CN112978004A - Cup-shaped container and method for manufacturing same - Google Patents
Cup-shaped container and method for manufacturing same Download PDFInfo
- Publication number
- CN112978004A CN112978004A CN202011489945.6A CN202011489945A CN112978004A CN 112978004 A CN112978004 A CN 112978004A CN 202011489945 A CN202011489945 A CN 202011489945A CN 112978004 A CN112978004 A CN 112978004A
- Authority
- CN
- China
- Prior art keywords
- heat
- main body
- fusible resin
- blank
- cup
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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Images
Classifications
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- B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
- B65D3/10—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines characterised by form of integral or permanently secured end closure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D3/00—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines
- B65D3/22—Rigid or semi-rigid containers having bodies or peripheral walls of curved or partially-curved cross-section made by winding or bending paper without folding along defined lines with double walls; with walls incorporating air-chambers; with walls made of laminated material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D65/00—Wrappers or flexible covers; Packaging materials of special type or form
- B65D65/38—Packaging materials of special type or form
- B65D65/40—Applications of laminates for particular packaging purposes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
- B65D85/70—Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for
- B65D85/72—Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for for edible or potable liquids, semiliquids, or plastic or pasty materials
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
- B65D85/00—Containers, packaging elements or packages, specially adapted for particular articles or materials
- B65D85/70—Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for
- B65D85/72—Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for for edible or potable liquids, semiliquids, or plastic or pasty materials
- B65D85/78—Containers, packaging elements or packages, specially adapted for particular articles or materials for materials not otherwise provided for for edible or potable liquids, semiliquids, or plastic or pasty materials for ice-cream
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Making Paper Articles (AREA)
- Packages (AREA)
Abstract
本发明涉及杯状容器及其制造方法。提供能够抑制由与内容物的接触引起的劣化等的杯状容器，作为能够使用纸杯的制造设备低价地进行制造且内容物的长期保存性优异并能够无菌杀菌、蒸煮杀菌的杯状容器。杯状容器包括：主体，其是将主体用坯料的两端缘部彼此交错并接合以成型为筒状而成的；和底体，其是将底体用坯料以形成底部和垂下部的方式成型而成的。垂下部的外表面与主体的下端部的内表面接合。主体用坯料及底体用坯料分别由包括金属箔层和在金属箔层的两面上层叠的热熔接性树脂层的层叠体形成。在主体的交错部中，主体用坯料的内侧端面由内侧树脂积存部被覆。
The present invention relates to a cup-shaped container and a method of making the same. To provide a cup-shaped container capable of suppressing deterioration due to contact with the content, etc., as a cup-shaped container that can be manufactured inexpensively using a paper cup manufacturing facility, has excellent long-term storage of the content, and is capable of aseptic sterilization and retort sterilization . The cup-shaped container includes: a main body formed by staggering and joining both end edges of a main body blank to form a cylindrical shape; and a bottom body formed by forming a bottom and a hanging portion from the bottom body blank formed. The outer surface of the hanging portion is engaged with the inner surface of the lower end portion of the main body. The raw material for the main body and the raw material for the base body are each formed of a laminate including a metal foil layer and a heat-fusible resin layer laminated on both surfaces of the metal foil layer. In the staggered portion of the main body, the inner end surface of the main body blank is covered with the inner resin reservoir.
Description
Technical Field
The present invention relates to a cup-shaped container containing food, drink, or the like such as ice cream or yogurt, and a method for manufacturing the same.
Background
As a container for filling and packaging a semisolid-shaped dairy product such as ice cream, yogurt, or the like, a paper cup-shaped container, that is, a paper cup is generally used.
The paper cup is generally formed by integrally joining a main body and a bottom body, each formed of a paper blank cut into a predetermined shape. In more detail, the body is formed as follows: the substantially fan-shaped body blank is formed into a tubular shape by overlapping (overlapping) both end edge portions of the blank, and is formed with a folded portion folded back inward at a lower end opening edge portion and a flange portion curled outward at an upper end opening edge portion. The bottom body has a substantially inverted U-shaped cross section formed by skirt-molding a substantially circular bottom body blank so as to form a suspended portion in the outer peripheral portion thereof. The hanging portion of the bottom body is enclosed by the folded portion of the main body and joined to integrate the main body and the bottom body.
Each of the blanks for the main body and the base body is formed of, for example, a laminate having a paper layer formed of a plain paper, a sour paper, a coated paper, or the like and a polyethylene resin (PE) layer laminated on one surface or both surfaces of the paper layer (for example, see patent document 1 below).
Further, a paper cup using a laminate in which a barrier layer made of an aluminum foil or the like is laminated in addition to a paper layer and a polyethylene resin (PE) layer as a material of each of the above blanks is also known (for example, see patent document 2 below).
Further, as containers for ice cream, yogurt, and the like, containers formed of plastic molded articles such as polypropylene resin (PP) are also known (for example, see patent document 3 below).
Documents of the prior art
Patent document
Patent document 1: japanese patent laid-open publication No. Sho 58-30955
Patent document 2: japanese laid-open patent publication No. 2007-210639
Patent document 3: japanese patent laid-open publication No. 2007-176505
Disclosure of Invention
Problems to be solved by the invention
However, paper cups are excellent in productivity and can be produced at low cost, but on the other hand, they have low barrier properties and are not suitable for long-term storage of contents.
In the case of a paper cup to which a barrier layer such as aluminum foil is added, although the long-term storage stability of the contents is improved, water easily enters from the end face of the paper layer, and retort sterilization cannot be performed.
In addition, in the case of a plastic container, the manufacturing facility costs high and is not suitable for long-term storage of the contents.
In order to solve the above problems, the inventors of the present application have previously proposed a cup-shaped container using a laminate formed of a metal foil layer and a heat-fusible resin layer laminated on at least one of both surfaces thereof as materials for a main body blank and a base body blank (japanese patent application No. 2019-106125).
According to the cup-shaped container, the cup-shaped container can be manufactured at low cost by using a paper cup manufacturing facility, has excellent long-term storage stability of the contents, and can be sterilized aseptically or by retort sterilization.
Here, in the case of the cup-shaped container, since the inside end surface of the body blank located inside the container is exposed to the contents at the staggered portion of the body, there is a possibility that deterioration due to delamination (interlayer peeling) or corrosion may occur at the inside end surface depending on the kind of the contents, and it is not preferable from a hygienic viewpoint.
In the case of the cup-shaped container, if the joining of both end edge portions of the body blank and the joining of the body and the bottom body are insufficient, the sealing property of the container may be deteriorated, and the contents may leak. On the other hand, if the sealing conditions are made strict in order to improve the joining strength, the appearance of the container may be impaired by deformation or the like at the joined portion.
The present invention aims to provide a cup-shaped container which can be produced at low cost as a production facility that can use paper cups, can suppress deterioration or the like due to contact with contents, has excellent long-term storage stability of the contents, and can be sterilized aseptically or by boiling.
Another object of the present invention is to provide a manufacturing method that can more reliably join both end edge portions of a body blank and join a body and a bottom body without causing appearance defects such as deformation of the container when manufacturing the cup-shaped container, and can improve the sealing property of the container.
Means for solving the problems
The present invention includes the following aspects to achieve the above object.
1) A cup-shaped container, comprising:
a main body formed by joining both end edge portions of a main body blank to each other in a staggered manner to form a cylindrical shape; and
a bottom body having a substantially inverted U-shaped cross section, which is formed by molding a bottom body blank so as to form a bottom portion and a hanging portion extending downward from an outer peripheral edge portion of the bottom portion,
in the cup-shaped container, the main body and the bottom body are integrated by joining the outer surface of the bottom portion of the bottom body to the inner surface of the lower end portion of the main body,
the body material is formed of a laminate including a metal foil layer and heat-fusible resin layers laminated on both surfaces of the metal foil layer, both end edge portions of the body material are joined by heat-fusing the heat-fusible resin layers constituting surfaces of the both end edge portions which are overlapped with each other,
the base material is formed of a laminate including a metal foil layer and a heat-fusible resin layer laminated on at least the upper surface of the base body out of both surfaces of the metal foil layer, the inner surface of the lower end portion of the main body and the outer surface of the bottom portion of the base body are joined by heat-fusing the heat-fusible resin layers constituting these surfaces to each other,
in the cup-shaped container, the inner end surface of the body blank located inside the body is covered with the inner resin reservoir formed when the heat-fusible resin layers at the both end edges of the body blank are heat-fused to each other at the intersection of the body.
2) The cup-shaped container according to 1) above, wherein when the thickness of the metal foil layer in the body material is T1, the thickness of the inner heat-fusible resin layer located inside the body is T2, and the thickness of the outer heat-fusible resin layer located outside the body is T3, T1: t2: t3 ═ 1: 0.3-1.5: 0.2-1 and T2 is not less than T3.
3) The cup-shaped container according to 1) or 2) above, wherein the melt mass flow rate, i.e., MFR, of the inner heat-fusible resin layer located inside the body in the body material is 1 to 10g/10 min.
4) The cup-shaped container according to any one of 1) to 3), wherein the inner heat-fusible resin layer located inside the body in the body material includes 2 or more thermoplastic resin layers, and an MFR, which is a melt mass flow rate of the sealing-side thermoplastic resin layer constituting the inner surface of the body, among the thermoplastic resin layers is 3 to 10g/10 min, and an MFR, which is a melt mass flow rate of the laminated-side thermoplastic resin layer laminated on the metal foil layer, among the thermoplastic resin layers is 3 to 10g/10 min.
5) The cup-shaped container according to any one of 1) to 4), wherein an inner end surface of the body material is formed as an inclined surface facing an outer side of the body.
6) The cup-shaped container according to any one of the above 1) to 5), wherein in the body blank, a stepped portion bent in a crank shape so as to face an inner end face of the body blank is formed in a portion adjacent to an outer end edge portion which becomes an outer side of the body out of the both end edge portions which are staggered, and an inner resin reservoir is formed between the stepped portion and the inner end face of the body blank.
7) The cup-shaped container according to any one of 1) to 6) above, wherein, further, at the intersection of the body, an outer end face of the body blank located outside the body is covered with an outer resin bank formed when the heat-fusible resin layers at both end edges of the body blank are heat-fused to each other.
8) A cup-shaped container, comprising:
a main body formed by joining both end edge portions of a main body blank to each other in a staggered manner to form a cylindrical shape; and
a bottom body having a substantially inverted U-shaped cross section, which is formed by molding a bottom body blank so as to form a bottom portion and a hanging portion extending downward from an outer peripheral edge portion of the bottom portion,
in the cup-shaped container, the main body and the bottom body are integrated by joining the outer surface of the bottom body's hanging part to the inner surface of the lower end part of the main body,
the body material is formed of a laminate including a metal foil layer and heat-fusible resin layers laminated on both surfaces of the metal foil layer, both end edge portions of the body material are joined by heat-fusing the heat-fusible resin layers constituting surfaces of the both end edge portions which are overlapped with each other,
the base material is formed of a laminate including a metal foil layer and a heat-fusible resin layer laminated on at least the upper surface of the base body out of both surfaces of the metal foil layer, the inner surface of the lower end portion of the main body and the outer surface of the bottom portion of the base body are joined by heat-fusing the heat-fusible resin layers constituting these surfaces to each other,
in the cup-shaped container, at least one of the 2 heat-fusible resin layers of the body blank includes 2 or more layers, and the melting point of the heat-fusible resin constituting the heat-fusible resin layer on the lamination side laminated on the metal foil layer among the 2 or more layers is lower than that of the heat-fusible resin constituting the other layers,
in the interleaved part of the body, the metal foil layer part of the inner end surface of the body blank positioned inside the body and the interface part of the metal foil layer and the heat-fusible resin layer are covered by a protective film formed by melting and solidifying the heat-fusible resin constituting the heat-fusible resin layer on the laminated side when the heat-fusible resin layers at both end edge parts of the body blank are heat-fused to each other.
9) The cup-shaped container according to 8) above, wherein, in the intersecting portion of the body, a portion of the metal foil layer located on the outer end surface of the body material outside the body and an interface portion between the metal foil layer and the heat-fusible resin layer are covered with a protective film formed by melting and curing the heat-fusible resin constituting the laminate-side heat-fusible resin layer when the heat-fusible resin layers at both end edges of the body material are heat-fused to each other.
10) The cup-shaped container according to the above 8) or 9), wherein a melting point of the heat-fusible resin constituting the laminated side heat-fusible resin layer is lower by 10 ℃ or more than a melting point of the heat-fusible resin constituting the other layer.
11) The cup-shaped container according to 10) above, wherein the melting point of the heat-fusible resin constituting the laminated heat-fusible resin layer is 110 to 140 ℃.
12) The cup-shaped container according to any one of the above 8) to 11), wherein an MFR that is a melt mass flow rate of the heat-fusible resin constituting the laminated-side heat-fusible resin layer is 1 to 5g/10 minutes or more larger than an MFR that is a melt mass flow rate of the heat-fusible resin constituting the other layer.
13) The cup-shaped container according to 12) above, wherein an MFR, which is a melt mass flow rate of the heat-fusible resin constituting the laminated side heat-fusible resin layer, is 4 to 10g/10 min.
14) A method for manufacturing a cup-shaped container according to 1) or 8) above, comprising:
punching a laminate including a metal foil layer and heat-fusible resin layers laminated on both surfaces of the metal foil layer to form a body blank;
punching a laminate including a metal foil layer and a heat-sealable resin layer laminated on at least an upper surface of a base body out of both surfaces of the metal foil layer to form a base body blank;
a step of forming a bottom body having a substantially inverted U-shaped cross section by drawing a bottom body blank so as to form a bottom portion and a suspended portion extending downward from an outer peripheral edge portion of the bottom portion;
a step of forming a tubular body by interleaving both end edge portions of a body blank and thermally welding the thermally-weldable resin layers constituting the surfaces of the both end edge portions that overlap each other; and
a step of integrating the main body and the base body by overlapping the inner surface of the lower end portion of the main body and the outer surface of the suspended portion of the base body and thermally welding the thermally-weldable resin layers constituting these surfaces to each other,
in the above manufacturing method, in the step of forming the cylindrical body, the heat welding of the heat-weldable resin layers at both end edge portions of the body material is performed 2 times, and the 2 nd heat welding is performed by high-frequency sealing.
