CN214649651U

CN214649651U - Cup-shaped container

Info

Publication number: CN214649651U
Application number: CN202023036289.2U
Authority: CN
Inventors: 苗村正
Original assignee: Showa Denko Packaging Co Ltd
Current assignee: Lishennoco Packaging Co ltd
Priority date: 2019-12-16
Filing date: 2020-12-15
Publication date: 2021-11-09
Anticipated expiration: 2030-12-15
Also published as: TW202130555A

Abstract

The utility model relates to a cup-shaped container. The object is to provide a cup-shaped container which has excellent sealing performance between a main body and a bottom body, can be manufactured at low cost as a manufacturing device using a paper cup, has excellent long-term storage performance of contents, and can be sterilized aseptically and steamed. The cup-shaped container includes: a main body formed by overlapping and joining both end edge portions of a main body blank to form a cylindrical shape; and a bottom body formed by molding a bottom body blank so as to form a bottom portion and a suspended portion. The outer surface of the depending portion engages the inner surface of the lower end portion of the body. The body blank and the base blank are each formed of a laminate including a metal foil layer and a heat-fusible resin layer stacked on both surfaces of the metal foil layer. At least an upper portion of the outer surface of the vertical portion of the bottom body is provided with a smooth surface portion continuous over the entire circumference.

Description

Cup-shaped container

Technical Field

The present invention relates to a cup-shaped container containing food, drink, or the like such as ice cream or yogurt.

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

SUMMERY OF THE UTILITY MODEL

Problem to be solved by utility model

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, if the sealing between the main body and the bottom body is not reliably performed, the content may leak out.

In the case of the cup-shaped container, when both end edge portions of the body material are heat-welded to each other, it is necessary to increase the sealing temperature or increase the sealing time in order to obtain sufficient sealing strength, but there is a possibility that a surface opposite to the heat-welded surface of the both end edge portions, that is, a surface of the seam portion of the body becomes rough by heat, and the appearance of the body is impaired.

An object of the present invention is to provide a cup-shaped container having excellent sealability between a main body and a bottom body, which can be manufactured at low cost as a manufacturing apparatus capable of using a paper cup, and which has excellent long-term storage stability of contents and can be sterilized by aseptic sterilization or retort sterilization.

Another object of the present invention is to provide a cup-shaped container having a body with excellent appearance, which can effectively suppress surface roughening of the body due to thermal welding between both end edge portions of the body blank.

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 overlapping and joining both end edge portions of a main body blank 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 a heat-fusible resin layer laminated on at least the inner surface of the body of 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 the 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 an upper portion of an outer surface of the hanging portion of the bottom body is provided with a smooth surface portion continuous over the entire circumference.

2) The cup-shaped container described in the above 1), wherein a difference between a thickness of the bottom portion of the bottom body and a thickness of an upper side portion of the hanging portion is 5 μm or less.

3) The cup-shaped container according to the above 2), wherein the thickness of the bottom portion of the bottom body and the thickness of the upper portion of the hanging portion are each 0.9 to 1.1 times the thickness of the blank for a bottom body before molding.

4) The cup-shaped container according to any one of 1) to 3), wherein the main body further has a folded-back portion that is folded back inward from a lower end opening edge portion of the main body so as to enclose a hanging-down portion of the bottom body and extends upward,

the folded portion of the main body and the hanging portion of the bottom body are joined by heat-welding the heat-fusible resin layers constituting the surfaces of the main body and the hanging portion that overlap each other.

5) The cup-shaped container according to any one of 1) to 4), wherein the laminated body forming the body blank has a heat-resistant resin layer laminated on an outer surface of the main body out of both surfaces of the metal foil layer, and the heat-resistant resin layer contains a resin having a melting point higher by 10 ℃ or more than a melting point of a resin constituting the heat-fusible resin layer laminated on an inner surface of the main body out of both surfaces of the metal foil layer.

6) The cup-shaped container according to the above 5), wherein both end edge portions of the body blank are overlapped in a palm shape and are joined by thermally welding the thermally-weldable resin layers constituting the surfaces of the both end edge portions overlapped with each other.

