forming device 4.

Meanwhile, while the photoconductor drum 5 rotates in a clockwise direction in FIG. 1, the image forming device 4 performs a predetermined series of image forming processes, such as a charging process, an exposing process, and a developing process, to form a toner image corresponding to the image data on the surface of the photoconductor drum 5.

After the image formation, the toner image formed on the surface of the photoconductor drum 5 is transferred by the transfer device 7, onto the sheet P conveyed by the registration roller pair 17.

Each of the four image forming devices 4 includes, for example, a charger, a developing device, a cleaner, and a charge neutralizer. Fresh toner (new toner) is appropriately supplied from the toner container 30 to the developing device. The toner container 30 has a substantially cylindrical shape. When the toner container 30 runs out of toner, the toner container 30 is replaced with a new toner container 30.

A description is now given of how the sheet Pis conveyed to the transfer device 7 (image forming portion).

One of the sheet feeding devices 12 and 13 included in the image forming apparatus 1 is automatically or manually selected. For example, the sheet feeding device 12 disposed inside the housing of the image forming apparatus 1 is selected. Then, the sheet feeding assembly 45 feeds the uppermost sheet P of the sheets P accommodated in the sheet feeding device 12, toward a sheet conveyance passage K. The sheet P thus fed then passes through the sheet conveyance passage K along which the downstream conveyance roller pair 16 is disposed and reaches the position where the registration roller pair 17 is located. When the sheet P reaches the registration roller pair 17, the registration roller pair 17 is stopped rotating.

As the leading end of the sheet P contacts the nip region formed by the rollers of the registration roller pair 17, skew of the sheet Pis corrected.

Then, the registration roller pair 17 starts rotating again, and the sheet P is then conveyed toward the transfer device 7 (i.e., the image forming portion) in sync with movement of the toner image formed on the surface of the photoconductor drum 5 for forming the toner image on the sheet P at the correct position. The image formed on the surface of the photoconductor drum 5 is transferred onto the sheet P by the transfer device 7. This process is the transfer process.

After the transfer device 7 transfers the toner image from the photoconductor drum 5 onto the sheet P in the transfer process, the sheet P passes the position of the transfer device 7 to be conveyed to the fixing device 20 along the sheet conveyance passage K. In the fixing device 20, the uppermost sheet Pis conveyed between the fixing roller 21 and the pressure roller 22, so that the toner image is fixed to the sheet P by application of heat applied by the fixing roller 21 and pressure applied by the fixing roller 21 and the pressure roller 22. This process is the fixing process. After the sheet P bearing the toner image fixed in the fixing process is conveyed out from the fixing nip between the fixing roller 21 and the pressure roller 22, the sheet Pis ejected from the housing of the image forming apparatus 1 onto the ejection tray 25 as a sheet having an output image.

Thus, a series of the image forming processes (print job) is completed.

A detailed description is now given of an example of the packaging box 50 in which the image forming apparatus 1 is packaged, with reference to FIGS. 2A and 2B.

FIGS. 2A and 2B are diagrams illustrating the image forming apparatus 1 held in the packaging box 50 with cushioning materials.

As described above, with reference to FIG. 1, the image forming apparatus 1 as a packaging object according to the present embodiment is conveyed while being packaged in the packaging box 50.

When the image forming apparatus 1 (as a packaging object) is started to be used at a user's place, the image forming apparatus 1 is taken out from the packaging box 50 together with cushioning materials 60A and 60B described below, and is set as a single apparatus.

As illustrated in FIGS. 2A and 2B, the image forming apparatus 1 as a packaging object is accommodated (packaged) in the packaging box 50 together with the cushioning materials 60A and 60B. In other words, the image forming apparatus 1 is held inside the packaging box 50 via the cushioning materials 60A and 60B.

Specifically, the packaging box 50 is contained in the packaging box 50 so that at least one cushioning material (in the present embodiment, two cushioning materials 60A and 60B) contacts the image forming apparatus 1 (packaging object). The image forming apparatus 1 is held by the two cushioning materials 60A and 60B so that six faces of the image forming apparatus 1, i.e., upper, lower, left, right, front, and rear faces, do not directly contact the packaging box 50. The above-described packaging can buffer the impact that the image forming apparatus 1 (packaging object) packaged in the packaging box 50 receives, for example, during transportation, and can reduce the failure that the image forming apparatus 1 is damaged or broken. Further, even when multiple packaging boxes 50 are stacked in, for example, a warehouse or a transportation, the lower packaging box 50 is less likely to be crushed by the weight of the upper packaging box 50.

In the present embodiment, two cushioning materials 60A and 60B having resemble shapes are used for one packaging object (image forming apparatus 1) packaging box 50. However, the number or shape of cushioning materials is not limited to the above-described packaging box 50.

