TRAY FOR BRITTLE COLUMNAR BODY
There is disclosed means for satisfactorily storing or transporting a columnar product formed of a brittle material which is easily damaged. The means is a plate-like tray 1 including two pockets. In this tray 1, a bottom surface forming the pockets 4 has bottom surface raised portions, and side surfaces forming the pockets 4 have side surface raised portions. When a brittle columnar body is held or transported using this tray 1, damage can be prevented.
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1. Field of the Invention
The present invention relates to a tray capable of satisfactorily transporting or storing a brittle columnar body without damaging the body.
2. Description of the Related Art
As a catalyst or a filter for a car which purifies an exhaust gas from the car, a honeycomb structure having a columnar shape including a circular or elliptic section which is vertical in an axial direction is used. To ship such a honeycomb structure as a product, the structure is subjected to operations such as packing, transporting and storing. However, the honeycomb structure is mainly made of a ceramic which is a brittle material. Therefore, this involves a problem that the structure is easily damaged under impact due to vibrations generated during the operations.
A similar problem applies to general ceramic products. Furthermore, the problem applies to all columnar products such as a narrow-sense glass product and a plastic product, excluding the ceramic product, which are formed of the brittle material. It is to be noted that examples of a prior document concerning prevention of the damage on the ceramic product include Japanese Patent Application Laid-Open No. 9-226837.
SUMMARY OF THE INVENTIONThe present invention has been developed in view of the above-mentioned situations, and an object thereof is to provide means for satisfactorily storing or transporting a columnar product formed of a brittle material which is easily damaged without damaging the product. As a result of repeated investigations, it has been found that, when the product is packaged using the following tray, the above object can be achieved.
That is, first, according to the present invention, there is provided a tray for a brittle columnar body (hereinafter referred to simply as the tray) which is used to transport or hold the brittle columnar body, the tray having a plate-like shape and at least one pocket for holding the brittle columnar body at the end side of the columnar body and having raised portions respectively on a bottom surface and side surfaces of the tray defining a part of a pocket except a corner portion of the pocket where the bottom surface and the side surface of the tray come in contact, relations of DS>TB and DB>TS being satisfied, in which TB is a height of the raised portion disposed on the bottom surface of the tray, DS is a distance between the side surface facing to the corner of the tray of the raised portion disposed on the bottom surface of the tray and the bottom surface of the tray, TS is a height of the raised portion disposed on the side surface of the tray, and DB is a distance between the side surface facing to the corner of the tray of the raised portion disposed on the bottom surface of the tray and the side surface of the tray.
In the present specification, the tray is expressed as the plate-like tray including the pocket. The tray is used to transport or hold an object, and can also be expressed as a server, a shallow box or a plate including a peripheral wall. The brittle columnar body is a formed brittle body which is easily damaged and which has a columnar shape. The pocket is not only a bag-like storage member but also a depression or a shallow hole.
In a preferable configuration, the raised portion has a constant height. However, when the height is not constant, the height TB of the raised portion disposed on the bottom surface and the height TS of the raised portion disposed on the side surface are heights of the highest portions from the bottom surface and the side surface. The distance DB between the side surface facing to the corner of the tray of the raised portion disposed on the bottom surface of the tray and the side surface of the tray and the distance DS between the side surface facing to the corner of the tray of the raised portion disposed on the side surface of the tray and the bottom surface are respectively the distances between the side surface or the bottom surface of the tray and each closest end side of raised portions.
In the tray for the brittle columnar body according 1Q to the present invention, it is preferable that the raised portion disposed on the side surface as a part of defining a pocket is constituted of a member which is different from that of the side surface (of a tray main body). In this case, the only raised portion may be attached as the separate member. Examples of an especially preferable configuration include a configuration where on one tray member which does not have the only raised portion disposed on the side surface forming the pocket, there is superimposed another tray member having the only raised portion disposed on the side surface of the tray defining a part of a pocket. That is, the examples include a tray having a double structure.
It is preferable that the tray for the brittle columnar body according to the present invention is formed of a main material including one of polypropylene, polyethylene, polyethylene terephthalate, vinyl chloride, iron, aluminum and paper. When the tray is formed of a plastic material such as polypropylene, polyethylene or polyethylene terephthalate, the tray has a preferable thickness of about 0.3 to 2.0 mm.
It is preferable that the tray for the brittle columnar body according to the present invention is formed of a foam material. Examples of a preferable foam material include a material obtained by foam-forming a polyolefin-based resin. The polyolefin-based resin is a copolymer or the like mainly made of polyethylene, polypropylene and olefin.