7) A cup-shaped container, comprising:

the body material is formed of a laminate including a metal foil layer, a heat-fusible resin layer laminated on an inner surface of the metal foil layer to be a main body, and a heat-resistant resin layer laminated on an outer surface of the metal foil layer to be a main body, wherein the heat-resistant resin layer contains a resin having a melting point higher by 10 ℃ or more than that of the heat-fusible resin constituting the heat-fusible resin layer, both end edge portions of the body material are overlapped in a palm-like shape and are joined by heat-fusing the heat-fusible resin layers constituting the surfaces of the both end edge portions overlapped with each other,

the base material is formed of 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, and 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.

8) The cup-shaped container according to the above 6) or 7), wherein the heat-resistant resin layer contains a thermoplastic resin,

the palm folding part of the main body is bent to one side in a mode of overlapping with the outer surface of the main body and is in hot melting connection with the outer surface.

9) A cup-shaped container, comprising:

the body material is formed of a laminate comprising a metal foil layer, a heat-fusible resin layer laminated on the inner side of the metal foil layer, and a heat-resistant resin layer laminated on the outer side of the metal foil layer, wherein the heat-resistant resin layer contains a resin having a melting point higher by 10 ℃ or higher than that of the heat-fusible resin constituting the heat-fusible resin layer, both end edge portions of the body material are joined by interleaving and heat-fusing the heat-fusible resin layer and the heat-resistant resin layer constituting the surfaces of the both end edge portions overlapping each other,

10) The cup-shaped container according to any one of the above 5) to 9), wherein the heat-resistant resin layer has a thickness of 5 to 30 μm.

11) A method for manufacturing the cup-shaped container according to the above 8),

the palm-fitting portion of the main body is bent to one side so as to overlap the outer surface of the main body, and is heat-welded to the outer surface by high-frequency sealing.

Effect of the utility model

According to the cup-shaped container of the above 1), since the smooth surface portion continuous over the entire circumference is provided at least in the upper portion of the outer surface of the suspended portion of the bottom body, and the irregularities such as wrinkles accompanying the molding are not generated in the upper portion, no gap is formed in the sealed portion formed by thermally welding the upper portion and the inner surface of the lower end portion of the main body, and it is possible to obtain excellent sealing performance, and leakage of the content and deterioration of barrier performance are effectively suppressed.

According to the cup-shaped container of the above 2), the above-described effects obtained by the cup-shaped container of the above 1) can be more reliably exhibited.

According to the cup-shaped container of the above 3), it is possible to suppress the metal foil layer from being thinned due to the molding of the blank for the bottom body, and thereby to suppress the strength of the bottom body from being lowered, or the metal foil layer from being cracked or generating pinholes.

According to the cup-shaped container of the above 4), the sealability and the barrier property at the joint portion between the lower end portion of the main body and the bottom body are improved, and the end faces of the main body blank and the bottom body blank are not exposed downward at the lower end portion of the container, so that the deterioration due to delamination (interlayer peeling) and corrosion can be suppressed.

According to the cup-shaped container of 5), 7) or 9) above, the surface of the opposite side to the heat-welded surface of the both end edge portions of the body blank, that is, the surface of the seam portion (the palm portion or the interlaced portion) of the body is composed of the heat-resistant resin layer, so that surface roughness caused by heat at the both end edge portions of the body blank is effectively suppressed, and a body having excellent appearance can be obtained.

In the specification of the present invention, the "melting point" refers to 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 6) or 7), since the heat-fusible resin layers of the both end edge portions of the body blank superimposed in a palm shape are heat-fused to each other, higher bonding strength can be obtained and the sealing property of the body can be improved as compared with, for example, a case where the both end edge portions of the body blank are staggered and bonded.

According to the cup-shaped container of the above 8), the folded palm portion of the main body and the outer surface of the main body overlapped therewith can be easily joined by thermal welding without using an adhesive.

Further, according to the cup-shaped container of the above 8), since the palm portion of the main body is joined to the outer surface of the main body, there is no problem in gripping the main body of the container by hand or in drinking the liquid filled in the container from the upper end opening edge portion of the main body.

