JP2023170007A - support panel - Google Patents

Abstract

To provide a support panel improved in durability.SOLUTION: A support panel 10 is held in an erected state and supports a roll-like product with a core material protruded from an end part to the axial direction in a suspended state, and has a synthetic resin body plate material 31 having a core material support part 33 with a cut-off shape downward from an upper end face in a U-shape, and an auxiliary plate material 40 having a core material receiving part 42 with a cut-off shape downward from the upper end in the U-shape, and jointed to at least one main surface of the body plate material 31. The body plate material 31 is a hollow plate material formed with multiple cells inside, or a foam plate material formed with multiple holes inside. A lower end edge 42c of the core material receiving part 42 is provided at the same position as a lower end face 33c of the core material support part 33 or higher.SELECTED DRAWING: Figure 9

Description

The present invention relates to a support panel for supporting a rolled product in a suspended state.

2. Description of the Related Art Roll-shaped products made by wrapping film, magnetic recording tape, etc. around a core material are known. If such a roll-shaped product is placed directly on the floor, the film or the like may be deformed or stained by its own weight. Therefore, it has been proposed to support the core material of a roll-shaped product in a suspended state for storage, transportation, etc.

Patent Document 1 describes an invention related to a roll product case for holding a roll product made of a long object such as a film in a suspended state. The roll product case includes an outer box that covers the circumferential surface of the roll product, and reinforcing plates arranged on both end faces of the outer box. The reinforcing plate is formed with a support portion cut out in a U-shape in order to support the core material protruding from the end surface of the roll-shaped product. By supporting both ends of the core material with two reinforcing plates, it is possible to hold the rolled product in a suspended state.

Japanese Patent Application Publication No. 2016-124561

The reinforcing plate described in Patent Document 1 is formed by folding a reinforcing plate base paper multiple times in the vertical and horizontal directions along fold lines. The reinforcing board base paper is formed into a shape in which a plurality of sections having the same planar shape as the reinforcing board are connected via fold lines. Therefore, in the support portion of the reinforcing plate formed by folding, the support portion portions of the plurality of laminated reinforcing plate base papers have the same shape, the same size, and are located at the same location.

When supporting the core material of a roll-shaped product with a reinforcing plate, the load of the roll-shaped product is applied to the lower edge of the support portion, and the load is concentrated. In the reinforcing plate described in Patent Document 1, the supporting portions of each section are formed in the same shape, size, and position, so that each of the supporting portions of the laminated reinforcing plate base paper The same load will be applied. Therefore, after long-term use, the support portion of the reinforcing plate may wear out or deform, and may not be able to maintain sufficient strength. In particular, since the reinforcing plate described in Patent Document 1 is made of paper, it may not be able to maintain sufficient strength not only after long-term use but also due to water absorption and the like. There is a problem with durability.

In order to solve the above problems, the support panel of the present invention is a support panel for supporting a roll-shaped product suspended in the air, which is held in an upright state and has a core material protruding from the end in the axial direction. , a main body plate made of synthetic resin on which a core material support part is cut out in a U-shape from the upper end surface downward, and a U-shaped cutout is cut out from the upper edge downward in the U-shape. and an auxiliary plate joined to at least one main surface of the main body plate, the main body plate being a hollow plate having a plurality of cells formed therein or having a plurality of cells inside The lower edge of the core receiving portion is provided at the same position or higher than the lower end surface of the core supporting portion.

When supporting a roll-shaped product in a suspended state, for example, it is possible to prepare two support panels and support each of the core members that protrude in the axial direction from both ends of the roll-shaped product with the support panel. .

The support panel configured as described above includes a synthetic resin main body plate made of a hollow plate having a plurality of cells formed therein or a foam plate having a large number of holes formed therein. Therefore, it has appropriate rigidity and strength. In addition, it is less susceptible to moisture than when it is made of paper. The durability of the support panel can be improved. Furthermore, since the weight can be reduced, workability and portability are improved.

In the support panel, an auxiliary plate is joined to at least one main surface of the main body plate. The lower end edge of the U-shaped core material receiving portion formed on the auxiliary plate material is provided at a position higher than the lower end surface of the U-shaped core material support portion formed on the main body plate material. Therefore, when supporting the core material of a roll-shaped product with a support panel, the core material hits at least the core receiving portion of the auxiliary plate material, and the situation where the core material hits only the core material supporting portion of the main plate material is suppressed. The presence of the auxiliary plate material prevents excessive load from being applied to the main body plate material. Even if the support panel is used for a long period of time, deformation or wear of the core support portion of the main body plate material is suppressed, and the durability of the support panel can be improved.

In the above configuration, it is preferable that the control plate further includes a regulating plate member joined to one main surface, and the regulating plate member is formed with a movement regulating portion that protrudes upward from the lower end edge of the core material receiving portion.

According to the above configuration, when the core material of the roll-shaped product is supported by the core material receiving part and the core material supporting part, or by the core material receiving part, the movement regulating part is positioned above the lower edge of the core material receiving part. positioned. Therefore, the axial end edge of the core material hits the movement restricting portion, and the axial movement of the roll-shaped product is restricted. Displacement of the roll-shaped product in the axial direction is suppressed, and the roll-shaped product can be stably supported.

In the above configuration, it is preferable that a resin end plate is joined to the upper end surface of the main body plate.
According to the above configuration, the upper end surface of the main body plate material can be protected. For example, when multiple upright support panels that support roll-shaped products are stacked vertically, the upper end surface of the lower support panel is exposed to the load from the upper support panel. It will cost. As a result, the main body plate material of the lower support panel may sag or become easily deformed. In this regard, if the resin end plate is joined to the upper end surface of the main body plate material, the load from the upper support panel can be received by the surface. As a result, the influence on the main body plate material is suppressed, and deformation of the main body plate material is suppressed. The strength of the main body plate material is improved, and the durability of the support panel is improved.

