PACKING MATERIAL, TRANSPORTATION METHOD USING PACKING MATERIAL, COMPONENT OF IMAGE FORMING APPARATUS, AND PROCESS CARTRIDGE

Description

BACKGROUND

Field of the Technology

The present disclosure relates to a packing material, a method of transportation using the packing material, a packed component of an image forming apparatus, and a packed process cartridge.

Description of the Related Art

In consideration of the global environment, it has been proposed to reduce the use of plastic in packing materials for image forming apparatuses, such as printing machines, copy machines, and printers. Japanese Patent Laid-Open No. 10-095057 discusses manufacturing packing boxes by folding paperboard.

SUMMARY

An aspect of the present disclosure provides a packing material configured to pack a component of an image forming apparatus. The packing material includes a first prismatic portion including a first surface and a second surface that face each other in a first direction, and a first side surface portion folded from the first surface toward the second surface along a first fold line. The first side surface portion includes a first portion, with a first length along a surface of the first side surface portion from the first fold line to a tip of the first portion being longer than a spacing between the first surface and the second surface in the first direction.

Features of the present disclosure will become apparent from the following description of embodiments with reference to the attached drawings. The following description of embodiments is described by way of example.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic cross-sectional view illustrating a schematic configuration of an image forming apparatus according to an embodiment.

FIG. 2 is a perspective view of a process cartridge according to an embodiment.

FIG. 3 is a perspective view of an image forming apparatus according to an embodiment.

FIG. 4 is a perspective view of a packing material according to an embodiment.

FIG. 5 is a perspective view of a packing material according to an embodiment.

FIG. 6 is a perspective view of a packing material according to an embodiment.

FIG. 7 is a development view of a packing material according to an embodiment.

FIG. 8 is a diagram illustrating a method of assembling a packing material according to an embodiment.

FIG. 9 is a diagram illustrating a packing method for a packing material according to an embodiment.

FIG. 10 is a perspective view of a packing material according to an embodiment.

FIG. 11 is a perspective view of a packing material according to an embodiment.

DESCRIPTION OF THE EMBODIMENTS

Methods of manufacturing packaging boxes include not only a folding process for paperboard but also processes such as an adhesion process and a tab insertion process. This complicates the manufacturing method, making it difficult to automate the production of packaging boxes. Accordingly, several embodiments of the present disclosure provide packing materials that can be easily assembled.

The techniques described herein have contributed to a sustainable society, including decarbonization and a promoting sound material-cycle practices.

Hereinafter, embodiments of a packing material for an image forming apparatus according to the present disclosure are described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals are assigned to the same or equivalent components or functions. For conciseness, redundant descriptions thereof are not repeated.

Image Forming Apparatus

FIG. 1 is a schematic diagram illustrating a configuration of an image forming apparatus 100. FIG. 2 is a perspective view of a process cartridge. FIG. 3 is a perspective view of the image forming apparatus 100, viewed from a front side.

As illustrated in FIG. 1, the image forming apparatus 100 is a full color printer including image forming units PY, PM, PC, and PK. An intermediate transfer unit 30 and a process cartridge 10 are detachably incorporated in a housing 101 of the image forming apparatus 100.

In the image forming unit PY, a yellow toner image is formed on a photosensitive drum 1Y and is primarily transferred to an intermediate transfer belt 31. In the image forming unit PM, a magenta toner image is formed on a photosensitive drum 1M and is primarily transferred to the intermediate transfer belt 31 so as to be superimposed on the yellow toner image. In the image forming units PC and PK, a cyan toner image and a black toner image are formed on photosensitive drums 1C and 1K, respectively, and are sequentially transferred onto the intermediate transfer belt 31 in a similar manner.