According to the cup-shaped container of the above 10), the metal foil layer of the body blank is reliably protected by the heat-resistant resin layer, and in the aspect of the above 8), the engagement between the palm portion formed by bending the body and the outer surface of the body overlapped therewith can be more reliably performed.

According to the method for manufacturing a cup-shaped container of the above 11), the engagement between the palm portion formed by bending the body and the outer surface of the body overlapped therewith can be surely performed while avoiding the occurrence of surface roughness due to heat.

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 is a horizontal cross-sectional view showing an enlarged cross section of the main body in the cup-shaped container.

Fig. 5 (a) is a plan view of the body blank, and (b) is a perspective view of the body formed from the body blank.

Fig. 6 (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. 7 is a perspective view showing 2 modes of the outer surface of the suspended portion of the bottom body.

Fig. 8 is a vertical sectional view sequentially showing a molding process of the base body.

Fig. 9 is a vertical sectional view showing a part of the bottom body in an enlarged manner.

Fig. 10 is a vertical sectional view showing a part of the process of manufacturing the cup-shaped container.

Fig. 11 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. 12 is a perspective view of a cup-shaped container according to embodiment 2 of the present invention.

Fig. 13 is a vertical sectional view taken along line XIII-XIII in fig. 12, 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, and a portion surrounded by a one-dot chain line D is an enlarged view of a portion surrounded by a one-dot chain line D.

Fig. 14 is a horizontal cross-sectional view taken along the XIV-XIV line of fig. 13, in which a portion surrounded by the one-dot chain line E is an enlarged view of a portion surrounded by the one-dot chain line E.

Fig. 15 (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. 16 (a) is a plan view of the body material, and (b) and (c) are horizontal sectional views sequentially showing a step of forming the body from the body material.

Description of the reference numerals

1. 1X: cup-shaped container

2: main body

2 a: lower end of the main body

21: interleaving part

21X: closing palm part

22: fold-back part

23: flange part

20A: blank for main body

20: laminated body

201: metal foil layer

202: inner side heat-fusible resin layer

203: outer heat-fusible resin layer

203X: heat-resistant resin layer

3: bottom body

31: bottom part

32: lower part of the drop

32 a: smoothing a face

30A: blank for base

30: laminated body

301: metal foil layer

302: upper side heat-fusible resin layer

303: lower heat-fusible resin layer

T1: thickness of the bottom

T2: thickness of upper portion of the drop

Detailed Description

Hereinafter, an embodiment of the present invention will be described with reference to fig. 1 to 16.

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 in fig. 2, 9 to 11, and 13), and "inner" refers to a side closer to the center of the cup-shaped container, main body, and bottom body (for example, an upper side in fig. 4 and a right side in fig. 9 to 11), and "outer" refers to a side farther from the center of the cup-shaped container, main body, and bottom body (for example, a lower side in fig. 4 and a left side in fig. 9 to 11).

< embodiment 1 >

Fig. 1 and 2 are views showing the overall structure 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. 5, 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. 6.

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 10).

As shown in a modification of fig. 11, the main body 2 and the bottom body 3 may be integrated by a coupling structure in which only 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.

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, pure aluminum foil or aluminum alloy foil may be used, and soft and hard materials may be used.

As a preferable embodiment of the metal foil layers 201 and 301, the metal foils constituting the metal foil layers 201 and 301 use tensile strength: 60 to 370MPa (preferably 70 to 200MPa), 0.2% yield strength: 25 to 370MPa (preferably 30 to 200MPa), thickness: 40 to 200 μm (preferably 70 to 160 μm) aluminum foil. By setting the tensile strength and 0.2% proof stress of the aluminum foil to the above ranges, sufficient strength required for the container can be obtained within a range not losing moldability. In addition, by setting the thickness of the aluminum foil to the above range, sufficient barrier properties and molding processability can be obtained.

