JP2021147068A - Vacuum and/or compressed air molded container, and method for manufacturing the same - Google Patents
Vacuum and/or compressed air molded container, and method for manufacturing the same Download PDFInfo
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- JP2021147068A JP2021147068A JP2020046770A JP2020046770A JP2021147068A JP 2021147068 A JP2021147068 A JP 2021147068A JP 2020046770 A JP2020046770 A JP 2020046770A JP 2020046770 A JP2020046770 A JP 2020046770A JP 2021147068 A JP2021147068 A JP 2021147068A
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- laminate
- compressed air
- thermoplastic resin
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- 238000000034 method Methods 0.000 title claims abstract description 18
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 7
- 229920005992 thermoplastic resin Polymers 0.000 claims abstract description 30
- 239000006260 foam Substances 0.000 claims abstract description 19
- 239000000463 material Substances 0.000 claims abstract description 19
- 238000005187 foaming Methods 0.000 claims abstract description 17
- 238000010438 heat treatment Methods 0.000 abstract description 5
- -1 polypropylene Polymers 0.000 description 65
- 239000004698 Polyethylene Substances 0.000 description 45
- 229920000573 polyethylene Polymers 0.000 description 45
- 239000010410 layer Substances 0.000 description 44
- 239000004743 Polypropylene Substances 0.000 description 20
- 229920001155 polypropylene Polymers 0.000 description 20
- 238000000465 moulding Methods 0.000 description 16
- 238000007666 vacuum forming Methods 0.000 description 12
- 238000002844 melting Methods 0.000 description 10
- 230000008018 melting Effects 0.000 description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 8
- 229920005989 resin Polymers 0.000 description 7
- 239000011347 resin Substances 0.000 description 7
- 235000013305 food Nutrition 0.000 description 5
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 230000037237 body shape Effects 0.000 description 3
- 239000000758 substrate Substances 0.000 description 3
- 238000001125 extrusion Methods 0.000 description 2
- 229920001903 high density polyethylene Polymers 0.000 description 2
- 239000004700 high-density polyethylene Substances 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 229920001179 medium density polyethylene Polymers 0.000 description 2
- 239000004701 medium-density polyethylene Substances 0.000 description 2
- 229920005990 polystyrene resin Polymers 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 229920000219 Ethylene vinyl alcohol Polymers 0.000 description 1
- 239000004793 Polystyrene Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 229920001328 Polyvinylidene chloride Polymers 0.000 description 1
- 241000692569 Stylephorus chordatus Species 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000004715 ethylene vinyl alcohol Substances 0.000 description 1
- RZXDTJIXPSCHCI-UHFFFAOYSA-N hexa-1,5-diene-2,5-diol Chemical compound OC(=C)CCC(O)=C RZXDTJIXPSCHCI-UHFFFAOYSA-N 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 235000008446 instant noodles Nutrition 0.000 description 1
- 235000014109 instant soup Nutrition 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 229920006350 polyacrylonitrile resin Polymers 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
- 229920005668 polycarbonate resin Polymers 0.000 description 1
- 239000004431 polycarbonate resin Substances 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 229920013716 polyethylene resin Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000009719 polyimide resin Substances 0.000 description 1
- 229920002223 polystyrene Polymers 0.000 description 1
- 229920005749 polyurethane resin Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000005033 polyvinylidene chloride Substances 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
Landscapes
- Containers Having Bodies Formed In One Piece (AREA)
- Packages (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Abstract
Description
本発明は真空および／または圧空成形容器に関する。より詳しくは、側面に発泡層を備えた真空および／または圧空成形容器に関する。 The present invention relates to vacuum and / or compressed air molded containers. More specifically, the present invention relates to a vacuum and / or compressed air molded container having a foam layer on the side surface.
現在、多種多様な容器が市場に流通している。容器はその用途に応じて、様々な機能が求められている。例えば、食品を内包した容器の場合、ガスバリア性、耐漏水性、耐熱性などの機能が求められる。これらの機能は、１又は２以上の素材を組み合わせることで達成されている。 Currently, a wide variety of containers are on the market. The container is required to have various functions depending on its use. For example, in the case of a container containing food, functions such as gas barrier property, water leakage resistance, and heat resistance are required. These functions are achieved by combining one or more materials.
容器に食品を内包して用いる一例として、即席麺やインスタントスープなどの即席食品が挙げられる。これらの即席食品は、容器内に規定量の熱湯を注湯することで喫食が可能となる。そのため、これらの即席食品には、耐漏水性が求められる。 An example of using food contained in a container is instant food such as instant noodles or instant soup. These instant foods can be eaten by pouring a specified amount of boiling water into the container. Therefore, these instant foods are required to have water leakage resistance.