The four color toner image carried on the intermediate transfer belt 31 is conveyed to a secondary transfer portion T2. The four color toner image on the intermediate transfer belt 31 is secondarily transferred collectively onto a recording medium P at the secondary transfer portion T2. The recording medium P, which has been drawn from a recording material cassette 17, are individually separated by a separation roller 11 and fed to a registration roller 12. The separated recording medium P waits at the registration roller 12 and is then fed to the secondary transfer portion T2, with its timing adjusted to coincide with the arrival of the toner image on the intermediate transfer belt 31. The recording medium P onto which the toner image has been secondarily transferred at the secondary transfer portion T2 is heated and pressed by a fixing device 15, whereby the toner image is fixed onto its surface, and is then discharged to the outside.

The image forming units PY, PM, PC, and PK are configured substantially identically, except for the colors of toner used in development devices 4Y, 4M, 4C, and 4K attached thereto, which are yellow, magenta, cyan, and black, respectively. In the following description, the black image forming unit PK will be described. For the other image forming units PY, PM, and PC, the suffix “K” in the reference numerals used in the description shall be read as “Y”, “M”, or “C”, respectively.

The image forming unit PK includes a charging unit 2K, an exposure device 3K, the development device 4K, and a primary transfer roller 5K around the photosensitive drum 1K. The photosensitive drum 1K is formed of a metal cylinder on which a photosensitive layer having a negative charging polarity is formed, and is configured to rotate in the direction indicated by an arrow at a predetermined process speed. The charging unit 2K charges the surface of the photosensitive drum 1K to a uniform negative potential. The exposure device 3K exposes the charged surface of the photosensitive drum 1K based on image data, thus forming an electrostatic latent image on the surface of the photosensitive drum 1K. The development device 4K develops the electrostatic latent image on the photosensitive drum 1K, thus forming a toner image on the surface of the photosensitive drum 1K.

The primary transfer roller 5K presses against the inner side surface of the intermediate transfer belt 31 to form a primary transfer section TK at a portion between the photosensitive drum 1K and the intermediate transfer belt 31. Application of a positive-polarity direct current (DC) voltage to the primary transfer roller 5K primarily transfers the toner image carried on the photosensitive drum 1K onto the intermediate transfer belt 31.

A secondary transfer roller 13 comes into contact with the intermediate transfer belt 31 supported by an opposing roller 14 to form the secondary transfer portion T2. When the recording medium P is conveyed while being sandwiched in an overlaid state with the toner image on the intermediate transfer belt 31, a positive-polarity voltage is applied to the secondary transfer roller 13, so that the toner image carried on the intermediate transfer belt 31 is secondarily transferred onto the recording medium P.

The intermediate transfer belt 31 is stretched and supported across a tension roller 33, a driving roller 32, and the opposing roller 14, and is driven by the driving roller 32 to rotate in an arrow R2 direction at a predetermined process speed.

As illustrated in FIG. 2, the process cartridge 10 is a replacement unit including the photosensitive drum 1K that is configured separately from the development device 4K. The process cartridge 10 is replaced by being guided, with fitting holes 57 and 58 aligned with a drum shaft 55, which is disposed on the housing 101, and then being pulled out to the front side.

The process cartridge 10 exposes the photosensitive drum 1K through an obliquely upper portion thereof facing the development device 4K and the lower surface facing the intermediate transfer belt 31. The process cartridge 10 has a groove portion 81, which is an example of a guide portion extending continuously along a longitudinal direction of the process cartridge 10, at a position away from the drum shaft 55 in a rotational direction of the intermediate transfer belt 31.

A separation mechanism 23 raises and lowers the secondary transfer roller 13 to bring the secondary transfer roller 13 into contact with, or to separate the secondary transfer roller 13 from, the secondary transfer portion T2. To prevent deformation of the secondary transfer roller 13, the secondary transfer roller 13 is separated from the intermediate transfer belt 31 except during image formation. This prevents unnecessary friction between the secondary transfer roller 13 and the intermediate transfer belt 31 when the intermediate transfer unit 30 is pulled out toward the front side.

A separation mechanism 20 lowers the intermediate transfer belt 31 to separate the intermediate transfer belt 31 from the photosensitive drums 1Y, 1M, 1C, and 1K. This prevents unnecessary friction between the intermediate transfer belt 31 and the photosensitive drums 1Y, 1M, 1C, and 1K when the intermediate transfer unit 30 is pulled out toward the front side.