Referring now to FIGS. 3A to 10, a detailed description is given of a configuration and operation of the cushioning material 60 according to the present embodiment.

As described above with reference to FIGS. 2A and 2B, in the present embodiment, two cushioning materials 60A and 60B are set in the packaging box 50. However, since the cushioning materials 60A and 60B are basically formed based on the same technical idea, the cushioning materials 60A and 60B are also referred to as the “cushioning material 60” in a single form without “A” and “B” below.

FIG. 3A is a perspective view of the cushioning material 60 after assembly.

FIG. 3B is a perspective views of the cushioning material 60 before assembly.

Referring to FIGS. 3A and 3B, the cushioning material 60 according to the present embodiment includes a base 61 and two bending portions 62A and 62B.

FIG. 4 is a cross-sectional view of a part of the cushioning material 60.

Referring to FIG. 4, the base 61 includes a main face 61a and a cushioning rib 61b protruding in a direction substantially orthogonal to the main face 61a. In the present embodiment, the cushioning rib 61b of the base 61 protrudes outward (to the side facing the inner wall face of the packaging box 50) from the main face 61a.

As a result, the cushioning rib 61b of the base 61 is a portion that directly contacts the inner wall face of the packaging box 50. The main face 61a of the base 61 is a portion that is separated from the inner wall face of the packaging box 50 by the length of the cushioning rib 61b.

On the other hand, each of the bending portions 62A and 62B includes a main face 62a and a cushioning rib 62b protruding in a direction substantially orthogonal to the main face 62a so that the bending portions 62A and 62B are bent to the base 61 in a direction substantially orthogonal to the base 61 (see FIG. 3A). In the present embodiment, the cushioning rib 62b of each of the bending portions 62A and 62B is formed to protrude inward (to the side facing the image forming apparatus 1 as a packaging object) from the main face 62a. As a result, the cushioning rib 62b of each of the bending portions 62A and 62B is a portion that directly contacts the image forming apparatus 1. The main face 62a of each of the bending portions 62A and 62B is a portion that directly contacts the inner wall face of the packaging box 50.

In the present embodiment, each of the cushioning ribs 61b and 62b are hollow (see FIG. 12). The bending direction of the bending portions 62A and 62B to the base 61 is a direction in which the base 61 and the bending portions 62A and 62B can face the image forming apparatus 1 (packaging object).

In the present embodiment, the cushioning rib 61b of the base 61 is formed to protrude outward from the main face 61a, and the cushioning rib 62b of each of the bending portions 62A and 62B is formed to protrude inward from the main face 62a. However, the protruding directions of the cushioning ribs 61b and 62b are not limited to the above-described configuration. For example, the cushioning rib 61b may be formed to protrude inward from the main face 61a or both inward and outward from the main face 61a, and the cushioning rib 62b may be formed to protrude outward from the main face 62a or both inward and outward from the main face 62a.

Specifically, the cushioning material 60 according to the present embodiment includes a molded pulp.

As illustrated in FIG. 3B, the cushioning material 60 taken out from the die (mold) in a manufacturing plant has the main face 61a of the base 61 and the main face 62a of each of the bending portions 62A and 62B are arranged on a single plane as a single unit with the base 61 and the bending portions 62A and 62B integrally formed.

Then, the two bending portions 62A and 62B are respectively bent toward the sides where the cushioning ribs 61b and 62b are formed, to the base 61, about a boundary M that divides the base 61 and the bending portions 62A and 62B. By so doing, the assembly of the cushioning material 60 having a substantially U shape is completed, as illustrated in FIG. 3A.

As described above with reference to FIGS. 3A and 3B, in the present embodiment, two bending portions 62A and 62B are included in the cushioning material 60. However, since the bending portions 62A and 62B are basically formed based on the same technical idea, the bending portions 62A and 62B are also referred to as the “bending portion 62” in a single form without “A” and “B” in FIGS. 4 to 10.

Referring to FIGS. 5 to 10, a detailed description is given of the cushioning material 60.

FIG. 5 is a perspective view of the cushioning material 60 before the bending portion 62 is bent to the base 61.

FIG. 6 is a perspective sectional view of the cushioning material 60 in a state where a projection of the bending portion 62 is fitted to an opening of the base 61.

FIG. 7 is a perspective sectional view of the cushioning material 60 in a state where a rim of the opening is elastically deformed when the projection of the bending portion 62 is fitted to the opening of the base 61.

FIGS. 8A and 8B are cross-sectional views of the cushioning material 60 in a state where the projection of the bending portion 62 is fitted to the opening of the base 61.

