U.S. patent application number 09/860449 was filed with the patent office on 2001-09-13 for packing method and package.
This patent application is currently assigned to Seiko Epson Corporation. Invention is credited to Koike, Motomu.
Application Number | 20010020595 09/860449 |
Document ID | / |
Family ID | 26399824 |
Filed Date | 2001-09-13 |
United States Patent
Application |
20010020595 |
Kind Code |
A1 |
Koike, Motomu |
September 13, 2001 |
Packing method and package
Abstract
The invention provides a packing method using pulp mold which
can be easily disposed of and recycled, and which has high
mechanical strength. A packing method, wherein a top pad 1, with a
recess and a protrusion, and a bottom pad, with a recess and a
protrusion, are positioned so as to oppose each other in order to
accommodate a delicate item to be protected therebetween. A
reinforcing pad, with a protrusion which is brought into contact
with the bottom pad, is also used.
Inventors: |
Koike, Motomu; (Suwa-shi,
JP) |
Correspondence
Address: |
OLIFF & BERRIDGE, PLC
P.O. Box 19928
Alexandria
VA
22320
US
|
Assignee: |
Seiko Epson Corporation
|
Family ID: |
26399824 |
Appl. No.: |
09/860449 |
Filed: |
May 21, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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09860449 |
May 21, 2001 |
|
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|
09393968 |
Sep 10, 1999 |
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Current U.S.
Class: |
206/521 ;
206/316.1; 206/320; 206/588; 206/592 |
Current CPC
Class: |
B65D 81/025
20130101 |
Class at
Publication: |
206/521 ;
206/588; 206/592; 206/316.1; 206/320 |
International
Class: |
B65D 081/113; B65D
085/38 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 18, 1998 |
JP |
10-264990 |
Mar 5, 1999 |
JP |
11-58815 |
Claims
What is claimed is:
1. A method of packing an item, comprising: placing the item
between a first pad having a plurality of protrusions and a
plurality of recesses, and a second pad having a plurality of
protrusions and a plurality of recesses; and positioning a third
pad having a protrusion which contacts at least one of the
plurality of recesses of the second pad, opposite to the first pad
with reference to the second pad.
2. The packing method according to claim 1, the protrusion of the
third pad being positioned such that the longitudinal direction
thereof is substantially perpendicular to the longitudinal
direction of the recesses of the second pad.
3. The packing method according to claim 2, the recesses of the
second pad being tapered.
4. The packing method according to claim 2, the protrusion of the
third pad being tapered.
5. The packing method according to claim 1, the depth of the
recesses of the second pad being substantially equal in value to
the height of the protrusion of the third pad.
6. The packing method according to claim 2, the depth of the
recesses of the second pad being substantially equal in value to
the height of the protrusion of the third pad.
7. The packing method according to claim 1, the first, second and
third pads being formed of pulp mold.
8. The packing method according to claim 1, the first, second and
third pads being formed of recycled pulp mold.
9. The packing method according to claim 1, the second pad and the
third pad being formed continuously through a hinge.
10. A package, comprising: a first pad having a plurality of
protrusions and a plurality of recesses; a second pad having a
plurality of protrusions and a plurality of recesses, an item to be
packed being placed between the first and second pads; and a third
pad having a protrusion which contacts at least one of the
plurality of recesses of the second pad, is positioned opposite to
the first pad with reference to the second pad.
11. The package according to claim 10, the protrusion of the third
pad being positioned such that the longitudinal direction thereof
is substantially perpendicular to the longitudinal direction of the
recesses of the second pad.
12. The package according to claim 11, the recesses of the second
pad being tapered.
13. The package according to claim 11, the protrusion of the third
pad being tapered.
14. The package according to claim 10, the depth of the recesses of
the second pad being substantially equal in value to the height of
the protrusion of the second pad.
15. The package according to claim 11, the depth of the recesses of
the second pad being substantially equal in value to the height of
the protrusion of the second pad.
16. The package according to claim 10, the first, second, and third
pads being formed of pulp mold.