As illustrated in FIG. 3, replacement doors 50Y, 50M, 50C, and 50K for toner bottles 7Y, 7M, 7C, and 7K of the corresponding colors are arranged on a front surface of the housing 101. The replacement doors 50Y, 50M, 50C, and 50K can be opened and closed independently, and are opened for replacement of the corresponding color toner bottles 7Y, 7M, 7C, and 7K.

The front surface of the housing 101 is provided with an openable/closable door unit 60 that is openable and closable relative to the housing 101.

To open the openable/closable door unit 60, a manual lever 68 is rotated to activate the separation mechanism 20 as illustrated in FIG. 1, thus separating the intermediate transfer belt 31 from the photosensitive drums 1Y, 1M, 1C, and 1K. During image formation, the manual lever 68 is rotated to a position at which the operation of pulling the openable/closable door unit 60 forward and then tilting it downward is prevented. In contrast, in inserting or removing the process cartridge 10, the manual lever 68 is rotated to a position at which the openable/closable door unit 60 is allowed to be tilted forward.

Guide members 90 and 91 are disposed on the upper surface of the openable/closable door unit 60 tilted to the front side. The guide members 90 and 91 guide the process cartridge 10 to move along the drum shaft 55 with the center of the photosensitive drum 1K positioned with respect to the drum shaft 55. This prevents contact between the intermediate transfer belt 31 of the intermediate transfer unit 30 and the process cartridge 10 when the process cartridge 10 is replaced.

The development device 4K is configured to receive a drive input from both sides in the longitudinal direction. Thus, motors 61 are mounted on the openable/closable door unit 60 as drive sources. A drive gear unit 62, which connects the respective motors 61 to the development device 4K, is also provided on the openable/closable door unit 60. The openable/closable door unit 60 is tilted forward around a rotation shaft 69.

To supply power to the respective motors 61, an electrical contact portion 63 is provided on the openable/closable door unit 60. Power is supplied to the respective motors 61 via an electrical harness extending from the electrical contact portion 63. When the openable/closable door unit 60 is closed, electrical conduction is established between the electrical contact portion 63 and an electrical contact portion provided on the housing 101. A shutter 64 is also provided to cover the electrical contact portion 63.

The process cartridge 10 is detached from the housing 101 and replaced with a new one according to the following procedure. (1) The manual lever 68 is tilted to move the intermediate transfer belt 31 of the intermediate transfer unit 30 vertically downward. This operation is performed because the openable/closable door unit 60 cannot be pulled out forward unless the manual lever 68 is released. (2) The openable/closable door unit 60 is once pulled out from the front of the housing 101, and the drum shaft 55 is pulled out from a fitting hole 67. Subsequently, the openable/closable door unit 60 is tilted forward and is lowered while being rotated vertically downward. Once the openable/closable door unit 60 is lowered, the guide members 90 and 91, which are used to pull out the process cartridge 10 from the housing 101, become visible. (3) The process cartridge 10 is pulled out while being guided by the drum shaft 55 and the guide members 90 and 91. (4) A new process cartridge 10 for replacement is inserted into the housing 101. During insertion, the process cartridge 10 is placed on the guide members 90 and 91, and the drum shaft 55 is positioned at the center of the photosensitive drum 1K. (5) The new process cartridge 10 is pushed in while being guided by the guide members 90 and 91. Through the above procedure, the process cartridge 10 is detached from the housing 101 and the new one is attached to the housing 101.

Packaging of Process Cartridge

FIG. 4 is a perspective view of a packing material 200 for packing the process cartridge 10. In FIG. 4, the process cartridge 10 is illustrated in a simplified form (as a prism indicated by a dotted line). A first end of the process cartridge 10 in the longitudinal direction is inserted into the packing material 200. The longitudinal direction of the process cartridge 10 is typically a direction in a rotation axis of a rotation body, such as a photosensitive drum. While not illustrated in FIG. 4, a second end of the process cartridge 10 in the longitudinal direction is inserted into another packing material 200. In other words, both ends of the process cartridge 10 in the longitudinal direction are inserted into the packing materials 200 of the same type. Packing material 200 has a function of packing the process cartridge 10. Packing material 200 according to the present embodiment also functions as a cushioning material that mitigates an impact applied to the process cartridge 10. The process cartridge 10 may be inserted into the packing materials 200 in a state of being wrapped in a packing sheet.

