Patent Grant
12037160
The present invention relates to a packaging container, a packaging method, and a method for carrying metal foil.
Various packaging containers for carrying roll materials has been known. For example, Japanese Patent Application Publication No. 2018-30591 A (Patent Literature 1) discloses an example of a card board container made of corrugated cardboard which includes a square pallet and a body frame placed on the pallet, and configured to house a roll material in a cylindrical body by supporting support shafts provided at both ends of the roll material by shaft bearing grooves formed in a body flame.
[Patent Literature 1] Japanese Patent Application Publication No. 2018-30591 A
When carrying the corrugated cardboard container as described in Patent Literature 1, the container is leaded while inserting forklift jaws of a forklift between girders at the bottom of the container. However, if the inserted position of the forklift jaws is improper, the forklift jaws may break through the container, causing damage to the container.
Another possible carrying method is to use a crane or other carrying apparatus to lift up the corrugated cardboard container via a rope or the like and carry the container while suspending it in the midair. However, depending on the shape and weight of the container, it may be deformed or may be inclined when it is carried, resulting in difficulty in stable carrying.
In light of the above problems, the present disclosure provides a packaging container, a packaging method, and a method for carrying metal foil, which can suppress damage and deformation of the packaging container and enable stable carrying even if the packaging container is carried while suspending it in the midair.
To solve the above problems, in an aspect, an embodiment according to the present invention encompasses a pallet including leg portions; a body frame arranged on the pallet and including bearing grooves provided at end wall portions opposing to each other; and a lid portion provided on the body frame, wherein the leg portions are arranged on an inner side than end wall portions of the pallet.
In another aspect, an embodiment according to the present invention encompasses a packaging method, the method including housing an object to be contained in the above packaging container, and binding a top surface of the lid portion of the packaging container containing the object and a bottom surface of the pallet together, using a binding member.
In yet another aspect of the present invention, an embodiment according to the present invention encompasses a method for carrying metal foil, the method including: housing in the above packaging container an object to be contained, the object being formed by winding a material comprised of metallic foil around its shaft center; binding a top surface of the lid portion of the packaging container containing the object and a bottom surface of the pallet together, using a binding member; bringing a lifting member for lifting and carrying into contact with a holding surface provided on a bottom surface between each of end wall portions and each of leg portions of the pallet of the packaging container containing the object; and carrying the packaging container while lifting up the packaging container.
According to the present disclosure, it is possible to provide a packaging container, a packaging method, and a method for carrying metal foil, which can suppress damage and deformation of the packaging container and enable stable carrying even if the packaging container is carried while suspending it in the midair.
Hereinafter, embodiments of the present invention will be described with reference to the drawings. It should be noted that embodiments shown below illustrate devices and methods for embodying the technical idea of the present invention, and the technical idea of the present invention is not intended to limit structures, arrangements, etc. of components to those described below. A plurality of components disclosed in the embodiments of the present invention may form various inventions by appropriate combinations. For example, some components may be removed from all the components shown in the embodiment, or components of different embodiments may be combined as appropriate.
(Packaging Container)
As shown in
An object 10 to be contained in the packaging container 1 is not particularly limited as long as it is a roll material formed by winding various films, sheets, foils, strips or other materials such as metals, plastics, paper and synthetic resins around a shaft center 12. In particular, this embodiment describes the use of a copper foil roll, in which copper foil or copper alloy foil is wound around the shaft center 12, as the object 10 to be contained, although not limited to thereto.
As shown in
As shown in
As shown in
By placing the leg reinforcing portion 21b on the laminate portion 21a, the hardness of the bottom surface can be increased, thereby preventing any defect due to deformation during carrying such as damages and dents caused in the leg portions 21 during carrying. The load weight that can be loaded by the pallet 2 and the strength of the leg portions 21 can be controlled by selecting materials of the liners and the core of the corrugated board that would make up the laminate portion 21a, or by controlling the number of laminated corrugated boards.
As shown in
Further, the method of carrying the packaging container 1 while lifting it up can allow the packaging container 1 containing heavy items to be carried by crane or the like, even in a facility having a construction in which a forklift or the like cannot be accommodated. By thus increasing the options of the carrying method, the restriction on the facility for carrying the object 10 to be contained, which is the content of the packaging container 1, can be mitigated. It can also lead to improved safety at the work site.