17. The package according to claim 10, the first, second, and third
pads being formed of recycled pulp mold.
18. The package according to claim 10, the second pad and the third
pad being formed continuously through a hinge.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention relates to a packing method, and
package within which an item is packed.
[0003] 2. Description of Related Art
[0004] A packing method using two pads is disclosed in, for
example, Japanese Unexamined Utility Model Publication No. 5-7662.
As illustrated in FIG. 2 of this document, the protrusion 6a is
formed so that it can come into contact with a packaging box 10
such as a corrugated cardboard box. In this case, it is true that
packing strength is ensured, but shock tends to be transmitted to
the packed item, which is particularly not desirable when packing
electronic devices such as optical devices or precision
instruments.
SUMMARY OF THE INVENTION
[0005] Accordingly, the present invention provides a packing method
which can overcome the above-described problem present in
conventional packing methods, and which allows the use of materials
which can be recycled.
[0006] There is provided a method of packing an item such that the
item is accommodated between a first pad, with a plurality of
protrusions and a plurality of recesses, and a second pad, with a
plurality of protrusions and a plurality of recesses, wherein a
third pad, with a protrusion which can come into contact with at
least one of the plurality of recesses of the second pad, is
disposed opposite to the first pad with reference to the second
pad.
[0007] When the protrusion of the third pad is disposed so that it
comes into contact with the recess or recesses of the second pad,
at least one of the recesses of the second pad does not come into
direct contact with the packaging box in which the item is
accommodated, and the protrusion of the third pad and the recesses
of the second pad can absorb shock to reduce the amount of shock
exerted on the packed item compared to that exerted on items packed
in conventional packaging boxes.
[0008] The protrusion of the third pad may be disposed such that
the longitudinal direction thereof is substantially perpendicular
to the longitudinal direction of the recesses of the second
pad.
[0009] When the protrusion is positioned substantially
perpendicular to the recesses, instead of in the same direction as
the recesses, the area of the protrusion of the third pad which
receives the load of the recess or recesses of the second pad
becomes narrower, making it possible to ensure deformation of the
pads by the required amount. Making the protrusion of the third pad
long in the longitudinal direction is more effective in ensuring
the required deformation.
[0010] The recesses of the second pad may be tapered, and the
protrusion of the third pad may be tapered. Tapers make it harder
for shock to reach the packed item. The depth of the recesses of
the second pad may be substantially equal in value to the height of
the protrusion of the third pad. When the depth is made
substantially equal in value to the height, it is possible to
ensure deformation of the pads by the required amount, thereby
increasing the shock absorbing capability of the pads. The pads may
be formed of pulp mold or recycled pulp mold. Paper pulp, instead
of the conventionally and generally used petroleum chemicals, may
be used, thereby facilitating recycling. The use of very firm,
recycled pulp, instead of virgin pulp, results in increased pad
strength.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of the pads and the packaging
box (corrugated cardboard box), used to illustrate the present
invention;
[0012] FIG. 2 is a perspective view of the pads and the electronic
device, used to illustrate the present invention;
[0013] FIG. 3 is a sectional view of the pads within which an item
is packed;
[0014] FIG. 4 is a perspective view of the top pad;
[0015] FIG. 5 is a perspective view of the bottom pad;
[0016] FIG. 6 is a perspective view of the reinforcing pad;
[0017] FIG. 7 is a plan view of the bottom pad;
[0018] FIG. 8 is a plan view of the reinforcing pad;
[0019] FIGS. 9(a) and 9(b) are horizontal sectional views of the
protrusions provided at the corners of the top and bottom pads;
[0020] FIG. 10 is a sectional view of pads, whose forms are
different from those of the pads of FIG. 3, within which an item is
packed;
[0021] FIG. 11 illustrates an integral structure of the bottom pad
20 and the reinforcing pad 30;
[0022] FIG. 12 is a sectional view of the integral structure of the
bottom pad and the reinforcing pad; and
[0023] FIG. 13 illustrates another integral structure of the bottom
pad 20 and the reinforcing pad 30.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0024] A description will now be given of the invention applied to
the packing of an electronic device, with reference to the
drawings.