As illustrated in FIG. 4, at least one surface of the packing material 200 has an opening 250. The process cartridge 10 is inserted into the opening 250. The surface opposite to the surface having the opening 250 has another opening 260. A part or the entirety of the process cartridge 10 is inserted into this opening 260. In such a manner, the process cartridge 10 is packed in the packing material 200.

Structure of Packing Material of Process Cartridge

The detailed structure of the packing material 200 will be described with reference to FIGS. 5 and 6. FIGS. 5 and 6 are perspective views of one of the packing materials 200, each illustrating the packing material 200 from a different viewing angle. The directions 310, 320, and 330 illustrated in FIGS. 5 and 6 are mutually orthogonal. Hereinafter, for convenience, the direction 320 may be referred to as a first direction, the direction 310 may be referred to as a second direction, and the direction 330 may be referred to as a vertical direction. In FIGS. 5 and 6, the same reference numerals are assigned to the same portions.

The packing material 200 includes two prismatic portions. As illustrated in FIG. 5, a prismatic portion 510 includes surfaces 201, 202, 203, and 204. As illustrated in FIG. 6, a prismatic portion 520 includes surfaces 205, 206, 207, and 208. A surface 209 connects the prismatic portion 510 and the prismatic portion 520. The surface 209 overlaps the surface 204 of the prismatic portion 510 and the surface 208 of the prismatic portion 520. Accordingly, the surface 209 may be regarded as a part of the prismatic portion 510 as well as a part of the prismatic portion 520.

Here, the surfaces 201 to 209 are each a plate-like member. Specifically, in the present embodiment, the term “surface” refers to a plate or a plate-like member. Two adjacent surfaces (e.g., surfaces 201 and 202) may be formed by folding a single plate-like member. In such a case, the fold line serves as the boundary between the two adjacent surfaces. Thus, in the present embodiment, terms such as “end” or “edge” of a surface may refer to either the portion of the above-described fold line or a discontinuity in the plate-like member.

Referring to FIG. 5, the prismatic portion 510 will be described. Initially, the surfaces 201 and 203 face each other in the first direction 320. In the present embodiment, the surfaces 201 and 203 are substantially parallel to each other. The surfaces 202 and 204 face each other in the vertical direction 330. In the present embodiment, the surfaces 202 and 204 are substantially parallel to each other. The surface 202 connects the surfaces 201 and 203. Specifically, the surface 202 is a connecting surface connecting the surface 201 and the surface 203.

As illustrated in FIG. 5, the surface 201 has the opening 250. During packing, the process cartridge 10 is inserted into the opening 250 in the first direction 320. A plurality of flaps 210 is disposed around the opening 250 of the surface 201. Each flap 210 is formed by being folded from the surface 201. The flaps 210 with such a configuration increase the insertable range in the second direction 310 and the vertical direction 330 when the process cartridge 10 is inserted into the opening 250. Additionally, with the process cartridge 10 inserted into the opening 250, the flaps 210 can reduce impact caused by movement of the process cartridge 10 in the second direction 310 and the vertical direction 330. As a result, the packing operation can be facilitated.

The surface 201 further includes cushioning openings 231 and 232.

When a strong force is applied to the packing material 200 in a state where the process cartridge 10 is packed, the surface 201 can deform to narrow the cushioning openings 231 and 232. This deformation can protect the process cartridge 10 from impact.

As illustrated in FIG. 6, the surface 203 has the opening 260. In a state where the process cartridge 10 is packed in the packing material 200, the process cartridge 10 is partially inserted through the opening 260. Such a configuration facilitates packing of the process cartridge 10, even in a case where the process cartridge 10 partially protrudes in the first direction 320.