耐漏水性を有する容器としては、ポリプロピレンやポリスチレンなどの熱可塑性樹脂からなる容器が知られている。熱可塑性樹脂からなる容器は耐漏水性に優れるが、容器内部の熱が容器の外側に伝わりやすいという特徴もある。そのため、容器内に熱湯などを注湯した場合、容器を直接把持することが難しい。 As a container having water resistance, a container made of a thermoplastic resin such as polypropylene or polystyrene is known. A container made of a thermoplastic resin has excellent water leakage resistance, but it also has a feature that heat inside the container is easily transferred to the outside of the container. Therefore, when hot water or the like is poured into the container, it is difficult to directly grip the container.
そこで、熱可塑性樹脂容器の外側にコルゲート紙を巻きつける方法や、熱可塑性樹脂容器との間に空気層ができるように熱可塑性樹脂容器よりも一回り大きな紙製容器と嵌合させた、いわゆる二重容器とする方法が従来から行われている（特許文献１、２参照）。 Therefore, there is a method of wrapping corrugated paper around the outside of the thermoplastic resin container, or fitting it with a paper container that is one size larger than the thermoplastic resin container so that an air layer is formed between the corrugated resin container and the so-called. A method of forming a double container has been conventionally performed (see Patent Documents 1 and 2).
ところで、コルゲート紙を巻きつけた場合、耐熱性は向上するが、美観が劣るといった問題が新たに生じる。そこで、コルゲート紙の表面に印刷を行うことも考えられる。しかし、コルゲート紙の場合、用いることができる色彩数に制限が生じることがある。また、熱可塑性樹脂容器にコルゲート紙を巻き付けたり、二重容器にしたりすると、嵩張ったり、スタッキングしづらくなったりするといった問題も生じる。さらに、重量も増加するため、輸送コストがかさむといった問題も生じる。さらにまた、熱可塑性樹脂容器にコルゲート紙を貼り付けたり、二重容器を一体化させたりするためには、別工程として行うための装置が必要となるといった問題も生じる。 By the way, when corrugated paper is wrapped, heat resistance is improved, but a new problem of poor aesthetics arises. Therefore, it is conceivable to print on the surface of corrugated paper. However, in the case of corrugated paper, the number of colors that can be used may be limited. Further, when the corrugated paper is wrapped around the thermoplastic resin container or made into a double container, problems such as bulkiness and difficulty in stacking occur. Further, since the weight is increased, there is a problem that the transportation cost is increased. Furthermore, in order to attach the corrugated paper to the thermoplastic resin container or to integrate the double container, there is a problem that a device for performing as a separate process is required.
本発明者らは、印刷性に優れ、嵩張りや大幅な重量増加がなく、しかも既存の設備を用いて耐熱性を備えた熱可塑性樹脂からなる容器が作れないか検討を行った。そして、発泡層を容器の側面に設けることで上記課題を解決できることを新たに見出し、本発明を完成するに至った。 The present inventors have investigated whether a container made of a thermoplastic resin having excellent printability, no bulkiness or significant weight increase, and having heat resistance can be made by using existing equipment. Then, they have newly found that the above problems can be solved by providing the foam layer on the side surface of the container, and have completed the present invention.
上記課題解決のため、本発明は、側面に発泡層を備えた真空および／または圧空成形容器を提供する。また、上記課題解決のため、本発明は、真空および／または圧空成形された熱可塑性樹脂からなる容器側面と、紙を主強度材とし最外層に発泡層を備えた積層体とが一体化している真空および／または圧空成形容器を提供する。さらに、上記課題解決のため、本発明は、金型の内壁面に沿って逆錐台状または筒状に成形した発泡前の積層体を配置する配置工程と、前記逆錐台状または筒状に成形した発泡前の積層体の内側に熱可塑性樹脂からなる容器が配置されるように、熱可塑性樹脂シートを真空および／または圧空加工する真空および／または圧空加工工程と、積層体を加熱して、積層体の最外層を発泡させる発泡工程と、を含む、真空および／または圧空成形容器の製造方法を提供する。 To solve the above problems, the present invention provides a vacuum and / or compressed air molded container having a foam layer on the side surface. Further, in order to solve the above problems, in the present invention, the side surface of the container made of a thermoplastic resin formed by vacuum and / or pneumatic molding and a laminate having paper as the main strength material and a foam layer as the outermost layer are integrated. Provide vacuum and / or pressure-pneumatic molded containers. Further, in order to solve the above problems, the present invention comprises an arrangement step of arranging a laminated body before foaming, which is formed into an inverted pyramid shape or a tubular shape along the inner wall surface of the mold, and the inverted cone trapezoidal shape or a tubular shape. A vacuum and / or pneumatic processing step of vacuuming and / or pneumatically processing the thermoplastic resin sheet and heating of the laminate so that the container made of the thermoplastic resin is arranged inside the laminated body before foaming formed in The present invention provides a method for producing a vacuum and / or pneumatic molded container, which comprises a foaming step of foaming the outermost layer of the laminate.