Further, it is possible to suppress the intrusion of water, dust, etc. into the holes of the main body plate material.
In the above configuration, it is preferable that the upper end surface of the main body plate is located above the upper edge of the auxiliary plate.

According to the above configuration, since the main body plate to which the resin end plates are joined projects upward, deformation of the auxiliary plate joined to the main surface of the main body plate is suppressed. Further, when joining the auxiliary plate material to the main surface of the main body plate material, sophisticated positioning is not required. Positioning work is easy, and work when joining auxiliary plate materials can be easily performed.

In the above configuration, it is preferable that at least one of the core material supporting part and the core material receiving part is formed with a pair of protrusions that protrude inward at positions facing each other in the horizontal direction.

According to the above configuration, since the pair of protrusions are formed, detachment of the support panel from the core material of the roll-shaped product is suppressed. For example, when transporting a rolled product, it may be necessary to lift the rolled product and move it to another location. In this case, the support panel does not easily come off from the core material even when the rolled product is lifted, so there is no need to support the support panel. After lifting the rolled product into position, the support panel can be removed. It is possible to prevent the support panel from falling inadvertently, resulting in good transport workability. Furthermore, since the support panel is lightweight, it is easy to carry the product by one person.

Further, when installing the core material of the rolled product on the support panel, there is no need for the operator to support the support panel. With the rolled product lifted into position, it is possible to attach the support panel. Installation work can be easily done by one person.

According to the present invention, the durability of the support panel can be improved.

It is a perspective view explaining the use state of the support panel of this embodiment. FIG. 3 is a perspective view of the support panel. FIG. 3 is an exploded perspective view of the support panel. It is a figure explaining a hollow structure. (a) is a partial perspective view of the hollow structure, (b) is a sectional view taken along the β-β line in (a), and (c) is a sectional view taken along the γ-γ line in (a). (a) to (c) are diagrams illustrating a method for manufacturing a hollow structure. It is a perspective view of a hollow plate material. It is a perspective view of a resin plate material. It is a perspective view of a regulation board material. FIG. 2 is a partial sectional view taken along the line IX-IX in FIG. 1. FIG. FIG. 3 is a partial cross-sectional view taken along the line X-X in FIG. 2; FIG. 3 is a perspective view illustrating a state in which support panels are stacked. It is a partial sectional view of the support panel of a modification. It is a front view of the support panel of a modification.

A support panel 10 according to an embodiment of the present invention will be described.
As shown in FIG. 1, the support panel 10 of this embodiment is used to support a long roll-shaped product 1 formed by a film 2 wound around a core material 3 in a suspended state. The film 2 is wound in such a manner that the core material 3 protrudes in the axial direction from both ends in the axial direction. When supporting the roll-shaped product 1 in a suspended state, two support panels 10 are used to support the core members 3 protruding from both ends of the roll-shaped product 1 in the longitudinal direction, respectively. The two support panels 10 are the same and are placed upside down facing each other on a pallet 6 serving as a base, with the front and back sides reversed.

The core material 3 around which the film 2 is wound is formed into a cylindrical shape, and a lifting shaft member 4 having a length projecting in the axial direction from both ends of the core material 3 is inserted into the interior thereof. When transporting the rolled product 1, the rope 5 may be hooked onto both ends of the lifting shaft member 4, lifted upward, and then moved to another location.

As shown in FIGS. 2 and 3, the support panel 10 includes a synthetic resin hollow plate 31 in which a plurality of cells S are arranged in parallel, and a resin plate 40 joined to both main surfaces 31a of the hollow plate 31. and a regulation plate member 50 joined to one resin plate member 40.

As shown in FIG. 4, the hollow plate material 31 is formed from a hollow structure 30 made of thermoplastic resin, in which a plurality of cells S are arranged in parallel. The hollow plate 31 corresponds to the main body plate defined in the claims.

<About the hollow structure 30>
First, the structure and manufacturing method of the hollow structure 30 that constitutes the hollow plate material 31 will be explained based on FIGS. 4 and 5.

As shown in FIG. 4(a), the hollow structure 30 is composed of a core layer 20 and skin layers 24 and 25 that are joined to cover the entire core layer 20 on both main surfaces of the core layer 20. There is.
As shown in FIGS. 5(a) to 5(c), the core layer 20 is formed by folding a single thermoplastic resin sheet material 100 molded into a predetermined shape. As shown in FIG. 4(a), the core layer 20 is erected between the closing walls 21 and 22 that close the cells S on both main surfaces of the core layer 20 and the closing walls 21 and 22. It is composed of a side wall portion 23 that partitions the cell S into a hexagonal column shape. As explained below, the closing walls 21 and 22 of the core layer 20 have a structure in which a one-layer structure and a two-layer structure are mixed, but in FIG. The parts 21 and 22 are shown as having a one-layer structure.

As shown in FIGS. 4(b) and 4(c), the cells S defined inside the core layer 20 include a first cell S1 and a second cell S2 having different configurations. As shown in FIG. 4(b), in the first cell S1, a two-layer closed wall portion 21 is provided above the side wall portion 23. As shown in FIG. Each layer of the two-layered closing wall portion 21 is joined to each other. In addition, an opening (not shown) is formed in the two-layer closed wall portion 21 by thermal contraction of the thermoplastic resin during molding of the core layer 20. In the first cell S<b>1 , a one-layer closed wall portion 22 is provided below the side wall portion 23 .

On the other hand, as shown in FIG. 4(c), in the second cell S2, a one-layer closed wall portion 21 is provided above the side wall portion 23. Further, in the second cell S2, a two-layered closing wall portion 22 is provided at the lower part of the side wall portion 23. Each layer of the two-layered closing wall portion 22 is joined to each other. An opening (not shown) is formed in the two-layer closed wall 22 by thermal contraction of the thermoplastic resin during molding of the core layer 20.