As illustrated in FIGS. 5 and 6, the prismatic portion 510 includes two side surface portions 212. Each side surface portion 212 is a plate-like member, as with the surfaces 201 to 209. In the present embodiment, the term “side surface” refers to a portion that is located on the lateral side of the opening 250 with respect to the first direction 320 in which the process cartridge 10 travels to be inserted into the opening 250.

Each side surface portion 212 is formed by being folded from the surface 201 toward the surface 203. Specifically, the fold lines between the surface 201 and the respective side surface portions 212 serve as the boundaries between the surface 201 and the side surface portions 212. Thus, the fold lines between the surface 201 and the side surface portions 212 serve as ends (edges) of both the surface 201 and the respective side surface portions 212.

Here, for convenience, the direction along the intersection line between the plane defined by the first direction 320 and the second direction 310 and the surface of the side surface portion 212 is referred to as the direction along the surface of the side surface portions 212 (hereinafter, referred to as a surface direction).

In the surface direction, the ends opposite to the above-described fold lines serve as the tips of the side surface portions 212.

As illustrated in FIG. 5, each side surface portion 212 includes three portions 212a, 212b, and 212c. The three portions 212a, 212b, and 212c have different lengths in the surface direction from the fold line to the tip. Specifically, the length of the portion 212b in the surface direction from the fold line to the tip is the longest. The length of portion 212c in the surface direction from the fold line to the tip is the shortest.

In the present embodiment, a length B from the fold line to the tip, in the surface direction, of the portion 212b of each side surface portion 212 is longer than a spacing A in the first direction 320 between the surfaces 201 and 203. In contrast, for the portions 212a and 212c of each side surface portion 212, the length from the fold line to the tip in the surface direction is shorter than the spacing A.

A description will be provided of the effect of the length B (FIG. 7) in the surface direction of the portion 212b of each side surface portion 212 being greater than the spacing A between the surfaces 201 and 203. As illustrated in FIG. 5, each side surface portion 212 is folded so as to be positioned within the inner space of the prismatic portion 510. The length B of a part of each side surface portion 212 (i.e., the portions 212b) being greater than the spacing A enables the side surface portions 212 to be prevented from returning toward the outside of the prismatic portion 510. In other words, the process of folding the side surface portions 212 allows the side surface portions 212 to be positioned at the intended location. Thus, operations, such as locking a part of each side surface portion 212 or fixing it with adhesive, can be omitted. This facilitates the assembly of the packing material.

In practice, in the present embodiment, the tip of the portion 212b of each side surface portion 212 is merely in contact with the surface 203. In other words, no operation, such as locking a part of each side surface portion 212 or fixing it to another member using adhesive, is performed. Thus, when a force is applied to any of the side surface portions 212 in a direction that pushes the side surface portion(s) 212 further into a space inside the prismatic portion 510, the tip of the corresponding portion(s) 212b can move away from the surface 203.

The effect of facilitating assembly of the packing material becomes more pronounced in a case where the assembly of the packing material is automated using robots. In robotic assembly operations, simple tasks, such as pressing one part of a sheet member while pushing another part, can be performed easily. On the other hand, tasks, such as inserting one part of a member into another member, or joining two members by applying adhesive, are complex. Thus, to automate these complex tasks, the robot tends to become complicated. Consequently, the possibility of trouble occurring in the automation line also increases. To address these, in the present embodiment, the packing material 200 can be assembled by folding the side surface portions 212 into the prismatic portion 510. This enables reduction or even elimination of the need for complex tasks such as those described above in the assembly process for the packing material 200.

In the present embodiment, each side surface portion 212 includes three portions 212a, 212b, and 212c. Alternatively, each side surface portion 212 may, in an embodiment, include only a portion corresponding to the portion 212b. In this configuration, the effect of facilitating the assembly operation as described above can also be achieved.