Preferably, the aluminum foil contains, in terms of mass ratio, Si: 0.02 to 0.5%, Fe: 0.05 to 1.7%, Cu: 0.01-0.3%, Mn: 1.5% or less, Mg: 100ppm or less, Al: 95% by mass or more. In particular, by setting the Mg content to 100ppm or less (preferably 10ppm or less), the adhesiveness between the metal foil layers 201 and 301 and the heat-fusible resin layers 202, 203, 302, and 303 is improved, and the occurrence of delamination can be effectively suppressed.

Specifically, for example, aluminum foils classified according to JIS H4140, of a8000 series (a8079H, a8021H, and the like), a1000 series (a1060H, a1100H, and the like), and a3000 series (a3004H, and the like) can be used.

In addition, as the aluminum foil, a work-hardened hard material (quality: H) is preferably used. This further improves the rigidity of the

laminated bodies

20 and 30, and prevents deformation such as dents from occurring in the main body of the container. However, a soft material (quality: O) may be used as the aluminum foil, and in this case, excellent moldability can be obtained.

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 the contents even when the contents having passed through the heat-fusible resin layers 202, 203, 302, and 303 are filled in the container 1.

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. 5 (a)).

Further, the laminated body 30 is punched out into a circular shape having a predetermined size, to form a blank for a base 30A (see fig. 6 (a)).

Then, the blank for a base 30A is subjected to drawing by using the forming apparatus 4 shown in fig. 8. The molding device 4 includes an annular die 41 and a blank holder 42 arranged to be vertically aligned, and a punch 43 that moves up and down at the center of the die 41 and the blank holder 42. The molding process was carried out as follows: the blank 30A for a base body, the surface of which is coated with a lubricant as necessary, is disposed between the die 41 and the hold-down portion 42, and the punch 43 is raised while the outer peripheral portion of the blank 30A for a base body is pressed against the lower surface of the die 41 with a necessary pressure by the hold-down portion 42. In this manner, the bottom body 3 having a substantially inverted U-shaped cross section and formed by the bottom portion 31 and the hanging portion 32 can be molded (see fig. 6 (b)).

Next, the base body 3 is placed in advance on 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 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. 10, 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 each other, and the hanging-down portion 32 of the base body 3 are 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.

The flange portion 23 is formed by crimping an upper end opening edge portion of the main body 2 outward using a predetermined crimping die (not shown) and pressing the same in the vertical direction to form a flat shape (see fig. 10).

Thus, cup-shaped container 1 shown in fig. 1 and 2 was produced.

In the cup-shaped container 1 of the present embodiment, a smooth surface portion 32a continuous over the entire circumference is provided on the outer surface of the hanging portion 32 of the bottom body 3. The smooth surface portion 32a is free from irregularities such as wrinkles associated with molding. Here, the "smooth surface portion" refers to a portion where unevenness such as a wrinkle pattern is not observed by visual observation. More specifically, for example, in the horizontal cross section of the hanging-down portion 32, a portion where unevenness having a height of more than 1mm (preferably 0.5mm) with respect to an imaginary circle is not observed is regarded as a "smooth face portion" with reference to the imaginary circle including most of the outer surface.

As shown in fig. 7 (a), the smooth surface portion 32a is most preferably formed on the entire outer surface of the hanging-down portion 32, but as shown in fig. 7 (b), it may be formed at least on a part of the upper side of the outer surface of the hanging-down portion 32.

The radius of curvature (R) of the corner portion between the bottom portion 31 and the hanging portion 32 in the outer surface of the bottom body 3 is smaller than that in the case of a paper cup (see fig. 9 and the like).

Referring to fig. 9, in the bottom body 3, the difference (| T1-T2|) between the thickness T1 of the bottom portion 31 and the thickness T2 of the upper portion of the hanging-down portion 32 is preferably 20 μm or less, more preferably 10 μm or less. Further, the thickness T2 of the upper portion of the hanging portion 32 is preferably substantially uniform over the entire circumference. It is considered that, according to the thickness ratio, a gap is less likely to be formed between the hanging portion 32 and the lower end portion 2a of the main body 2 and the folded portion 22, and the sealing property is improved.