15) A method of manufacturing a cup-shaped container, comprising:
punching a laminate including a metal foil layer and a heat-sealable resin layer laminated on at least an inner surface of a main body of both surfaces of the metal foil layer to form a main body blank;
punching a laminate including a metal foil layer and a heat-sealable resin layer laminated on at least an upper surface of a base body out of both surfaces of the metal foil layer to form a base body blank;
a step of forming a bottom body having a substantially inverted U-shaped cross section by drawing a bottom body blank so as to form a bottom portion and a suspended portion extending downward from an outer peripheral edge portion of the bottom portion;
a step of overlapping both end edge portions of a body blank and thermally welding the thermally-weldable resin layers constituting the surfaces of the overlapped both end edge portions to each other to form a cylindrical body; and
a step of overlapping the inner surface of the lower end part of the main body with the outer surface of the suspended part of the bottom body and thermally welding the thermally-weldable resin layers constituting the surfaces to integrate the main body and the bottom body,
in the step of forming the cylindrical body, the heat-fusible resin layers at both end edge portions of the body blank are heat-fused 2 times, and the 2 nd heat-fusion is heat-fused by high-frequency sealing.
16) The method of manufacturing a cup-shaped container according to the above 15), wherein a laminate having a heat-fusible resin layer laminated on both surfaces of a metal foil layer is used as the laminate in the step of forming the body material,
in the step of forming the tubular main body, both end edge portions of the main body blank are overlapped in a palm shape, and the heat-fusible resin layers constituting the overlapped surfaces of the both end edge portions are joined to each other by performing the 1 st heat fusion to form the tubular main body having the palm portion, and then the palm portion is folded to one side and overlapped with the outer surface of the main body, and the 2 nd heat fusion is performed by the high-frequency sealing to join the palm portion to the outer surface of the main body.
17) The method of manufacturing a cup-shaped container according to any one of the above 14) to 16), wherein in the step of integrating the body and the base, the heat welding of the heat-fusible resin layer of the lower end portion of the body and the portion of the base that hangs down is performed 2 times, and the 2 nd heat welding is performed by high-frequency sealing.
18) A method of manufacturing a cup-shaped container, comprising:
punching a laminate including a metal foil layer and a heat-sealable resin layer laminated on at least an inner surface of a main body of both surfaces of the metal foil layer to form a main body blank;
punching a laminate including a metal foil layer and a heat-sealable resin layer laminated on at least an upper surface of a base body out of both surfaces of the metal foil layer to form a base body blank;
a step of forming a bottom body having a substantially inverted U-shaped cross section by drawing a bottom body blank so as to form a bottom portion and a suspended portion extending downward from an outer peripheral edge portion of the bottom portion;
a step of overlapping both end edge portions of a blank for a main body and thermally welding the thermally-weldable resin layers constituting the surfaces of the overlapped both end edge portions to each other to form a cylindrical main body; and
integrating the main body and the bottom body by thermally welding the thermally-weldable resin layers constituting the inner surface of the lower end portion of the main body and the outer surface of the bottom portion of the bottom body to each other,
in the step of integrating the body and the base, the heat-fusion bonding of the heat-fusion bonding resin layer of the lower end portion of the body and the hanging portion of the base is performed 2 times, and the 2 nd heat-fusion bonding is performed by high-frequency sealing.
19) The method of manufacturing a cup-shaped container according to 17) or 18), wherein a laminate having a heat-fusible resin layer laminated on both surfaces of a metal foil layer is used as the laminate in the step of forming the base material,
in the step of integrating the main body with the base body, the main body is folded back inward from the lower end opening edge portion thereof so as to enclose the suspended portion of the base body to form a folded-back portion, the main body and the base body are integrated by thermally welding the thermally fusible resin layers constituting the surfaces of the lower end portion of the main body and the folded-back portion, which overlap with each other, of the suspended portion of the base body to each other, and the thermally welding of the lower end portion of the main body and the thermally fusible resin layers of the folded-back portion and the suspended portion of the base body to each other is performed 2 times and the 2 nd thermally welding is performed by high frequency sealing.
Effects of the invention
According to the cup-shaped container of the above 1), the inner end face of the body blank located inside the body is covered with the inner resin reservoir portion formed when the heat-fusible resin layers at both end edge portions of the body blank are heat-fused to each other at the interleaved portion of the body, and is not exposed to the contents, so that deterioration due to delamination or corrosion of the inner end face can be effectively suppressed, and it is also preferable in terms of hygiene.
The cup-shaped container according to 2) to 6) above can more reliably exhibit the above-described effects of the cup-shaped container according to 1) above.
According to the cup-shaped container of the above 7), the outer end surface of the body blank located outside the body is also covered with the outer resin reservoir portion formed when the heat-fusible resin layers at both edge portions of the body blank are heat-fused to each other at the intersection of the body, and therefore, deterioration due to delamination and corrosion of the outer end surface can be effectively suppressed.
According to the cup-shaped container of the above 8), the metal foil layer portion of the inner end surface of the body material located inside the body and the interface portion between the metal foil layer and the heat-fusible resin layer are covered with the protective film formed by melting and solidifying the low-melting-point heat-fusible resin in the laminated heat-fusible resin layer among the heat-fusible resin layers including 2 or more layers constituting the body material at the time of heat-fusing, and are not exposed to the contents, at the intersecting portion of the body, and therefore, deterioration due to delamination and corrosion of the inner end surface can be effectively suppressed, and it is also preferable in terms of hygiene.
In the specification of the present invention, the "melting point" means a melting peak temperature (Tmp) measured by Differential Scanning Calorimetry (DSC) in accordance with JIS K7121-1987.
According to the cup-shaped container of the above 9), the metal foil layer portion of the outer end surface of the body blank located outside the body and the interface portion between the metal foil layer and the heat-fusible resin layer are also covered with the protective film formed by melt-curing the low-melting-point heat-fusible resin in the heat-fusible resin layer on the lamination side among the heat-fusible resin layers including 2 or more layers constituting the body blank at the time of heat-fusing at the interleaved portion of the body, and therefore, deterioration due to delamination and corrosion of the outer end surface can be effectively suppressed.
The above-described effects of the cup-shaped container of 8) or 9) can be more reliably exhibited by the cup-shaped container of 10) to 13) described above.
According to the method for manufacturing the cup-shaped container of 14) or 15), since the heat-fusible resin layers at the both end edge portions of the body blank are also heat-fused by heating from the metal foil layer which becomes high temperature by induction heating of high-frequency sealing, the both end edge portions of the body blank can be more reliably joined to each other, and resin pools are easily formed at the corresponding joining portions along with the heat-fusion, whereby not only can the sealability of the container be improved, but also the occurrence of defects in appearance such as deformation of the container along with the heat-fusion can be effectively suppressed.
According to the method for producing a cup-shaped container of 16) above, occurrence of delamination and the like can be suppressed by preventing both end surfaces of the body material from contacting the contents, and a container which is easy to sterilize and is sanitary can be easily produced by forming the surface contacting the contents with 1 type of resin.
Further, according to the method of manufacturing the cup-shaped container of 16) above, since the step of joining the palm portion of the main body to the outer surface of the main body can be performed by heating from the metal foil layer by ultrasonic sealing, the heat for thermal welding is uniformly transmitted to the respective thermal welding resin layers, so that the joining of the two can be performed more reliably, which is also advantageous in terms of manufacturing efficiency.
According to the method of manufacturing the cup-shaped container of 17) or 18) above, the lower end portion of the main body and the suspended portion of the bottom body are more reliably joined by high-frequency sealing, and resin pools are easily formed at the corresponding joining portions along with the thermal welding, whereby not only can the sealability of the container be improved, but also the occurrence of defects in appearance such as deformation along with the thermal welding can be effectively suppressed.
According to the method for manufacturing a cup-shaped container of 19) above, the sealing property of the joint portion between the main body and the bottom body can be further improved, including the inside of the folded-back portion.
Drawings
Fig. 1 is a perspective view of a cup-shaped container according to embodiment 1 of the present invention.
Fig. 2 is a vertical sectional view taken along line II-II of fig. 1, in which a portion surrounded by a one-dot chain line a is an enlarged view of a portion surrounded by a one-dot chain line a, and a portion surrounded by a one-dot chain line B is an enlarged view of a portion surrounded by a one-dot chain line B.
Fig. 3 (a) is an enlarged cross-sectional view showing the layer structure of the laminate as a material of the main body blank, and (b) is an enlarged cross-sectional view showing the layer structure of the laminate as a material of the bottom body blank.
Fig. 4 (a) is an enlarged cross-sectional view showing the layer structure of the laminate as the material of the main body blank, and (b) is an enlarged cross-sectional view showing the layer structure of the laminate as the material of the base body blank, and shows an aspect in which each heat-fusible resin layer has a 3-layer structure.
Fig. 5 is a horizontal cross-sectional view showing an enlarged view of the staggered portion of the main body in the cup-shaped container.
Fig. 6 is a horizontal cross-sectional view showing another mode of the staggered portion of the main body in the cup-shaped container in an enlarged manner.
Fig. 7 is a horizontal cross-sectional view showing another mode of the staggered portion of the main body in the cup-shaped container in an enlarged manner.
Fig. 8 is a horizontal cross-sectional view showing another mode of the staggered portion of the main body in the cup-shaped container in an enlarged manner.
Fig. 9 (a) is a plan view of the body blank, and (b) is a perspective view of the body formed from the body blank.
Fig. 10 (a) is a plan view of the bottom body blank, and (b) is a perspective view of the bottom body molded from the bottom body blank.
Fig. 11 is a vertical sectional view showing a part of the process of manufacturing the cup-shaped container.
Fig. 12 is a partially enlarged vertical sectional view showing a modification of the coupling structure between the main body and the bottom body in the cup-shaped container.
Fig. 13 is a diagram showing a cup-shaped container according to embodiment 2 of the present invention, wherein (a) is an enlarged cross-sectional view showing a layer structure of a laminate of materials as a body material, and (b) is an enlarged cross-sectional view showing a layer structure of a laminate of materials as a base material, and shows a mode in which each heat-fusible resin layer has a 2-layer structure.
Fig. 14 (a) is an enlarged cross-sectional view showing the layer structure of the laminate as the material of the main body blank, and (b) is an enlarged cross-sectional view showing the layer structure of the laminate as the material of the base body blank, and shows an aspect in which each heat-fusible resin layer has a 3-layer structure.
Fig. 15 is a horizontal cross-sectional view showing an enlarged view of the staggered portion of the main body in the cup-shaped container.
Fig. 16 is a horizontal cross-sectional view showing another mode of the staggered portion of the main body in the cup-shaped container in an enlarged manner.
Fig. 17 is a horizontal cross-sectional view showing an enlarged cross section of a main body in the cup-shaped container according to embodiment 4 of the present invention.
Fig. 18 is a horizontal cross-sectional view sequentially showing a part of the manufacturing process of the cup-shaped container main body.
Fig. 19 is a horizontal sectional view of the cup-shaped container according to embodiment 5 of the present invention, in which a portion surrounded by a one-dot chain line C is an enlarged view of a portion surrounded by a one-dot chain line C.
Fig. 20 is a horizontal cross-sectional view showing a part of the manufacturing process of the cup-shaped container main body.
Fig. 21 is a view showing the cup-shaped container according to embodiment 6 of the present invention, and is a horizontal cross-sectional view showing an enlarged view of one mode of the staggered portion of the main body.
Fig. 22 is a horizontal cross-sectional view showing another mode of the staggered portion of the main body in the cup-shaped container in an enlarged manner.
Fig. 23 is a view showing a cup-shaped container according to embodiment 7 of the present invention, and is a horizontal cross-sectional view showing an enlarged view of one mode of the staggered portion of the main body.
Fig. 24 is a horizontal cross-sectional view showing another mode of the staggered portion of the main body in the cup-shaped container in an enlarged manner.
Fig. 25 is a partially enlarged cross-sectional view sequentially showing a step of forming a hot-press worked portion at an inner end edge portion of a body blank.
Fig. 26 is a view showing a cup-shaped container according to embodiment 8 of the present invention, and is a horizontal cross-sectional view showing an enlarged manner of a staggered portion of a main body in the cup-shaped container.
Fig. 27 is a horizontal cross-sectional view showing another mode of the staggered portion of the main body in the cup-shaped container in an enlarged manner.
Fig. 28 is a horizontal cross-sectional view showing still another mode of the staggered portion of the main body in the cup-shaped container in an enlarged manner.
Fig. 29 is a partial enlarged sectional view taken along line XXIX-XXIX of (a) of fig. 9, and (a) to (c) respectively show 3 ways different in cross-sectional shape.
Description of the reference numerals
1. 1X, 1Y: cup-shaped container
2: main body
2 a: lower end of the main body
21: interleaving part
21Y: closing palm part
23: flange part
20A: blank for main body
20: laminated body
201: metal foil layer
202: inner side heat-fusible resin layer
202 a: thermoplastic resin layer on sealing side
202 b: thermoplastic resin layer on laminated side
203: outer heat-fusible resin layer
203 a: sealing side heat-fusible resin layer
203 b: multilayer heat-fusible resin layer
204. 204X: inner side end face
205: outer end face
206: step part
3: bottom body
31: bottom part
32: lower part of the drop
30A: blank for base
30: laminated body
301: metal foil layer
302: upper side heat-fusible resin layer
303: lower heat-fusible resin layer
R1: inner resin reservoir
R2: outer resin reservoir
M1: protective film
M2: protective film
Detailed Description
Embodiments of the present invention will be described below with reference to fig. 1 to 29.
In the following description, "up and down" refers to up and down of the cup-shaped container, main body, and bottom body (for example, up and down of fig. 2, 11, and 12), in addition, "inner" refers to a side of the cup-shaped container, main body, and bottom body closer to the center (for example, a lower side of fig. 5 to 8, 15, 16, 21 to 24, and 26 to 28, and a right side of fig. 11 and 12), and "outer" refers to a side of the cup-shaped container, main body, and bottom body farther from the center (for example, an upper side of fig. 5 to 8, 15, 16, 21 to 24, and 26 to 28, and a left side of fig. 11 and 12).