Preferably, between the leg portions 21 of the bottom surface 22 of the pallet 2 is a bottom surface reinforcing portion 25 that can reinforce the bottom surface 22 of the pallet 2. This can reinforce the bottom surface 22 of the pallet 2 to suppress deformation of the packaging container 1 and improve its strength. Further, even if the binding force of a binding member 71 such as a band, as described below, is strong enough to dent into the bottom surface reinforcing portion 25 upon binding of the packaging container 1 with the binding member 71, any deformation of the pallet 2 itself can be suppressed. The binding member 71 is bound so that it is brough into contact with the bottom surface reinforcing portion 25 to allow the binding member 71 to dent into the bottom surface reinforcing portion 25, whereby the strength of the binding strength can also be improved.
As described above, when the lifting member such as a rope is brought into contact with the holding surfaces 26 to lift up the packaging container 1, the load is applied near the center of the packaging container 1, and as a result, the packaging container 1 may be deformed. To address this problem, the bottom surface reinforcing portion 25 can be provided to prevent the packaging container 1 from bending near the center when it is lifted up and carried. When the packaging container 1 is carried using a forklift or the like, any damage to the bottom surface 22 of the pallet 2 can be prevented even if the forklift jaws of the forklift are incorrectly operated.
The arrangement location, shape, and thickness of the bottom surface reinforcing portion 25 are not limited, and they may be selected in various ways depending on applications. The bottom reinforcing portion 25 can be further positioned on the holding surface 26 to further suppress the damage to the packaging container 1 during carrying.
The pallet 2 is provided with four folding lines RL each extending upward in a diagonal direction from each of four corners C of the rectangular bottom surface 22 of pallet 2 on each of the side wall portions 24. Each folding line RL is inclined at an inclination of about 45 degrees from a point (corner C) where the three planes of the bottom surface 22, the end wall portion 23 and the side wall portion 24 come into contact with one another, relative to a line L1 where the bottom surface 22 and the side wall portion 24 come into contact with each other. By folding the folding slines RL in a mountain fold manner, the pallets 2 can be stacked and stored while folding the end wall portions 23 and the side wall portions 24, so that storage spaces prior to assembly as the packaging container 1 can be reduced. When using the packaging container 1, it is sufficient to raise the end wall portions 23 and the side wall portions 24 of the pallet 2, so that it is easy to assemble the pallet 2.
As shown in
The body frame main body 30 has a pair of end wall portions 32 opposing to each other and a pair of side wall portions 33 opposing to each other, and the side wall portions 33 are provided between the end wall portions opposing to each other. The body frame main body 30 has first bearing grooves 310 for supporting the shaft support portions 11 of the object 10 in the end wall portions 32.
The body frame main body 30 is formed into a cylindrical body as shown in
The first bearing groove 310 has a housing portion 311 that can house the shaft support portion 11 at the lower end portion, and has a housing portion 313 that can house an upper holding member 55 at the upper end portion. The side surface of the first bearing groove 310 is provided with a locking portion 312 protruding toward an inner central direction of the first bearing groove 310, in order to come into contact with a lower end portion 54 (see
The first bearing groove 310 has a size such that a width W1 in an arc horizontal direction of the lower end portion of the first bearing groove 310 has the same as or equivalent to a diameter of the shaft support portion 11 of the object 10. This allows the lower end portions of the first bearing grooves 310 to house the shaft support portions 11 protruding from both ends of the object 10. A width W2 in a horizontal direction of the upper end portion of the first bearing groove 310 is broader than the width W1 of the lower end portion of the first bearing groove 310. This can allow for easy housing of the shaft support portions 11 of the object 10 while preventing the damage to the end wall portions 32 of the body frame main body 30.