[0025] As shown in FIGS. 1 to 3, an electronic device (projector),
being an item 40 to be packed, is packed by placing a top pad 10
and a bottom pad 20 upon each other so that the protrusions 11 of
the top pad 10 and the protrusions 21 of the bottom pad 20 come
into contact. As shown in FIGS. 2 and 3, the item 40 is
accommodated in the space between the protrusions 11 of the top pad
10 and the protrusions 21 of the bottom pad 20. FIG. 3 is a
horizontal sectional view of the center portion where the top pad
10 and the bottom pad 20 are placed upon each other.
[0026] The portions of the top pad 10 which come into contact with
the top planar surface of the item 40 are called flat portions 14,
while the portions of the bottom pad 20 which come into contact
with the bottom planar surface of the item 40 are called flat
portions 24; and the portions of the top pad 10 which extend from
their respective flat portions 14 and which are spaced from the
item 40 are called recesses 12, while the portions of the bottom
pad 20 which extend from their respective flat portions 24 and
which are spaced from the item 40 are called recesses 22. Skirts 13
and 23, provided at the lower portions of their respective
protrusions 11 and 21, are formed continuously along the outer
periphery of the pads 10 and 20, resulting in increased strength of
the respective pads 10 and 20. Ordinarily, the item 40, which has
been packed using the top and bottom pads 10 and 20, are
accommodated in a packaging box 60, such as a corrugated cardboard
box, along with an additional box 70, and then shipped or stored.
In FIG. 1, reference numerals 8 and 9 denote corrugated cardboard
holding plates.
[0027] When the item 40, accommodated in the packaging box 60, is
dropped with the bottom surface (the bottom pad 20 side) of the
packing item 40 faced downward, and is subjected to external shock,
the weight of the item 40 is transmitted to the bottom pad 20
primarily through the flat portions 24. In this case, the recesses
22 of the bottom pad 20, and the skirt 23 below the protrusions 21
get deformed in order to prevent transmission of shock, produced
when the packaging box 60 is dropped, to the item 40. Accordingly,
they act as shock absorbers. When the pads are formed of pulp mold,
or when the item 40 is relatively heavy, the respective pads may
break. A possible solution to this problem is to strengthen the
pads by forming the protrusions 21 and the recesses 22 without
tapers so that their wall surfaces are perpendicular to their
respective flat portions 24. However, when the protrusions 21 and
the recesses 22 are formed in this manner, the pads tend to resist
getting deformed, causing transmission of shock to the item 40, and
in worst cases breakage of the item 40.
[0028] Therefore, the protrusions 21 and the recesses 22 are formed
with tapers so that they are deformed easily, thereby making it
difficult for shock to reach the item 40. In addition, a
reinforcing pad 30, with protrusions 31 formed at locations which
allow them to come into contact with the recesses 22 of the bottom
pad 20, is placed between the packaging box 60 and the bottom pad
20 so that shock, produced when the packaging box 60 is dropped, is
absorbed by the protrusions 31.
[0029] The number and size of the protrusions 31 of the reinforcing
pad 30 are determined based on the material of the pads 10, 20, and
30, and the weight of the packing item 40. When the recesses 22
have substantially a rectangular shape when viewed in a plane, it
is preferable that the protrusions 31 be positioned at
substantially right angles to the recesses 22, as shown in FIGS. 1
to 3 and 8, rather than being formed into the same shape as the
recesses 22 and being positioned so as to overlap the recesses 22.
In the latter case, the protrusions 31 and the recesses 22 become
more rigid, so that shock tends to be transmitted to the item 40.
In the former case, as shown in FIGS. 3 and 8, the load of each
recess 22 is received by a narrow portion of its associated
protrusion 31, so that compared to the latter case the protrusions
31 and the recesses 22 become less rigid, thereby reducing the
amount of shock. Here, when the depth of each recess 22 (as
measured from its associated flat portion 24) and the height of
each protrusion 31 (as measured from its associated flat portion
24) are made substantially the same in value, they can be deformed
by the greatest amount possible, thereby increasing their
capability to function as shock-absorbers.