Further, as shown in FIGS. 4(b) and 4(c), the adjacent first cells S1 and the adjacent second cells S2 are each partitioned by side wall portions 23 having a two-layer structure. There is. The side wall portion 23 having the two-layer structure has a portion in the center of the core layer 20 in the thickness direction that is not thermally welded to each other. Therefore, the internal space of each cell S of the core layer 20 communicates with the internal space of the other cells S via the side wall portions 23 of the two-layer structure.

As shown in FIG. 4(a), the first cells S1 are arranged in rows along the X direction. Similarly, the second cells S2 are arranged in rows along the X direction. The rows of first cells S1 and the rows of second cells S2 are arranged alternately in the Y direction orthogonal to the X direction. The core layer 20 has a honeycomb structure as a whole due to these first cells S1 and second cells S2.

The thermoplastic resin constituting the core layer 20 and the skin layers 24 and 25 may be any conventionally known thermoplastic resin, such as polypropylene resin, polyamide resin, polyethylene resin, acrylonitrile-butadiene-styrene copolymer resin, acrylic resin, etc. resin, polybutylene terephthalate resin, etc. The core layer 20 and skin layers 24 and 25 of this embodiment are made of polypropylene resin. It is preferable that the thermoplastic resin forming the core layer 20 and the thermoplastic resin forming the skin layers 24 and 25 are made of the same material. In this embodiment, the skin layer 24 and the skin layer 25 have the same thickness.

Next, a method for manufacturing the hollow structure 30 will be explained.
As shown in FIG. 5, the hollow structure 30 is manufactured by forming a core layer 20 from a single sheet material 100 and bonding skin layers 24 and 25 to the core layer 20.

As shown in FIG. 5(a), the sheet material 100 is formed by molding one thermoplastic resin sheet into a predetermined shape. In the sheet material 100, band-shaped planar regions 110 and bulging regions 120 are arranged alternately in the longitudinal direction (X direction) of the sheet material 100. In the bulging region 120, a first bulging portion 121 having a downward groove shape in cross section and consisting of an upper surface and a pair of side surfaces is formed over the entire length of the bulging region 120 in the extending direction (Y direction). Note that the angle between the top surface and the side surface of the first bulging portion 121 is preferably 90 degrees, and as a result, the cross-sectional shape of the first bulging portion 121 has a downward U-shape. Further, the width of the first bulging portion 121 (the length in the lateral direction of the upper surface) is equal to the width of the plane area 110, and the bulging height of the first bulging portion 121 (the length in the lateral direction of the side surface) is equal to the width of the plane area 110. ) is set to be twice the length.

Further, in the bulging region 120, a plurality of second bulging portions 122 each having a trapezoidal cross-sectional shape obtained by bisecting a regular hexagon by the longest diagonal line are arranged perpendicularly to the first bulging portion 121. It is formed. The height of the second bulge 122 is set to be equal to the height of the first bulge 121 . Furthermore, the interval between adjacent second bulges 122 is equal to the width of the upper surface of the second bulges 122 .

Note that the first bulging portion 121 and the second bulging portion 122 are formed by partially bulging the sheet upward using the plasticity of the sheet. Moreover, the sheet material 100 can be molded from one sheet by a well-known molding method such as a vacuum forming method or a compression molding method.

As shown in FIGS. 5A and 5B, the core layer 20 is formed by folding the sheet material 100 configured as described above along the boundary lines P and Q. Specifically, the sheet material 100 is valley-folded along the boundary line P between the flat area 110 and the bulging area 120, and mountain-folded along the boundary line Q between the top surface and the side surface of the first bulging part 121. compress it in the X direction. As shown in FIGS. 5(b) and 5(c), the upper surface and the side surface of the first bulging part 121 are folded together, and the end face of the second bulging part 122 and the plane area 110 are folded, so that one One prismatic partition body 130 extending in the Y direction is formed for each bulging region 120 . A hollow plate-shaped core layer 20 is formed by continuously forming such partitions 130 in the X direction.

When the sheet material 100 is compressed as described above, the upper surface and side surfaces of the first bulging portion 121 form the closing wall portion 21 of the core layer 20, and the end surface and the flat area 110 of the second bulging portion 122 form the closed wall portion 21 of the core layer 20. The closing wall portion 22 of the core layer 20 is formed by this. As shown in FIG. 5(c), the upper surface and the side surface of the first bulging part 121 of the closing wall part 21 overlap to form a two-layer structure, and the second bulging part of the closing wall part 22 The portions where the end surfaces of 122 and the planar region 110 are folded to form a two-layer structure become overlapping portions 131, respectively.

Further, the hexagonal column-shaped area formed by folding the second bulging portion 122 becomes the second cell S2, and the hexagonal column-shaped area partitioned and formed between the pair of adjacent partition bodies 130 becomes the second cell S2. One cell becomes S1. In the present embodiment, the upper surface and the side surface of the second bulging portion 122 constitute the side wall portion 23 of the second cell S2, and the side surface of the second bulging portion 122 and the second bulging portion 122 in the bulging region 120 constitute the side wall portion 23 of the second cell S2. The plane portion located in between constitutes the side wall portion 23 of the first cell S1. The contact area between the upper surfaces of the second bulging part 122 and the contact area between the flat parts of the bulge area 120 form the side wall part 23 having a two-layer structure. In addition, when implementing such a folding process, it is preferable that the sheet material 100 is heat-treated and softened.

Subsequently, the skin layer 24 is superimposed on one main surface of the core layer 20, and the skin layer 25 is superimposed on the other main surface of the core layer 20. The skin layers 24 and 25 are preferably heated and softened. By heat-treating the skin layers 24 and 25, the thermoplastic resin adhesive layer coated on the skin layers 24 and 25 is partially thermally melted. Therefore, the skin layers 24 and 25 superimposed on the core layer 20 are positioned while being temporarily joined to the core layer 20. The adhesive layer is solidified by the temperature drop of the core layer 20 and the skin layers 24 and 25, and the skin layers 24 and 25 are bonded to the core layer 20 to form the hollow structure 30.