かかる構成によれば、熱可塑性樹脂からなる容器と発泡層を備えた積層体とが一体成形されているため、コルゲート紙を熱可塑性樹脂からなる容器に巻き付けるよりも印刷性に優れ、嵩張りや大幅な重量増加も防ぐことができる。また、金型を用いることで、熱可塑性樹脂からなる容器と発泡層を備えた積層体とが一体成形を容易に行うことができる。 According to this configuration, since the container made of the thermoplastic resin and the laminate provided with the foam layer are integrally molded, the printability is superior to that of wrapping the corrugated paper around the container made of the thermoplastic resin, and the bulkiness is increased. A large increase in weight can also be prevented. Further, by using a mold, a container made of a thermoplastic resin and a laminate provided with a foam layer can be easily integrally molded.
本発明によれば、既存の設備を用いて、印刷性、耐熱性に優れた熱可塑性樹脂からなる容器を提供することができる。また、容器と積層体とが一体成形されるため、外れにくい。さらに、積層体は一体成形時には発泡させず、一体成形後に発泡可能であるため、嵩張りを抑えることができる。 According to the present invention, it is possible to provide a container made of a thermoplastic resin having excellent printability and heat resistance by using existing equipment. Further, since the container and the laminate are integrally molded, they are hard to come off. Further, since the laminate is not foamed during integral molding and can be foamed after integral molding, bulkiness can be suppressed.
以下、本発明の実施の形態を説明する。本実施形態にかかる成形容器は、熱可塑性樹脂からなる容器本体と、最外層に発泡層を備えた積層体が一体化している丼型形状を例に説明する。 Hereinafter, embodiments of the present invention will be described. The molded container according to the present embodiment will be described by taking as an example a bowl-shaped shape in which a container body made of a thermoplastic resin and a laminate having a foam layer on the outermost layer are integrated.
本実施形態における容器本体は、糸尻部を備えた丼型形状であり、開口部から外側に延びるフランジ部を備えている。 The container body in the present embodiment has a bowl-shaped shape having a thread tail portion, and includes a flange portion extending outward from the opening.
容器本体に用いることができる熱可塑性樹脂としては、ポリエステル樹脂、ポリエチレン樹脂、ポリプロピレン樹脂、ポリスチレン樹脂、ポリアミド樹脂、ポリカーボネート樹脂、ポリアクリロニトリル樹脂、ポリイミド樹脂、ポリ塩化ビニル樹脂、ポリ塩化ビニリデン樹脂、ポリビニルアルコール樹脂、エチレンビニルアルコール樹脂、ポリウレタン樹脂が挙げられる。熱可塑性樹脂層は単層でも良いし、積層であっても良い。このうち、成形のしやすさの観点から、ポリスチレン樹脂またはポリプロピレン樹脂が好ましい。 The thermoplastic resin that can be used for the container body includes polyester resin, polyethylene resin, polypropylene resin, polystyrene resin, polyamide resin, polycarbonate resin, polyacrylonitrile resin, polyimide resin, polyvinyl chloride resin, polyvinylidene chloride resin, and polyvinyl alcohol. Examples thereof include resins, ethylene vinyl alcohol resins, and polyurethane resins. The thermoplastic resin layer may be a single layer or a laminated layer. Of these, polystyrene resin or polypropylene resin is preferable from the viewpoint of ease of molding.
本実施形態にかかる熱可塑性樹脂容器の成形方法としては、射出成形、真空成形、圧空成形、真空圧空成形、熱板成形などの慣用の成形方法を用いることができる。本実施形態においては、真空成形、圧空成形または真空圧空成形が好ましい。
ここで、真空成形とは、加熱して可撓性を高めた熱可塑性樹脂シートを吸引して型に密着させることで、所定の形状に成形する方法を言う。圧空成形とは、加熱して可撓性を高めた熱可塑性樹脂シートを下側の型と上側の圧空BOXにて挟み、圧力により熱可塑性樹脂シートを型に密着させることで、所定の形状に成形する方法を言う。真空圧空成形とは、真空成形と圧空成形とを組み合わせた成形方法をいう。
As a molding method for the thermoplastic resin container according to the present embodiment, conventional molding methods such as injection molding, vacuum molding, pressure molding, vacuum pressure molding, and hot plate molding can be used. In this embodiment, vacuum forming, compressed air forming or vacuum forming is preferable.
