EP3835227B1 - Paper container and method for manufacturing paper container - Google Patents

Paper container and method for manufacturing paper container Download PDF

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Publication number
EP3835227B1
EP3835227B1 EP19848634.2A EP19848634A EP3835227B1 EP 3835227 B1 EP3835227 B1 EP 3835227B1 EP 19848634 A EP19848634 A EP 19848634A EP 3835227 B1 EP3835227 B1 EP 3835227B1
Authority
EP
European Patent Office
Prior art keywords
blank
layer
paper
sealant layer
paper container
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.)
Active
Application number
EP19848634.2A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP3835227A1 (en
EP3835227A4 (en
Inventor
Hideki Yamamoto
Akira Watanabe
Masayuki Taniguchi
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Toppan Inc
Original Assignee
Toppan Printing Co Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Priority claimed from JP2018151561A external-priority patent/JP7268300B2/ja
Priority claimed from JP2018245476A external-priority patent/JP7156017B2/ja
Application filed by Toppan Printing Co Ltd filed Critical Toppan Printing Co Ltd
Publication of EP3835227A1 publication Critical patent/EP3835227A1/en
Publication of EP3835227A4 publication Critical patent/EP3835227A4/en
Application granted granted Critical
Publication of EP3835227B1 publication Critical patent/EP3835227B1/en
Active legal-status Critical Current
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Classifications

    • 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
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/20—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form
    • B65D5/2038—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form at least two opposed folded-up portions having a non-rectangular shape
    • B65D5/2047—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form at least two opposed folded-up portions having a non-rectangular shape trapezoidal, e.g. to form a body with diverging side walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/26—Folding sheets, blanks or webs
    • B31B50/44—Folding sheets, blanks or webs by plungers moving through folding dies
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
    • B31B50/60—Uniting opposed surfaces or edges; Taping
    • B31B50/64—Uniting opposed surfaces or edges; Taping by applying heat or pressure, e.g. by welding
    • B31B50/642—Uniting opposed surfaces or edges; Taping by applying heat or pressure, e.g. by welding using sealing jaws or sealing dies
    • 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
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/20—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form
    • B65D5/24—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with adjacent sides interconnected by gusset folds
    • B65D5/244—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with adjacent sides interconnected by gusset folds and the gussets folds connected to the outside of the container body
    • B65D5/246—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding-up portions connected to a central panel from all sides to form a container body, e.g. of tray-like form with adjacent sides interconnected by gusset folds and the gussets folds connected to the outside of the container body the container body comprising a continuous rim or flange
    • 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
    • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
    • B65D5/42—Details of containers or of foldable or erectable container blanks
    • B65D5/56—Linings or internal coatings, e.g. pre-formed trays provided with a blow- or thermoformed layer
    • B65D5/563—Laminated linings; Coatings
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B2100/00—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs
    • B31B2100/002—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs characterised by the shape of the blank from which they are formed
    • B31B2100/0024—Rigid or semi-rigid containers made by folding single-piece sheets, blanks or webs characterised by the shape of the blank from which they are formed having all side walls attached to the bottom
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B2110/00—Shape of rigid or semi-rigid containers
    • B31B2110/10—Shape of rigid or semi-rigid containers having a cross section of varying size or shape, e.g. conical or pyramidal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B31—MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31B2120/00—Construction of rigid or semi-rigid containers
    • B31B2120/40—Construction of rigid or semi-rigid containers lined or internally reinforced

Definitions

  • the present invention relates to a paper container, and a method for manufacturing the paper container.
  • a paper container disclosed in Patent Document 1 is known as a packaging container for frozen food.
  • the paper container is formed by folding a sheet which is a paper blank and adhering predetermined surfaces thereof.
  • Patent Document 1 Japanese Patent No. 3687396
  • JP 2004 017449 A describes a laminate for the paper container which is formed of a laminate having paper and polypropylene resin layers laminated on the paper. Paper with a density of 0.60-1.00 g/cm 3 is used.