<About the support panel 10>
Next, the shape and configuration of the support panel 10 will be explained.
As shown in FIGS. 2 and 3, the support panel 10 includes a hollow plate 31, two resin plates 40, and a regulation plate 50. The hollow plate material 31, the resin plate material 40, and the regulation plate material 50 are fixed in a joined state with metal rivets (not shown). The hollow plate 31 corresponds to a main body plate as defined in the claims, and the resin plate 40 corresponds to an auxiliary plate as defined in the claims.

As shown in FIGS. 1 and 2, when the roll-shaped product 1 is supported by the support panel 10, it is used in an upright state perpendicular to a horizontal surface. Therefore, below, the upper and lower sides of the support panel 10 will be defined based on the usage state of the support panel 10.

As shown in FIG. 2, the support panel 10 is formed with a U-shaped notch 11 extending downward from the upper end surface 10a. The notch 11 is constituted by a core support portion 33, a core support portion 42, and a movement restriction portion 52, which will be described later. A pair of protrusions 12 are formed on the inner surface 11a of the notch 11 at opposing positions. The protrusion 12 is formed by protrusions 35 and 43, which will be described later.

<About the hollow plate material 31>
As shown in FIG. 6, the hollow plate material 31 is formed by cutting the hollow structure 30 into a predetermined shape. The hollow plate material 31 has a shape in which a U-shaped notch is formed in the hollow structure 30 cut into a square plate shape downward from the upper end surface 31b side. The U-shaped cutout constitutes a core material support section 33 that supports the core material 3 of the roll-shaped product 1.

The core support portion 33 includes a pair of vertical surfaces 33a that extend in the vertical direction, and a circular surface 33b that is semicircular in plan view and is connected to the lower end of the vertical surface 33a. The distance between the pair of vertical surfaces 33a is slightly larger than the outer diameter of the core material 3 of the rolled product 1. The diameter of the circular surface 33b is slightly larger than the outer diameter of the core material 3.

As shown in FIG. 6, each of the vertical surfaces 33a of the core support portion 33 is formed with a protrusion 35 that projects toward the other vertical surface 33a. The protrusions 35 formed on each vertical surface 33a are formed at positions facing each other in the horizontal direction and at the same height. The protrusion 35 is formed to have the same cross-sectional shape throughout the thickness direction of the hollow plate material 31. Both protrusions 35 are formed to have the same shape and the same size. The protruding length of the protrusion 35 from the vertical surface 33a is preferably about 1 to 8%, more preferably about 2 to 5%, of the distance between the pair of vertical surfaces 33a.

Since the hollow plate material 31 is formed by cutting the hollow structure 30, the internal space of the cell S defined by the side wall portion 23 extending in the thickness direction is exposed at the cut end face. In the hollow plate material 31 of this embodiment, the end surface 31b is formed by covering the cut end surface of the hollow structure 30 with a resin end plate 32 which is a resin plate material.

The resin end plate 32 is formed by thermally compressing each side end portion of the hollow structure 30 cut into a square plate shape. Specifically, as will be explained later in the hollow plate forming step, each side end portion constituting the four sides of the cut hollow structure 30 is thermally bent using a heating jig, so that it is integrated with the hollow plate 31. is formed. The resin end plate 32 has a width comparable to the thickness of the hollow plate material 31, and is joined over the entire length of each side of the hollow plate material 31. As a result, the cells S are not exposed to the outside at the end surface 31b of the hollow plate 31.

A plurality of holes 36 penetrating in the thickness direction are formed in the hollow plate material 31. A total of ten holes 36 are formed in four locations in the vertical direction parallel to the vertical surface 33a. The holes 36 are formed in the hollow plate 31 for riveting the resin plate 40 and the regulating plate 50.

<About the resin plate material 40>
As shown in FIG. 7, the resin plate material 40 has a shape in which a U-shaped notch is formed downward from the upper edge (short side) 41 in a plate material cut into a rectangular plate shape. There is. The U-shaped cutout constitutes a core material receiving portion 42 for receiving the core material 3 of the roll-shaped product 1. The resin plate 40 of this embodiment is joined to the hollow plate 31 with the core receiving portion 42 aligned with the position of the core supporting portion 33 . The resin plate material 40 is joined to both main surfaces 31a of the hollow plate material 31, respectively. Both resin plate materials 40 have the same shape and size.

As shown in FIG. 10, the length of the long side of the resin plate material 40 is slightly shorter than the length of one side of the hollow plate material 31. In this embodiment, it is about several mm shorter than the length of one side of the hollow plate material 31, and about the same length as the thickness of the resin end plate 32. When the resin plate 40 is joined to the hollow plate 31, the upper edge 41 of the resin plate 40 is lower than the upper end surface 31b of the hollow plate 31. For example, it is about as low as the thickness of the resin end plate 32. Further, the position of the lower edge 41 of the resin plate material 40 is approximately the same as the lower end surface 31b of the hollow plate material 31.

The resin constituting the resin plate material 40 may be any conventionally known thermoplastic resin. The resin plate material 40 of this embodiment, whose material is not particularly limited, is made of the same polypropylene resin as the hollow plate material 31.

As shown in FIG. 7, the core material receiving part 42 includes a pair of vertical parts 42a extending in the vertical direction and a circular part 42b having a semicircular shape in plan view and connected to the lower end of the vertical part 42a. The core material receiving part 42 of this embodiment is formed in the same shape and the same size as the core material supporting part 33 of the hollow plate material 31. That is, the distance between the pair of vertical parts 42a is slightly larger than the outer diameter of the core material 3 of the rolled product 1, and the diameter of the circular part 42b is slightly larger than the outer diameter of the core material 3. Therefore, the lower end edge 42c of the core material receiving part 42 is at the same position as the lower end surface 33c of the core material supporting part 33.