FIG. 9 is a perspective view of the area near the opening of the base 61 of the cushioning material 60.

FIG. 10 is a perspective view of the cushioning material 60 indicating the relation in the width direction between the opening of the base 61 and the projection of the bending portion 62.

In the cushioning material 60 according to the present embodiment with reference to FIGS. 5 to 10, the bending portion 62 has a projection 62d and the base 61 has an opening 61c and cut portions 61c2.

The projection 62d of the bending portion 62 protrudes in a direction substantially orthogonal to the main face 62a and has a substantially rectangular shape.

The opening 61c of the base 61 is fitted to the projection 62d of the bending portion 62 when the bending portion 62 is bent to the base 61. The opening 61c includes a rim 61cl so that the rim 61cl of the opening 61c contacts the projection 62d to maintain the bending of the bending portion 62 (the state in FIG. 3A). Specifically, the rim 61cl contacts the protrusion 62d to support the protrusion 62d, so that the bending portion 62 remains bent without changing to the original shape.

The cut portions 61c2 of the base 61 are formed in the rim 61cl to facilitate elastic deformation of the rim 61cl when the bending portion 62 is bent to the base 61 so that the protrusion 62d fits to the opening 61c while elastically deforming the rim 61cl of the opening 61c.

The rim 61c1 formed in the opening 61c to contact the protrusion 62d is a bent rim at the position furthest from the main face 61a of the base 61 (the upper portion viewed from the main face 61a as the bottom), out of multiple rims (four rims in the present embodiment) forming the opening 61c having a substantially rectangular shape.

As illustrated in FIG. 9, the cut portions 61c2 are formed at both ends of the rim 61c1 in the width direction that is a direction in which the boundary M extends.

A description is now given of a method of assembling the cushioning material 60. As the bending portion 62 is bent from the state of FIGS. 3B and 5 to the state of FIG. 3A, the protrusion 62d presses and bends (elastically deforms) the rim 61cl (wall) as illustrated with a broken line in FIG. 7, so that the leading end of the protrusion 62d is inserted to the opening 61c. When the protrusion 62d is inserted (fitted) to the opening 61c, the rim 61cl that is bent by the protrusion 62d returns to the original shape. As a result, as illustrated in FIGS. 6 and 8, the rim 61cl is caught by the protrusion 62d with no space. Further, the rim 61cl contacts the projection 62d not in the state where the rim 61cl is bent in a straight line. By so doing, the contact force (catching force) substantially downward is applied to the protrusion 62d by the rim 61cl that stands downward in the vertical direction (or in a substantially obliquely downward direction). As a result, the bending portion 62 hardly returns to the state of FIG. 5, and remains bent.

In particular, since the cushioning material 60 according to the present embodiment includes multiple bending portions 62A and 62B, to a single base 61, multiple cushioning ribs 61b and 62b are disposed to multiple faces of the image forming apparatus 1 (packaging object), with a strong holding force.

As the bending portion 62 is bent from the state of FIGS. 3B and 5 to the state of FIG. 3A to cause the protrusion 62d to elastically deform the rim 61c1, the force of elastic deformation is less than the force for a configuration in which a rim without the cut portions 61c2, due to the cut portions 61c2 of the rim 61c1. Due to such a configuration, the workability of the worker who assembles the cushioning material 60 is enhanced.

Then, in the above-described procedure, the rim 61c1 that is elastically deformed returns to the original shape by the resilience and engages with the protrusion 62d. By so doing, a movement of the protrusion 62d is reduced or prevented to maintain the bending of the bending portion 62.

As a result, in the cushioning material 60 with the bending portion 62 remaining bent, the cushioning ribs 61b and 62b vertically standing on the main face 61a of the base 61 and the main face 62a of the bending portion 62, respectively, are brought to contact multiple faces of the image forming apparatus 1 (packaging object) with the multiple faces substantially orthogonal to each other. Due to such a configuration, a loss in height of the cushioning rib due to a draft angle θ from a die (mold) of the cushioning material 60 can be eliminated.

The draft angle θ from a die (mold) of the cushioning material 60 will be described below with reference to FIGS. 11 to 14.

FIG. 11 is a perspective view of the cushioning material 60 schematically indicating the main face and the cushioning rib.

FIG. 12 is a perspective view of the cushioning material 60 schematically indicating the main face and the cushioning rib.

FIG. 13 is a perspective view of a cushioning material 160 as a first comparative example.

FIG. 14 is a cross sectional view of a part of the cushioning material 160 in FIG. 13. Accordingly, the present disclosure can provide the cushioning material 60 having a high impact-cushioning performance against an impact applied to each face of the image forming apparatus 1 (packaging object).