  • the polypropylene resin layers are constituted by coating the surface of the paper with aqueous anchor coat agents and laminating the polypropylene resin layers on the coated surface of the paper after drying.
  • the laminate for the paper container is molded to manufacture the paper container.
  • US 2016/325876 A1 describes an one-piece paper container is formed by cutting and pressing a single-layer coated paper into an unfolded container body and cover, then steaming to soften one of the surfaces thereof and thermoforming with an upper and lower moldings at 120° C-160° C., combining a coating film covering on a plurality of coincided surfaces at the corners and forming enhanced surfaces with protrusions at on the container body and the cover in the meantime.
  • JP 2012 024965 A describes that a heating device in a paper container forming machine includes a heater ejecting hot air toward the front surface of one end of the blank or the rear surface of the other end of the blank and a heat insulation member which is closely adhered to the front surface or the rear surface, exposes the area where a synthetic resin is softened or melted of the front surface or the rear surface to the hot air and shields all places except the area of the front surface or the rear surface from the hot air.
  • Patent Document 1 is appropriate as a container for food eaten without heating, for example, ice cream or the like, there is still room for improvement in this paper container for a container for food that is heated with a microwave oven and used for eating and drinking.
  • a polyethylene layer is provided on one surface of the blank that is an inner surface of the container; however, when the layer is heated by a microwave oven, the polyethylene layer may foam to form pinholes, and ingredients of the food may pass through the polyethylene layer to contaminate the paper.
  • the present invention is directed to providing a paper container that can be efficiently manufactured and that is suitable for heating using a microwave oven, and a method for manufacturing the same.
  • a first aspect of the present invention is a paper container including a container main body formed by folding a blank formed of a sheet-shaped material as defined in claim 1.
  • a second aspect of the present invention is a method for manufacturing a paper container as defined in claim 6, which is provided to manufacture the paper container according to the first aspect.
  • a paper container is constituted by a container main body formed by folding and heat-welding a blank formed by punching a sheet-shaped material, and a lid member attached to the container main body.
  • the sheet-shaped material is mainly formed of paper.
  • Fig. 1 shows a shape of a blank 1.
  • the blank 1 has a rectangular parallelepiped shape, and a plurality of folding lines are formed thereon through embossing of the like. Parts of the folding lines are used for four sides, and a quadrangular bottom surface section 10 that constitutes a bottom surface of the paper container is provided at a central section thereof.
  • Four quadrangular side surface sections 11, 12, 13 and 14 are provided around the bottom surface section 10 such that each shares one of four sides with the bottom surface section 10.
  • Joining sections 21, 22, 23 and 24 joined through heat welding are provided between neighboring side surface sections.
  • Each of the joining sections is constituted by two substantially rectangular shapes that are line-symmetrical to each other.
  • Flange sections 31, 32, 33 and 34 having substantially fixed widths are provided on sides of the side surface sections 11, 12, 13 and 14 opposite to the bottom surface section 10.
  • One side of the triangular shapes of the joining sections have assistant flanges 21a, 22a, 23a and 24a with the same width as the flange section.
  • Fig. 2 shows a layer composition of the blank 1.
  • the blank 1 includes a base material 2 made of paper, an anchor layer 3 formed on a first surface 2a of the base material 2, and a sealant layer 4 formed on the anchor layer 3.
  • the layer composition of the blank 1 is the same as the layer composition of the sheet-shaped material.
  • the lid member may be formed of a material different from that of the blank 1, when the lid member is formed of the same material as that of the blank 1, the entire paper container can be disposed of as combustible waste after use, and does not require sorting.
  • Various types of paper boards such as coated board, coated manila, ivory board, or the like, can be used as the base material 2.
  • Various printing may be applied to one or both sides of the base material 2 for the purpose of improvement of design, imparting information, or the like.
  • the sealant layer 4 is formed of a homopolymer-type polypropylene as a main ingredient.
  • the polypropylene has the melting point of at least 135 °C or more such that it can sufficiently withstand heat applied during a manufacturing process, which will be described below.