Next, according to the present invention, there is provided a packaging body comprising: two trays for the brittle columnar body described above; and a box in which the two trays for the brittle columnar body and the brittle columnar body supported by two trays for the brittle columnar body are held. As the box in which the brittle columnar body is held, a cardboard box is preferably used.
The tray for the brittle columnar body according to the present invention, has raised portions respectively on a bottom surface and side surfaces of the tray defining a part of a pocket at portions except a corner portion of the pocket where the bottom surface and the side surface of the tray come in contact, wherein a height of the raised portion TB disposed on the bottom surface of the tray, a distance DS is a distance between the side surface facing to the corner of the tray of the raised portion disposed on the side surface of the tray and the bottom surface of the tray, a height of the raised portion TS disposed on the side surface of the tray, and a distance DB is a distance between the side surface facing to the corner of the tray of the raised portion disposed on the bottom surface of the tray and the side surface of the tray, meet relations of DS>TB and DB>TS, therefore the bottom surface and the side surface forming the pocket are provided with the raised portions disposed at portions except the corners of the pocket where the bottom surface comes in contact with the side surface, respectively. Therefore, when an end surface of the brittle columnar body is held in the pocket at the end side of the columnar body, the end surface of the brittle columnar body abuts on the raised portion of the pocket forming bottom surface of the tray. Moreover, a peripheral surface of the brittle columnar body abuts on the raised portion of the pocket forming side surface of the tray, and the brittle columnar body is firmly fixed. Furthermore, as a result, an edge portion (a portion where the end surface comes in contact with the peripheral surface) of the brittle columnar body which is supposed to be most easily damaged does not abut on the tray. Therefore, in a case where this tray is used during packaging, even if vibrations are caused by a transporting or storing operation after the pack aging, the brittle columnar body does not unintentionally move in the packaging body. Moreover, any useless stress is not applied to the edge portion of the brittle columnar body. Therefore, when the brittle columnar body is held or transported, the problem does not occur that the edge portion of the brittle columnar body touches the tray and the packaging body and is impacted and damaged.
In the tray for the brittle columnar body according to the present invention, in the preferable configuration, the raised portion disposed on the side surface forming the pocket is constituted of the member which is different from that of the side surface. In a further preferable configuration, the tray has a double structure where the one tray member which does not have the only raised portion disposed on the bottom surface forming the pocket is superimposed on the other tray member having the only raised portion disposed on the bottom surface forming the pocket. Therefore, the tray is easily prepared. That is, it is sometimes difficult to especially form the raised portion disposed on the pocket forming side surface, depending on the material for use in the tray and a method of forming the tray. However, when this portion is constituted of the (attachable) separate member, difficulty in forming the tray can be overcome.
A mode for carrying out the present invention will hereinafter be described with reference to the drawings as desired, but the present invention should not be limited to these examples when interpreted. The present invention can variously be changed, modified, improved and replaced based on knowledge of any person skilled in the art. For example, the drawings show preferable modes for carrying out the present invention, but the present invention is not limited by the modes shown in the drawings and information shown in the drawings. To carry out or verify the present invention, means similar or equivalent to means described in the present specification can be applied, but preferable means are means described below.
A tray 1 shown in
The raised portion includes a bottom surface raised portion 2 corresponding the raised portion of the bottom surface, and side surface raised portions 3 corresponding to the raised portions of the side surfaces. As apparent from
In the tray 1, as shown in
In the tray 1, a height of the bottom surface raised portion 2 disposed on the bottom surface is smaller than a distance from the side surface raised portion 3 disposed on the side surface to the bottom surface, and a height of the side surface raised portion 3 disposed on the side surface is smaller than a distance from the bottom surface raised portion 2 disposed on the bottom surface to the side surface. This respect as a characteristic of the tray (for the brittle columnar body) according to the present invention will be described with reference to
In
The tray (for the brittle columnar body) according to the present invention can be used alone in transporting, storing and holding the brittle columnar body. Especially, A set of trays is used to hold a honeycomb structure at the respective ends of the structure, and are preferably used as a packaging body together with a box (the packaging body according to the present invention).