As described above, the cushioning material 60 according to the present embodiment has good assemblability when the bending portion 62 is bent to the base 61 to complete the assembly of the cushioning material 60, and the bending of the bending portion 62 can be easily maintained after completion of the assembly.

Referring to FIG. 5, the cushioning rib 61b of the base 61 has a recess 61b1 in an opposing face (a side face of the cushioning rib 61b) facing the bending portion 62 that is bent to the base 61.

The opening 61c is formed in the opposing face of the base 61 in an area other than the area in which the recess 61b1 is formed.

On the other hand, the cushioning rib 62b of the bending portion 62 has a projection 62c that fits to the recess 61b1, on the opposing face facing the base 61 with the cushioning rib 62b being bent.

The protrusion 62d is formed in a portion where a projection 62c is not formed on the opposing face of the bending portion 62 described above.

In other words, as the bending portion 62 is bent about the boundary M, the projection 62c of the bending portion 62 fits to a recess 61b1 of the base 61 and, at the same time, the protrusion 62d of the bending portion 62 fits to the opening 61c of the base 61.

The cushioning material 60 configured as described above can maintain the bending of the bending portion 62 to the base 61 more easily (the state illustrated in FIG. 3A). In particular, the cushioning material 60 according to the present embodiment has multiple recesses 61b1 in the base 61 and multiple projections 62c on the bending portion 62 corresponding to the multiple recesses 61b1 in the base 61. Due to such a configuration, the above-described effect is more easily achieved.

The inventor of the present disclosure has found through simulation that the cushioning material 60 according to the present embodiment has a holding force ten times or more as large as the holding force where the bending of the bending portion 62 is maintained by the bending force alone due to the bending posture without the fitting between the recesses 61b1 and the multiple projections 62c or the fitting between the opening 61c and the protrusion 62d.

Referring to FIG. 4, the cushioning material 60 according to the present embodiment has a depression M1 inward to a valley fold side of the boundary M that divides the base 61 and the bending portion 62.

Specifically, the depression M1 has a length of 3 to 8 mm in a direction orthogonal to the direction in which the boundary M extends (the left-and-right direction in FIG. 4) and a depth of substantially half or quarter of the thickness of each of the main faces 61a and 62a.

Due to such a configuration, the operability in bending of the bending portion 62 to the base 61 is enhanced.

Referring to FIGS. 8A and 8B, the cushioning material 60 according to the present embodiment is formed such that the length of the protrusion 62d in the protruding direction (the horizontal direction in FIGS. 8A and 8B) is greater than the thicknesses (wall thicknesses) of the rim 61c1.

Due to such a configuration, when the bending portion 62 is bent to the base 61 as described above, the protrusion 62d is reliably caught by the rim 61cl of the opening 61c, so that the bending of the bending portion 62 can be easily maintained.

Referring to FIG. 5, in the present embodiment, the protrusion 62d and the opening 61c are formed near the boundary M that divides the base 61 and the bending portion 62.

Due to such a configuration, the protrusion 62d and the opening 61c are smoothly fitted to each other without being displaced from each other, as compared with a configuration or structure in which the protrusion 62d and the opening 61c are formed at positions away from the boundary M as in the cushioning material 60 illustrated in FIG. 19 as a comparative example.

Referring to FIG. 10, in the present embodiment, the protrusion 62d has a length N2 in the width direction and the opening 61c has a length N1 in the width direction.

The length N2 of the protrusion 62d is shorter than the length N1 of the opening 61c (N2<N1).

The reason for this configuration is that, as described above, the opening 61c has four rims and the rim 61cl on the upper part of the four rims of the opening 61c can greatly contribute to the holding (supporting) of the protrusion 62d. Accordingly, a clearance is provided between the other rims of the four rims of the opening 61c and the protrusion 62d, so as to give the priority to easy insertion of the protrusion 62d into the opening 61c.

A description is now given of the effect with the cushioning material 60 according to an embodiment of the present disclosure, with reference to FIGS. 11 to 18.

FIG. 15 is a perspective view of a cushioning material of a second comparative example.

FIG. 16 is a cross sectional view of the cushioning material in FIG. 15 in a state where the cushioning material holds a packaging object.

FIG. 17 is a cross sectional view of the cushioning material in FIG. 15 indicating a failure state when the cushioning material is set into a packaging box together with a packaging object.

FIG. 18 is a diagram illustrating a failure of assembly of a cushioning material as a third comparative example.

The structure or shape of the cushioning material 60 that is used as a packaging material is determined based on the shape or strength of the packaging object (object to be packaged) to be packaged, and the packaging object to be packaged wears such cushioning materials and is packaged in the packaging box 50 (exterior box).