To the first bearing groove 310 of the body frame main body 30, one or more reinforcing pads 38 as shown in
The reinforcing pad 38 has a bearing groove 318 including: housing portions 3138, 3138 and a locking portion 3128 having substantially the same shape as the housing portions 311, 313 and the locking portion 312, respectively. Since the bearing groove 318 and the first bearing groove 310 have substantially the same shape, it is possible to prevent rattling when the shaft support portion 11 is placed. On the other hand, since the body frame main body 30 and the reinforcing pad 38 are made of corrugated cardboard, a certain dimensional allowance may be required, because the first bearing groove 310 and the bearing groove 318 may also be deformed due to the weight of the object 10 loaded on the bearing groove 318 and the first bearing groove 310 via the shaft support portions 11. Therefore, the first bearing groove 310 of the body frame main body 30 and the bearing groove 318 of the reinforcing pad 38 may not have exactly the same shape. The number of the reinforcing pads 38 stacked on the end wall portions 32 may be appropriately adjusted in view of the weight of the object 10 to be contained and the length of the shaft support portion 11 of the object 10.
At least one auxiliary frame 34, 35 is stacked on the body frame main body 30. As shown in
The auxiliary frame 35 may have the same structure as that of the auxiliary frame 34. That is, the auxiliary frame 35 includes: an auxiliary side wall portion 335; and a first auxiliary end wall portion 325a and a second auxiliary end wall portion 325b arranged at both ends of the auxiliary side wall portion 335. The first auxiliary end wall portion 325a includes a second bearing groove 315a having: housing portion 3115, 3135 and a locking portion 3125 which have substantially the same shape as the first bearing groove 310. The second auxiliary end wall portion 325b includes a carrying arm insertion groove 315b in which the width W3 in the arc horizontal direction at the lower end portion is narrower than the width W1 in the arc horizontal direction at the lower end portion of the first bearing groove 310.
The width W3 narrower than the width W1 means that the outside of the shaft support portion 11 comes into contact with the second auxiliary end wall portion 324b, and the second auxiliary end wall portion 324b cover a part of the shaft center 12 of the shaft support portion 11 (see
The width W3 of the carrying arm insertion groove 314b may be narrower than the width W1 to the extent that the axial movement of the object 10 can be restricted. Particularly, in an embodiment where the shaft center 12 of the shaft support portions 11 has a hollow structure, and the carrying arm of the carrying device for the object 10 is inserted into an inner side of the shaft center 12, there is a preferable embodiment as described later. For example, assuming that the width W3 is enough to allow the carrying arm to be inserted, the carrying device can be used when the object 10 that is a roll material wound around the axial center 12 having a hollow is placed in the packaging container 1, whereby the object 10 can be efficiently carried by the machine.
On the first auxiliary end wall portion 324a of the auxiliary frame 34, a reinforcing pad 39a having a carrying arm groove 391 having a width W3 that is substantially the same as that of the second auxiliary end wall portion 324b at the lower end portion may be provided. On the second auxiliary end wall portion 324b of the auxiliary frame 34, a reinforcing pad 39b having a carrying arm groove 392 having a width W3 that is substantially the same as that of the second auxiliary end wall portion 324b at the lower end portion may be provided. As with the auxiliary frame 34, the auxiliary frame 35 can also be provided with reinforcing pads 39a, 39b. This can lead to increased rigidity of the entire packaging container 1, ensuring the strength of the packaging container 1 when it is carried while suspending it. The reinforcing pads 39a, 39b may be omitted as needed.
When assembling the body frame 3, the first auxiliary end wall portion 325a and the second auxiliary end wall portion 324b are stacked on the body frame main body 30 such that the second bearing groove 315a and the carrying arm insertion groove 314b are stacked in this order on one of the first bearing grooves 310 of the body frame main body 30.
As shown on the right side of
As shown on the left side of
By having such a stacked structure, the shaft support portion 11 on the right side of the
The materials making up the body frame main body 30, the auxiliary frames 34, 35 and the reinforcing pads 38, 39a, 39b may be of the same type. However, when members having different strengths are used, it is preferable that the body frame main body 30 is made of a material having higher strength than that of the auxiliary frames 34, 35, more particularly, a material having higher compressive strength, because the first bearing groove 310 supports the shaft support portion 11 of the object 10 on the innermost side.
It is preferable that the auxiliary frames 34, 35 and the reinforcing pads 38, 39a, 39b are made of the same material as that of the body frame main body 30. On the other hand, the use of the material having the higher compressive strength may significantly increase the material cost. Therefore, depending on the strength required for the packaging container 1, one may appropriately select whether or not the materials of the auxiliary frames 34, 35 and the reinforcing pads 38, 39a, 39b are the same as those of the body frame main body 30.