[0030] A description will now be given in more detail of the
protrusions, the flat portions, and the recesses of the top and
bottom pads 10 and 20, and the protrusions of the reinforcing pad
30, with reference to FIGS. 4 to 8.
[0031] The top and bottom pads 10 and 20 are rectangular in shape
when viewed in a plane, with protrusions 11 and 21 being formed so
as to be disposed at predetermined intervals along the side edges
of their respective top and bottom pads 10 and 20.
[0032] As shown in FIGS. 5 and 7, flat portions 24 (24a to 24i) are
formed inwardly of the protrusions 21 of the bottom pad 20,
substantially in correspondence with their respective protrusions
21 and so as to be surrounded by the protrusions 21; and as shown
in FIG. 4, flat portions 14 (14c, 14d, 14e, 14f, 14h, and 14i) are
formed inwardly of the protrusions 11 of the top pad 10,
substantially in correspondence with their respective protrusions
11 and so as to be surrounded by the protrusions 11.
[0033] In the bottom pad 20, recesses 22 (22a to 22i) are formed
between their respective flat portions 24 and their respective
protrusions 21, with a shallow recess 22j, being rectangular when
viewed in a plane, being formed at the center of the bottom pad
20.
[0034] The recesses 22 (22a to 22i), which are formed between their
respective flat portions 24 (24a to 24i) and their respective
protrusions 21 so as to protrude downward, form ribs which extend
along the side edges of the pad 20. The ribs make the entire bottom
pad 20 more rigid and thus more resistant to deformation.
[0035] Reference numeral 26 (or reference numerals 26a and 26b)
denote deep recesses, or legs, disposed along the locations where
the recesses 22, or ribs 22, are formed, with the amount by which
they protrude downward being substantially the same in value as the
height of the skirt 23.
[0036] More specifically, the amount by which the respective
recesses 26a, disposed near the corners of the bottom pad 20,
protrude downward is equal in value to the height of the skirt 23,
so that when the bottom pad 20 is placed upon the reinforcing pad
30, the recesses 26a come into contact with the flat portion 34 of
the reinforcing pad 30, and cooperate with the skirt 23 to support
the weight of the item 40.
[0037] The amount by which the pair of recesses 26b, disposed at
substantially the center of the long side of the bottom pad 20, is
slightly less in value than the height of the skirt 23 (or the
amount by which the recesses 26a protrude downward), so that when
the bottom pad 20 is placed upon the reinforcing pad 30, the
recesses 26b are located slightly above the flat portion 34 of the
reinforcing pad 30. Therefore, although, unlike the recesses 26a,
the recesses 26b do not directly support the weight of the item 40,
they cooperate with the skirt 23 and the recesses 26a to absorb the
shock produced when the packaging box 60, in which the item 40 is
accommodated, is dropped with the bottom pad 20 facing
downward.
[0038] Similarly with the bottom pad 20, in the top pad 10 shown in
FIG. 4, protrusions 12 are formed between the protrusions 11 and
the corresponding flat portions 14, and form ribs which make the
entire top pad 10 more rigid. Deep recesses 16 (16a and 16b), or
legs, having a depth substantially equal in value to the height of
the skirt 13, are formed in correspondence with the deep recesses
26 of the bottom pad 20 in the vertical direction.