The main function of the cushioning material 60 is to buffer the impact applied to the packaging object when the packaging object receives the impact in the packaging box 50. The cushioning material 60 can adjust the impact acceleration applied to the packaging object when the shock is applied by adjusting the rib height H (see FIG. 11) of the cushioning rib 61b and the contact face with the packaging object, with respect to the cushioning rib 61b (shock buffering rib) included in the cushioning material 60.

The cushioning material 60 made of a molded pulp is manufactured by a molding method based on the principle of paper making. For this reason, the draft angle θ (see FIG. 12) on the side of the cushioning material 60 is increased in order to facilitate the removal of the cushioning material 60 from the mold. Specifically, while a cushioning material of the foamed resin system has the draft angle θ of 1 to 1.5 degrees, the cushioning material 60 made of a molded pulp has the draft angle θ of 5 to 8 degrees.

Due to the influence of the size of the draft angle θ, when a cushioning material 160 (see FIG. 13) in which cushioning ribs 160b are arranged in multiple directions with respect to the packaging object 1 is formed, the rib heights A and B (see FIG. 14) are largely lost in some of the cushioning ribs 160b, and the function of buffering the impact is lost.

In order to eliminate such an inconvenience, as in the cushioning material illustrated in FIGS. 15 to 17, a cushioning material in which a face (bending portion 62) including the cushioning ribs 62b is bent to the base 61 may be used. The cushioning material having the bending portion 62 formed as described above changes the arrangement direction of the cushioning ribs 62b by bending the bending portion 62, and enhances the inconvenience of the rib heights lost by the draft angle θ, so that the cushioning material can obtain sufficient buffer rib heights to the packaging object.

However, in the cushioning material having the bending portion 62 formed as described above, the bending of the bending portion 62 cannot be maintained due to elasticity of the cushioning material, and the bending portion 62 attempts to return to the original position. Due to the attempts of the bending portion, in the operation of setting the cushioning material together with the packaging object 1 in the packaging box 50, the bending portion of the cushioning material is likely to be caught by the packaging box (see FIG. 17).

As a result, the cushioning material 60 that can maintain the bending of the bending portion 62 is strongly demanded by the workers. In response to such a demand, as illustrated in FIG. 18, a countermeasure of providing a cushioning material that fits a projection 162c on the bending portion 62 to a recess 161b1 in the base with the bending portion 62 being bent. However, in a case where the countermeasure is used and the fitting between the recess 161b1 and the projection 162c is loose by focusing on the assemblability when the bending portion is bent to the base to complete the assembly of the cushioning material, the bending of the bending portion is difficult to be maintained by the resilience of the bending portion after completion of the assembly.

In contrast, in a case where the fitting between the recess 161b1 and the projection 162c is tight to easily maintain the bending of the bending portion, there is an inconvenience that deteriorates the assemblability at the time of completing the assembly of the cushioning material by bending the bending portion to the base.

In particular, the cushioning material 60 according to the present embodiment is manufactured by pulp molding with low dimensional accuracy, and the dimensions of the cushioning material 60 tend to fluctuate to the loose side or the tight side. Due to such a configuration, the above-described inconvenience becomes significant.

Further, a supplemental description is further given of the above-described various relation with the techniques known in the art.

The known cushioning material including a base and a bending portion could not maintain the bending of the bending portion by the resilience of the bending portion during the assembly of the cushioning material (in the operation of the bending of the bending portion). To eliminate such an inconvenience, a countermeasure in which the base and the bending portion are press-fitted by using the recess in the base and the projection on the bending portion can be employed. However, when such a countermeasure is employed, the accuracy of dimension of each of the recess and the projection cannot be increased by the molded pulp. For this reason, the press-fitting accuracy of the base and the bending portion is also reduced.

In the cushioning material including a paper material and having an elastic property, the bending portion attempts to return to the original position before the bending. As a result, when the cushioning material is attached to the packaging object inside the packaging box, the bending portion of the cushioning material is easily caught by the packaging box. To eliminate such an inconvenience, the bending of the bending portion is to be maintained, and a countermeasure is considered in which the bending portion and the base have the projection and the recess having respective shapes to fit to each other and the dimension of the projection is slightly greater than the dimension of the recess, so that the projection is press-fitted to the recess when the bending portion is bent.

However, even when such a countermeasure is employed, the following two inconveniences have occurred.

The first one of the inconveniences is that, since the cushioning material is made of a hard paper material, if the difference in dimension between the projection and the recess is greater than an ideal value, the press-fitting operation is hard and difficult. Specifically, even if a difference in dimension is only 0.5 mm, it is difficult to press-fit the projection and the recess.