The reason why each side surface portion 212 includes the portion 212a and 212c, in addition to the portion 212b, in the present embodiment will be described. As described above, the tips of the portions 212b come into contact with the surface 203, which generates a force that prevents the side surface portions 212 from moving outward from the prismatic portion 510. At the same time, a resistance force acts against the folding of the side surface portions 212 when the side surface portions 212 are being folded inward into the space inside the prismatic portion 510 during the assembly of the packing material 200. This resistance force increases as the length of each tip that contacts the surface 203 increases. In other words, the longer the width of the tip of the portion 212b (i.e., the length in the vertical direction 330) of each side surface portion 212, the greater the resistance force becomes.

Thus, in the present embodiment, the portions 212a and 212c of each side surface portion 212, which are distinct from the portion 212b, have lengths, in the surface direction, that are shorter than the spacing A between the surfaces 201 and 203 in the first direction 320. As a result, when each side surface portion 212 is folded toward the inner space of the prismatic portion 510, the tip of the corresponding portion 212a remains separated from the surface 203. Similarly, when each side surface portion 212 is folded inward toward the prismatic portion 510, the tip of the corresponding portion 212c also remains separated from the surface 203. In other words, the tips of the surfaces 201 and 203 do not contribute to the resistance force. Consequently, the side surface portions 212 can be folded with a small force.

The force that restrains the side surface portions 212 from moving outward from the prismatic portion 510 increases as the contact area between each side surface portion 212 and the surface 203 (i.e., the width of the tip of each portion 212b) increases. Thus, if the width of the tip of each portion 212b falls within the range of 50% to 95% of the length of the fold line of the side surface portion 212, it becomes easier to achieve a balance between the resistance force and the restraining force. For a typical size of the process cartridge 10, the width of the tip of each portion 212b often falls within the range of 10 mm to 100 mm.

In addition, if the length B of the portion 212b of each side surface portion 212 in the surface direction is too long, the possibility that the side surface portions 212 may unintentionally be folded at an intermediate position during assembly increases. Thus, if the length B of the portion 212b of each side surface portion 212 in the surface direction is equal to or less than 140% of the spacing A between the surfaces 201 and 203, the possibility of such unintended folding of the side surface portion 212 can be reduced.

Next, the prismatic portion 520 will be described with reference to FIG. 6. The prismatic portion 520 has a structure having functions equivalent to a part of the prismatic portion 510. For conciseness, a detailed description of the prismatic portion 520 is incorporated by reference rather than being repeated.

As described above, the prismatic portion 520 includes the surfaces 205 to 208. Initially, the surfaces 205 and 207 face each other in the first direction 320. In the present embodiment, the surfaces 205 and 207 are approximately parallel. The surfaces 206 and 208 face each other in the vertical direction 330. In the present embodiment, the surfaces 206 and 208 are approximately parallel. The surface 206 connects the surfaces 205 and 207. Specifically, the surface 206 is a connecting surface connecting the surfaces 205 and 207.

Here, the functional correspondence between the prismatic portion 520 and the prismatic portion 510 is described. The surfaces 205 to 208 of the prismatic portion 520 respectively correspond to the surfaces 201 to 204 of the prismatic portion 510. The surfaces 205 and 207 of the prismatic portion 520 do not have an opening.

As described above, in the prismatic portion 520, side surface portions 220 are formed by being folded from the surface 205 toward the surface 207. The structures of the side surface portions 220 of the prismatic portion 520 are equivalent to those of the side surface portions 212 of the prismatic portion 510. Thus, all descriptions regarding the side surface portions 212 also apply to the side surface portions 220, and are incorporated by reference, for conciseness.

In the present embodiment, each side surface portion 220 includes two parts, as illustrated in FIG. 6. A portion 220b of each side surface portion 220 corresponds to the portion 212b of the respective side surface portions 212. The other portion of each side surface portion 220, which is a portion 220a, corresponds to either the portion 212a or the portion 212c of the respective side surface portions 212.