  • the melting point is preferably 150 °C or more.
  • a thickness of the sealant layer 4 is 20 ⁇ m or more and less than 60 ⁇ m.
  • the anchor layer 3 is formed of an acid-modified polypropylene resin aqueous dispersion as a main ingredient, and increases adhesion between the base material 2 and the sealant layer 4.
  • the polypropylene contained in the anchor layer 3 has a melting point of at least 120 °C or more such that it can sufficiently withstand heat applied during a manufacturing process, which will be described below.
  • the melting point is preferably 150 °C or more.
  • a resin layer may be formed on a second surface opposite to the first surface 2a.
  • a material of the resin layer may be appropriately set in consideration of a use or the like of the paper container, and may be the same as the sealant layer 4.
  • the sheet-shaped material that is a material of the blank 1 configured as described above can be manufactured by forming the anchor layer 3 through coating or the like of an acid-modified polypropylene resin aqueous dispersion on the first surface 2a of the base material 2, and then, laminating a melting resin that is a sealant layer on the anchor layer 3 through extrusion lamination. When the sheet-shaped material is punched into a predetermined shape, the blank 1 is thus completed.
  • the blank 1 is disposed on a female mold having a shape corresponding to an appearance of the paper container while a surface on which the sealant layer 4 is formed is directed upward (process A).
  • the disposition is performed by a vacuum pad, a chuck, or the like.
  • hot air supply units 101 are disposed at four corners of the blank 1 (process B), and the four corners of the blank 1 are supported by the hot air supply units 101.
  • the hot air supply units 101 prevent the blank 1 from warping before manufacture of a box.
  • the female mold is not shown because it is disposed below the blank 1.
  • Each of the hot air supply units 101 has an ejection hole (not shown). Hot air at hundreds of °C can be supplied from the exhaust nozzles.
  • the exhaust nozzles are directed toward the joining sections 21, 22, 23 and 24 that are disposed at four corner sections of the blank 1 in the process B.
  • the hot air is ejected from the exhaust nozzles. At least a part of the sealant layer 4 in the joining sections 21, 22, 23 and 24 is melted by the hot air, and is brought into a heat-weldable state (process D).
  • the sealant layer 4 on the assistant flanges 21a, 22a, 23a and 24a is further welded, and is brought into a heat-weldable state.
  • the covers 102 are retracted, and a male mold having a shape corresponding to an inner shape of the paper container is made to approach the blank 1 from above the blank 1.
  • the male mold comes in contact with the blank 1 and presses the blank 1 toward the female mold (process E).
  • the pressed blank 1 is folded along the folding line.
  • each of the joining sections 21, 22, 23 and 24 is folded along the folding line between two substantially triangular shapes.
  • the sealant layers 4 having two substantially triangular shapes approach and join each other.
  • the joining sections 21, 22, 23 and 24, which were joined are folded along one of side surface sections standing upward from the bottom surface section through folding. According to this movement, the sealant layer 4 on which the assistant flanges 21a, 22a, 23a and 24a are melted approaches a back side of the flange section of the side surface section along which the joining section is disposed, and the assistant flange and the flange section are joined to each other.
  • the completed container main body 50 is carried to the next process, and the internal space is filled with contents.
  • a packing body filled with contents is completed.
  • predetermined processing such as freezing, drying, or the like, may be performed with respect to the contents at an appropriate timing.
  • a part of the sealant layer formed on the blank constitutes the innermost surface of the paper container.
  • the sealant layer is formed of polyethylene, since the thermal resistance is poor, the sealant layer may foam when heated in a microwave oven, and pinholes are easily generated. When pinholes are generated, seasoning ingredients, an oil content, or the like, of the food permeates into the base material, which greatly impairs the appearance.
  • the sealant layer is formed of a polyester-based resin such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or the like, and a resin material having a high melting point such as polymethylpentene (PMP) or the like, it is possible to reduce the likelihood of the generation of pinholes.