Preferably, the thickness T3 of the lower portion of the hanging portion 32 is greater than the thickness T1 of the bottom portion 31 and the thickness T2 of the upper portion of the hanging portion 32. It is considered that, according to the thickness ratio, not only the strength of the hanging portion 32 is improved, but also a gap is less likely to be generated between the hanging portion 32 and the lower end portion 2a of the main body 2 and the folded portion 22, and the sealing property is improved.

The thickness T1 of the bottom 31 and the thickness T2 of the upper portion of the hanging-down portion 32 are preferably 0.9 to 1.1 times, more preferably 0.95 to 1.0 times, the thickness of the blank for a bottom 30A before molding. The thickness T3 of the lower portion of the hanging-down portion 32 is preferably 1.05 to 1.4 times, more preferably 1.15 to 1.30 times, the thickness of the blank for a chassis 30A before molding. According to the thickness ratio, it is possible to suppress the strength of the base body 3 from being reduced due to the thinning of the metal foil layer 301 accompanying the molding of the base body blank 30A, and to suppress the occurrence of pinholes due to the cracking of the metal foil layer 301. Further, according to the thickness ratio, since the outer peripheral portion of the bottom body material 30A is less stretched in the drawing process, it is difficult to form an ear portion at the lower end of the hanging-down portion 32 of the formed bottom body 3. Accordingly, since the height of the hanging portion 32 is substantially the same over the entire circumference or the difference in height is suppressed to within about 2mm, it is possible to suppress the occurrence of a gap between the hanging portion 32 and the lower end portion 2a of the main body 2 and the folded portion 22 joined thereto, and even if a gap is generated, the sealing performance of both is not affected.

Referring to fig. 4, 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 heat-fused to each other at both end edges of the body material 20A is preferably 8 to 150 μm, and more preferably 16 to 80 μm. 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 8 mm. 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 acting on 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.

In addition to the above-described staggered manner, the joining of the both end edge portions of the body blank 20A may be performed, for example, by overlapping the both end edge portions in a palm shape and joining them, and in this case, the outer heat-fusible resin layer 203 of the body blank 20A may be omitted.

According to the cup-shaped container 1 of the present embodiment, 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) The bottom body 3 is formed by drawing the bottom body blank 30A, and a smooth surface portion 32a continuous over the entire circumference is provided at least in an upper portion of the outer surface of the suspended portion 32 of the bottom body 3, and since unevenness such as wrinkles accompanying the forming does not occur in the smooth surface portion 32a, the sealing property between the suspended portion 32 of the bottom body 3 and the lower end portion 2a of the main body 2 and the folded portion 22 is improved, and leakage of contents and a decrease in barrier property do not occur.

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 (i.e., R) of the corner portion between the bottom portion 31 and the suspended portion 32 in the outer surface of the bottom body 3 can be made smaller than that of a paper cup, the sterilizing liquid is less likely to remain 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.

< embodiment 2 >

Fig. 12 to 16 show a cup-shaped container 1X according to embodiment 2 of the present invention.

Cup-shaped container 1X of the present embodiment is substantially the same as cup-shaped container 1 of embodiment 1 shown in fig. 1 to 11, except for the following points.

That is, the body 2 of the cup-shaped container 1X is formed by overlapping and joining both end edge portions of a body blank 20A (see fig. 16 (a)) formed in a fan shape in a palm shape. Therefore, the main body 2 has a fitting portion 21X extending in the height direction thereof. The engaging palm portion 21X is bent to one side so as to overlap with the outer surface of the main body 2 and is joined to the outer surface. The width (overlapping amount) of the palm portion 21X 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 21X may become difficult. On the other hand, if the width exceeds 20mm, the width of the fitting portion 21X becomes too large, which increases the cost, and when the fitting portion 21X 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 21X.

As shown in fig. 15, the body blank 20A is formed of a laminated body 20, and the laminated body 20 includes: a metal foil layer 201; a heat-fusible resin layer 202 laminated on the inner surface of the main body 2 among both surfaces of the metal foil layer 201; and a heat-resistant resin layer 203X laminated on the outer surface of the main body 2 out of the two surfaces of the metal foil layer 201, wherein the main body blank 20A does not have a paper layer.