Next,
A tray member 31 shown in
The side surfaces of the tray member 31 are not provided with any raised portion. Therefore, when the tray members are superimposed to form a tray 41, this is realized by a tray member 21 shown in
The tray 41 constituted by superimposing the tray member 21 on the tray member 31 as shown in
In the tray 41, as shown in
Next,
The tray 51 is used to transport or hold two cylindrical honeycomb structures. The tray 51 has a plate-like shape as a whole, and includes two pockets 4 which are spaces to hold the surfaces of two honeycomb structures in the end sides. In this tray 51, a bottom surface and side surfaces forming the pockets 4 are provided with raised portions at portions except corners 4a of the pockets 4 where the bottom surface comes in contact with the side surfaces.
The raised portions include bottom surface raised portions 52 corresponding to the raised portions of the bottom surface, and side surface raised portions 53 corresponding to the raised portions of the side surfaces. As apparent from
Next, a method of manufacturing the tray for the brittle columnar body according to the present invention will be described. The tray for the brittle columnar body according to the present invention can be prepared by a vacuum forming process or the like by use of a plastic material including a main component such as polypropylene, polyethylene, polyethylene terephthalate or vinyl chloride. Alternatively, the tray may be prepared by a foam forming operation, an attaching operation and the like by use of polypropylene, polyethylene, polyethylene terephthalate or the like as a main material. There is not any special restriction on specific means, and the tray may be prepared by a known method. Furthermore, the tray may be prepared by a punch forming operation, a member attaching operation and the like by use of paper, especially cardboard paper or hard paper. Especially, the tray prepared by a foam-formed foam material has a further improved damage preventing performance owing to a buffer property and elasticity of the material.
The tray for the brittle columnar body according to the present invention is usable as means for satisfactorily storing or transporting brittle columnar products such as a ceramic product, a narrow-sense glass product and a plastic product. Especially, the tray is preferably used as means for storing or transporting the honeycomb structure for use as a catalyst or a filter to purify an exhaust gas from a car.
Claims
1. A tray for a brittle columnar body which is used to transport or holding the brittle columnar body,
- the tray having a plate-like shape and at least one pocket for holding the brittle columnar body at the end side of the columnar body; and
- having raised-portions respectively on a bottom surface and side surfaces of the tray defining a part of said pocket at portions except a corner portion of the pocket where the bottom surface and the side surface of the tray come in contact,
- wherein a height of the raised portion disposed on the bottom surface of the tray: TB, a distance between the side surface facing to the corner of the tray of the raised portion disposed on the side surface of the tray and the bottom surface of the tray: DS, a height of the raised portion disposed on the side surface of the tray: TS, and a distance between the side surface facing to the corner of the tray of the raised portion disposed on the bottom surface of the tray and the side surface of the tray: DB,
- meet relations of DS>TB and DB>TS.
2. The tray for the brittle columnar body according to claim 1, wherein the raised portion is disposed on the side surface as a part for defining a pocket and said raised portion is constituted of a member which is different from that of the side surface.
3. The tray for the brittle columnar body according to claim 2, wherein on one tray member which does not have the only raised portion disposed at the side surface forming the pocket, there is superimposed another tray member having the only raised portion disposed at the side surface forming the pocket.
4. The tray for the brittle columnar body according to claim 1, which is formed of a main material including one of polypropylene, polyethylene, polyethylene terephthalate, vinyl chloride, iron, aluminum and paper.
5. The tray for the brittle columnar body according to claim 4, which is formed of a foam material.
6. A packaging body comprising:
- A set of two trays for the brittle columnar body;
- each tray having a plate-like shape and at least one pocket for holding the brittle columnar body at side of said columnar body; and
- having a raised portions respectively on bottom surfaces and side surfaces of the tray defining a part of a pocket except a corner portion of the pocket where the bottom surface and the side surface of the tray come in contact,
- wherein a height of the raised portion disposed on the bottom surface of the tray: TB, a distance between the side surface facing to the corner of the tray of the raised portion disposed on the side surface of the tray and the bottom surface of the tray: DS, a height of the raised portion disposed on the side surface of the tray: TS, and a distance between the side surface facing to the corner of the tray of the raised portion disposed on the bottom surface of the tray and the side surface of the tray: DB,
- meet relations of DS>TB and DB>TS; and,
- a box for housing the set of two trays for the brittle columnar body and the brittle columnar body supported by the two trays for the brittle columnar body.
Type: Application
Filed: Aug 1, 2007
Publication Date: Feb 14, 2008
Applicant: NGK INSULATORS, LTD. (NAGOYA-CTY)
Inventors: Koji SHIRAKI (Nagoya-city), Toru HOSOI (Nagoya-city)
Application Number: 11/832,350
International Classification: B65D 73/00 (20060101);