  • the sealant layer formed of these materials may not melt sufficiently even when hot air is applied in the above-mentioned process D because the melting point is too high, and the production efficiency may significantly decrease.
  • the base material may be charred.
  • the resin material may flow because the resin material is at a high temperature and move to areas other than the joining section to spoil the appearance, and instances in which a stable seal strength cannot be obtained may occur.
  • PP polypropylene
  • PP has a low adhesion to the base material of the paper, and after lamination, the sealant layer may peel from the base material during punching when the blank is formed. Since the adhesion is further reduced under a high temperature atmosphere, the sealant layer may naturally peel from the base material due to heating in a microwave oven.
  • the inventors repeated various examinations under the above-mentioned circumstances. The result was that, in the above-mentioned manufacturing process, a configuration in which a sealant layer can be reliably melted and efficiently manufactured was found, while reducing the probability of generation of pinholes upon manufacture of the box and heating in a microwave oven, by forming the sealant layer of a homopolymer type polypropylene having a melting point of a predetermined value or more and having a thickness of a predetermined value or more and further making the melting point of the polypropylene contained in the anchoring agent a predetermined value or more, and using an anchoring agent containing an acid-modified polypropylene resin aqueous dispersion as a main ingredient.
  • the adhesion between the paper base material and the sealant layer is also improved, and the probability of peeling off of the sealant layer upon formation of the blank or heating in a microwave oven is significantly reduced.
  • a sheet material for examination was formed using the following materials.
  • a sealant layer material was laminated on one surface of the base material through extrusion lamination, and a plurality of types of sheet-shaped materials having different thicknesses of the sealant layer was obtained.
  • the thicknesses of the sealant layer were the four types including 14 ⁇ m, 17 ⁇ m, 20 ⁇ m, and 50 ⁇ m.
  • the paper container for examination was fabricated according to the above-mentioned manufacturing procedure (a hot air temperature of 520 °C, an air volume of 430 ml/min, a box manufacture speed of 50 pcs/min) using the blank obtained by punching the sheet-shaped material.
  • a sheet material for examination was formed using the following materials.
  • the anchor layer was formed on one surface of the base material according to any one of the above-mentioned A1 to A3. In the cases of A2 and A3, an application quantity was 0.5 g/m 2 in terms of solid content. Three types of sheet-shaped materials were obtained by laminating a sealant layer material on the anchor layer through extrusion lamination. The thickness of the sealant layer was 40 ⁇ m.
  • Peeling conditions were the following two types.
  • Paper peeling in Table 2 means a phenomenon that a part of the paper base material peels off from the remaining part of the paper base material while still in close contact with the sealant layer. That is, it can be said that the adhesion between the sealant layer formed of PP and the paper base material is strong in a sheet-shaped material in which this paper peeling occurs.
  • adhesion between the paper base material and the sealant layer formed of PP can be enhanced by configuring the anchor layer with the acid-modified polypropylene resin aqueous dispersion, and the adhesion is maintained even in a high temperature environment.
  • a sheet material for examination was formed using the following materials.
  • the anchor layer was formed on one surface of the base material according to all of the above-mentioned B1 to B4. In all of these cases, an application quantity was 0.5 g/m 2 in terms of solid content.
  • the sealant layer material was laminated on the anchor layer through extrusion lamination, and four types of sheet-shaped materials were obtained. The thickness of the sealant layer was 40 ⁇ m.
  • a specimen was fabricated using each of the sheet-shaped materials, and 180° peeling was performed by grasping the base material layer and the sealant layer, a peeling strength was measured, and a degree of adhesion was checked.
  • the peeling conditions were the following three types.
  • the paper container was fabricated under the same conditions as in Examination 1 using each of the sheet-shaped materials fabricated in Examination 3. In addition, the paper container was filled with contents and heated in a microwave oven under the same conditions as those of Examination 1.
  • the specimen was fabricated using the paper container immediately after manufacture of the box and the paper container after heating in a microwave oven, 180° peeling was performed by grasping the base material layer and the sealant layer, and the degree of adhesion was checked.