The second one of the inconveniences is that, since the cushioning material including a molded pulp is molded by the principle of paper making, the accuracy in dimension of the projection and the recess is low, and dimensional errors of about 0.5 mm can sufficiently occur.

For these reasons, an inconvenience has been occurred that, due to the dimensional variation in mass production of cushioning materials, the setting property is poor (hard) in the operation step of press-fitting and setting the cushioning materials, and the operation cannot be performed.

To eliminate the above-described various inconveniences, the cushioning material 60 according to the present embodiment has the opening 61c to maintain the bending of the bending portion 62 by fitting the protrusion 62d of the bending portion 62 to the base 61 when the bending portion 62 is bent to bring the rim 61cl to contact the protrusion 62d. Further, the base 61 has the cut portions 61c2 in the rim 61c1 to facilitate the elastic deformation of the rim 61cl as the bending portion 62 is bent to cause the projection 62d to fit to the opening 61c while elastically deforming the rim 61cl of the opening 61c. Accordingly, the cushioning material 60 has good assemblability when the bending portion 62 is bent to the base 61 to complete the assembly of the cushioning material 60, and the bending of the bending portion 62 can be easily maintained after completion of the assembly.

Modification 1

FIG. 20 is a perspective view of the cushioning material 60 as Modification 1 before the bending portion 62 is bent to the base 61.

As illustrated in FIG. 20, the cushioning material 60 according to Modification 1 includes the bending portion 62 in which the leading end of the projection 62d in the protruding direction (the portion surrounded by the broken line) is formed in an R shape (or a tapered shape).

Due to such a configuration, in the operation of bending the bending portion 62 about the boundary M, the projection 62d is smoothly inserted into the opening 61c without being caught, and thus the operability is enhanced.

Modification 2

FIG. 21 is a perspective view of the cushioning material 60 as Modification 2 indicating a state before the bending portion 62 is bent to the base 61.

As illustrated in FIG. 21, the cushioning material 60 according to Modification 2 has multiple projections 62d spaced in the width direction on the bending portion 62 and multiple openings 61c in the base 61 at positions corresponding to the multiple projections 62d. Due to such a configuration, the fitting force of the multiple projections 62d to the openings 61c increases, and the bending of the bending portion 62 is further easily maintained.

Modification 3

FIGS. 22A and 22B are perspective views of the cushioning material 60 according to Modification 3 near the opening 61c of the base 31.

As illustrated in FIG. 22A, in the cushioning material 60 according to Modification 3, the cut portion 61c2 is formed in the central portion in the width direction of the rim 61cl of the opening 61c.

Further, in the cushioning material 60 as illustrated in FIG. 22B, the cut portion 61c2 is formed in multiple portions spaced from each other in the width direction of the rim 61cl of the opening 61c.

Even in the above-described configurations, as in the configuration described above with reference to FIG. 9, as the bending portion 62 is bent so that the projection 62d elastically deform the rim 61c1, the projection 62d applies a relatively small force to the rim for the elastic deformation. Due to such a configuration, the workability of the worker who assembles the cushioning material 60 is enhanced.

As described above, the cushioning material 60 according to the present embodiment includes the base 61 in which the cushioning rib 61b is formed to protrude in the direction substantially orthogonal to the main face 61a.

The cushioning material 60 according to the present disclosure further includes the bending portion 62 in which the cushioning rib 62b is formed to protrude in the direction substantially orthogonal to the main face 62a so that the bending portion 62 is bent so as to be substantially orthogonal to the base 61. The bending portion 62 includes the projection 62d that protrudes in the direction substantially orthogonal to the main face 62a. The base 61 has the opening 61c to which the projection 62d fits when the bending portion 62 is bent to the base 61 to cause the rim 61cl to contact the projection 62d, so that the bending portion 62 remains bent. Further, the base 61 has the cut portions 61c2 in the rim 61cl to facilitate the elastic deformation of the rim 61cl as the bending portion 62 is bent to the base 61 to cause the projection 62d to fit to the opening 61c while elastically deforming the rim 61cl of the opening 61c.

As a result, the cushioning material 60 has good assemblability when the bending portion 62 is bent to the base 61 to complete the assembly of the cushioning material 60, and the bending of the bending portion 62 can be easily maintained after completion of the assembly.

In the embodiments and modifications described above, the present disclosure is applied to the cushioning material 60 packed packaging box 50 together with the image forming apparatus 1 as a packaging object. However, a cushioning material to which the present disclosure is applied is not limited to the above-described cushioning material, and the present disclosure can be applied to the cushioning materials packed in a packaging box together with various packaging objects other than the image forming apparatus 1, for example.