[0039] A plurality of protrusions 31 (31a to 31e, 31h, and 31i) are
formed on the flat portion 34 of the bottom surface of the
reinforcing pad 30, being rectangular in shape when viewed in a
plane like the top and bottom pads 10 and 20, so as to protrude
from the flat portion 34. The protrusions 31a, 31b, 31c, 31d, 31e,
31h, and 31i are formed in correspondence with the recesses, or
ribs, 22a, 22b, 22c, 22d, 22e, 22h, and 22i of the bottom pad 20,
while the pair of protrusions 31j and 31j at the center of the flat
portion 34 are formed in correspondence with the shallow, center
recess 22j of the bottom pad 20. When the bottom pad 20 is placed
upon the reinforcing pad 30, the recesses 22a, 22b, 22c, 22d, 22e,
22h, 22i, and 22j of the bottom pad 20 are, as indicated by phantom
lines in FIG. 8, positioned so as to be in contact with their
respective protrusions 31 a, 31b, 31c, 31d, 31e, 31h, 31i, and 31j
of the reinforcing pad 30.
[0040] The respective recesses 22 of the bottom pad 20 and the
respective protrusions 31 of the reinforcing pad 30 are brought
into contact with each other such that the longitudinal direction
of the recesses is substantially perpendicular to that of their
respective protrusions. The recesses 22 of the bottom pad 20 and
the protrusions 31 of the reinforcing pad 30 cooperate with the
skirt 23 and the deep recesses 26 of the bottom pad 20 to support
the weight of the item 40 and to act as shock absorbers for
absorbing the shock produced by the item 40 which has been
dropped.
[0041] Reference numeral 36 denotes a rib extending primarily along
the side edges of the reinforcing pad 30, and acts to increase the
rigidity, and thus, to reduce warpage of the entire reinforcing pad
30. Reference numeral 38 denotes an arrow formed between the
protrusion 31a and the protrusion 31b, and is provided on the
reinforcing pad 30 to indicate the positioning of the projecting
lens of a projector 40.
[0042] Reference numeral 21c.sub.1 in FIGS. 5 and 7 denotes curved
accommodating faces for accommodating the projecting lens of a
projector 40. The accommodating faces correspond to the opposing
side faces of the protrusions 21 c provided at substantially the
center of a short side of the bottom pad 20. As shown in FIGS. 1,
2, and 7, the projector 40 is accommodated in the packaging box 60
by, in general, packing it within the top and bottom pads 10 and 20
such that the projecting lens 42 faces the additional box 70. Prior
to accommodating the projector 40, it is necessary to accommodate
the reinforcing pad 30 in the packaging box 60. One cannot tell
which of the short sides is the projecting lens positioning side
(or additional box 70 accommodating side) by just looking at the
reinforcing pad 30. To overcome this problem, the arrow mark 38 is
provided on the reinforcing pad 30 to indicate which of the short
sides is the projecting lens positioning side, making it possible
to prevent the reinforcing pad 30 from being accidentally placed in
the packaging box 60 when its projecting lens positioning side is
not facing the additional box 70.
[0043] As shown in FIG. 9(a), the protrusions 11a, provided at the
corners of one of the short sides of the top pad 10, and the
protrusions 21 a, provided at the corners of one of the short sides
of the bottom pad 20, are formed into a simple, substantially L
shape when viewed in a plane; and as shown in FIG. 9(b) the
protrusions 11b, provided at the corners of the other short side of
the top pad 10, each have vertical grooves 19 at side surfaces
thereof, and the protrusions 21b, provided at the corners of the
other short side of the bottom pad 20, each have vertical grooves
29 at side surfaces thereof, so that the protrusions 11b and 21b
have a complicated, odd shape when viewed in a plane.
[0044] Since the additional box 70 is accommodated adjacent to the
protrusions 1 la of the pad 10 and the protrusions 21a of the pad
20, the impact force, which acts, as indicated by arrows P.sub.1 in
FIG. 7, on the corners where the protrusions 11a and 21a adjacent
to the packaging box 60 are formed, is absorbed by the additional
box 70, thereby reducing the amount of impact force acting on the
protrusions 11a and 21a.
[0045] Accordingly, the protrusions 11a and 21 a are formed into a
simple, substantially L shape, so that they are not very rigid, and
thus can absorb as much small impact forces as possible, thereby
not allowing the impact forces to reach the item 40.