The bearing groove 31 of the body frame 3 that supports the shaft support portions 11 of the object 10 is affected by the weight of the object 10 and external force during carrying, and tends to generate deformation or damage such as crushing. Therefore, it is preferable that the bearing groove 31 of the body frame 3 is arranged in the vertical direction of the leg portion 21.
When the body frame 3 has a three-layer structure of the body frame main body 30 and the auxiliary frames 34, 35, among the first bearing grooves 310 and the second bearing grooves 314a, 315a forming the bearing groove 31, the first bearing grooves 310 of the body frame main body 30 that support the shaft support portions 11 of the object 10 on the innermost side may be affected by the weight of the object 10 and the external force during carrying. Therefore, the packaging container 1 is preferably configured such that at least the leg portions 21 of the pallet 2 are arranged on a vertical line (on the vertical direction) of innermost contact points of the first bearing grooves 310 of the body frame main body 30 with the shaft support portions 11 of the object 10.
Examples of such a configuration includes adjusting the positions of the innermost contact points of the shaft support portions 11 with the first bearing grooves 310 with respect to the leg portions 21 by adjusting the number of the body frame main body 30, the auxiliary frames 34, 35 and the reinforcing pads 38, 39a, 39b. This can allow the weight of the object 10 transmitted from the shaft support portions 11 supported by the bearing groove 31 of the body frame 3 to be supported by the leg portions 21, thereby preventing deformation and breakage of the packaging container 1 due to the weight of the container 1 even during long-term transportation.
Further, the auxiliary frames 34, 35 disposed so as to surround the body frame main body 30 can be arranged directly above the holding surface 26 for hooking and holding the lifting tool on both ends of the packaging container 1, thereby improving a load bearing property and support the weight of the object 10 without difficulty. Therefore, a stable carrying state can be achieved.
During storage, both the tubular body frame main body 30 and the auxiliary frames 34, 35 can be bent and folded, so that the storage area can be saved. At the time of use, the cylindrical body frame main body 30 and the auxiliary frames 34, 35 can be assembled and used, so that the packaging container 1 can be more efficiently stored without requiring a large storage space as in the conventional wooden container.
As shown in
The guide pad 52 on the base pad 51 has a structure in which a plurality of corrugated cardboards are laminated via an adhesive. The laminated height of the guide pad 52 is preferably adjusted so as to match the thickness of the laminated portion laminated on the end wall portion 32 of the body frame main body 30. The arrangement of the upper holding member 5 in the bearing groove 31 of the body frame 3 can restrict the movement of the object 10 in the body frame 3 when it is carried. Further, the arrangement of the spacer pad 6 provided with a groove 61 as shown in
As shown in
At both ends of the top surface reinforcing portion 44 are notch portions 45 that are concave in the central direction. Further, each end wall portion 42 is provided with a protruding portion 46 that protrudes downward from the tip of the end wall portion 42. The notch portions 45 and the protruding portions 46 are formed so as to have substantially the same shape. Since the notch portions 45 and the protruding portions 46 have substantially the same shape, as shown in
Each protruding portion 46 has a blindfold function. Since the body frame 3 has the first bearing grooves 310, the second bearing grooves 314a, 315a and the carrying arm insertion grooves 314b, 315b, the packaging of the body frame as it is will cause the first bearing grooves 310, the second bearing grooves 314a, 315a and the carrying arm insertion grooves 314b, 315b to be exposed to the outside. This will lead to unwanted adhesion of dust to the first bearing grooves 310, the second bearing grooves 314a, 315a, the carrying arm insertion grooves 314b, 315b, or the object 10 therein. By providing the protruding portions 46 on the end wall portions 42 of the lid portion 4, the first bearing grooves 310, the second bearing grooves 314a, 315a and the carrying arm insertion grooves 314b, 315b are covered, so that the dust from the outside can be prevented from entering.