The heat-resistant resin layer 203X constitutes the outer surface of the main body 2 of the container 1, and functions to protect the metal foil layer 201 and impart moldability to the laminate 20.

As the resin constituting the heat-resistant resin layer 203X, a resin having a melting point higher than that of the heat-fusible resin constituting the heat-fusible resin layer 202 by 10 ℃ or higher, preferably 20 ℃ or higher is used. Preferably, the resin is a thermoplastic resin, so that the palm-fitted portion 21 formed by bending the main body 2 can be easily joined to the outer surface of the main body 2 by thermal welding.

Specific examples of the heat-resistant resin layer 203X include Polyester (PS) films such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), and polyethylene naphthalate (PEN), Polyamide (PA) films, and biaxially stretched polypropylene (OPP) films. In particular, when a polyethylene terephthalate (PET) film is used as the heat-resistant resin layer 203X, excellent water resistance can be obtained, and since the film has printability and stability when a printing layer is laminated, visibility can be easily given to the surface of the main body 2.

The thickness of the heat-resistant resin layer 203X is preferably 5 to 30 μm, more preferably 8 to 20 μm. When the thickness is within the above range, the metal foil layer 201 of the body blank 20A can be reliably protected by the heat-resistant resin layer 203X, and the folded-back portion 21X formed by folding the body 2 can be more reliably joined to the outer surface of the body 2 superposed thereon, and the thickness of the body blank 20A can be reduced.

The lamination of the metal foil constituting the metal foil layer 201 and the film constituting the heat-resistant resin layer 203X is performed by a dry lamination method via an adhesive layer (not shown) formed of a two-pack curable polyester-urethane adhesive or a polyether-urethane adhesive, for example.

In manufacturing the cup-shaped container 1X, for example, the body blank 20A is wound around the outer peripheral surface of a mold (not shown) having the bottom body 3 placed on the top surface thereof, and after both end edge portions thereof are overlapped with each other in a palm shape, the heat-fusible resin layers 202 constituting the overlapped surfaces of the both end edge portions are heat-fused with each other, thereby molding the body 2 in a tapered cylindrical shape (see fig. 16 (b)).

Here, the thermal welding of the both end edge portions of the body blank 20A is generally performed by heat sealing using a hot plate, but may be performed by high-frequency sealing, ultrasonic sealing, or the like. For example, in the case where the heat-fusible resin layer 202 is formed of an unstretched polypropylene film (CPP), it is preferable that the sealing temperature: 160-220 ℃ and load: 80-200 kgf, sealing time: and carrying out heat sealing under the condition of 1-5 seconds. In addition, when the heat-fusible resin layer 202 is 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 stacked in a palm shape from both sides of both end edge portions thereof at a temperature 20 to 40 ℃ higher than the melting point of the resin constituting the heat-fusible resin layer 202.

Further, after the fitting portion 21X of the main body 2 is folded to one side and overlapped with the outer surface of the main body 2, the both are joined by thermal welding (see (c) of fig. 16). The heat welding of the palm portion 21X of the main body 2 and the outer surface of the main body 2 is preferably performed by high-frequency sealing. High frequency sealing at, for example, output: 0.5-1.5 kW, sealing time: 3-5 seconds, distance from coil: 0.5-15 mm, load: under the condition of 100 to 200 kgf.

According to cup-shaped container 1X of embodiment 2, in addition to the effects of a) to g) described above by cup-shaped container 1 of embodiment 1, the following effects are also obtained.

h) Since the surface of the fitting portion 21X of the main body 2 is formed of the heat-resistant resin layer 203X, surface roughening associated with thermal welding of the both end edge portions of the main body blank 20A can be effectively suppressed, and the main body 2 having excellent appearance can be obtained

i) The palm-fitted portion 21X formed by bending the main body 2 can be easily joined to the outer surface of the main body 2 superposed thereon by thermal welding without using an adhesive. Further, since the fitting portion 21X of the main body 2 is joined to the outer surface of the main body 2, it does not interfere with gripping the main body 2 by hand or drinking the liquid filled in the container 1 from the upper end opening edge portion of the main body 2.

j) Since the heat-fusible resin layers 202 on both end edge portions of the palm-like body blank 20A are heat-fused to each other, a higher bonding strength can be obtained and the sealing property of the body 2 can be improved as compared with a case where, for example, both end edge portions of the body blank are interlaced and bonded.