< embodiment 1 >
Fig. 1 and 2 are views showing the overall configuration of a cup-shaped container 1 according to embodiment 1 of the present invention, in which the container 1 is formed by integrally joining a main body 2 formed from a main body blank 20A and a bottom body 3 formed from a bottom body blank 30A.
The main body 2 has a tapered cylindrical structure, and as shown in fig. 9, both end edge portions of a main body blank 20A formed in a fan shape are formed by being engaged with each other while being staggered. Therefore, the main body 2 has the interleaved portion 21 extending in the height direction thereof.
A folded portion 22 folded inward is formed at the lower end opening edge portion of the main body 2.
Further, a flange portion 23 bent outward is provided at an upper end opening edge portion of the main body 2. The flange portion 23 is folded back downward and formed into a substantially horizontal flat shape. The flange portion may be formed into a substantially arc-shaped cross section by, for example, being curled downward in a manner other than the illustrated manner.
The bottom body 3 has a substantially inverted U-shaped cross section, includes a horizontal bottom portion 31 formed in a circular shape and a hanging portion 32 extending downward from an outer peripheral edge portion of the bottom portion 31, and is formed by drawing a circular bottom body blank 30A as shown in fig. 10.
The outer surface of the hanging portion 32 of the bottom body 3 is joined to the inner surface of the lower end portion 2a of the main body 2, and the folded portion 22 of the main body 2 is joined to the inner surface of the hanging portion 32, whereby the main body 2 and the bottom body 3 are integrated (see fig. 2 and 11).
As shown in a modification of fig. 12, the main body 2 and the bottom body 3 may be integrated by a coupling structure in which the outer surface of the hanging-down portion 32 of the bottom body 3 is joined to the inner surface of the lower end portion 2a of the main body 2 without forming the folded-back portion 22 at the lower end opening edge portion of the main body 2. According to this configuration, even when the hanging portion 32 is slightly wrinkled during molding of the bottom body 3, air or the like is not mixed in, and the lower end portion 2a of the main body 2 and the hanging portion 32 of the bottom body 3 can be reliably sealed.
As shown in fig. 3 (a), the body material 20A is formed of a laminate 20, and the laminate 20 includes: a metal foil layer 201; an inner heat-fusible resin layer 202 laminated on an inner surface of the main body 2 out of both surfaces of the metal foil layer 201; and an outer heat-fusible resin layer 203 laminated on an outer surface of the main body 2 out of both surfaces of the metal foil layer 201, wherein the main body material 20A does not have a paper layer.
As shown in fig. 3 (b), the blank for a chassis 30A is formed of a laminate 30, and the laminate 30 includes: a metal foil layer 301; an upper heat-fusible resin layer 302 laminated on an upper surface of the base body 3 out of both surfaces of the metal foil layer 301; and a lower heat-fusible resin layer 303 laminated on a lower surface of the metal foil layer 301 to be the base 3, wherein the base material 30A has no paper layer.
Preferably, the thickness of each laminate 20, 30 is less than 250 μm, more preferably less than 200 μm. By setting the thickness of each laminate 20, 30 to the above range, it is possible to reliably avoid the problem that the difference in level of the portion of the flange portion 23 of the main body 2 formed by the intersecting portion 21 is excessively large, or the joining of the lower end portion 2a of the main body 2 and the folded portion 22 to the hanging portion 31 of the bottom body 3 is unstable, as in a paper cup using a laminate having a thickness of about 250 to 400 μm as a material of a blank.
The metal foil layers 201 and 301 function as barrier layers for protecting the contents from gas, water vapor, light, and the like.
As the metal foil constituting the metal foil layers 201 and 301, aluminum foil, iron foil, stainless steel foil, copper foil, and the like can be used, and aluminum foil is preferably used. In the case of aluminum foil, both pure aluminum foil and aluminum alloy foil may be used, and both soft and hard materials may be used, and for example, a soft material (O material) after completion of annealing treatment of a8000 series (particularly a8079H and a8021H) classified according to JIS H4160 is excellent in formability and thus can be preferably used. Further, when a hard material (H material) is used as the aluminum foil constituting the metal foil layers 201 and 301 (particularly, the metal foil layer 201 of the body blank 20A), it is considered that the strength of the flange portion 23 is improved, and deformation of the flange portion 23 due to unexpected impact can be suppressed, and further, the shape retention property as the entire cup-shaped container 1 is improved.
If necessary, both surfaces of the metal foil layers 201 and 301 are subjected to a subbing treatment such as a chemical conversion treatment. Specifically, for example, the surface of the degreased metal foil is coated with any one of aqueous solutions 1) to 3) below, and then dried, and subjected to chemical conversion treatment to form a coating film:
1) contains phosphoric acid;
chromic acid; and
aqueous solution of a mixture of at least 1 compound selected from the group consisting of metal salts of fluorides and non-metal salts of fluorides
2) Contains phosphoric acid;
at least 1 resin selected from the group consisting of acrylic resins, chitosan derivative resins, and phenolic resins; and
aqueous solution of a mixture of at least 1 compound selected from the group consisting of chromic acid and chromium (III) salts
3) Contains phosphoric acid;
at least 1 resin selected from the group consisting of acrylic resins, chitosan derivative resins, and phenolic resins;
at least 1 compound selected from the group consisting of chromic acid and chromium (III) salts; and
an aqueous solution of a mixture of at least 1 compound selected from the group consisting of metal salts of fluorides and non-metal salts of fluorides.
The coating formed on the surface of the metal foil layer 201 or 301 by the chemical conversion treatment is preferably such that the amount of chromium deposited (per surface) is 0.1mg/m2～50mg/m2Particularly preferably 2mg/m2～20mg/m2。
The thickness of the metal foil layers 201, 301 is preferably 40 to 200 μm, and more preferably 80 to 160 μm. By setting the thickness of the metal foil layers 201 and 301 to the above range, sufficient barrier properties and moldability can be obtained.
The heat-sealable resin layers 202, 203, 302, 303 constitute the inner and outer surfaces of the container 1, serve to protect the metal foil layers 201, 301 and impart moldability to the laminates 20, 30, and also serve as heat-sealable layers when joining the end edge portions of the main body blank 20A and the lower end portion 2a and the folded-back portion 22 of the main body 2 to the hanging-down portion 32 of the base body 3.
The heat-fusible resin layers 202, 203, 302, and 303 are made of a general-purpose film such as a heat-fusible polypropylene (PP) film or Polyethylene (PE) film, or a composite film obtained by laminating them, and an unstretched polypropylene film (CPP) having excellent heat resistance and stretch moldability is particularly preferable. The heat-fusible resin layers 202, 203, 302, and 303 may be formed of a coating layer of maleic acid-modified polyethylene, maleic acid-modified polypropylene, ethylene-vinyl acetate, epoxy resin, shellac resin, or the like, instead of the film.
The thickness of the heat-fusible resin layers 202, 203, 302, 303 is preferably 5 to 80 μm, more preferably 10 to 60 μm. By setting the thickness of the heat-fusible resin layers 202, 203, 302, 303 to the above range, sufficient adhesive strength can be obtained at the joint portion between the both end edge portions of the body blank 20A, the joint portion between the lower end portion 2a of the body 2 and the folded-back portion 22 and the hanging-down portion 32 of the base body 3, and the difference in level of the portion constituted by the staggered portion 21 in the upper surface of the flange portion 23 of the body 2 can be made gentle, so that the sealing property at the time of sealing with the lid material is good.
The lamination of the metal foil constituting the metal foil layers 201 and 301 and the films constituting the heat-fusible resin layers 202, 203, 302, and 303 is performed by a dry lamination method via an adhesive layer (not shown), for example. For example, two-pack curable polyester-polyurethane adhesives or polyether-polyurethane adhesives are used as the adhesive layer.
Due to the presence of the adhesive layer, even when the heat-fusible resin layers 202 and 203 at the both end edges of the body blank 20A are thinned by heat-fusion in the staggered portion 21 of the body 2, the metal foil layers 201 are prevented from contacting each other, and the sealing property is maintained. Further, the presence of the adhesive layer can prevent the metal foil layers 201 and 301 from corroding and leaking out even when the contents are filled through the heat-fusible resin layers 202, 203, 302, and 303.
The laminated body 20 constituting the body blank 20A and the laminated body 30 constituting the bottom body blank 30A are generally the same, but may be different in material and/or thickness.
Next, an example of a method for forming cup-shaped container 1 using the above-described laminated bodies 20 and 30 will be described.
First, the laminated body 20 is punched out into a fan shape having a predetermined size, to form a body blank 20A (see fig. 9 (a)).
The laminated body 30 is punched out into a circular shape having a predetermined size to form a bottom body blank 30A (see fig. 10 (a)), and the bottom body 3 having a substantially inverted U-shaped cross section including the bottom portion 31 and the suspended portion 32 is formed by drawing the blank 30A using a die (not shown) (see fig. 10 (b)). No wrinkles are generated in the obtained chassis 3. In addition, a corner portion between the bottom portion 31 and the hanging-down portion 32 in the outer surface of the bottom body 3 forms an angle.
Then, the base body 3 is set in advance in a substantially conical trapezoidal mold (not shown) so that the upper surface of the bottom portion 31 thereof overlaps the top surface thereof, and then the body blank 20A is wound around the outer peripheral surface of the mold so that both end edge portions thereof are staggered with each other, and then the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces of the staggered portion 21 that overlap with each other are heat-fused to mold the tapered cylindrical body 2. The means for heat-sealing the interlaced part 21 may be high-frequency sealing, ultrasonic sealing, or the like, in addition to heat-sealing using a hot plate.
Next, as shown in fig. 11, the lower end opening edge of the main body 2 is folded back inward, and after the folded-back portion 22 is pressed against the hanging-down portion 32 of the base body 3 by a disk-shaped rotary die (not shown), the inner heat-fusible resin layer 202, which constitutes the surface where the lower end portion 2a of the main body 2 and the folded-back portion 22 overlap with the hanging-down portion 32 of the base body 3, is heat-fused to the upper heat-fusible resin layer 302 and the lower heat-fusible resin layer 303, thereby joining and integrating the main body 2 and the base body 3.
Further, the upper end opening edge portion of the main body 2 is curled outward using a predetermined curl forming die (not shown), and is pressed in the vertical direction to be formed into a flat shape, thereby forming the flange portion 23 (see fig. 11).
Thus, cup-shaped container 1 shown in fig. 1 and 2 was produced.
The cup-shaped container 1 according to embodiment 1 has the following features in the structure of the staggered portion 21 of the main body 2.
That is, as shown in fig. 5, the inner end surface 204 of the body blank 20A located inside the body 2 is covered with an inner resin bank R1 formed when the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces of the both end edges of the body blank 20A that overlap each other are heat-fused.
The outer end surface 205 of the body blank 20A located outside the body 2 is also covered with an outer resin bank R2 formed when the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces of the both end edges of the body blank 20A that overlap each other are heat-fused (see fig. 5). However, the outer resin reservoir R2 is not necessarily formed.
The inner resin reservoir R1 and the outer resin reservoir R2 are formed as follows: when the staggered both end edge portions of the body material 20A are heat-welded to each other, a part of the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces of the both end edge portions overlapping each other are melted, and the melted resin is pushed out in the width direction of the staggered portion 21 by the pressure force at the time of heat welding, thereby forming the inner resin reservoir R1 and the outer resin reservoir R2. It is to be noted that the inner resin reservoir R1 may be formed of a resin obtained by melting the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the inner end surface 204 of the body blank 20A and a part of the inner heat-fusible resin layer 202 adjacent to the inner end surface 204, and the outer resin reservoir R2 may be formed of a resin obtained by melting the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the outer end surface 205 of the body blank 20A and a part of the outer heat-fusible resin layer 203 adjacent to the outer end surface 205.
These resin reservoirs R1 and R2 can be formed by, for example, controlling the sealing conditions (sealing temperature, pressure, sealing time, sealing range, etc.) during thermal welding, or by appropriately setting the structure of the body material 20A as described later.
In the body material 20A, when the thickness of the metal foil layer 201 is T1, the thickness of the inner heat-fusible resin layer 202 is T2, and the thickness of the outer heat-fusible resin layer 203 is T3, it is preferable that the thickness of T1: t2: t3 ═ 1: 0.3-1.5: 0.2-1 and T2 is not less than T3. More preferably T1: t2: t3 ═ 1: 0.5-0.8: 0.4 to 0.7. With the above ratio configuration, the probability of forming the inner resin reservoir R1 that covers the inner end surface 204 of the main body blank 20A can be increased. Further, if T2 is made larger than T3, the sealability between the lower end portion 2a of the main body 2 and the folded portion 22 and the hanging portion 32 of the bottom body 3 can be improved.
The melt mass flow rate, i.e., MFR, of the inner heat-fusible resin layer 202 of the body material 20A is preferably 1 to 20g/10 min, more preferably 7 to 18g/10 min. Here, when the inner heat-fusible resin layer 202 has 2 or more layers, the MFR is an average value thereof. When the MFR of the inner heat-fusible resin layer 202 is within the above range, the probability of forming the inner resin reservoir R1 in particular can be increased.
In the specific description of the present invention, "MFR" means a molecular weight ratio based on JIS K7210-1: 2014, determined by a standard test method for MFR. For example, in the case where the inner heat-fusible resin layer 202 is formed of polypropylene, MFR is a value measured under the conditions of a temperature of 230 ° and a load of 2.16kgf based on the above-described test method.
The MFR of the outer heat-fusible resin layer 203 of the body material 20A is preferably 1 to 15g/10 min, more preferably 4 to 10g/10 min. Here, when the outer heat-fusible resin layer 203 has 2 or more layers, the MFR is an average value thereof. When the MFR of the outer heat-sealable resin layer 203 is set to the above range, the molten resin is less likely to flow during heat sealing, and the roughness of the surface of the sealed portion is reduced.
Fig. 4 (a) is a diagram showing a preferable embodiment in the case where the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the laminate 20 constituting the body material 20A are each formed of 2 or more thermoplastic resin layers.
In fig. 4 (a), the inner heat-fusible resin layer 202 of the body blank 20A has a 3-layer structure including a sealing-side thermoplastic resin layer 202a constituting the inner surface of the body 2, a laminating-side thermoplastic resin layer 202b laminated on the metal foil layer 201, and an intermediate thermoplastic resin layer 202c interposed between these layers 202a and 202 b.