In the present embodiment, a length X from the fold line in the surface direction to the tip of the portion 220b of each side surface portion 220 is longer than a spacing Y between the surfaces 205 and 207 in the first direction 320, as illustrated in FIG. 7. In contrast, for the portion 220a of each side surface portion 220, the length from the fold line to the tip in the surface direction is shorter than the spacing Y. The effect of this length relationship is similar to that in the side surface portions 212 and such description is incorporated by reference.

Next, the differences between the prismatic portion 510 and the prismatic portion 520 will be described. As described above, the surface 206 of the prismatic portion 520 is a connecting surface connecting the surfaces 205 and 207. Flap portions 218 are disposed at both ends of the surface 206 of the prismatic portion 520. The flap portions 218 are formed by being folded from the surface 206.

Structure of Packing material in Modified Example

Depending on the magnitude and direction of expected impact during transportation, the process cartridge 10 can be protected even if only one of the prismatic portion 510 and the prismatic portion 520 is provided with side surface portions. Thus, only one of the prismatic portion 510 and the prismatic portion 520 may be provided with side surface portions. Specifically, in a first modified example, the prismatic portion 510 includes the side surface portions 212, while the prismatic portion 520 is not provided with side surface portions 220. In a second modified example, the prismatic portion 510 is not provided with side surface portions 212, while the prismatic portion 520 includes the side surface portions 220. In either modified example, the effect of simplifying the process of forming the side surface portions can be achieved.

Assembly of Packing Material

A method of assembling the packing material 200 according to the present embodiment will be described with reference to FIGS. 7, 8 and 9.

FIG. 7 is a plan view illustrating the packing material 200 in an unfolded state. The packing material 200 in the unfolded state refers to the packing material 200 before it is assembled. The packing material 200 in the unfolded state is a single plate-like member 700 formed in a predetermined shape. The plate-like member 700 has openings or cuts. In FIG. 7, the same reference numerals are used for the portions that are the same as those in FIGS. 5 and 6.

The packing material 200 is formed by the plate-like member 700 in the state illustrated in FIG. 7 being folded along the plurality of fold lines 701 to 714. FIG. 8 is a perspective view illustrating the packing material 200 in the process of being assembled. FIG. 8 illustrates a state in which the plate-like member 700 is folded along the fold lines 702 to 704 and 706 to 708 illustrated in FIG. 7. From the state illustrated in FIG. 8, the plate-like member 700 is further folded along the fold line 701 and the fold line 705, so that the prismatic portions 510 and 520 are arranged side by side along the first direction 320. Subsequently, the plate-like member 700 is folded along the fold lines 709 to 712, thus forming the side surface portions 212 and the side surface portions 220.

The above assembly process includes a process of folding the plate-like member 700. Thus, automation using robots is easily achievable. In particular, forming the side surface portions 212 and the side surface portions 220 only through their respective folding processes simplifies the assembling process of the packing material 200.

The process cartridge 10 is inserted into the packing materials 200 that has undergone the above assembly process.

The direction in which the process cartridge 10 is inserted is illustrated in FIG. 4.

After both ends of the process cartridge 10 are packed in the packing materials 200, the process cartridge 10 and the packing materials 200 are housed in a box 280. FIG. 9 illustrates how the process cartridge 10 and a packing material 200 are accommodated within the box 280. As illustrated in FIG. 9, during the process of placing the packing material 200 into the box 280, the flap portions 218 come into contact with a part of the box 280. As the packing material 200 continues to enter the box 280 in this state, the flap portions 218 are folded in the directions indicated by arrows 950. Eventually, the flap portions 218 in the state illustrated in FIGS. 5 and 6 are formed. This method allows the folding process for forming the flap portions 218 to be integrated into the boxing process. As a result, the assembly process of the packing materials 200, or the packing process of the process cartridge 10, can be streamlined.

The plate-like member 700 in the present embodiment is made of a material that can be formed by folding.

Additionally, the plate-like member 700 is made of a material that has downward flexibility. This is because the packing material 200 also functions as a cushioning material. For example, cardboard may be used for the plate-like member 700.

Alternatively, thick sheet may be used for the plate-like member 700.