Although not shown in detail, the heat-resistant resin layer 203X of embodiment 2 described above may be applied to the cup-shaped container 1 of embodiment 1 in which the main body 2 has the interleaved section 21 (see fig. 1 to 11) instead of the heat-fusible resin layer 203 on the outer side of the laminated body 20 forming the blank 20A for the main body.

In the case of the above-described embodiment, the inner heat-fusible resin layer 202 and the heat-resistant resin layer 203X constituting the surfaces of the both end edges of the body material 20A that overlap each other are heat-fused by, for example, heat sealing in the interleaved section 21 of the body 2, and the heat-resistant resin layer 203X forms the outer heat-fusible resin layer. Therefore, the heat-resistant resin layer 203X needs to be made of a thermoplastic resin that can be heat-welded to the inner heat-weldable resin layer 202. Specifically, for example, when the inner heat-fusible resin layer 202 is formed of low-density polyethylene (LDPE), high-density polyethylene (HDPE) is used as the heat-resistant resin layer 203X. When the inner heat-fusible resin layer 202 is formed of a polyethylene random copolymer (rPP), a polypropylene homopolymer (hPP) or a polypropylene block copolymer (bPP) is used as the heat-resistant resin layer 203X.

The heat-sealing of the staggered both end edge portions of the body blank 20A to each other is generally performed by heat-sealing using a hot plate. However, the thermal welding of the above-described portions may be performed by high-frequency sealing, ultrasonic sealing, or the like. In the case of performing heat sealing, it is preferable to perform the sealing at a sealing temperature: 160 to 200 ℃ on the heat-resistant resin layer 203 side, 80 to 120 ℃ on the heat-fusible resin layer 202 side, and a load: 80-200 kgf, sealing time: 2-5 seconds. That is, the sealing temperature on the X side of the heat-resistant resin layer 203 is preferably set to 10 to 30 ℃ higher than the melting point of the resin constituting the layer 203. However, if the sealing temperature is too high, the surface of the body material 20A may become rough, resulting in poor appearance. On the other hand, if the sealing temperature on the side of the heat-fusible resin layer 202 is set to a temperature near the melting point of the resin constituting the heat-fusible resin layer 202, the main body 2 may not be released from the mold, and therefore, it is preferably set to a temperature 20 to 40 ℃.

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 was coated on each of both sides of a100 μm thick aluminum foil (A8021H-O) subjected to chemical conversion treatment²The two-pack curable polyurethane adhesive of (2) was used to dry laminate an unstretched polypropylene film (CPP) having a thickness of 30 μm. 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. 5 and 6).

Then, a cup-shaped container was produced by the same procedure as in embodiment 1 using the body blank and the bottom body blank, and this was defined as example 1. The main body and the bottom body are joined together in the manner shown in fig. 11. The cup-shaped container is a container having a good barrier property, which is substantially impermeable to oxygen and water vapor, because aluminum foil having a thickness of 100 μm is used.

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 a leg (hanging portion (32)) of the cup-shaped container: 6mm

Width of the staggered portion of the main body (overlap amount): 8mm

In the manufacturing process of the cup-shaped container, the thickness of each part of the bottom body obtained by molding the bottom body blank (thickness 160 μm) with a molding apparatus was measured with a micrometer, and the thickness T1 of the bottom part was 160 μm, the thickness T2 of the upper side part of the hanging part was 162 μm, and the thickness T3 of the lower side part of the hanging part was 185 μm (see fig. 9).

When the outer surface of the suspended portion of the bottom body was visually observed, the occurrence of unevenness such as wrinkles due to molding was not observed, and the entire range was smooth.

< test of sealing >

After 10 cup-shaped containers of example 1 were prepared and left to stand for 120 minutes in a state in which 50cc of water was added, it was visually observed whether or not water leaked from the sealed portion between the lower end portion of the main body and the bottom portion of the bottom body, and no water leakage was observed in any of the containers.