The MFR of the sealing side thermoplastic resin layer 202a is preferably 3 to 10g/10 min, more preferably 4 to 9g/10 min. The MFR of the thermoplastic resin layer 202b at the lamination side is preferably 3 to 10g/10 min, more preferably 4 to 9g/10 min. The MFR of the intermediate thermoplastic resin layer 202c is preferably 0.5 to 5g/10 min, more preferably 1.5 to 4g/10 min, which is smaller than the MFR of the sealing-side thermoplastic resin layer 202a and the laminating-side thermoplastic resin layer 202 b. By defining the range of MFR of the 3 layers 202a, 202b, 202c as described above, the probability of forming the inner resin reservoir R1 can be increased, and the main body material 20A, in particular, the inner end surface 204 can be reliably covered and protected.
Similarly, the outer heat-fusible resin layer 203 of the body blank 20A has a 3-layer structure including a sealing-side thermoplastic resin layer 203a constituting the outer surface of the body 2, a laminated-side thermoplastic resin layer 203b laminated on the metal foil layer 201, and an intermediate thermoplastic resin layer 203c interposed between these layers 203a and 203 b. The MFR of each of the layers 203a, 203b, and 203c can be set to the same range as the MFR of the corresponding layer 202a, 202b, and 202c of the inner heat-fusible resin layer 202.
The inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 having the above-described layer structure can be formed of, for example, 2 types of 3 layers (random polypropylene (rPP)/block polypropylene (bPP)/random polypropylene (rPP)) or 1 type of 3 layers (random polypropylene (rPP)/random polypropylene (rPP)) of unstretched polypropylene films (CPP).
As shown in fig. 4 (b), the upper heat-fusible resin layer 302 and the lower heat-fusible resin layer 303 of the laminate 30 constituting the base material 30A may have a 3-layer structure formed of the sealing-side heat- plastic resin layers 302a and 303a, the laminate-side heat-plastic resin layers 302b and 303b, and the intermediate thermoplastic resin layers 302c and 303c, as in the above.
The body material 20A and the bottom body material 30A may have not only the 3-layer structure described above but also a 2-layer structure formed of a sealing-side thermoplastic resin layer and a laminating-side thermoplastic resin layer. In this case, the MFR of the sealing-side thermoplastic resin layer may be increased and the MFR of the laminating-side thermoplastic resin layer may be decreased.
In the interlaced part 21 of the body 2 of the cup-shaped container 1, the total thickness T4 of the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 which are heat-fused to each other at both end edges of the body blank 20A is preferably 8 to 150 μm, and more preferably 16 to 80 μm (see fig. 5). If the total thickness T4 is less than 8 μm, the sealability of the interleaved section 21 may be insufficient. On the other hand, if the total thickness T4 exceeds 150 μm, the barrier properties of the interleaved section 21 may be impaired.
In the interleaved part 21 of the main body 2, the overlapping width W1 of the metal foil layers 201, 201 at both end edges of the main body blank 20A as viewed in the thickness direction is preferably 2 to 10mm, more preferably 4 to 8mm (see fig. 5). If the overlap width W1 is less than 2mm, the barrier properties of the interlaced part 21 may be impaired, and the sealing width may be too small to achieve sufficient sealing properties. On the other hand, if the overlap width W1 exceeds 10mm, the width of the interleaved section 21 becomes too large, which increases the cost, and there is a possibility that appearance defects such as wrinkles may occur in the inner portion of the interleaved section 21 due to a difference in stress applied to the inner portion (one end edge portion of the main body blank 20A) and the outer portion (the other end edge portion of the main body blank 20A) of the interleaved section 21.
Fig. 6 to 8 show another mode of the interleaved part 21 of the main body 2 in the cup-shaped container 1.
In the case of the interleaved part 21 of the main body 2 shown in fig. 6, the inner end surface 204X of the main body blank 20A is formed as an inclined surface facing the outside of the main body 2.
As compared with the embodiment shown in fig. 5, the inner end surface 204X formed by the inclined surface has a smaller and acute angle with the inner surface angle of the portion of the blank 20A for the main body adjacent to the outer end edge portion that becomes the outer side of the main body 2 out of the both end edge portions that are staggered. Therefore, the space between these surfaces is easily filled with the inner resin reservoir R1, and the inner side end surface 204X can be more reliably covered with the inner resin reservoir R1.
The inner end surface 204X formed by such an inclined surface can be formed, for example, by: the laminate 20 is cut from the outer heat-fusible resin layer 203 side toward the inner heat-fusible resin layer 202 side to form a body material 20A.
Although not shown, in addition to the above configuration, the outer end surface 205 of the main body blank 20A may be formed as an inclined surface facing the inside of the main body 2. This enables the outer end surface 205 to be more reliably coated with the outer resin reservoir R2.
In the interleaved part 21 of the main body 2 shown in fig. 7, a stepped part 206 bent in a crank shape so as to face the inner end face 204 of the main body blank 20A is formed in a part of the main body blank 20A adjacent to the outer end edge part which becomes the outer side of the main body 2 out of the interleaved end edge parts. An inner resin reservoir R1 is formed between the stepped portion 206 and the inner end surface 204.
In this case, the angle formed by the inner end surface 204X of the body blank 20A and the inner surface of the stepped portion 206 is smaller than that in the embodiment shown in fig. 5 and is an acute angle. Therefore, the space between these surfaces is easily filled with the inner resin reservoir R1, and the inner side end surface 204X can be more reliably covered with the inner resin reservoir R1.
The stepped portion 206 can be formed by deforming a desired portion of the body blank 20A by a pressing force generated by a hot plate or the like, for example, when both end edge portions of the body blank 20A are interlaced and heat-welded.
In the case of the interleaved part 21 of the main body 2 shown in fig. 8, the inner end surface 204X of the main body blank 20A is formed as an inclined surface facing the outside of the main body 2. Further, a stepped portion 206 bent in a crank shape is formed in a portion of the main body blank 20A adjacent to an outer end edge portion which becomes an outer side of the main body 2 out of both end edge portions which are staggered so as to face the inner end surface 204X of the main body blank 20A. An inner resin reservoir R1 is formed between the stepped portion 206 and the inner end surface 204X formed by the inclined surface.
In the case of the above-described embodiment, the gap between the inner end surface 204X of the body blank 20A and the inner surface of the stepped portion 206 is narrower than the embodiments shown in fig. 6 and 7, and therefore the filling with the inner resin bank R1 is facilitated, and the inner end surface 204X can be more reliably covered with the inner resin bank R1.
According to the cup-shaped container 1 of embodiment 1, the following effects are provided.
a) The body material 20A and the bottom material 30A are each formed of a laminate 20, 30, and the laminate 20, 30 includes a metal foil layer 201, 301 and a heat- sealable resin layer 202, 203, 302, 303 laminated on both surfaces thereof, and therefore can be manufactured at low cost using a paper cup manufacturing facility.
b) Since the laminated bodies 20 and 30, which are materials of the respective blanks 20A and 30A, have the metal foil layers 201 and 301, the long-term storage stability of the contents is excellent.
c) Since the thickness of the body blank 20A is smaller than that of a paper cup, the step of the portion of the upper surface of the flange portion 23 of the body 2 formed by the staggered portion 21 can be made smaller, and therefore, a sealing failure is less likely to occur when sealing a lid to the upper surface of the flange portion 23 of the container 1. In addition, in the case of aseptic (aseptic) filling, the sterilizing liquid is less likely to remain on the upper surface of the flange portion 23 at the level difference.
d) Since the bottom body 3 is formed by drawing the bottom body blank 30A, the bottom body 3 is not wrinkled, and thus, a poor joint or a reduction in barrier property between the hanging portion 32 of the bottom body 3 and the lower end portion 2a of the main body 2 and the folded portion 22 is not caused as in the conventional paper cup.
e) Since the thickness of the main body blank 20A and the bottom body blank 30A is smaller than that of the paper cup, the lower end portion 2a and the folded portion 22 of the main body 2 and the hanging portion 32 of the bottom body 3 can be stably joined.
f) Since the radius of curvature R of the corner portion between the bottom portion 31 and the hanging portion 32 on the outer surface of the bottom body 3 can be made smaller than that of a paper cup, it is difficult to leave the sterilizing liquid at the boundary portion between the upper surface of the bottom body 3 and the inner peripheral surface of the main body 2 of the cup-shaped container 1 when aseptic (aseptic) filling is performed.
g) Since the laminated bodies 20 and 30, which are materials of the respective blanks 20A and 30A, do not have paper layers, retort sterilization can be performed without trouble.
h) In the interleaved part 21 of the main body 2, the inner end faces 204, 204X of the main body blank 20A positioned inside the main body 2 are covered with the inner resin bank R1 formed when the heat-fusible resin layers 202, 203 at the both end edges of the main body blank 2 are heat-fused to each other, and are not exposed to the contents, so that deterioration due to delamination and corrosion of the inner end faces 204, 204X can be effectively suppressed, and it is also preferable from the hygienic viewpoint.
i) In the interleaved part 21 of the body 2, the outer end surface 205 of the body blank 20A located outside the body 2 is covered with the outer resin bank R2 formed when the heat-fusible resin layers 202 and 203 at the both end edges of the body blank 2 are heat-fused to each other, and therefore, deterioration due to delamination and corrosion of the outer end surface 205 can be effectively suppressed.
< embodiment 2 >
Fig. 13 to 16 are views showing a cup-shaped container according to embodiment 2 of the present invention. The cup-shaped container of this embodiment is substantially the same as the cup-shaped container 1 of embodiment 1 shown in fig. 1 to 12, except for the following points.
In the cup-shaped container 1 of the present embodiment, first, the body blank 20A has the following features. That is, at least one (preferably both) of the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body blank 20A includes 2 or more layers.
As shown in fig. 13 (a), when both the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body blank 20A have a 2-layer structure, the melting point of the heat-fusible resin constituting the laminate side heat-fusible resin layers 202b and 203b laminated on the metal foil layer 201 in each of the layers 202 and 203 is lower than the heat-fusible resin constituting the sealing side heat- fusible resin layers 202a and 203a (constituting the inner surface or the outer surface of the body 2).
As shown in fig. 14 (a), when both the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body blank 20A have a 3-layer structure, the melting point of the heat-fusible resin constituting the lamination-side heat-fusible resin layers 202b and 203b laminated on the metal foil layer 201 in each of the layers 202 and 203 is lower than the heat-fusible resin constituting the sealing-side heat- fusible resin layers 202a and 203a (which constitute the inner surface or the outer surface of the body 2) and the heat-fusible resin constituting the intermediate heat-fusible resin layers 202c and 203c (which are interposed between the lamination-side heat-fusible resin layers 202b and 203b and the sealing-side heat- fusible resin layers 202a and 203 a).
Similarly, as shown in fig. 13 (b), the base body blank 30A may have a 2-layer structure in both the upper heat-fusible resin layer 302 and the lower heat-fusible resin layer 303, and in each of the layers 302 and 303, the melting point of the heat-fusible resin constituting the lamination-side heat-fusible resin layers 302b and 303b laminated on the metal foil layer 301 may be lower than the heat-fusible resin constituting the sealing-side heat- fusible resin layers 302a and 303a located on the surface side of the base body 3. Alternatively, as shown in fig. 14 (b), both the upper heat-fusible resin layer 302 and the lower heat-fusible resin layer 303 may have a 3-layer structure, and in each of the layers 302 and 303, the melting point of the heat-fusible resin constituting the lamination side heat-fusible resin layers 302b and 303b laminated on the metal foil layer 301 may be lower than the heat-fusible resin constituting the sealing side heat- fusible resin layers 302a and 303a positioned on the surface side of the base body 3 and the heat-fusible resin constituting the intermediate heat-fusible resin layers 302c and 303c (which are interposed between the lamination side heat-fusible resin layers 302b and 303b and the sealing side heat- fusible resin layers 302a and 303 a).
The melting point of the heat-fusible resin constituting the lamination side heat- fusible resin layers 202b, 203b, 302b, 303b is preferably 10 ℃ or higher, more preferably 20 ℃ or higher lower than the melting point of the heat-fusible resin constituting the sealing side heat- fusible resin layers 202a, 203a, 302a, 303a (and the intermediate heat- fusible resin layers 202c, 203c, 302c, 303 c). In the case of the heat-fusible resin layer formed of 3 or more layers, the difference in melting point defined here is the difference between the melting point of the heat-fusible resin constituting the heat-fusible resin layer on the side of the laminate and the lowest melting point of the heat-fusible resins constituting the other 2 or more layers.
More specifically, the melting point of the heat-fusible resin constituting the laminated side heat- fusible resin layers 202b, 203b, 302b, 303b is preferably 110 to 140 ℃, and more preferably 120 to 135 ℃.
When the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body blank 20A and the upper heat-fusible resin layer 302 and the lower heat-fusible resin layer 303 of the base blank 30A have a 2-layer structure, the melting point of the heat-fusible resin constituting the sealing-side heat- fusible resin layers 202a, 203a, 302a, and 303a is preferably 150 to 165 ℃, and more preferably 155 to 160 ℃.
When the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body blank 20A and the upper heat-fusible resin layer 302 and the lower heat-fusible resin layer 303 of the base blank 30A have a 3-layer structure, the melting point of the heat-fusible resin constituting the sealing-side heat- fusible resin layers 202a, 203a, 302a, and 303a is preferably 110 to 140 ℃, more preferably 120 to 135 ℃, and the melting point of the heat-fusible resin constituting the intermediate heat- fusible resin layers 202c, 203c, 302c, and 303c is preferably 150 to 165 ℃, more preferably 155 to 160 ℃.
In addition to the above difference in melting point, the MFR that is the melt mass flow rate of the heat-fusible resin constituting the laminated side heat- fusible resin layers 202b, 203b, 302b, and 303b is preferably larger than the MFR that is the melt mass flow rate of the heat-fusible resin constituting the sealing side heat- fusible resin layers 202a, 203a, 302a, and 303a (and the intermediate heat- fusible resin layers 202c, 203c, 302c, and 303c), more preferably 1 to 5g/10 min or more, and still more preferably 2 to 4g/10 min or more. In the case of a heat-fusible resin layer formed of 3 or more layers, the difference in MFR, which is the melt mass flow rate defined herein, is the difference in MFR between the MFR of the heat-fusible resin constituting the laminated side heat-fusible resin layer and the MFR of the maximum value of the MFRs of the heat-fusible resins constituting the other 2 or more heat-fusible resin layers.