Moreover, each of the vertical parts 42a of the core material receiving part 42 is formed with a protrusion 43 that projects toward the other vertical part 42a. The formation position, shape and size of the protrusion 43 in plan view are the same as the protrusion 35 formed on the hollow plate material 31.

A plurality of holes 44 are formed in the resin plate material 40 to penetrate in the thickness direction. The holes 44 are formed for riveting to the hollow plate 31. Therefore, when the resin plate 40 is joined to the main surface 31a of the hollow plate 31, it is formed in the same shape and size as the hole 36 in the hollow plate 31 at a position overlapping with the hole 36.

<About the regulation plate material 50>
As shown in FIG. 8, the regulation plate material 50 has a shape in which a U-shaped notch is formed downward from the upper edge (short side) 51 in a plate material cut into a rectangular plate shape. There is. The U-shaped cutout constitutes a movement restriction portion 52 that restricts movement of the core material 3 of the roll-shaped product 1 in the axial direction. The regulation plate 50 is joined to one of the resin plates 40 with its short and long sides aligned with the resin plate 40.

As shown in FIG. 10, the length of the long side of the regulation plate 50 is slightly shorter than the length of one side of the hollow plate 31, and is the same as the length of the long side of the resin plate 40. In the state where the regulation plate material 50 is joined to the resin plate material 40, the position of the upper edge 51 of the regulation plate material 50 is approximately the same as the position of the upper edge 41 of the resin plate material 40. Further, the position of the lower edge 51 of the regulation plate material 50 is substantially the same as the position of the lower edge 41 of the resin plate material 40.

The resin constituting the regulation plate material 50 can be appropriately selected from conventionally known thermoplastic resins. The regulation plate 50 of this embodiment is made of the same polypropylene resin as the hollow plate 31 and the resin plate 40.

As shown in FIG. 8, the movement regulating portion 52 includes a pair of vertical portions 52a extending in the vertical direction, and a circular portion 52b having a semicircular shape in plan view and connected to the lower end of the vertical portion 52a. In the movement regulating portion 52 of this embodiment, the vertical portion 52a has the same shape and size as the vertical surface 33a of the core support portion 33 of the hollow plate 31 and the vertical portion 42a of the resin plate 40.

On the other hand, the shape of the circular portion 52b is different from the circular surface 33b of the hollow plate material 31 and the circular portion 42b of the resin plate material 40. The diameters of the circular surface 33b and the circular portion 42b are slightly larger than the outer circumferential diameter of the core material 3, whereas the diameter of the circular portion 52b is smaller than the outer circumferential diameter of the core material 3. Therefore, as shown in FIG. 9, the lower end edge 52c of the movement regulating part 52 projects upward from the lower end surface 33c of the core material support part 33 and the lower end edge 42c of the core material receiving part 42.

As shown in FIG. 8, a plurality of holes 53 penetrating in the thickness direction are formed in the regulation plate material 50. The holes 53 are formed for riveting to the hollow plate material 31 and the resin plate material 40. Therefore, they are formed in the same shape and size as the holes 36 and 44 at positions overlapping with the holes 36 of the hollow plate material 31 and the holes 44 of the resin plate material 40.

<About the manufacturing method of the support panel 10>
Next, a method for manufacturing the support panel 10 will be explained.
The support panel 10 is manufactured through a hollow plate forming process, a temporary bonding process, a notch forming process, a regulating plate forming process, and a bonding process.

In the hollow plate forming step, first, the hollow structure 30 is cut into square shapes. Next, each of the side ends constituting the four sides of the cut hollow structure 30 is thermally compressed from one main surface side using a heating jig to form a thin plate-like side part of the hollow structure 30. do. The width of each side end portion to be thermally compressed is approximately equal to the thickness of the hollow structure 30. Then, the thin plate-shaped portion is bent toward one main surface and thermally welded. Thereby, the thin plate-shaped portion formed in the hollow structure 30 becomes the resin end plate 32, and constitutes the end surface 31b of the hollow plate material 31. The interior space of the hollow plate member 31 is closed by the resin end plate 32 .

In the temporary bonding step, two plates made of polypropylene resin (plates that will later become the resin plates 40) cut into rectangular plates are prepared. Then, a double-sided tape is applied to one main surface of the plate material, and the plate material is temporarily bonded to both main surfaces of the hollow structure 30 (later to become the hollow plate material 31) formed in the hollow plate material forming process. At this time, the upper side of the plate material that will become the resin plate material 40 is temporarily joined so that the edge thereof is displaced inward by about the thickness of the resin end plate 32 from the end face of the cut hollow structure 30. do. On the other hand, the lower side of the plate material that will become the resin plate material 40 is temporarily joined so that its edge is at the same position as the end surface of the cut hollow structure 30. Further, the plates are temporarily joined so that the short sides of the plates are located at the center of the cut hollow structure 30 in the width direction.

Subsequently, in the notch forming step, a U-shaped notch is integrally formed in the temporarily joined hollow structure 30 and the plate material. The notch is formed by placing the temporarily joined hollow structure 30 and the plate material on a plate provided with a cutting jig. By forming the notches, the cut hollow structure 30 becomes a hollow plate material 31, and the plate material becomes a resin plate material 40.

When forming the notches, the protrusions 35 of the core material support section 33 and the protrusions 43 of the core material receiving section 42 are also formed at the same time as the cutting. As a result, a core support portion 33 having a protrusion 35 is formed in the hollow plate 31, and a core receiving portion 42 having a protrusion 43 is formed in the resin plate 40. The core support portion 33 and the core receiving portion 42 have the same shape and the same size, and the protrusion 35 and the protrusion 43 have the same shape and the same size. The protrusions 35 and 43 become the protrusion 12 of the support panel 10.