< example 2 >

On one side of an aluminum foil (A8021H-O) having a thickness of 100 μm and having both sides subjected to chemical conversion treatment, about 3g/m was coated²The two-pack curable polyurethane adhesive of (2) was dry-laminated with a30 μm thick unstretched polypropylene (CPP) (i.e., a heat-sealable resin layer). Further, the other side of the aluminum foil was coated with about 3g/m²The two-pack curable polyurethane adhesive of (2) was used to dry laminate a polyethylene terephthalate (PET) film (i.e., a heat-resistant resin layer) having a thickness of 12 μm. 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 material is molded (see fig. 16).

Further, 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 used to dry laminate a non-oriented polypropylene resin film (CPP) having a thickness of 60 μm. Then, a predetermined aging treatment is performed to cure the adhesive, thereby producing a laminate. Then, the obtained laminate is punched out into a predetermined shape to be moldedA blank for a base body (see fig. 6).

Next, a cup-shaped container shown in fig. 12 and 13 was produced as example 2 by the same steps as in embodiment 2 using the body blank and the bottom body blank.

Here, the joining of the two end edges of the body blank, which are superposed in a palm shape, to each other is performed at a sealing temperature: 200 ℃ and load: 150kgf, sealing time: and heat sealing under the condition of 3 seconds. In addition, the joint of the folded palm portion and the surface of the main body outputs: 1.5kW, sealing time: 3 seconds, distance from coil: 5mm, load: the sealing was carried out by high frequency sealing under 150 kgf.

The cup-shaped container thus obtained was excellent in barrier properties against permeation of oxygen and water vapor because it used an aluminum foil having a thickness of 100 μm.

The cup-shaped container has the same size as in example 1.

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 closing palm portion of the main body (overlap amount): 15mm

< inspection of surface State of body part >

As a result of visually observing the surface state of the body with respect to the cup-shaped container of example 2, no surface roughness was observed due to heat sealing of the palm portion, and a good appearance was exhibited.

Industrial applicability

The present invention can be preferably used as a cup-shaped container containing, for example, a flowable food or a beverage, and a method for manufacturing the same.

Claims

1. A cup-shaped container, comprising:

in which a main body and a bottom body are integrated by engaging an outer surface of a hanging portion of the bottom body at an inner surface of a lower end portion of the main body, characterized in that,

the body material is formed of a laminate including a metal foil layer and a heat-fusible resin layer laminated on at least the inner surface of the body, of 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 the surfaces of the both end edge portions that overlap each other,

in the cup-shaped container, at least an upper portion of an outer surface of a hanging portion of the bottom body is provided with a smooth surface portion continuous over the entire circumference.

2. The cup-shaped container according to claim 1, wherein the difference between the thickness of the bottom portion in the bottom body and the thickness of the upper side portion of the hanging portion is 5 μm or less.

3. The cup-shaped container according to claim 2, wherein the thickness of the bottom portion of the bottom body and the thickness of the upper side portion of the hanging portion are each 0.9 to 1.1 times the thickness of the blank for the bottom body before molding.

4. The cup-shaped container according to claim 1, wherein the main body further has a folded-back portion folded back inward from a lower end opening edge portion of the main body so as to wrap a hanging-down portion of the bottom body and extending upward,

5. The cup-shaped container according to claim 1, wherein the laminated body forming the body blank has a heat-resistant resin layer laminated on an outer side of the main body out of both surfaces of the metal foil layer, and the heat-resistant resin layer contains a resin having a melting point higher by 10 ℃ or more than a melting point of a resin constituting the heat-fusible resin layer laminated on an inner side of the main body out of both surfaces of the metal foil layer.

6. The cup-shaped container according to claim 5, wherein both end edge portions of the body blank are overlapped in a palm shape and are joined by heat-welding the heat-weldable resin layers constituting the surfaces of the both end edge portions overlapped with each other.

7. The cup-shaped container according to claim 6, wherein the heat-resistant resin layer contains a thermoplastic resin,

8. The cup-shaped container according to claim 5, wherein the heat-resistant resin layer has a thickness of 5 to 30 μm.