The MFR is a value determined by a standard test method based on MFR specified in JIS K7210-1-2014. For example, when each of the heat-fusible resin layers is formed of polypropylene, the MFR is a value measured by the above-described test method under the conditions of a temperature of 230 ℃ and a load of 2.16 kgf.
More specifically, the MFR of the heat-fusible resin constituting the laminated side heat- fusible resin layers 202b, 203b, 302b, 303b is preferably 4 to 10g/10 min, more preferably 5 to 8g/10 min.
When the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body blank 20A and the upper heat-fusible resin layer 302 and the lower heat-fusible resin layer 303 of the base blank 30A have a 2-layer structure, the MFR of the heat-fusible resin constituting the sealing-side heat- fusible resin layers 202a, 203a, 302a, and 303a is preferably 4 to 10g/10 min, and more preferably 5 to 8g/10 min.
When the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body preform 20A and the upper heat-fusible resin layer 302 and the lower heat-fusible resin layer 303 of the base preform 30A have a 3-layer structure, the MFR of the heat-fusible resin layers constituting the sealing-side heat- fusible resin layers 202a, 203a, 302a, and 303a is preferably 4 to 10g/10 min, more preferably 5 to 8g/10 min, and the MFR of the heat-fusible resin layers constituting the intermediate heat- fusible resin layers 202c, 203c, 302c, and 303c is preferably 2 to 5g/10 min, more preferably 3 to 4g/10 min.
In the cup-shaped container 1 according to embodiment 2, the cross portion 21 of the main body 2 has the following features.
That is, as shown in fig. 15, the metal foil layer 201 portion of the inner end surface 204 of the main body blank 20A positioned inside the main body 2 and the interface portions between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 are covered with a protective film M1, and the protective film M1 is formed by melting and solidifying the heat-fusible resin constituting the laminated side heat-fusible resin layers 202b and 203b when the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces of the both end edges of the main body blank 20A overlapping each other are heat-fused.
In the case of the interleaved part 21 of the body 2 of the embodiment shown in fig. 16, in addition to the coating of the inner end surface 204 by the protective film M1, the metal foil layer 201 portion of the outer end surface 205 of the body blank 20A positioned outside the body 2 and the interface portion between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 are further coated by a protective film M2, and the protective film M2 is formed by melting and curing the heat-fusible resin constituting the laminated side heat-fusible resin layers 202b and 203b when the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces overlapping each other at both end edges of the body blank 20A are heat-fused.
According to the cup-shaped container 1 of embodiment 2, the following effects can be exhibited.
j) In the interleaved part 21 of the main body 2, the metal foil layer 201 portion of the inner end surface 204 of the main body blank 20A positioned inside the main body 2 and the interface portions between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 are covered with the protective film M1 (which is formed by melt-curing the low-melting-point heat-fusible resin constituting the laminated heat-fusible resin layers 202b and 203b among the heat-fusible resin layers 202 and 203 having a multi-layer structure in the main body blank 20A at the time of heat-fusing) without being exposed to the contents, and therefore, deterioration due to delamination and corrosion of the inner end surface 204 can be effectively suppressed, and it is also preferable from the hygienic viewpoint.
k) In the interleaved part 21 of the body 2, the metal foil layer 201 portion of the outer end surface 205 of the body blank 20A positioned outside the body 2 and the interface portions between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 are covered with the protective film M2 (which is formed by melt-curing the low-melting-point heat-fusible resin constituting the laminated side heat-fusible resin layers 202b and 203b among the heat-fusible resin layers 202 and 203 in the multilayer structure in the body blank 20A at the time of heat-fusing), and therefore, the deterioration due to delamination and corrosion of the outer end surface 205 can be effectively suppressed for a long period of time.
Although not shown, the end face of the blank 30A for the base body, that is, the lower end face of the hanging-down portion 32 of the base body 3, may be covered with a protective film formed by melting and solidifying a low-melting-point heat-fusible resin constituting the laminated-side heat- fusible resin layers 302b, 303b, and 202b when the heat-fusible resin layers 302, 303, and 202 constituting the mutually overlapped surfaces of the hanging-down portion 32 of the base body 3, the lower end portion 2a of the main body 2, and the folded-back portion 22 are heat-fused to each other, at the interface portions of the metal foil layer 301 and the heat-fusible resin layers 302 and 303. This effectively suppresses deterioration due to delamination and corrosion of the lower end face of the suspended portion 32 of the bottom body 3.
Further, the upper and lower end edge surfaces of the body material 20A, that is, the front end surface of the flange portion 23 of the body 2 and the front end surface of the folded portion 22 of the body 2 (the lower end surface of the body 2 in the case where the body 2 does not have the folded portion 22), are also covered with a protective film formed by melting and solidifying the low melting point heat-fusible resin of the laminated heat- fusible resin layers 202b, 203b, 302b, 303b among the heat-fusible resin layers 202, 203, 302, 303 constituting these multilayer structures when the lid member is heat-fused to the flange portion 23 of the body 2 and the lower end portion 2a of the body 2 and the folded portion 22 and the hanging portion 32 of the base body 3, as described above, whereby deterioration due to delamination and corrosion of the respective front end surfaces can be effectively suppressed.
In the cup-shaped container according to embodiment 2, the body may be formed by overlapping both end edge portions of the body blank in a palm shape and joining the two end edge portions. In this embodiment as well, similarly to the above-described embodiment, the metal foil layer portion of at least one of the 2 end faces of the body material and the interface portion between the metal foil layer and the heat-fusible resin layer are covered with a protective film formed by melting and solidifying the low-melting-point heat-fusible resin constituting the laminated side heat-fusible resin layer in the inner heat-fusible resin layers of the multilayer structure at the both end edge portions of the body material when the inner heat-fusible resin layers of the multilayer structure are heat-fused to each other, whereby the deterioration due to delamination and corrosion of the end faces can be effectively suppressed.
< embodiment 3 >
Hereinafter, a method for manufacturing the cup-shaped container 1 according to embodiment 3 will be described with reference to fig. 2, 9 to 12, and the like.
The manufacturing method includes the following 1 st to 6 th steps. The order of the steps may be changed as appropriate.
(step 1)
The 1 st step is a step of punching out a laminate 20 including a metal foil layer 201 and an inner heat-fusible resin layer 202 and an outer heat-fusible resin layer 203 laminated on both surfaces of the metal foil layer 201 into a fan shape having a predetermined size to form a body blank 20A (see fig. 9 (a)).
(step 2)
The 2 nd step is a step of punching out a laminate 30 including a metal foil layer 301 and upper and lower heat-fusible resin layers 302 and 303 laminated on both surfaces of the metal foil layer 301 into a circular shape having a predetermined size to form a base material 30A (see fig. 10 (a)).
(step 3)
The 3 rd step is a step of subjecting the bottom body blank 30A to a drawing process using a die (not shown) to form the bottom body 3 having a substantially inverted U-shaped cross section formed by the bottom portion 31 and the suspended portion 32 (see fig. 10 (b)).
No wrinkles are generated in the obtained chassis 3. In addition, a corner portion between the bottom portion 31 and the hanging-down portion 32 in the outer surface of the bottom body 3 forms an angle.
(step 4)
The 4 th step is a step of forming the tubular body 2 by interleaving both end edge portions of the body blank 20A and heat-welding the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting surfaces of the both end edge portions that overlap each other (see fig. 9 (b) and the like).
This procedure is generally carried out as follows: the base body 3 is previously set so that the upper surface of the bottom portion 31 thereof overlaps the top surface of a substantially conical trapezoidal mold (not shown), and then the body blank 20A is wound around the outer peripheral surface of the mold, and after both end edge portions thereof are staggered, the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces of the both end edge portions that overlap each other are heat-fused.
In the 4 th step, the both end edge portions of the body material 20A are heat-welded together 2 times. The 1 st heat fusion is usually performed by heat sealing using a hot plate or the like, and may be performed by high-frequency sealing, ultrasonic sealing or the like. And, the 2 nd heat fusion is performed by high frequency sealing. By the above 2 stages of heat welding, both end edge portions of the body blank 20A can be more reliably joined to each other, resin pools are easily formed at the corresponding joining portions due to the heat welding, and the occurrence of deformation or the like due to the heat welding is further suppressed.
Here, for example, when the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 are formed of an unstretched polypropylene film (CPP), it is preferable that the sealing temperature: 160-220 ℃, load (sealing pressure): 80-200 kgf, sealing time: and carrying out heat sealing under the condition of 1-5 seconds. When the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 are formed of a polyethylene film (PE), it is preferable that the sealing temperature: 140-220 ℃ and load: 80-200 kgf, sealing time: is carried out for 1-5 seconds. That is, in the case of heat sealing, it is preferable to heat the body material 20A from both sides of the edge portions of the both ends thereof, which are staggered, at a temperature 20 to 40 ℃ higher than the melting point of the resin constituting the heat-fusible resin layers 202 and 203.
In addition, it is preferable to output: 0.5-1.5 kW, sealing time: 3-5 seconds, distance from coil: 0.5-15 mm, load: sealing at high frequency under the condition of 100-200 kgf.
(step 5)
The 5 th step is a step of: the body 2 is folded back inward so as to wrap the hanging portion 32 of the base body 3 from the lower end opening edge portion thereof to form the folded-back portion 22, and the body 2 and the base body 3 are integrated by heat-welding the inner heat-fusible resin layer 202, the upper heat-fusible resin layer 302, and the lower heat-fusible resin layer 303, which constitute surfaces of the lower end portion 2a of the body 2 and the folded-back portion 22, which overlap with the hanging portion 32 of the base body 3 (see fig. 2 and 11).
This step is usually performed by folding back the lower end opening edge of the main body 2 inward, pressing the folded-back portion 22 against the suspended portion 32 of the base body 3 with a disk-shaped rotary die (not shown), and then thermally welding the upper thermal adhesive resin layer 302 and the lower thermal adhesive resin layer 303 of the inner thermal adhesive resin layer 202 constituting the surfaces of the lower end portion 2a of the main body 2 and the folded-back portion 22 that overlap with each other with the suspended portion 32 of the base body 3.
In the 5 th step, the heat-fusible resin layers 202, 302, and 303 of the lower end portion 2a of the main body 2 and the folded-back portion 22 and the suspended portion 32 of the base body 3 are heat-fused together 2 times in total. The 1 st heat fusion is usually performed by heat sealing using a hot plate or the like, and may be performed by high-frequency sealing, ultrasonic sealing or the like. The 2 nd heat fusion was performed by high frequency sealing. In the case of high-frequency sealing, the metal foil layer becomes high in temperature by induction heating, and heat generated from the metal foil layer promotes thermal welding between the thermally-weldable resin layers. By the above 2 stages of heat welding, the lower end portion 2a of the main body 2 and the folded portion 22 are more reliably joined to the hanging portion 32 of the bottom body 3, and resin pools are easily formed at the corresponding joining portions due to the heat welding, thereby further suppressing the occurrence of deformation or the like due to the heat welding. The preferable conditions for performing the heat sealing and the high-frequency sealing are the same as those in the case of the 4 th step.
In the case of manufacturing a container of a type in which the folded-back portion 22 is not formed at the lower end opening edge portion of the main body 2 and the outer surface of the suspended portion 32 of the bottom body 3 is joined to the inner surface of the lower end portion 2a of the main body 2 as shown in fig. 12, the main body 2 and the bottom body 3 may be integrated by substantially the same step as the above-described 5 th step, that is, by the following method: the inner surface of the lower end portion 2a of the body 2 and the outer surface of the hanging portion 32 of the base body 3 are overlapped, and the inner heat-fusible resin layer 202 and the upper heat-fusible resin layer 302 constituting these surfaces are heat-fused 2 times, and the 2 nd heat-fusion is performed by high-frequency sealing.
(step 6)
The 6 th step is a step of forming a flange portion 23 by outwardly crimping an upper end opening edge portion of the main body 2 using a predetermined crimping die (not shown) and pressing the same in the vertical direction to form a flat shape (see fig. 11).
Depending on the shape of the flange portion, the flange portion may be formed by means and steps different from those described above.
According to the method of manufacturing the cup-shaped container 1 of embodiment 3, the following effects can be exhibited.
l) in the 4 th step of forming the cylindrical body 2, the heat-fusion of the heat-fusion resin layers at both end edge portions of the body material is performed 2 times in total, and the 2 nd heat-fusion is performed to enable high-frequency sealing by heating from the metal foil layer, so that both end edge portions of the body material 20A can be more reliably joined to each other, and resin pools are easily formed at the corresponding joining portions along with the heat-fusion, so that the sealability of the container 1 can be improved. Further, the occurrence of defects in appearance such as deformation of the container 1 can be effectively suppressed.
m) in the 5 th step of integrating the main body and the base body, the heat welding of the heat-fusible resin layers 202, 302, 303 of the lower end portion 2a and the folded-back portion 22 of the main body 2 and the hanging-down portion 32 of the base body 3 is performed 2 times in total, and the 2 nd heat welding is performed by high-frequency sealing, so that the lower end portion 2a and the folded-back portion 22 of the main body 2 can be more reliably joined to the hanging-down portion 32 of the base body 3, and resin pools are easily formed at the corresponding joining portions along with the heat welding, and therefore, the sealing property of the container 1 can be improved. Further, the occurrence of defects in appearance such as deformation of the container 1 can be effectively suppressed.
< embodiment 4 >
Fig. 17 and 18 are diagrams illustrating a cup-shaped container 1X according to embodiment 4 of the present invention and a method for manufacturing the same.
This embodiment is substantially the same as the method for manufacturing the cup-shaped container 1 of embodiment 1 or 2 and the cup-shaped container of embodiment 3 shown in fig. 1 to 16, except for the following points.
That is, as shown in fig. 17 and 18, in the cup-shaped container 1X of the present embodiment, of both end edge portions of the body blank 20A, the end edge portion 204 that becomes the inner side of the body 2 is folded back so as to overlap the surface of the body blank 20A that becomes the outer side of the body 2 and is heat-welded to the surface, and the folded-back end edge portion 204 and the other end edge portion 205 are staggered, and the inner heat-weldable resin layers 202 that constitute the surfaces of the 204 and 205 that overlap each other are heat-welded to each other.