Even in such a configuration, the same effect as the configuration according to the present embodiment can be achieved.

Numerous additional modifications and variations are possible in light of the above teachings. It is therefore to be understood that, within the scope of the above teachings, the present disclosure may be practiced otherwise than as specifically described herein. With some embodiments having thus been described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the scope of the present disclosure and appended claims, and all such modifications are intended to be included within the scope of the present disclosure and appended claims. For example, the number, position, shape, and so on of the above-described components are not limited to the number, position, shape, and so on of the above-described embodiment unless in particular specified but may be, for example, any suitable number, position, and shape.

Aspects of the present disclosure are, for example, as follows.

Aspect 1

In Aspect 1, a cushioning material includes a base and a bending portion. The base includes a first cushioning rib and a first main face. The first cushioning rib protrudes in a first direction substantially orthogonal to the first main face. The bending portion includes a second cushioning rib, a second main face, and a protrusion. The second cushioning rib protrudes in a second direction substantially orthogonal to the second main face. The bending portion is bent in a third direction substantially orthogonal to the base. The protrusion protrudes in the second direction substantially orthogonal to the second main face. The base further includes an opening having a rim, and a cut portion. The opening engages with the protrusion in response to a bending of the bending portion to the base, and causes the rim to contact the protrusion to maintain the bending of the bending portion. The cut portion is formed in the rim to facilitate elastic deformation of the rim when the bending portion is bent to the base to fit the protrusion to the opening while the protrusion elastically deforms the rim of the opening.

Aspect 2

In Aspect 2, in the cushioning material according to Aspect 1, the first cushioning rib of the base has a recess in an area on an opposing face facing the bending portion that is bent. The opening of the base is in the opposing face of the base, in another area other than the area where the recess is formed. The second cushioning rib of the bending portion has a projection that fits to the recess, on the opposing face facing the base with the cushioning rib 62b being bent. The protrusion is on the opposing face of the bending portion, in yet another area other than the area where the projection is formed.

Aspect 3

In Aspect 3, the cushioning material according to Aspect 1 or 2 further includes multiple rims including the rim. The rim formed in the opening to contact the protrusion is bent at a position furthest from the main face of the base, out of the multiple rims.

Aspect 4

In Aspect 4, the cushioning material according to any one of Aspects 1 to 3 further includes a boundary that divides the base and the bending portion. The boundary has a depression inward to a valley fold side of the boundary.

Aspect 5

In Aspect 5, the cushioning material according to any one of Aspects 1 to 4 further comprising a boundary that divides the base and the bending portion. The protrusion and the opening are formed near the boundary.

Aspect 6

In Aspect 6, in the cushioning material according to any one of Aspects 1 to 5, the protrusion has a length in a protruding direction, and the length of the protrusion is greater than a thickness of the rim.

Aspect 7

In Aspect 7, in the cushioning material according to any one of Aspects 1 to 6, the protrusion has a length in a width direction and the opening has a length in the width direction, and the length of the protrusion is shorter than the length of the opening.

Aspect 8

In Aspect 8, in the cushioning material according to any one of Aspects 1 to 7, the protrusion has a leading end extending in a protruding direction, and the leading end is an R-shaped portion or a tapered portion.

Aspect 9

In Aspect 9, in the cushioning material according to any one of Aspects 1 to 8, the cut portion is included, in the rim, in one of a center portion in a width direction, both end portions in the width direction, and multiple portions spaced from each other in the width direction.

Aspect 10

In Aspect 10, in the cushioning material according to any one of Aspects 1 to 9, the base has multiple bending portions.

Aspect 11

In Aspect 11, in the cushioning material according to any one of Aspects 1 to 10, the cushioning material includes a molded pulp.

Aspect 12

In Aspect 12, in the cushioning material according to any one of Aspects 1 to 11, the rim contacts the protrusion in a straight line in response to completion of assembling the cushioning material.

Aspect 13

In Aspect 13, a packaging box includes the cushioning material according to any one of Aspects 1 to 11 to be packaged in contact with at least one packaging object.

Aspect 14 (claim 1)

In Aspect 14, a cushioning material includes a base and a bending portion. The base includes a first main face, and a first cushioning rib protruding orthogonally to the first main face. The bending portion is bent orthogonally to the base, and includes a second main face, a second cushioning rib protruding orthogonally to the second main face, and a protrusion protruding orthogonally to the second main face. The base has an opening and a cut portion. The opening has a rim contacting and engaging with the protrusion of the bending portion bent orthogonally to the base. The cut portion in the rim causes the rim to elastically deform in response to an engagement of the protrusion of the bending portion with the opening.