  • the lid member is formed of the same sheet-shaped material as that of the blank, it is speculated that the same phenomena also occur in the sealant layer of the sheet-shaped material. That is, since the lid member is formed of the same sheet-shaped material as that of the container main body, upon opening after heating in a microwave oven, the base material and the sealant layer of the lid member can also be appropriately prevented from peeling.
  • a paper container of the embodiment is constituted by a container main body formed by folding and heat-welding a blank formed by punching a sheet-shaped material, and a lid member attached to the container main body.
  • the sheet-shaped material is paper as a main material.
  • Fig. 9 shows a shape of a blank 201 according to the embodiment.
  • the blank 201 has a substantially rectangular shape, and a plurality of folding lines are formed through embossing or the like. Parts of the folding lines are four sides and have a quadrangular bottom surface section 210 that constitutes a bottom surface of a paper container at a central section thereof.
  • Four quadrangular side surface sections 211, 212, 213 and 214 are provided around the bottom surface section 210, each sharing one of the bottom surface section 210 and the four sides.
  • Joining sections 221, 222, 223 and 224 joined to each other through heat welding are provided between the neighboring side surface sections.
  • Each of the joining sections is constituted by two substantially triangular shapes that are line-symmetrical to each other.
  • Flange sections 231, 232, 233 and 234 having a substantially fixed width are provided at sides of the side surface sections 211, 212, 213 and 214 opposite to the bottom surface section 210.
  • Assistant flanges 221a, 222a, 223a and 224a having the same width as that of the flange section are formed at one of the triangular shapes of each of the joining sections.
  • Each of the flange sections and each of the assistant flanges are disposed to extend along a circumferential edge of the container main body in the completed container main body.
  • Fig. 10 shows a layer composition of the blank 201.
  • the blank 201 includes the base material 2 of the paper, the anchor layer 3 formed on the first surface 2a of the base material 2, and the sealant layer 4 formed on the anchor layer 3.
  • a layer composition of the blank 201 is equal to a layer composition of the sheet-shaped material.
  • the lid member may be formed of a material different from that of the blank 201, when the lid member is formed of the same sheet-shaped material as that of the blank 201, the entire paper container can be disposed of as combustible waste after use, and sorting is not required.
  • the sheet-shaped material that forms the lid member may not have a heat seal layer, which will be described below.
  • Various types of paper boards such as coated board, coated manila, ivory board, or the like, can be used as the base material 2.
  • Various printing may be applied to one or both sides of the base material 2 for the purpose of improvement of design, imparting information, or the like.
  • the sealant layer 4 is configured as a homopolymer type polypropylene as a main ingredient.
  • the polypropylene has a melting point of at least 135 °C or more such that it can sufficiently withstand the heat acting in the manufacturing process, which will be described below.
  • the melting point is preferably 150 °C or more.
  • the thickness of the sealant layer 4 is 20 ⁇ m or more and less than 60 ⁇ m.
  • the anchor layer 3 enhances adhesion between the base material 2 and the sealant layer 4. While the material of the anchor layer 3 can be appropriately selected, it is preferable to use the acid-modified polypropylene resin aqueous dispersion as the main ingredient.
  • the polypropylene contained in the anchor layer 3 has a melting point of at least 120 °C or more such that it can sufficiently withstand the heat acting in the manufacturing process, which will be described below.
  • the melting point is preferably 150 °C or more.
  • Fig. 11 shows a layer composition of a flange section 231.
  • Heat seal layers 205 are formed at both end portions of the flange section 231 in the longitudinal direction on a second surface 2b opposite to the first surface 2a.
  • the heat seal layers 205 are provided at both end portions of the longitudinal shape in the same aspect even in a flange section 233 opposite to the flange section 231 with the bottom surface section 210 sandwiched therebetween (see Fig. 9 ).
  • the heat seal layers 205 are formed of a heat sealing agent containing acid-modified polypropylene resin aqueous dispersion.