In the regulation plate material forming step, one polypropylene resin plate cut into a rectangular plate shape is prepared. Then, a U-shaped notch is formed in this plate material. Thereby, the regulation plate material 50 in which the movement regulation part 52 is formed is obtained. Double-sided tape is pasted on one main surface of the regulation plate material 50 and temporarily joined to one of the resin plate materials 40. At this time, the temporary joining is performed such that the position of the long side of the regulation plate 50 matches the position of the long side of the resin plate 40, and the position of the short side of the regulation plate 50 matches the position of the short side of the resin plate 40.

Subsequently, the temporarily joined hollow plate material 31, resin plate material 40, and regulation plate material 50 are placed on a plate provided with a penetration jig. Then, the holes 36, 44, and 53 are simultaneously formed in the hollow plate material 31, the resin plate material 40, and the regulation plate material 50.

In the joining process, metal rivets are passed through the holes 36, 44, and 53 to fix the hollow plate 31, the resin plate 40, and the regulation plate 50 in a joined state.
The support panel 10 is manufactured through each of the above steps.

<About the function of the support panel 10>
Next, the function of the support panel 10 will be explained.
As shown in FIG. 1, when the support panel 10 of this embodiment is used to support the rolled product 1 in a suspended state, two sheets are placed on the pallet 6 with the regulating plate 50 side facing outward. Support panels 10 are arranged facing each other. The two support panels 10 are arranged such that the distance between their outer surfaces is slightly longer than the length of the core material 3 of the rolled product 1 in the axial direction.

The rolled product 1 is lifted by hooking the rope 5 on both ends of the lifting shaft member 4, and with the core material 3 disposed between the two support panels 10, along the inner surface 11a of the notch 11. lower it. The vertical surface 33a of the core material supporting part 33, the vertical part 42a of the core material receiving part 42, and the vertical part 52a of the movement regulating part 52, which constitute the inner surface 11a of the notch 11, are spaced at intervals slightly wider than the diameter of the core material 3, respectively. formed in parallel. Therefore, the core material 3 descends along the inner surface 11a of the notch 11.

As shown in FIG. 9, in the support panel 10 of this embodiment, the lower edge 42c of the core receiving portion 42 and the lower end surface 33c of the core supporting portion 33 are provided at the same position. Therefore, when the core material 3 that has descended along the inner surface 11a of the notch 11 reaches the lowest end of the notch 11, the core material 3 moves between the lower end surface 33c of the core material support part 33 and the lower end of the core material receiving part 42. It hits the edge 42c. As a result, the weight of the rolled product 1 is suppressed from being applied only to the hollow plate material 31, and the load from the rolled product 1 is distributed to the core support portion 33 and the core receiving portion 42.

Further, the diameter of the circular portion 52b of the movement regulating portion 52 of the regulating plate material 50 is smaller than the diameter of the circular surface 33b of the hollow plate material 31 and the diameter of the circular portion 42b of the resin plate material 40. Therefore, when the core material 3 reaches the lowermost end of the notch 11 of the support panel 10, the movement regulating portion 52 of the regulating plate material 50 is in contact with the axial end surface of the core material 3. As a result, movement of the core material 3 in the axial direction of the roll-shaped product 1 is restricted.

When moving the rolled product 1 for transportation or the like, the rope 5 is hooked onto both ends of the lifting shaft member 4 and lifted up in the same way as before. Since the protrusion 12 is formed in the notch 11 of the support panel 10, the roll-shaped product 1 is lifted up with the support panel 10 in a state where the protrusion 12 is engaged with the core material 3. Once the rolled product 1 has been lifted to a certain height, the support panel 10 can be removed.

As shown in FIG. 11, when storing a large number of roll-shaped products 1, two support panels 10 arranged on a pallet 6 are used as a set, and the products are arranged horizontally or vertically. Stack them up. As shown in FIG. 10, the upper end surface 10a of the support panel 10 is located above the upper edge 41 of the resin plate material 40 and the upper edge 51 of the regulation plate material 50. Therefore, when stacked, the load from the pallet 6 located on the upper stage side is suppressed from being applied to the resin plate material 40 and the regulation plate material 50.

At the upper end surface 10a of the support panel 10, a resin end plate 32 is formed integrally with the hollow plate member 31 and joined. Therefore, on the upper end surface 31b of the hollow plate 31, the load from the pallet 6 located on the upper stage side is received by the entire surface of the resin end plate 32.

According to this embodiment, the following effects can be obtained.
(1) The support panel 10 includes a hollow plate 31 on which cells S are arranged in parallel, and a resin plate 40 joined to both main surfaces 31a of the hollow plate 31. The lower end surface 33c of the core material supporting portion 33 formed on the hollow plate material 31 is provided at the same position as the lower end edge 42c of the core material receiving portion 42 formed on the resin plate material 40.

Therefore, the load from the core material 3 of the roll-shaped product 1 is distributed to the core material support part 33 and the core material receiving part 42, and is suppressed from being applied only to the core material support part 33. The durability of the support panel 10 can be improved.

(2) When the support panel 10 is held in an upright state, the load from the core material 3 of the rolled product 1 is applied to the hollow plate material 31 in the direction in which the cells S are arranged side by side. In this regard, by providing the core material receiving part 42, the load from the core material 3 of the rolled product 1 is suppressed from being applied only to the core material support part 33, so that the influence on the cells S is reduced. suppressed. Even if the support panel 10 is used for a long period of time, the core support portion 33 of the hollow plate member 31 is prevented from being deformed or worn out, and the durability of the support panel 10 can be improved.