According to the cup-shaped container 1X, since the both end surfaces of the body blank 20A do not come into contact with the contents stored in the container 1X at the intersecting portion 21 of the body 2, occurrence of delamination, corrosion, and the like can be suppressed, and since the surface in contact with the contents can be formed of 1 resin, sterilization becomes easy, which is advantageous also in terms of hygiene.
The folded width of the folded end edge portion 204 is substantially the same as the width of the both end edge portions 204 and 205, but may be different from each other.
Further, although not shown, at least the portions of the metal foil layers 201 on both end surfaces of the body material 20A positioned outside the body 2 may be covered with an outer resin bank or a protective film formed when the inner heat-fusible resin layers 202 constituting the surfaces of both end edge portions of the body material 20A overlapping each other are heat-fused, as in embodiment 1 or 2, whereby deterioration due to delamination or corrosion of the end surfaces can be effectively suppressed for a long period of time.
The 4 th step of forming the main body 2 in the manufacture of the cup container 1X is performed as follows.
That is, of both end edge portions of the main body material 20A, the end edge portion 204 that becomes the inner side of the main body 2 is folded back so as to overlap the surface of the main body material 20A that becomes the outer side of the main body 2, and the folded-back end edge portion 204 and the other end edge portion 205 are staggered, and the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 that constitute the surfaces of the folded-back end edge portions 204 and 205 that overlap each other are heat-fused 2 times in total.
The 1 st heat sealing is usually performed by heat sealing using a hot plate or the like, or may be performed by high-frequency sealing, ultrasonic sealing or the like. And, the 2 nd heat fusion is performed by high frequency sealing. By the above 2 stages of heat welding, both end edge portions of the body blank 20A can be more reliably joined to each other, and resin pools are easily formed at the corresponding joining portions due to the heat welding, and the occurrence of deformation or the like due to the heat welding is further suppressed.
< embodiment 5 >
Fig. 19 and 20 are views showing a cup-shaped container 1Y according to embodiment 5 of the present invention and a method for manufacturing the same.
This embodiment is substantially the same as the method for manufacturing the cup-shaped container 1 of embodiment 1 or 2 and the cup-shaped container of embodiment 3 shown in fig. 1 to 16, except for the following points.
That is, as shown in fig. 19 and 20, in the cup-shaped container 1Y of the present embodiment, the body 2 is formed into a cylindrical shape by overlapping both end edge portions of the body blank 20A into a palm shape and joining them (see fig. 20 (a)). More specifically, the opposite end edges of the body blank 20A, which are overlapped in a palm shape, are joined by heat-welding the inner heat-weldable resin layers 202 to each other.
Further, the palm portion 21Y of the main body 2 is bent to one side so as to intersect with the outer surface of the main body 2 and is heat-welded to the outer surface (see fig. 20 (b)).
The width (overlapping amount) of the grip portion 21Y of the main body 2 is preferably 5 to 20mm, and more preferably 10 to 18 mm. If the width is less than 5mm, the sealing operation of the palm portion 21Y may become difficult. On the other hand, if the width exceeds 20mm, the width of the fitting portion 21Y becomes too large, which increases the cost, and when the fitting portion 21Y is folded to one side so as to overlap the outer surface of the main body 2 and is joined to the outer surface, there is a possibility that appearance defects such as wrinkles occur in the fitting portion 21Y.
According to the cup-shaped container 1Y, since both end surfaces of the body blank 20A do not come into contact with the content contained in the container 1X at the half-closed portion 21Y of the body 2, occurrence of delamination, corrosion, or the like can be suppressed. Further, according to the container 1Y, since the surface contacting the content can be formed of 1 type of resin, sterilization becomes easy, and it is advantageous in terms of hygiene.
Further, according to the cup-shaped container 1Y, the fitting portion 21Y of the main body 2 is bent to one side and heat-welded to the outer surface of the main body 2, and therefore, the sealing property and the barrier property of this portion are improved. Further, according to the cup-shaped container 1Y, the grip portion 21Y does not protrude outward, and therefore the appearance is improved and the grip is easy.
Although not shown, at least the metal foil layer 201 portion of both end surfaces of the body material 20A positioned outside the body 2 may be covered with an outer resin bank or a protective film formed when the inner heat-fusible resin layers 202 constituting the surfaces overlapping with each other of both end edge portions of the body material 20A are heat-fused to each other, as in embodiment 1 or 2, whereby deterioration due to delamination or corrosion of the end surfaces can be effectively suppressed for a long period of time.
The 4 th step of forming the main body 2 in the production of the cup container 1Y is performed as follows.
That is, the tubular main body 2 having the fitting portion 21Y is formed by overlapping both end edge portions of the main body blank 20A in a fitting state and performing the 1 st heat welding to join the inner heat-weldable resin layers 202 constituting the surfaces overlapped with each other. The 1 st heat sealing is usually performed by heat sealing using a hot plate or the like, or may be performed by high-frequency sealing, ultrasonic sealing or the like.
Next, the palm portion 12Y is folded to one side and overlapped with the outer surface of the main body 2, and in this state, the 2 nd heat welding is performed by high frequency sealing. Thus, the inner heat-fusible resin layers 202 constituting the surfaces of the both end edges of the body blank 20A overlapping each other are further heat-fused to each other, and the inner side surface constituting the folded grip portion 21Y and the outer heat-fusible resin layer 203 constituting the outer surface of the body 2 overlapping the inner side surface are heat-fused to each other, so that the grip portion 21Y and the outer surface of the body 2 are joined to each other.
By the above 2 stages of heat welding, both end edge portions of the body blank 20A can be joined more reliably, resin pools are easily formed at the respective joining portions along with the heat welding, and the occurrence of deformation or the like along with the heat welding can be further suppressed.
< embodiment 6 >
Fig. 21 and 22 are views showing a cup-shaped container 1 according to embodiment 6 of the present invention.
In the cup-shaped container 1 of the present embodiment, a structure having the following features is used as the body material 20A. That is, at least one (preferably both) of the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body material 20A contains a modified polyolefin.
More specifically, as shown in fig. 3 (a), when both the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body material 20A are single layers, each of the layers 202 and 203 is formed of a modified polyolefin. As shown in fig. 13 (a) and 14 (a), when the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 of the body blank 20A are both 2 or 3 or more layers, among the respective layers 202 and 203, the sealing-side heat- fusible resin layers 202a and 203a constituting the inner surface or the outer surface of the body 2 are formed of a non-modified heat-fusible resin, and the lamination-side heat-fusible resin layers 202b and 203b laminated on the metal foil layer 201 are formed of a modified polyolefin.
In the bottom body blank 30A, similarly to the main body blank 20A, when both the upper side heat fusion resin layer 302 and the lower side heat fusion resin layer 303 are single layers, each layer 302, 303 may be formed of modified polyolefin (see fig. 3 (b)), and when both the upper side heat fusion resin layer 302 and the lower side heat fusion resin layer 303 are 2 layers or 3 layers or more, among the layers 302, 303, the sealing side heat fusion resin layers 302a, 303a constituting the inner surface or the outer surface of the hanging part 32 of the bottom body 3 may be formed of unmodified heat fusion resin, and the lamination side heat fusion resin layers 302b, 303b laminated on the metal foil layer 301 may be formed of modified polyolefin (see fig. 13 (b), fig. 14 (b)).
Examples of the modified polyolefin include carboxylic acids such as maleic acid, fumaric acid, mesaconic acid, citraconic acid, itaconic acid, aconitic acid, crotonic acid, succinic acid, oxalic acid, malonic acid, malic acid, thiomalic acid, tartaric acid, adipic acid, citric acid, pimelic acid, suberic acid, azelaic acid, and sebacic acid, and polyolefins (polypropylene (PP), Polyethylene (PE), and copolymers thereof) modified with carboxylic anhydrides such as maleic anhydride, itaconic anhydride, citraconic anhydride, and succinic anhydride. Maleic acid-modified polyolefins and maleic anhydride-modified polyolefins are preferably used. The films or coatings made of these modified polyolefins are used to form the single heat-fusible resin layers 202, 203, 302, 303, and the laminated heat- fusible resin layers 202b, 203b, 302b, 303b of the multi-layered heat-fusible resin layers 202, 203, 302, 303.
As the non-modified heat-fusible resin constituting the sealing-side heat- fusible resin layers 202a, 203a, 302a, 303a, for example, a general-purpose film such as a polypropylene (PP) film or a Polyethylene (PE) film having heat-fusible property, or a composite film obtained by laminating these films is used. Preferably, an unstretched polypropylene film (CPP) is used.
The heat-fusible resin layers 202, 203, 302, and 303 may include layers other than those described above, specifically, general-purpose films (preferably, unstretched polypropylene films (CPP)) such as polypropylene (PP) films and Polyethylene (PE) films having heat-fusible properties, composite films obtained by laminating these films, and layers formed of coatings such as maleic acid-modified polyethylene, maleic acid-modified polypropylene, ethylene-vinyl acetate, epoxy resins, and shellac resins.
The cup-shaped container 1 according to embodiment 6 has the following features in the structure at the intersection 21 of the main body 2.
That is, as shown in fig. 21, the portion of the metal foil layer 201 located on the inner end surface 204 of the main body material 20A located inside the main body 2 and the interface portions between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 are covered with a protective film M1, and the protective film M1 is formed by melting and solidifying the modified polyolefin when the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces of the both end edges of the main body material 20A that overlap each other are heat-fused.
In the case of the interleaved part 21 of the body 2 of the embodiment shown in fig. 22, in addition to the coating of the inner end surface 204 by the protective film M1, the metal foil layer 201 portion of the outer end surface 205 of the body blank 20A positioned outside the body 2 and the interface portion between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 are coated by a protective film M2, and the protective film M1 is formed by melting and solidifying the modified polyolefin when the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 constituting the surfaces of the both end edges of the body blank 20A that overlap each other are heat-fused.
In the staggered portion 21 of the main body 2 shown in fig. 22, a stepped portion 206 bent in a crank shape so as to face the inner end face 204 of the main body blank 20A is formed in a portion adjacent to the outer end edge portion that becomes the outer side of the main body 2 out of the staggered end edge portions of the main body blank 20A. The stepped portion 206 can be formed by deforming a desired portion of the body blank 20A by a pressing force generated by a hot plate or the like, for example, when both end edge portions of the body blank 20A are interlaced and heat-welded.
In the crossing part 21 of the body 2 of the cup-shaped container 1, the total thickness T1 of the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 which are heat-fused to each other at both end edge parts of the body blank 20A is preferably 8 to 150 μm, and more preferably 16 to 80 μm (see fig. 21). If the total thickness T1 is less than 8 μm, the sealing performance of the interleaved part 21 may be insufficient. On the other hand, if the total thickness T1 exceeds 150 μm, the barrier properties of the interleaved section 21 may be impaired.
In the interleaved part 21 of the main body 2, the overlapping width W1 of the metal foil layers 201, 201 at both end edges of the main body blank 20A as viewed in the thickness direction is preferably 2 to 10mm, and more preferably 4 to 8 mm. If the overlap width W1 is less than 2mm, the barrier properties of the interlaced part 21 may be impaired, and the seal width may be too small to ensure sufficient sealing properties. On the other hand, if the overlap width W1 exceeds 10mm, the width of the interleaved section 21 becomes too large, which increases the cost, and there is a possibility that appearance defects may occur such as wrinkles forming in the inner portion of the interleaved section 21 due to a difference in stress applied to the inner portion (one end edge portion of the main body blank 20A) and the outer portion (the other end edge portion of the main body blank 20A) of the interleaved section 21.
According to the cup-shaped container 1 of embodiment 6, the following effects can be exhibited.
n) at the intersection portion 21 of the main body 2, the metal foil layer 201 portion of the inner end surface 204 of the main body material 20A located inside the main body 2 and the interface portions between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 are covered with the protective film M1 formed by melt-curing the modified polyolefin contained in the heat-fusible resin layers 202 and 203 of the main body material 20A at the time of heat-fusing, and are not exposed to the contents, so that deterioration due to delamination and corrosion of the inner end surface 204 can be effectively suppressed, and it is also preferable from the hygienic viewpoint. In particular, since the protective film M1 is formed of a modified polyolefin having excellent adhesion strength to the metal foil layer 202, it is considered that the above-described effect can be sustained for a long period of time.
o) at the intersection 21 of the body 2, the metal foil layer 201 portion of the outer end surface 205 of the body material 20A located outside the body 2 and the interface portion between the metal foil layer 201 and the heat-sealable resin layers 202 and 203 are covered with the protective film M2 formed by melt-curing the modified polyolefin contained in the heat-sealable resin layers 202 and 203 of the body material 20A at the time of heat sealing, and therefore, the deterioration due to delamination and corrosion of the outer end surface 205 can be effectively suppressed for a long period of time.
Although not shown, the end face of the blank 30A for the base body, that is, the lower end face of the hanging-down portion 32 of the base body 3, may be covered with a protective film formed by melting and solidifying the modified polyolefin contained in at least one of 1 heat-sealable resin layers 302, 303, and 202 when the heat-sealable resin layers 302, 303, and 202 constituting the surfaces of the hanging-down portion 32 of the base body 3 and the lower end portion 2a and the folded-back portion 22 of the main body 2, which surfaces are overlapped with each other, are heat-sealable with each other at the interface between the metal foil layer 301 and the heat-sealable resin layers 302 and 303. This effectively suppresses deterioration due to delamination and corrosion of the lower end face of the suspended portion 32 of the bottom body 3.
Further, the upper and lower end edge surfaces of the body material 20A, that is, the front end surface of the flange portion 23 of the body 2 and the front end surface of the folded portion 22 of the body 2 (the lower end surface of the body 2 in the case where the body 2 does not have the folded portion 22), may be covered with a protective film formed by melting and solidifying the modified polyolefin contained in the heat-fusible resin layers 202, 203, 302, 303 when the lower end portion 2a of the body 2 and the folded portion 22 are heat-fused to the suspended portion 32 of the base body 3, for example, when the lid member is heat-fused to the flange portion 23 of the body 2, as described above, thereby effectively suppressing deterioration due to delamination and corrosion of the respective front end surfaces.