[0046] Unlike the protrusions 11a and 21a, the protrusions 11b of
the pad 10 and the protrusions 21b of the pad 20 are formed close
to corners of the packaging box 60. Therefore, the impact force,
acting on the corners where the protrusions 11b and 21b in the
packaging box 60 are formed, act directly on the protrusions 11b
and 21b, as shown by arrows P.sub.2 of FIG. 7.
[0047] Therefore, the protrusions 11b and 21b are formed into a
complicated, odd shape, with the transverse sectional area
(horizontal sectional area) of the walls where the protrusions 11 b
and 21b are formed being large. Although this makes the protrusions
11b and 21b more rigid, making it easier for small impact forces to
be transmitted thereto, this makes them harder to break, making it
possible to protect the item 40 from large impact forces.
[0048] Marks (not shown) are provided at the inside center portion
of the top and bottom pads 10 and 20 in order to allow anyone to
identify pads. The marks can eliminate the problem of a user
placing the top pad 10 at the bottom and the bottom pad 20 at the
top.
[0049] FIG. 10 illustrates the pads used in another embodiment of
the present invention, and corresponds to FIG. 3 illustrating the
pads used in the first embodiment of the present invention. The
difference between the pads of FIGS. 3 and 10 is that the pads of
FIG. 10 do not have flat portions 14 between their respective
protrusions 11 and their respective recesses 12 and between their
respective protrusions 21 and their respective recesses 22. In both
cases, the longitudinal direction (or horizontal direction along
the plane of FIG. 10) of the protrusions 31 is substantially
perpendicular to the longitudinal direction (vertical direction
along the plane of FIG. 10) of their respective recesses 22.
[0050] FIG. 11 illustrates the bottom pad 20 and the reinforcing
pad 30 formed into an integral structure, in which the reinforcing
pad 30 is formed by cutting out the center portion of the
reinforcing pad 30 shown in FIG. 3, and the resulting portions of
the reinforcing pad 30 are joined to the ends of the bottom pad 20
through hinges 50. When this type of integral structure is used, it
is possible to use fewer parts.
[0051] More specifically, as shown in FIG. 12, the bottom pad and
the reinforcing pad, which are formed continuously through the
hinges 50 at the outer sides of the bottom pad 20, are molded into
an integral structure. When, as indicated by the phantom lines in
FIG. 12, the portions, formed by cutting, of the reinforcing pad 30
are bent inwards at the locations where the hinges 50 are formed,
the integral structure takes the form shown in FIG. 11.
[0052] The hinges 50 may have a thin-walled structure, as shown in
FIG. 12, or a structure containing perforations formed at a
predetermined pitch.
[0053] Like the structure illustrated in FIG. 11, the structure
shown in FIG. 13 is an integral structure of the bottom pad 20 and
the reinforcing pad 30, wherein tongue-shaped areas 38, surrounded
by a slit 39 with a U shape when viewed in a plane, are formed in
the bottom surface wall of the bottom pad 20. When the
tongue-shaped areas 38 are bent, as indicated by phantom lines in
FIG. 13, at their respective hinges 50, a structure is formed,
which can support the recesses 22 of the bottom pad 20 by their
respective protrusions 31 of the reinforcing pad 30 as the
tongue-shaped areas 38, from below the recesses 22.
[0054] Although engineering plastics such as polypropylene (PP) or
polyethylene teraphtalate (PET), may be used as pad material in the
above-described embodiments, it is preferable, from the point of
view of environmental protection, to use pulp mold which can be
easily recycled or disposed of. In order to increase pad strength,
it is preferable to use pulp mold composed of recycled pulp rather
than virgin pulp.
[0055] In the above-described embodiments, a structure in which a
reinforcing pad is placed between the bottom pad and the packaging
box has been given as an example. However, when necessary, a
structure may be used, in which a reinforcing pad is placed between
the top pad and the packaging box such that the recesses of the top
pad and the protrusions of the reinforcing pad similarly come into
contact with each other. This structure is effective when the
packaging box is placed with its top and bottom sides reversed, or
when the top pad is dropped with the top pad facing downward.
* * * * *