  • the melting point of the polypropylene that constitutes the acid-modified polypropylene resin aqueous dispersion is 100 °C or more, and preferably 150 °C or more.
  • the sheet-shaped material that is a material of the blank 201 configured as above forms the anchor layer 3 on the first surface 2a of the base material 2 by coating or the like varnish etc that becomes an anchor layer, and then, the melting resin that becomes the sealant layer is laminated on the anchor layer 3 through extrusion lamination.
  • the sheet-shaped material can be manufactured by coating a heat sealing agent that becomes the heat seal layers 205 on a predetermined place of the second surface 2b. When the sheet-shaped material is punched in a predetermined shape, the blank 201 is completed.
  • the blank 201 is disposed on a female mold having a shape corresponding to an external form of the paper container while a surface on which the sealant layer 4 is formed is directed upward (process A).
  • the disposition is performed by a vacuum pad, a chuck, or the like.
  • the hot air supply units 101 are disposed at four corners of the blank 201 (process B), and the four corners of the blank 201 are supported by the hot air supply units 101.
  • the hot air supply units 101 prevent the blank 201 from warping before manufacture of the box.
  • the female mold is not shown because the female mold is disposed below the blank 201.
  • Each of the hot air supply units 101 has an ejection hole (not shown). Hot air of hundreds °C can be supplied from the exhaust nozzles.
  • the exhaust nozzles are directed toward the joining sections 221, 222, 223 and 224 that are four corner sections of the blank 201 in the process B.
  • the hot air is ejected from the exhaust nozzle. At least a part of the sealant layer 4 in the joining sections 221, 222, 223 and 224 are melted by the hot air, and can become a heat-weldable state (process D').
  • the sealant layer 4 of the assistant flanges 221a, 222a, 223a and 224a is also further melted, and the heat seal layers 205 formed at back sides of the flange section 231 and 233 are also softened.
  • the covers 102 are retracted, and the male mold having the shape corresponding to the internal form of the paper container approaches the blank 201 from above the blank 201.
  • the male mold comes in contact with the blank 201, and is directed toward the female mold to press against the blank 201 (process E').
  • the pressed blank 201 is bent along the folding line.
  • each of the joining sections 221, 222, 223 and 224 is folded along the folding line between the two substantially triangular shapes.
  • the sealant layers 4 of the two substantially triangular shapes approach each other and join each other.
  • the joining sections 221, 222, 223 and 224 that are joined to each other are folded along the side surface section 211 or 213 of the side surface sections 211, 212, 213 and 214 standing upward from the bottom surface section due to the folding.
  • the sealant layer 4 on which the assistant flanges 221a, 222a, 223a and 224a are melted approaches back sides of the flange section 231 or 233 provided on the side surface section along which the joining section is provided, and comes in contact with the heat seal layers 205. Since the heat seal layer 205 is formed of a polypropylene-based material, the heat seal layer 205 is appropriately joined to the sealant layer 4 of each of the assistant flanges.
  • a container main body 250 is completed.
  • the container main body 250 that was completed is transported to the next process, and the internal space is filled with contents. Finally, as shown in Fig. 17 , when the upper opening of the container main body 250 is covered with a lid member 260, and the circumferential edge portion of the lid member 260 and the flange section of the container main body 250 are joined to each other throughout the circumference, a packing body filled with the contents is completed. After filling with the contents, predetermined processing such as freezing, drying, or the like, with respect to the contents may be performed at an appropriate timing.
  • a part of the sealant layer formed on the blank constitutes the innermost surface of the paper container.
  • the sealant layer is formed of polyethylene
  • the thermal resistance is deteriorated, the foaming occurs when heating in the microwave oven, and the pinholes are easily generated.
  • a seasoning ingredient, an oil content, or the like, of the food permeates into the base material, which greatly impairs the appearance.
  • the sealant layer is formed of a polyester-based resin such as polyethylene terephthalate (PET), polybutylene terephthalate (PBT), or the like, and a resin material having a high melting point such as polymethylpentene (PMP) or the like, it is possible to reduce possibility of generating the pinholes.