Here, vacuum forming refers to a method of forming a predetermined shape by sucking a thermoplastic resin sheet having increased flexibility by heating and bringing it into close contact with a mold. Compressed air molding is a process in which a thermoplastic resin sheet that has been heated to increase its flexibility is sandwiched between a lower mold and an upper compressed air BOX, and the thermoplastic resin sheet is brought into close contact with the mold by pressure to form a predetermined shape. Refers to the molding method. Vacuum pressure air forming refers to a forming method that combines vacuum forming and compressed air forming.
本実施形態にかかる積層体は、紙を主強度材とし最外層に発泡層を備えている。具体的には、紙基材の片面にポリエチレンＡの層が、もう片面にポリエチレンＡよりも融点の高いポリエチレンＢの層で構成されている。ここで、発泡前の積層体の厚みとしては３０〜１００μｍが好ましい。３０μｍ未満だと、紙基材やポリエチレン層の十分な厚みが確保できず、結果として十分な発泡層が得られない。一方、１００μｍより厚すぎると、嵩張ってしまう。また、発泡後の積層体の厚みとしては１２００μｍ未満が好ましい。１２００μｍ以上だと、嵩張ってしまったり、スタッキングしづらくなったりしてしまう。さらに、発泡層の厚みとしては４００μｍ以上であることが好ましい。 The laminate according to the present embodiment uses paper as the main strength material and has a foam layer as the outermost layer. Specifically, one side of the paper substrate is composed of a layer of polyethylene A, and the other side is composed of a layer of polyethylene B having a melting point higher than that of polyethylene A. Here, the thickness of the laminate before foaming is preferably 30 to 100 μm. If it is less than 30 μm, a sufficient thickness of the paper base material or the polyethylene layer cannot be secured, and as a result, a sufficient foam layer cannot be obtained. On the other hand, if it is too thick than 100 μm, it will be bulky. The thickness of the laminated body after foaming is preferably less than 1200 μm. If it is 1200 μm or more, it becomes bulky and it becomes difficult to stack. Further, the thickness of the foam layer is preferably 400 μm or more.
紙基材の坪量は、取り扱い性等により適宜選択可能であるが、通常は２００ｇ／ｍ２以上４００ｇ／ｍ２以下程度のものが好ましく、２５０ｇ／ｍ２以上３５０ｇ／ｍ２以下のものがより好ましい。本発明では、紙基材中に含まれる水分を利用して発泡前の発泡層（以下、単に「未発泡層 」とも言う。）を発泡させて発泡層とするため、紙基材に含まれる水分が重要である。紙基材の含水率としては、約５〜１０重量％の範囲内であることが好ましい。 The basis weight of the paper base material can be appropriately selected depending on the handleability and the like, but usually 200 g / m 2 or more and 400 g / m 2 or less is preferable, and 250 g / m 2 or more and 350 g / m 2 or less is usually used. More preferred. In the present invention, since the foamed layer before foaming (hereinafter, also simply referred to as “unexpanded layer”) is foamed to form a foamed layer by utilizing the moisture contained in the paper base material, it is contained in the paper base material. Moisture is important. The water content of the paper substrate is preferably in the range of about 5 to 10% by weight.
次に、ポリエチレンについて説明する。本発明においては種々のポリエチレンを用いることができるが、ポリエチレンＡとしては低〜中密度ポリエチレンを、ポリエチレンＢとしては中〜高密度ポリエチレンを用いることが好ましい。大まかな定義としては、低密度ポリエチレンは、融点が９５〜１３０℃、密度が０．９１〜０．９２９ｇ／ｃｍ３のポリエチレンをさす。中密度ポリエチレンは、融点が１１０〜１３５、密度が０．９３〜０．９４１ｇ／ｃｍ３のポリエチレンをさす。高密度ポリエチレンとは、融点が１２０〜１４０℃、密度が０．９４２〜０．９７ｇ／ｃｍ３のポリエチレンをさす。 Next, polyethylene will be described. Although various types of polyethylene can be used in the present invention, it is preferable to use low to medium density polyethylene as polyethylene A and medium to high density polyethylene as polyethylene B. As a rough definition, low density polyethylene refers to polyethylene with a melting point of 95-130 ° C. and a density of 0.91 to 0.929 g / cm 3 . Medium-density polyethylene refers to polyethylene having a melting point of 110 to 135 and a density of 0.93 to 0.941 g / cm 3 . High-density polyethylene refers to polyethylene having a melting point of 120 to 140 ° C. and a density of 0.942 to 0.97 g / cm 3 .