(3) The hollow plate material 31 is a polypropylene resin plate material in which a plurality of cells S partitioned by side wall portions 23 extending in the thickness direction are arranged in parallel. Therefore, the support panel 10 has appropriate rigidity and strength. In addition, since the weight can be reduced, workability and portability are improved. Furthermore, it is less susceptible to moisture than paper products. The durability of the support panel can be improved.

(4) The support panel 10 includes a regulation plate 50 joined to one resin plate 40. A movement regulating portion 52 is formed on the regulating plate 50 and projects upward from the lower end edge 42c of the core receiving portion 42.

Therefore, when the core material 3 of the roll-shaped product 1 is supported by the core material supporting section 33 and the core material receiving section 42, the axial end surface of the core material 3 hits the movement regulating section 52. This restricts the movement of the rolled product 1 in the axial direction. Displacement of the roll-shaped product 1 in the axial direction is suppressed, and the roll-shaped product 1 can be stably supported.

(5) A resin end plate 32 formed by thermal bending of the hollow structure 30 is integrally formed and joined to the upper end surface 31b of the hollow plate member 31. Therefore, the upper end surface 31b of the hollow plate 31 can be protected. When the support panels 10 supported on the pallet 6 are used by stacking them in multiple stages in the vertical direction, the upper end surface of the lower support panel 10 has a resin end plate 32 facing the upper support panel 10. It will be subjected to the load of Sagging, deformation, etc. of the hollow plate material 31 of the lower support panel 10 is suppressed. The strength of the hollow plate material 31 is improved, and the durability of the support panel 10 can be improved.

(6) The end surface 31b of the hollow plate 31 is covered with a resin end plate 32. Therefore, entry of water, dust, etc. into the cells S of the hollow plate material 31 can be suppressed.
(7) The upper end surface 31b of the hollow plate 31 is located above the upper edges 41 and 51 of the resin plate 40 and the regulation plate 50. Therefore, when the support panels 10 are stacked, deformation of the resin plate material 40 and the regulation plate material 50 is suppressed.

(8) The length of the resin plate material 40 and the regulation plate material 50 in the longitudinal direction is shorter than the length of the side of the hollow plate material 31 by about the thickness of the resin end plate 32. Therefore, when temporarily joining the resin plate material 40 and the regulation plate material 50 to the main surface 31a of the hollow plate material 31, the position of the longitudinal edge of the resin plate material 40 can be adjusted from the end surface of the hollow plate material 31 without performing sophisticated positioning. An inwardly displaced position is easily achieved. The positioning work is easy, and the workability when temporarily joining the resin plate material 40 and the regulation plate material 50 is good.

(9) The notch 11 of the support panel 10 is formed with a protrusion 12 that protrudes inward. The protrusions 12 are formed at horizontally opposing positions. Therefore, detachment of the support panel 10 from the core material 3 of the rolled product 1 is suppressed. When lifting the roll-shaped product 1, the support panel 10 is prevented from falling down carelessly.

Moreover, since the protrusion 12 is formed and engages with the core material 3 of the rolled product 1, when the rolled product 1 is lifted, the support panel 10 is also lifted together with the rolled product 1. Therefore, after lifting the rolled product 1 to a predetermined position, the support panel 10 can be removed. Inadvertent falling of the support panel 10 can be suppressed, and transport workability is improved.

The above embodiment can be modified as follows. Note that the above embodiment and the following modification examples can be applied in combination with each other within a technically consistent range.
- In the support panel 10 of the above embodiment, the lower end edge 42c of the core material receiving part 42 is provided at the same position as the lower end surface 33c of the core material supporting part 33; The location is not limited to this. As shown in FIG. 12, the lower edge 42c of the core receiving portion 42 may be located higher than the lower end surface 33c of the core supporting portion 33. In this case, since the core material 3 can be received by the core material receiving part 42, the concentration of load on the core material supporting part 33 is further suppressed.

- The shape of the core support portion 33 is not limited to that of the above embodiment. For example, the vertical surfaces 33a may not be parallel to each other. Moreover, the circular surface 33b does not have to have a semicircular shape in plan view. The same applies to the core receiving portion 42 and the movement regulating portion 52.

- As shown in FIG. 13, a sloped portion 13 may be formed at the upper end of the notch 11 of the support panel 10. When the inclined portion 13 is formed, it becomes easier to insert the core material 3 of the rolled product 1.
- The support panel 10 does not need to be provided with the regulation plate material 50.

- The upper end surface 31b of the hollow plate 31 does not need to be located above the upper edges 41 and 51 of the resin plate 40 and the regulation plate 50. For example, the upper end surface 31b of the hollow plate 31 may be at the same position as the upper edges 41 and 51 of the resin plate 40 and the regulation plate 50, or may be located several mm below.

- The lower end surface 31b of the hollow plate 31 does not have to be in the same position as the upper edges 41 and 51 of the resin plate 40 and the regulation plate 50. For example, the lower end surface 31b of the hollow plate 31 may be located several mm below or several mm above the lower edges 41 and 51 of the resin plate 40 and the regulation plate 50. It's okay.

- The resin plate material 40 and the regulation plate material 50 may be formed into a square plate shape having approximately the same size as the hollow plate material 31.
- The resin plate material 40 may be joined only to one main surface 31a of the hollow plate material 31.

- The resin plate material 40 may be formed of a plate material made of low foaming resin.
- The core material supporting part 33 of the hollow plate material 31 and the core material receiving part 42 of the resin plate material 40 do not need to be integrally formed in a temporarily joined state. You may make it temporarily join the hollow board material 31 in which the core material support part 33 was formed, and the resin board material 40 in which the core material receiving part 42 was formed.

- In the above embodiment, the resin end plate 32 of the hollow plate 31 is formed integrally with the hollow plate 31 by thermal bending of the hollow structure 30. The present invention is not limited to this, and a separate resin end plate 32 may be joined to the cut end surface of the hollow structure 30 by heating.