  • the sealant layer formed of these materials may not melt sufficiently even when hot air is applied in the above-mentioned process D' because the melting point of the sealant layer is too high, the production efficiency is significantly decreased.
  • the base material may be charred.
  • the resin material even when the resin material was melted, the resin material flowed due to the high temperature thereof, the appearance was spoiled by moving the resin material to an area other than the joining section, and an event occurred in which stable seal strength could not be obtained.
  • PP polypropylene
  • the inventors repeated various examinations under the above-mentioned circumstances. As a result, the inventors found that the joining of the flange sections can be strengthened by providing the heat seal layer containing the acid-modified polypropylene resin aqueous dispersion on the back side of the flange section in which the sealant layers of the assistant flanges are joined to each other. In addition, the inventors have established a configuration that the joining strength of the flange section is not decreased even when the polypropylene is heated in the microwave oven after manufacture of the box by making the melting point of the polypropylene contained in the acid-modified polypropylene resin aqueous dispersion be a predetermined value or more. In the paper container of the embodiment, both of reduction in generation of the pinholes or the like in the inner surface and improvement of production efficiency due to reliable joining of the flange sections are accomplished.
  • a sheet-shaped material for examination using the following material was formed.
  • the sealant layer material was laminated on one surface of the base material through extrusion lamination, and the sheet-shaped material having the sealant layer of a thickness of 40 ⁇ m was obtained.
  • the sheet-shaped material three patterns with different configurations of flange sections were fabricated as described below.
  • the paper container of each example of experiment was fabricated according to the above-mentioned manufacturing procedure (a hot air temperature of 520 °C, an air volume of 430 ml/min, and a box manufacture speed of 50 pcs/min) using the blank obtained by punching the sheet-shaped material having each pattern.
  • the specimen was fabricated using each paper container, and measurement was performed by grasping the flange section and the assistant flange and performing 180° peeling.
  • a state of a peeling interface was visually checked.
  • the "paper peeling" in Table 5 means a phenomenon that a part of any one of the paper base materials is peeled off from the remaining portion of the paper base material while still in close contact with the sealant layer. That is, in the paper container in which the paper peeling occurred, it can be said that the adhesion between the flange section and the assistant flange is enhanced.
  • the heat seal layer is formed of the acid-modified polypropylene resin aqueous dispersion on the flange section, the assistant flange and the flange section having the sealant layer formed of PP can be strongly joined to each other upon manufacture of the box.
  • a sheet material for examination was formed using the following material.
  • the paper container of each example of the experiment was fabricated in the same sequence as that of Examination 1, and filled with macaroni au gratin of 300g as contents. After that, the opening was covered with the lid formed by punching the sheet-shaped material, and the heat seal layers facing each other in the flange section were heat-welded to join the lid to the paper container. After that, the container and the contents were frozen, and a sealed container for each example of the experiment in which the contents were sealed in a frozen state was fabricated.
  • Conditions of heating in the microwave oven were output of 500 W for six minutes. When the temperature of the contents immediately after heating was measured, it was 92 °C to 95 °C.
  • the joining strength of the flange section was sufficient.
  • the joining strength of the flange sections was decreased due to heating in the microwave oven, and the interface peeling was observed between the flange section and the assistant flange. It is conceivable that the heat seal layer was softened as a result of the temperature of the filling material reaching the melting point or more of PP contained in the heat seal layer due to heating in the microwave oven.
  • the paper container of the embodiment is suitable for the purpose of accommodating the food to be heated in the microwave oven and eaten.
  • Fig. 18 shows a schematic cross-sectional view of a blank 301 according to an embodiment of the present invention.
  • the blank 301 has a coat layer 302 formed of acid-modified polypropylene as a main ingredient on the base material 2.
  • the coat layer 302 is formed by applying the acid-modified polypropylene resin aqueous dispersion on the base material 2 and then removing solvent through drying or the like.
  • the paper container can be manufactured.