In the cup-shaped container of the present embodiment, the body may be joined by overlapping both end edge portions of the body blank in a palm shape (see fig. 19 and 20). In this embodiment, as in the above-described embodiment, it is also preferable that the metal foil layer portion of at least one of the 2 end faces of the body material and the interface portion between the metal foil layer and the heat-fusible resin layer are covered with a protective film formed by melting and solidifying the modified polyolefin contained in the inner side heat-fusible resin layers when the heat-fusible resin layers are heat-fused to each other, whereby the deterioration due to delamination and corrosion of the end faces can be effectively suppressed.
< 7 th embodiment >
Fig. 23 to 25 are views showing a cup-shaped container 1 according to embodiment 7 of the present invention.
The cup-shaped container 1 of the present embodiment has the following features in the structure of the staggered portion 21 of the main body 2.
That is, as shown in fig. 23 and 24, at least one of the heat-fusible resin layers 202 and 203 of the body blank 20A (both the heat-fusible resin layers 202 and 203 in the embodiment of fig. 23, and the inner heat-fusible resin layer 202 in the embodiment of fig. 24) has extending portions 2021a and 2031a extending outward in the circumferential direction of the end surface of the metal foil layer 201 at the inner end edge portion 204 of the both end edge portions of the body blank 20A, which is the inner side of the body 2. The end surface of the metal foil layer 201 is covered with the extending portions 2021a and 2031 a.
Accordingly, the end face of the metal foil layer 201 and the interfaces between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 can be prevented from coming into contact with the contents stored in the container 1 at the inner end edge portion 204 of the body material 20A.
The extending portions 2021a, 2031a are preferably formed by hot-pressing portions 2021, 2031 formed on one or both surfaces of the inner end edge portion 204 of the body blank 20A.
More specifically, as shown in fig. 25 (a), for example, the inner end edge portion 204 to be the inside of the main body 2 among the both end edge portions of the main body blank 20A shown in fig. 9 (a) is hot-pressed by using the seal bars B1, B2 disposed on both sides thereof.
Thereby, the portions of the heat-fusible resin layers 202 and 203 heated and pressed by the sealing bars B1 and B2 are compressed to have a reduced thickness and extend outward in the circumferential direction of the end face of the metal foil layer 201. As described above, the inner end portion 204 of the body blank 20A is formed with the thermocompression bonded portions 2021, 2031 that are thinly extended in the heat-fusible resin layers 202, 203 on both the inner and outer sides, and the extension portions 2021a, 2031a are formed by the portions of the thermocompression bonded portions 2021, 2031 that extend outward in the circumferential direction than the end surface of the metal foil layer 201. Further, since the 2 extending portions 2021a, 2031a are heated by the seal bars B1, B2 to be in a softened state or a fluid state, they can be deformed and flowed in directions to approach each other, thereby being able to cover the end face of the metal foil layer 201 (see fig. 25 (B)).
The hot pressing is performed, for example, at a heating temperature of 180 to 220 ℃, under a pressure of 0.05 to 0.4MPa, and for a heating and pressurizing time of 1 to 5 seconds. The seal bars B1, B2 are preferably arranged such that a part of the seal bars in the width direction thereof protrudes from the inner end edge portion 204 of the body blank 20A in plan view.
It is not essential that the end surfaces of the metal foil layer 201 be coated with the extending portions 2021a and 2031a of the heat-fusible resin layers 202 and 203 in the inner end edge portion 204 of the body blank 20A at the same time as the formation of the hot-pressed portions 2021 and 2031. That is, for example, in the form shown in fig. 24, at the inner end edge portion 204 of the body blank 20A, the extending portion 2021a of the inner heat-fusible resin layer 202 is heated to be in a softened state or a fluidized state at the time of heat-fusing the both end edge portions 204, 205 of the body blank 20A which are staggered, and is deformed and fluidized toward the metal foil layer 201 side to cover the end face of the metal foil layer 201.
The thickness T2 of the thermocompression processed portions 2021, 2031 of the heat-fusible resin layers 202, 203 is preferably 1/5 to 1/2 times, and more preferably 1/3 to 1/2 times, the thickness T1 of the other portions of the heat-fusible resin layers 202, 203. Specifically, for example, when the thickness T1 of the normal portion of the heat-fusible resin layers 202 and 203 is 5 to 80 μm, the thickness T2 of the hot-pressed parts 2021 and 2031 is about 1 to 40 μm. In addition, the circumferential width W1 of the portion of the hot-pressed portion 2021 or 2031 laminated on the metal foil layer 201 is preferably 2 to 10mm (more preferably 4 to 8mm), and the extended protrusion width W2 of the extended portion 2021a or 2031a is preferably 1 to 4mm (more preferably 1 to 3 mm).
In the intersecting part 21 of the body 2 of the cup-shaped container 1, the total thickness T3 of the inner heat-fusible resin layer 202 and the outer heat-fusible resin layer 203 which are heat-fused to each other at the both end edge parts 204 and 205 of the body blank 20A is preferably 8 to 150 μm, and more preferably 16 to 80 μm (see fig. 23 and 24). If the total thickness T3 is less than 8 μm, the sealing performance of the interleaved part 21 may be insufficient. On the other hand, if the total thickness T3 exceeds 150 μm, the barrier properties of the interleaved section 21 may be impaired.
In the interleaved part 21 of the main body 2, the overlapping width W3 of the metal foil layers 201, 201 of the both end edges 204, 205 of the main body blank 20A as viewed in the thickness direction is preferably 2 to 10mm, more preferably 4 to 8mm (see fig. 23 and 24). If the overlap width W3 is less than 2mm, the barrier properties of the interlaced part 21 may be impaired, and the seal width may be too small to ensure sufficient sealing properties. On the other hand, if the overlap width W3 exceeds 10mm, the width of the interleaved section 21 becomes too large, which increases the cost, and there is a possibility that appearance defects may occur such as wrinkles forming in the inner portion of the interleaved section 21 due to a difference in stress applied to the inner portion (the inner end edge portion 204 of the main body blank 20A) and the outer portion (the outer end edge portion 205 of the main body blank 20A) of the interleaved section 21.
According to the cup-shaped container 1 of embodiment 7, the following effects can be exhibited.
p) the heat-fusible resin layers 202 and 203 of the body blank 20A have extending portions 2021a and 2031a extending outward in the circumferential direction of the end surface of the metal foil layer 201 at the inner end edge portion 204 which is the inner side of the body 2 among the both end edge portions of the body blank 20A, and the end surface of the metal foil layer 201 and the interfaces between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 are covered with the extending portions 2021a and 2031a, so these portions are not exposed to the contents. Therefore, deterioration due to delamination or corrosion at the inner end edge portion 204 of the body blank 20A can be effectively suppressed, and this is also preferable from the viewpoint of hygiene.
In addition, when the extending portions 2021a, 2031a are formed by a part of the hot- press working portions 2021, 2031 formed on one or both surfaces of the inner end edge portion 204 of the body blank 20A, the forming of the extending portions 2021a, 2031a can be easily and reliably performed, and the end surfaces of the metal foil layer 201 and the like can be simultaneously coated with the extending portions 2021a, 2031 a.
In addition to the above-described configuration, in the case of the cup-shaped container 1 according to embodiment 7, the heat-sealable resin layers 202 and 203 of the body blank 20A may have extended portions 2021a and 2031a extending outward in the circumferential direction of the end face of the metal foil layer 201 at the outer end edge portions 205 that become the outer sides of the body 2 out of the both end edge portions of the body blank 20A, and the end face of the metal foil layer 201 may be covered with the extended portions 2021a and 2031 a. This can effectively suppress deterioration due to delamination and corrosion even at the outer edge portion 205 of the body blank 20A.
In the cup-shaped container of the present embodiment, the body may be joined by overlapping both end edge portions of the body blank in a palm shape (see fig. 19 and 20). In this aspect, as in the above-described aspect, it is also preferable that the heat-fusible resin layer of the body material has an extended portion extending outward in the circumferential direction of the end face of the metal foil layer at one or both end edges of the body material, and the end face of the metal foil layer is covered with the extended portion, whereby deterioration due to delamination or corrosion at the end edge can be effectively suppressed.
< embodiment 8 >
Fig. 26 to 29 are views showing a cup-shaped container 1 according to embodiment 8 of the present invention.
In the cup-shaped container 1 of the present embodiment, the staggered portion 21 of the main body 2 has the following features in terms of configuration.
That is, as shown in fig. 26 to 29, the thickness T1 of the portion of the metal foil layer 201 constituting the body blank 20A located on the inner end surface 204 of the body blank 20A located on the inner side of the body 2 is smaller than the thickness T2 of the other portion of the metal foil layer 201. This reduces the area of the portion of the metal foil layer 201 on the inner end surface 204 of the blank 20A for a main body.
The portion of the metal foil layer 201 and the interface portions between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 on the inner end surface 204 of the body blank 20A are covered with a resin film or resin bank R1 formed by partially melting and solidifying the resin of at least one of the heat-fusible resin layers 202 and 203 of the body blank 20A at the time of heat-fusing.
Here, the thickness T1 of the portion of the metal foil layer 201 constituting the inner end surface 204 of the body blank 20A is preferably 1/100 to 1/2 times, and more preferably 1/10 to 1/3 times, the thickness T2 of the other portion of the metal foil layer 201 (see fig. 29). If the thickness T1 is less than 1/100 times the thickness T2, the inner end surface 204 is easily deformed, and the possibility of adversely affecting the joint of the interleaved part 21 and the feel after processing is increased. On the other hand, if the thickness T1 exceeds 1/2 times the thickness T2, it is difficult to sufficiently insert the resin during thermal welding. Specifically, the thickness T1 of the metal foil layer 201 is, for example, 1 to 100 μm (preferably 5 to 60 μm), and the thickness T2 is, for example, 40 to 200 μm (preferably 80 to 160 μm).
To explain the above configuration in more detail, in the interleaved part 21 of the body 2 of the cup-shaped container 1, the portion 201a of the metal foil layer 201 of the body blank 20A constituting the inside end surface 204 of the body blank 20A and the vicinity thereof has a wedge-shaped cross section.
The circumferential width W1 of the wedge-shaped cross section 201a is preferably 0.01 to 10mm, more preferably 0.1 to 8 mm.
In the embodiment shown in fig. 26 and 29 (a), the metal foil layer 201 of the blank 20A for a main body has a wedge-shaped cross section portion 201a having a cross section of substantially an isosceles trapezoid (or substantially an isosceles triangle), wherein an outer side surface of the main body 2 is formed as an inclined surface forming an obtuse angle with an outer side surface of the other portion of the metal foil layer 201, and an inner side surface of the main body 2 is formed as an inclined surface forming an obtuse angle with an inner side surface of the other portion of the metal foil layer 201. Accordingly, the inner end surface 204 and the portion in the vicinity thereof in the body blank 20A also have a substantially isosceles trapezoidal cross section as a whole.
In this embodiment, as shown in fig. 26, a stepped portion 206 bent in a crank shape so as to follow the inclined surface of the outer surface of the wedge-shaped portion 201a constituting the metal foil layer 201 is formed on the outer end edge portion located on the outer side of the main body 2 out of the both end edge portions of the main body blank 20A which are staggered. The inner end surface 204 of the body blank 20A is more easily covered with the resin film or resin bank R1 generated by the thermal welding by the stepped portion 206.
In the embodiment shown in fig. 27 and 29 (b), the wedge-shaped cross section portion 201a of the metal foil layer 201 has a cross section of a substantially non-isosceles trapezoid (or a substantially right triangle), wherein the outer side surface of the main body 2 is formed as an inclined surface forming an obtuse angle with the outer side surface of the other portion of the metal foil layer 201, and the inner side surface of the main body 2 is flush with the inner side surface of the other portion of the metal foil layer 201. Accordingly, the inner end surface 204 of the body blank 20A and its vicinity also have a cross section of a substantially isosceles trapezoid as a whole.
In this embodiment, as shown in fig. 27, a stepped portion 206 bent in a crank shape so as to follow the inclined surface on the outer surface of the tapered portion 201a constituting the metal foil layer 201 is formed on the outer edge portion positioned on the outer side of the main body 2 among the two staggered edge portions of the main body material 20A.
In the embodiment shown in fig. 28 and 29 (c), the wedge-shaped cross section portion 201a of the metal foil layer 201 has a cross section of a substantially non-isosceles trapezoid (or a substantially right triangle), in which the outer surface of the outer side of the main body 2 is flush with the outer surface of the other portion of the metal foil layer 201, and the inner surface of the inner side of the main body 2 is an inclined surface in which the inner surface of the other portion of the metal foil layer 201 forms an obtuse angle. Accordingly, the inner end surface 204 of the body blank 20A and its vicinity also have a cross section of a substantially isosceles trapezoid as a whole.
The above-described cross-sectional wedge-shaped portion 201a of the metal foil layer 201 of the blank 20A for the body can be obtained, for example, by: the body blank 20A is obtained by punching the laminate 20 to be a material so as to form a bevel or the like at a contact portion of a die by a punching method, thereby forming the body blank 20A.
The portion 201a may be formed by pressing a desired portion of the body blank 20A formed by a general method.
According to the cup-shaped container 1 of the present embodiment, the following effects can be exhibited.
q) at the interleaved section 21 of the main body 2, the thickness T1 of the portion of the metal foil layer 201 of the main body blank 20A constituting the inner end face 204 of the main body blank 20A located on the inner side of the main body 2 is smaller than the thickness T2 of the other portion of the metal foil layer 201, whereby the area of the portion of the metal foil layer 201 of the inner end face 204 of the main body blank 20A is reduced. Therefore, the metal foil layer 201 portion and the interface portions between the metal foil layer 201 and the heat-fusible resin layers 202 and 203 in the inner end surface 204 of the body blank 20A are easily covered with the resin film or the resin bank R1 formed by partially melting and curing the resin constituting the heat-fusible resin layers 202 and 203 of the body blank 20A at the time of heat-fusing, and are not easily exposed to the contents, so that deterioration due to delamination and corrosion of the inner end surface 204 can be effectively suppressed, and it is preferable from the hygienic viewpoint. Further, since the step generated inside the interleaved part 21 of the main body 2 is reduced, a gap is less likely to be generated in the overlapped portion at the joint portion between the lower end part 2a of the main body 2 and the folded part 22 and the hanging part 32 of the bottom body 3 and the flange part 23 of the main body 2.