The lid portion 4 is provided with four folding lines RL2 respectively extending in a diagonal direction from the four corner portions P of the top surface 41 on the side wall portions 43. Each folding line RL2 is inclined at an inclination of about 45 degrees from the point (corner P) where the top surface 41, the end wall portion 42, and the side wall portion 43 come into contact with one another, relative to the line where the top surface 41 and the side wall portion 43 come into contact with each other. By folding the folding lines RL2 in a mountain fold manner, the lid portion 4 can be stacked and stored in a state where the end wall portions 42 and the side wall portions 43 are folded, so that the storage space before assembling them as the packaging container 1 can be reduced. When the packaging container 1 is used, it is sufficient to raise the end wall portions 42 and the side wall portions 43, so that the lid portion 4 can be easily assembled.
An example of a packaging method using the packaging container 1 according to the embodiment of the present invention will now be described. First, the pallet 2, the body frame main body 30 forming the body frame 3, the auxiliary frames 34, 35, and the lid portion 4 are assembled so as to have a predetermined three-dimensional shape. The body frame 3 is then arranged on the pallet 2 by arranging the body frame main body 30 on the pallet 2, arranging the auxiliary frames 34, 35 arranged around the body frame main body 30, and assembling the body frame 3. The shaft support portions 11 of the object 10 are supported by a carrying arm or the like of a carrying device and carried in the body frame 3, and the object 10 is housed such that the shaft support portions 11 are supported by the bearing groove 31 of the body frame 3.
Further, the upper holding member 5 is inserted from above the bearing groove 31, and the shaft support portions 11 supported by the bearing groove 31 are fixed from above by the upper holding member 5. The spacer pad 6 is arranged in the gap portion between the end portion of the object 10 and the body frame main body 30 to fill the gap between the end surface of the object 10 and the body frame main body 30. The lid portion 4 is then arranged on the body frame 3, and as shown in
The lifting member for lifting and carrying is then brought into contact with the holding surface 26 provided between each end wall portion 23 and each leg portion 21, the holding surface 26 being located on the bottom surface 22 of the pallet 2 of the packaging container 1 containing the object 10, and the packaging container is lifted up, and a plurality of packaging containers 1 are stacked, and the reinforcing member is placed on the uppermost packaging container 1, and the stacked packaging container is bound by using the band-shaped binding member 71, and the bound packaging container is transported to an area to be transported.
As described above, according to the packaging container, the packaging method, and the method for carrying metal foil according to the embodiment of the invention, the leg portions 21 of the pallet 2 are located on an inner side of the end wall portions 23 of the pallet 2 at certain intervals S, whereby the packaging container 1 can be lifted up and carried while suspending the object 10 in the midair at an appropriate position. That is, it is possible to take any carrying manner other than the carrying manner while lifting up the packaging container 1 with the forklift jaws of the forklift as in the conventional art, which can lead to diversification of carrying means and improve a carrying efficiency.
Further, by forming the end wall portions 32 as a stacked structure with the body frame main body 30 and the auxiliary frames 34, 35, and arranging the leg portions 21 on the vertical line of the innermost contact point of the bearing groove 31 of the body frame 3 (the first bearing groove 310 of the body frame main body 30) that supports the gravity of the object 10 with the shaft support portions 11 of the object 10, the weight of the object 10 transmitted through the bearing groove 31 can be directly supported by the leg portions 21, so that it is possible to suppress deformation and damage such as crushing of the packaging container 1 when it is carried.
Further, by producing the packaging container 1 from corrugated cardboard, the packaging container 1 can be folded and housed during storage, which can save the space and decrease the weight as compared with the conventional wooden container. Therefore, an emission rate of CO2 of the carrying means can be expected to be reduced, and more environmentally friendly packaging containers can be provided.
While the present invention has been described in accordance with the above embodiments, the descriptions and drawings that form a part of this disclosure should not be understood to limit this invention. That is, the present disclosure is not limited to the embodiments as described above, and the components can be modified and embodied without departing from the spirit of the present invention.
Although
| Number | Date | Country | Kind |
|---|---|---|---|
| 2020015490 | Jan 2020 | JP | national |
| Filing Document | Filing Date | Country | Kind |
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| PCT/JP2021/002330 | 1/22/2021 | WO |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2021/153463 | 8/5/2021 | WO | A |
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