  • the coat layer 302 can be formed using the acid-modified polypropylene resin aqueous dispersion used when the anchor layer 3 is formed. In this case, the application quantity becomes larger than in the case in which the anchor layer 3 is formed.
  • the application quantity is 0.1 g/cm 2 or more, for example, 0.5 to 3.0 g/cm 2 in terms of solid content.
  • a large amount of acid-modified polypropylene resin is disposed on the base material 2 by applying a large amount of acid-modified polypropylene resin aqueous dispersion.
  • the acid-modified polypropylene resin is coated due to heat or the like upon removal of solvent, and the coat layer 302 is formed.
  • the coat layer 302 is a membrane-like structure formed of the acid-modified polypropylene resin as a main ingredient, a waterproof characteristic is appeared, and permeation of the contents into the base material 2 is prevented. Since the coat layer 302 functions as a sealant because it is heat-weldable. Meanwhile, since the coat layer 302 is different from the sealant layer 4 and not peeled in a layer shape, the blank 301 has a good design property.
  • the melting point of the polypropylene in the coat layer 302 can be appropriately set. Since the melting point of the polypropylene is increased, the blank 301 can be suitably applied to the paper container for food that is heated in the microwave oven and eaten. When the blank 301 is applied to the paper container for food that is not heated, the melting point of the polypropylene may not be high.
  • the coat layer 302 may be provided on both surfaces of the base material 2. In this case, the water resistance of the manufactured paper container can be further increased.
  • the side surface sections folded along the joining section are not limited to the above-mentioned side surface sections 211 and 213 and may be appropriately set.
  • the number of the side surface sections along which the joining sections are provided is not limited to two, and may be three or four.
  • the flange section of the side surface section along which the joining section is provided the above-mentioned effects can be exhibited as long as the heat seal layer is formed at a position corresponding to the assistant flange.
  • the present invention can be applied to a paper container.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Package Specialized In Special Use (AREA)
  • Cartons (AREA)
EP19848634.2A 2018-08-10 2019-08-02 Paper container and method for manufacturing paper container Active EP3835227B1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
JP2018151561A JP7268300B2 (ja) 2018-08-10 2018-08-10 紙製容器および紙製容器の製造方法
JP2018245476A JP7156017B2 (ja) 2018-12-27 2018-12-27 紙製容器および紙製容器の製造方法
PCT/JP2019/030404 WO2020031870A1 (ja) 2018-08-10 2019-08-02 紙製容器および紙製容器の製造方法

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EP3835227A1 EP3835227A1 (en) 2021-06-16
EP3835227A4 EP3835227A4 (en) 2022-04-06
EP3835227B1 true EP3835227B1 (en) 2023-10-18

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WO (1) WO2020031870A1 (ja)

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SE2230408A1 (en) * 2022-12-12 2024-06-13 Stora Enso Oyj A tray and a method for forming a tray

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US5433374A (en) * 1992-02-06 1995-07-18 Westvaco Corporation Venting/opening for paperboard carton
JP3687396B2 (ja) 1999-03-02 2005-08-24 凸版印刷株式会社 トレー容器用ブランク
JP2001205717A (ja) * 2000-01-26 2001-07-31 Toppan Printing Co Ltd 紙製トレー容器の製函方法
JP2004017449A (ja) * 2002-06-14 2004-01-22 Dainippon Printing Co Ltd 紙容器用積層体およびそれを用いた紙容器
JP5354171B2 (ja) * 2009-02-18 2013-11-27 凸版印刷株式会社 トレー状容器及びその製造方法
JP5587077B2 (ja) * 2010-07-21 2014-09-10 株式会社日本デキシー 紙容器成形機
US20160325876A1 (en) * 2015-05-05 2016-11-10 Master Paper Container Corp. Structure of a one-piece paper container and the manufacturing process thereof
JP2018151561A (ja) 2017-03-14 2018-09-27 株式会社リコー 画像投写装置

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EP3835227A4 (en) 2022-04-06
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