In addition, in the metal foil layer 201 constituting the main body material 20A, the portion 201A having a wedge-shaped cross section in the inner end surface 204 of the main body material 201A and the vicinity thereof is formed as an inclined surface in which the outer side surface forming the outer side of the main body 2 forms an obtuse angle with the outer side surface of the other portion of the metal foil layer 201, and the outer end edge portion of the main body material 20A is formed with the step portion 206 (see fig. 26 and 27) bent in a crank shape along the inclined surface, in which case the inner end surface 204 of the main body material 20A is more easily covered with the resin film or the resin bank R1 formed at the time of thermal welding, and the above-described effects can be more reliably exhibited.
In addition to the above-described configuration, in the cup-shaped container 1 of the present embodiment, the area of the portion of the metal foil layer 201 of the outer end surface 205 of the body blank 20A may be reduced by making the thickness of the portion of the metal foil layer 201 constituting the outer end surface 205 of the body blank 20A located outside the body 2 smaller than the thickness of the other portion of the metal foil layer 201 in the interleaved section 21 of the body 2. According to the above configuration, the metal foil layer 201 portion of the outer end surface 205 of the body blank 20A and the interface portions between the metal foil layer 201 and the heat-sealable resin layers 202 and 203 are easily covered with the resin film or resin deposit formed by partially melting and solidifying the resin of at least one of the heat-sealable resin layers 202 and 203 constituting the body blank 20A at the time of heat sealing, and therefore, deterioration due to delamination and corrosion of the outer end surface 205 can be effectively suppressed.
In the cup-shaped container of the present embodiment, the body may be joined by overlapping both end edge portions of the body blank in a palm shape (see fig. 19 and 20). In this aspect, as in the above-described aspect, it is preferable that at least a portion of the metal foil layer of the body material constituting at least one end face of the body material is smaller in thickness than other portions of the metal foil layer, whereby deterioration due to delamination and corrosion of the end face can be effectively suppressed.
Examples
Next, specific examples of the present invention will be described, but the present invention is not limited to these examples.
< example 1 >
About 3g/m of aluminum foil (A8021H-O) having a thickness of 100 μm was coated on each of the two sides of the aluminum foil subjected to the chemical conversion treatment2The two-pack curable polyurethane adhesive of (4) was dry-laminated with an unstretched polypropylene film (CPP) having a thickness of 60 μm. Then theThe adhesive is subjected to a predetermined aging treatment for curing, thereby producing a laminate. Here, the unstretched polypropylene film uses a 3-layer configuration including random polypropylene (rPP). By a method based on JIS K7210-1: the MFR of each layer measured by the test method 2014 (temperature 230 DEG, load 2.16kgf) is 7 to 18, and the average MFR of 3 layers is 11.
Next, the obtained laminate is punched out into a predetermined shape to form a body blank and a bottom body blank (see fig. 9 and 10).
Then, a cup-shaped container shown in fig. 1 and 2 was produced as example 1 by the same steps as in embodiment 1 using the body blank and the bottom body blank.
The cup-shaped container thus obtained was excellent in barrier properties, since it was made of an aluminum foil having a thickness of 100 μm and hardly permeated oxygen and water vapor.
The cup-shaped container has the following dimensions.
(size of cup-shaped Container)
Inner diameter of opening of upper portion of cup-shaped container: 65mm
Inner diameter of lower part of cup-shaped container: 50mm
Width of flange portion: 4mm
Height of the cup-shaped container: 95mm
Height of leg portion (folded portion 22) of cup-shaped container: 6mm
Width of the staggered portion of the main body (overlap amount): 8mm
Further, it was confirmed that the inner end face of the body material was covered with the inner resin bank formed at the time of heat welding, and the outer end face of the body material was covered with the outer resin bank formed at the time of heat welding.
< example 2 >
About 3g/m of aluminum foil (A8021H-O) having a thickness of 100 μm was coated on each of the two sides of the aluminum foil subjected to the chemical conversion treatment2A two-pack curable polyurethane adhesive was used to dry laminate a 40 μm thick unstretched polypropylene film (CPP). Then, in order toThe adhesive is cured and subjected to a predetermined aging treatment to obtain a laminate. Here, a co-extruded film comprising an ethylene-propylene random copolymer layer having a thickness of 12 μm (melting point 130 ℃) and a homo-polypropylene (rPP) layer having a thickness of 28 μm (melting point 160 ℃) was used as the unstretched polypropylene film, and the ethylene-propylene random copolymer layer side surface of the co-extruded film was bonded to an aluminum foil.
Next, the obtained laminate is punched out into a predetermined shape to form a body blank and a bottom body blank (see fig. 9 and 10).
Then, a cup-shaped container shown in fig. 1 and 2 was produced by the same steps as in embodiment 2 using the body blank and the bottom body blank, and this was set as example 2.
The cup-shaped container thus obtained was excellent in barrier properties, since it was made of an aluminum foil having a thickness of 100 μm and hardly permeated oxygen and water vapor.
The cup-shaped container has the following dimensions.
Inner diameter of opening of upper portion of cup-shaped container: 65mm
Inner diameter of lower part of cup-shaped container: 50mm
Width of flange portion: 4mm
Height of the cup-shaped container: 95mm
Height of a leg portion (folded portion (22)) of the cup-shaped container: 6mm
Width of the staggered portion of the main body (overlap amount): 8mm
Further, the cross section of the main body of the cup-shaped container was cut in the transverse direction and observed with a microscope, and it was confirmed that the inner end face of the main body preform was covered with the protective film formed during thermal welding and the outer end face of the main body preform was covered with the protective film formed during thermal welding and formed during random ethylene-propylene co-polymerization.
< example 3 >
About 3g/m of aluminum foil (A8021H-O) having a thickness of 100 μm was coated on each of the two sides of the aluminum foil subjected to the chemical conversion treatment2The two-pack curable polyurethane adhesive of (2) and dry-laminating 30 μm thick unstretched polypropyleneFilm (CPP). Then, a predetermined aging treatment is performed to cure the adhesive, thereby producing a laminate.
Next, the obtained laminate is punched out into a predetermined shape, and a body blank and a bottom body blank are molded (see fig. 9 and 10).
Then, a cup-shaped container of the embodiment shown in fig. 1 and 2 was produced by the same steps as in embodiment 3 using the body blank and the bottom body blank, and this was set as example 3.
The cup-shaped container is a container having a good barrier property to substantially prevent permeation of oxygen and water vapor because aluminum foil having a thickness of 100 μm is used.
The cup-shaped container has the following dimensions.
Inner diameter of opening of upper portion of cup-shaped container: 65mm
Inner diameter of lower part of cup-shaped container: 50mm
Width of flange portion: 4mm
Height of the cup-shaped container: 95mm
Height of a leg (hanging portion (32)) of the cup-shaped container: 6mm
Width of the staggered portion of the main body (staggered amount): 8mm
In the case of manufacturing the cup-shaped container, the heat welding in 2 stages is performed under the following sealing conditions in each of the 4 th step of forming the body and the 5 th step of integrating the body and the bottom body.
[ 1 st Heat fusion ]
Using a machine: heat sealing machine
Sealing temperature: 180 deg.C
Sealing time: 2sec
Load: 150kgf
[ 2 nd Heat fusion ]
Using a machine: high-frequency sealing device (BME model BMD-1S, manufactured by Kyowa Kagaku Co., Ltd.)
Output setting: 0.75kW
Sealing time: 3.0sec
Load: 100kgf
Coil distance: 5mm
< comparative example 1 >
A cup-shaped container was produced in the same manner as in example 3 except that in each of the 4 th step of forming the body and the 5 th step of integrating the body and the bottom body, heat welding was performed only 1 time under the same conditions as in the 1 st heat welding of example 3, and this was assumed to be comparative example 1.
< testing of the tightness of the containers >
The test was performed as follows: 10 cup-shaped containers of example 3 and comparative example 1 were prepared, left for 120 minutes in a state where 50cc of water colored with red ink was added, and then, whether or not coloring was observed in the staggered portion of the body or the sealed portion between the lower end portion of the body and the bottom portion of the bottom body was visually observed, and it was confirmed whether or not water leaked from the staggered portion of the body or the sealed portion between the lower end portion of the body and the bottom portion of the bottom body.
In example 3, in each container, no coloring was observed at the intersection of the main body and the sealed portion between the lower end of the main body and the bottom portion of the bottom body.
On the other hand, in comparative example 1, in 2 containers, coloring was observed at the staggered portion of the main body.
Industrial applicability
The present invention can be preferably used for a cup-shaped container containing, for example, a flowable food or a beverage, and a method for manufacturing the same.
Claims (18)
Applications Claiming Priority (6)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2019-226555 | 2019-12-16 | ||
| JP2019226555 | 2019-12-16 | ||
| JP2019233927 | 2019-12-25 | ||
| JP2019233925 | 2019-12-25 | ||
| JP2019-233927 | 2019-12-25 | ||
| JP2019-233925 | 2019-12-25 |
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| CN112978004A true CN112978004A (en) | 2021-06-18 |
| CN112978004B CN112978004B (en) | 2023-04-25 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202023036904.XU Withdrawn - After Issue CN214649652U (en) | 2019-12-16 | 2020-12-15 | Cup-shaped container |
| CN202011489945.6A Active CN112978004B (en) | 2019-12-16 | 2020-12-15 | Cup-shaped container and method for manufacturing same |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202023036904.XU Withdrawn - After Issue CN214649652U (en) | 2019-12-16 | 2020-12-15 | Cup-shaped container |
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| KR (1) | KR20210076849A (en) |
| CN (2) | CN214649652U (en) |
| TW (1) | TWI874525B (en) |
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| KR20210076849A (en) * | 2019-12-16 | 2021-06-24 | 쇼와 덴코 패키징 가부시키가이샤 | Cup shaped container and manufacturing method therof |
Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1134388A (en) * | 1995-04-28 | 1996-10-30 | 东洋油墨制造株式会社 | Paper containers for fluid substances and their inner lids |
| JPH1029617A (en) * | 1996-07-16 | 1998-02-03 | Toppan Printing Co Ltd | Paper container with plastic ring |
| JP2003200920A (en) * | 2002-01-10 | 2003-07-15 | Tokan Kogyo Co Ltd | Cup-like heat-resistant paper container and its manufacturing method |
| JP2005112425A (en) * | 2003-10-09 | 2005-04-28 | Toppan Printing Co Ltd | Wrapping paper and a packaging container made using the packing paper |
| JP2008222244A (en) * | 2007-03-09 | 2008-09-25 | Toppan Printing Co Ltd | Cup-shaped paper container and manufacturing method thereof |
| JP2009102038A (en) * | 2007-10-23 | 2009-05-14 | Toppan Printing Co Ltd | Paper container |
| CN102438909A (en) * | 2009-05-21 | 2012-05-02 | 米德韦斯瓦科公司 | Hermetically sealed paperboard container with enhanced barrier properties |
| CN102459010A (en) * | 2009-06-23 | 2012-05-16 | 凸版印刷株式会社 | Retort cup |
| CN103189198A (en) * | 2011-09-28 | 2013-07-03 | 卞东奂 | Method of forming side paper of a foldable paper cup, and foldable paper cup |
| CN214649652U (en) * | 2019-12-16 | 2021-11-09 | 昭和电工包装株式会社 | Cup-shaped container |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5830955A (en) | 1981-08-10 | 1983-02-23 | 三陽紙器株式会社 | Vessel with sealing cover |
| JP2007176505A (en) | 2005-12-27 | 2007-07-12 | Yoshino Kogyosho Co Ltd | Synthetic resin cuplike container |
| JP2007210639A (en) | 2006-02-09 | 2007-08-23 | Dainippon Printing Co Ltd | Paper cup |
| JP7291494B2 (en) * | 2018-04-02 | 2023-06-15 | 株式会社レゾナック・パッケージング | Laminate for molded container, molded container and package |
-
2020
- 2020-12-11 KR KR1020200173060A patent/KR20210076849A/en active Pending
- 2020-12-14 TW TW109144088A patent/TWI874525B/en active
- 2020-12-15 CN CN202023036904.XU patent/CN214649652U/en not_active Withdrawn - After Issue
- 2020-12-15 CN CN202011489945.6A patent/CN112978004B/en active Active
Patent Citations (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN1134388A (en) * | 1995-04-28 | 1996-10-30 | 东洋油墨制造株式会社 | Paper containers for fluid substances and their inner lids |
| JPH1029617A (en) * | 1996-07-16 | 1998-02-03 | Toppan Printing Co Ltd | Paper container with plastic ring |
| JP2003200920A (en) * | 2002-01-10 | 2003-07-15 | Tokan Kogyo Co Ltd | Cup-like heat-resistant paper container and its manufacturing method |
| JP2005112425A (en) * | 2003-10-09 | 2005-04-28 | Toppan Printing Co Ltd | Wrapping paper and a packaging container made using the packing paper |
| JP2008222244A (en) * | 2007-03-09 | 2008-09-25 | Toppan Printing Co Ltd | Cup-shaped paper container and manufacturing method thereof |
| JP2009102038A (en) * | 2007-10-23 | 2009-05-14 | Toppan Printing Co Ltd | Paper container |
| CN102438909A (en) * | 2009-05-21 | 2012-05-02 | 米德韦斯瓦科公司 | Hermetically sealed paperboard container with enhanced barrier properties |
| CN102459010A (en) * | 2009-06-23 | 2012-05-16 | 凸版印刷株式会社 | Retort cup |
| CN103189198A (en) * | 2011-09-28 | 2013-07-03 | 卞东奂 | Method of forming side paper of a foldable paper cup, and foldable paper cup |
| CN214649652U (en) * | 2019-12-16 | 2021-11-09 | 昭和电工包装株式会社 | Cup-shaped container |
Also Published As
| Publication number | Publication date |
|---|---|
| TWI874525B (en) | 2025-03-01 |
| CN112978004B (en) | 2023-04-25 |
| CN214649652U (en) | 2021-11-09 |
| KR20210076849A (en) | 2021-06-24 |
| TW202142450A (en) | 2021-11-16 |
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