- As shown in FIG. 6, a resin end plate 34, which is a resin plate, may be joined to the core support portion 33 of the hollow plate member 31, similarly to the resin end plate 32. The interior space of the hollow structure 30 is covered with the resin end plate 34, and exposure of the cells S is suppressed. In this case, the resin end plate 34 joined to the core support part 33 may be integrally formed by heat bending after the core support part 33 is formed, like the resin end plate 32 of the above embodiment. Alternatively, separate pieces may be joined.

- The protrusion 12 may be omitted.
- The protrusion 12 may be formed as the protrusion 35 only on the hollow plate material 31, and the protrusion 43 on the resin plate material 40 may be omitted. Alternatively, the protrusion 43 may be formed only on the resin plate 40, and the protrusion 35 on the hollow plate 31 may be omitted.

- Although the hollow plate material 31 of the above embodiment is a synthetic resin plate material in which a plurality of cells S are arranged in parallel, the hollow plate material 31 is not limited to this. For example, it may be a plate material made of a low-foam resin with a plurality of holes formed inside. The plate material in this case is the foamed plate material referred to in the claims.

- The shape and number of cells S of the hollow plate material 31 are not limited to those of the above embodiment. The shape and number of cells S can be changed as appropriate.
- Instead of the resin plate material 40, a metal plate material may be joined. Strength can be improved by using metal plates. The same applies to the regulation plate material 50.

- The thickness of the resin plate material 40 may be made thicker than the thickness of the skin layers 24 and 25 of the hollow structure 30 that constitutes the hollow plate material 31. By doing so, rigidity can be imparted to the resin plate material 40, and the strength of the support panel 10 is improved.

- Although the hollow plate material 31, the resin plate material 40, and the regulation plate material 50 are all made of polypropylene resin, the material may be changed for each of the plate materials 31, 40, and 50. For example, the thermoplastic resin forming the resin plate 40 and the regulating plate 50 may be harder than the thermoplastic resin forming the hollow plate 31. By doing so, rigidity can be imparted to the resin plate material 40 and the regulation plate material 50, and the strength of the support panel 10 is improved.

- In the temporary bonding step, a polypropylene resin plate cut into a rectangular plate shape was temporarily bonded to the cut hollow structure 30 with double-sided tape, but the temporary bonding method is not limited to this. Bonding with adhesive may also be used. The same applies to the temporary joining of the regulating plate material 50 in the regulating plate material forming process.

- In the joining process, the hollow plate material 31, the resin plate material 40, and the regulation plate material 50 are fixed with metal rivets, but resin rivets may be used. Resin rivets can be recycled.
The technical idea understood from the above embodiment will be described below.

(a) A support panel for supporting in a suspended state a roll-shaped product that is held in an upright state and has a core material protruding from the end in the axial direction, and is divided by a plurality of side walls extending in the thickness direction. The hollow plate includes a hollow plate made of synthetic resin in which cells are arranged in parallel, and a resin plate joined to at least one main surface of the hollow plate, and the hollow plate has a U shape extending downward from an upper end surface. A core material supporting portion having a shape cut out in a letter shape is formed, and a core material receiving portion having a shape cut out in a U shape downward from the upper end edge is formed in the resin plate material. The lower end edge of the material receiving portion is provided at the same position or higher than the lower end surface of the core material supporting portion.

The support panel configured as described above includes a hollow plate made of synthetic resin in which a plurality of cells are arranged in parallel. Therefore, it has appropriate rigidity and strength. In addition, since the weight can be reduced, workability and portability are improved. Furthermore, it is less susceptible to moisture than paper products. The durability of the support panel can be improved.

When supporting the core material of a roll-shaped product with a support panel, the core material hits at least the core material receiving portion of the resin plate material, and the situation where the core material hits only the core material supporting portion of the hollow plate material is suppressed. The presence of the resin plate material prevents excessive load from being applied to the hollow plate material. Thereby, even if a load from the core material is applied in the direction in which the cells are arranged side by side, the influence on the cells is suppressed. Even if the support panel is used for a long period of time, deformation or wear of the core support portion of the hollow plate material is suppressed, and the durability of the support panel can be improved.

1... Roll-shaped product 3... Core material 10... Support panel 11... Notch 12... Projection 31... Hollow board material (main board material)
31a...Main surface 31b...End surface 32...Resin end plate 33...Core support portion 35...Protrusion 33c...Lower end surface 40...Resin plate material (auxiliary plate material)
42...Core material receiving part 42c...Lower edge 43...Protrusion 50...Regulation plate material 52...Movement restriction part

Claims (5)

A support panel for supporting in a suspended state a roll-shaped product that is held in an upright state and has a core material protruding from an end in the axial direction,
A main body plate made of synthetic resin and having a U-shaped core support portion cut out from the upper end surface downward;
A U-shaped core receiving portion is formed downward from the upper edge, and an auxiliary plate member is joined to at least one main surface of the main body plate member,
The main body plate is a hollow plate with a plurality of cells formed inside or a foam plate with many holes formed inside,
A support panel characterized in that a lower end edge of the core material receiving portion is provided at a position equal to or higher than a lower end surface of the core material supporting portion. Further comprising a regulating plate material joined to one main surface,
2. The support panel according to claim 1, wherein the restriction plate material is provided with a movement restriction portion that projects upward from a lower edge of the core receiving portion. 3. The support panel according to claim 2, wherein a resin end plate is joined to the upper end surface of the main body plate. 4. The support panel according to claim 3, wherein the upper end surface of the main body plate is located above the upper edge of the auxiliary plate. Claims 1 to 4, wherein at least one of the core material support portion and the core material receiving portion is formed with a pair of protrusions that protrude inward at horizontally opposing positions. A support panel according to any one of the preceding paragraphs.

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