Cushioning Function of Packing Material

Next, the cushioning function of the packing materials 200 in the present embodiment will be described. During the packing or transportation of the process cartridge 10, it is assumed that external impacts may be applied to the box 280. For example, vibrations occurring while transportation apparatuses, such as airplanes or trucks, are in motion may cause impacts to the box 280. Alternatively, an impact may be applied to the box 280 if it is unintentionally dropped. When such impacts are applied to the box 280, the packing materials 200 function as cushioning materials that prevent or reduce the transmission of the impact to the process cartridge 10. The side surface portions 212, the side surface portions 220, and the flap portions 218 in the present embodiment each contribute to reinforcing the packing materials 200 as cushioning members.

The effect of the reinforcement will be described with reference to FIGS. 10 and 11. FIGS. 10 and 11 are perspective views of a packing material 200. The viewing direction in FIG. 10 is the same as that in FIG. 5, and the viewing direction in FIG. 11 is the same as that in FIG. 6.

It is assumed that a force is applied to the packing material 200 in the direction of arrows 901 in FIG. 10. For example, such a force in the direction of the arrows 901 is applied when the process cartridge 10 is inserted into the opening 250 of the surface 201 with misalignment relative to the intended position. In this case, the surface 201 of the prismatic portion 510 may deform into the shape as indicated by a dotted line 903 in FIG. 10. The side surface portions 212 resist such a deformation, with the side surface portions 212 having been formed by being folded from the surface 201. Thus, ridge lines along the fold lines 710 reinforce the surface 201. As a result, the surface 201 can be prevented from deforming into a shape as indicated by the dotted line 903, or the amount of such a deformation can be reduced. Portions corresponding to the fold lines between the side surface portions 220 and the flap portions 218 also produce a similar reinforcing effect as that produced by the side surface portions 212.

Although not illustrated in FIG. 10, after the process cartridge 10 is inserted into the opening 250, a force may be applied to the process cartridge 10, potentially causing movement of the process cartridge 10 in the second direction 310 or the vertical direction 330. The surface 201 resists such a force. In addition, when a strong force is applied in the vertical direction 330, the cushioning openings 231 and 232 induce deformation of the surface 201 or 202 through the collapse of the respective openings, thus mitigating impact.

Next, it is assumed that forces are applied to the packing material 200 in the directions of arrows 905 in FIG. 11. After the process cartridge 10 is inserted into the opening 250, forces may be applied to the process cartridge 10, potentially causing movement of the process cartridge 10 in the first direction 320. In such cases, forces indicated by the arrows 905 in FIG. 11 may be exerted. In particular, the forces represented by the arrows 905 may occur at the position of the surface 206 in the vertical direction 330. As a result, the prismatic portion 520 may deform into the shape as indicated by a dotted line 907. In contrast, the side surface portions 220 are disposed within the internal space of the prismatic portion 520, thus enabling the side surface portions 220 to maintain the angles at the corners of the prismatic portion 520 at approximately 90 degrees. Consequently, deformation of the prismatic portion 520 into the shape as illustrated by the dotted line 907 can be prevented, or the amount of such deformation can be reduced. Although the prismatic portion 520 and the side surface portions 220 have been described as an example, the side surface portions 212 of the prismatic portion 510 can also produce a similar effect.

As described above, in the present embodiment, the strength of the packing material 200 is enhanced by the side surface portions 212 and the side surface portions 220, and the flap portions 218. When the packing material 200 is also used as a cushioning material, it is desirable that the packing material 200 do not deform, even with application of a strong impact. Thus, the enhancement of the strength of the packing material 200 contributes to improving its function as a cushioning material.

According to the present disclosure, a packaging material for an image forming apparatus can be provided, which can be easily assembled.

While the present disclosure has been described with reference to embodiments, it is to be understood that the present disclosure is not limited to the disclosed embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.

This application claims priority to and the benefit of Japanese Patent Application No. 2024-166173, filed Sep. 25, 2024, which is hereby incorporated by reference herein in its entirety.