Aspect 15

In Aspect 15, in the cushioning material according to Aspect 14, the first cushioning rib of the base has a recess in a first area, the recess facing the bending portion bent orthogonally to the base. The opening is in a second area different from the first area to face the protrusion of the bending portion bent orthogonally to the base. The second cushioning rib of the bending portion has a projection, fittable to the recess with the bending portion bent orthogonally to the base, in a third area of the bending portion. The protrusion is in a fourth area different from the third area of the bending portion.

Aspect 16

In Aspect 16, the cushioning material according to Aspect 14 or 15 further includes multiple rims including the rim. The rim is at a position furthest from the main face of the base among the multiple rims.

Aspect 17

In Aspect 17, the cushioning material according to any one of Aspects 14 to 16 further includes a boundary that divides the base and the bending portion. The boundary has a depression inward to a valley fold side of the boundary.

Aspect 18

In Aspect 18, the cushioning material according to any one of Aspects 14 to 17 further includes a boundary that divides the base and the bending portion. The protrusion and the opening are formed adjacent to the boundary.

Aspect 19 In Aspect 19, in the cushioning material according to any one of Aspects 14 to 18, the protrusion has a length in a protruding direction, and the length of the protrusion is greater than a thickness of the rim.

Aspect 20

In Aspect 20, in the cushioning material according to any one of Aspects 14 to 19, the protrusion has a length in a width direction and the opening has a length in the width direction, and the length of the protrusion is shorter than the length of the opening.

Aspect 21

In Aspect 21, in the cushioning material according to any one of Aspects 14 to 20, the protrusion has a leading end extending in a protruding direction, and the leading end is an R-shaped portion or a tapered portion.

Aspect 22

In Aspect 22, in the cushioning material according to any one of Aspects 14 to 21, the cut portion is included, in the rim, in one of a center portion in a width direction, both end portions in the width direction, and multiple portions spaced from each other in the width direction.

Aspect 23

In Aspect 23, in the cushioning material according to any one of Aspects 14 to 22, the base has multiple bending portions.

Aspect 24

In Aspect 24, in the cushioning material according to any one of Aspects 14 to 23, the cushioning material includes a molded pulp.

Aspect 25

In Aspect 25, in the cushioning material according to any one of Aspects 14 to 24, the rim contacts the protrusion in a straight line in response to completion of assembling the cushioning material.

Aspect 26

In Aspect 26, a packaging box includes the cushioning material according to any one of Aspects 14 to 24 to be packaged in contact with at least one packaging object.

Aspect 27

In Aspect 27, a cushioning material includes a base and a bending portion. The base includes a first main face, and a cushioning rib protruding from the first main face. The bending portion includes a second main face, a first protrusion, and a second protrusion. The second main face is bent against the base in a bending direction. The first protrusion is fitted to the cushioning rib of the base with the second main face bent against the base. The base further includes a restrictor to restrict a movement of the second protrusion in an opposite direction opposite to the bending direction of the second main face.

Aspect 28

In Aspect 28, in the cushioning material according to Aspect 27, the second protrusion includes a first face facing a side face of the restrictor, and a second face protruding to the first face to contact a leading end of the restrictor.

Aspect 29

In Aspect 29, the cushioning material according to Aspect 27 further includes multiple first protrusions including the first protrusion. The second protrusion is disposed between adjacent two of the multiple first protrusions.

Aspect 30

In Aspect 30, a packaging box includes the cushioning material according to Aspect 27 to be packaged in contact with at least one packaging object.

The present disclosure is not limited to specific embodiments described above, and numerous additional modifications and variations are possible in light of the teachings within the technical scope of the appended claims. It is therefore to be understood that, the disclosure of this patent specification may be practiced otherwise by those skilled in the art than as specifically described herein, and such, modifications, alternatives are within the technical scope of the appended claims. Such embodiments and variations thereof are included in the scope and gist of the embodiments of the present disclosure and are included in the embodiments described in claims and the equivalent scope thereof.

The effects described in the embodiments of this disclosure are listed as the examples of preferable effects derived from this disclosure, and therefore are not intended to limit to the embodiments of this disclosure.

The embodiments described above are presented as an example to implement this disclosure. The embodiments described above are not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, or changes can be made without departing from the gist of the invention. These embodiments and their variations are included in the scope and gist of this disclosure and are included in the scope of the invention recited in the claims and its equivalent.

Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above.

Each of the functions of the described embodiments may be implemented by one or more processing circuits or circuitry. Processing circuitry includes a programmed processor, as a processor includes circuitry. A processing circuit also includes devices such as an application specific integrated circuit (ASIC), digital signal processor (DSP), field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions.

CUSHIONING MATERIAL AND PACKAGING BOX

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Priority Claims (1)