なお、ポリエチレンＡとポリエチレンＢとは、融点の差が５℃以上あることが好ましく、１０℃以上あることがより好ましい。ポリエチレンＡとポリエチレンＢとの融点の差が小さいと、発泡させる際の温度制御が困難となる。 The difference in melting point between polyethylene A and polyethylene B is preferably 5 ° C. or higher, and more preferably 10 ° C. or higher. If the difference in melting point between polyethylene A and polyethylene B is small, it becomes difficult to control the temperature during foaming.
さらに、本発明においては、容器本体と積層体とを一体化させるために、ポリエチレンＢに容器本体と同じ素材を添加することが好ましい。容器本体と同じ素材を用いることで、積層体と容器本体との接着力が増し、一体化させることができる。本実施形態においては、ポリエチレンＢにポリプロピレンを添加することが好ましい。ここで、ポリエチレンＢに添加するポリプロピレン量としては、１０〜５０重量％であることが好ましい。１０％未満だと容器本体との接着力が不十分であり、５０％より多いと積層体の成形に支障をきたす恐れがある Further, in the present invention, it is preferable to add the same material as the container body to polyethylene B in order to integrate the container body and the laminate. By using the same material as the container body, the adhesive force between the laminate and the container body is increased and can be integrated. In this embodiment, it is preferable to add polypropylene to polyethylene B. Here, the amount of polypropylene added to polyethylene B is preferably 10 to 50% by weight. If it is less than 10%, the adhesive force with the container body is insufficient, and if it is more than 50%, it may hinder the molding of the laminate.
ポリエチレンＢに容器本体と同じ素材を添加する以外に、ポリエチレンＢ層の上に容器本体と同じ素材の層を一層設けてもよい。本実施形態においては、ポリエチレンＢ層の上にポリプロピレン層を設けることが好ましい。ポリプロピレン層の厚みとしては、５〜１５μｍが好ましい。５μｍ未満だと接着性が安定しない。１５μｍより厚くすると、加工性が悪くなる。 In addition to adding the same material as the container body to polyethylene B, a layer of the same material as the container body may be further provided on the polyethylene B layer. In the present embodiment, it is preferable to provide a polypropylene layer on the polyethylene B layer. The thickness of the polypropylene layer is preferably 5 to 15 μm. If it is less than 5 μm, the adhesiveness will not be stable. If it is thicker than 15 μm, the workability deteriorates.
積層体の製造方法について説明する。ここでは、ポリエチレンの塗工方法としてＴダイを用いた場合を例に説明するが、これに限られるものではない。積層体は、ロール状に巻かれた紙基材（原紙）を巻き出しながら、ガイドローラーに従って紙基材を最初のＴダイまで送る。Ｔダイから押出ラミネートを行い、溶融したポリエチレンＡを紙基材の片面に塗工する。ポリエチレンＡを塗工した面をチルドローラーで冷却し、ポリエチレンＡ層を設ける。なお、ポリエチレンＡ層の厚みとしては４０〜２００μｍが好ましい。この範囲であれば、発泡後に十分な断熱性を実現できる。 A method for manufacturing the laminate will be described. Here, a case where a T-die is used as a polyethylene coating method will be described as an example, but the present invention is not limited to this. The laminate feeds the paper base material to the first T-die according to the guide roller while unwinding the paper base material (base paper) wound in a roll shape. Extrusion laminating is performed from the T die, and the molten polyethylene A is applied to one side of the paper substrate. The surface coated with polyethylene A is cooled by a chilled roller to provide a polyethylene A layer. The thickness of the polyethylene A layer is preferably 40 to 200 μm. Within this range, sufficient heat insulating properties can be realized after foaming.
紙基材の片面にポリエチレンＡ層を設けた後、今度はポリエチレンＡ層とは反対側の面にポリエチレンＢ層を設ける。具体的には、Ｔダイから押出ラミネートを行い、溶融したポリエチレンＢをポリエチレンＡ層とは反対側の紙基材に塗工する。ポリエチレンＢ層を塗工した面をチルドローラーで冷却し、ポリエチレンＢ層を設ける。これにより、紙基材の両面にポリエチレン層が設けられた積層体が得られる。ポリエチレンＢ層の厚みとしては、２５〜８０μｍであることが好ましい。なお、本実施形態ではポリエチレンＡを先に塗工したが、ポリエチレンＢを先に塗工してもよい。また、ポリエチレンＡ層とポリエチレンＢ層とを設ける（時間）間隔は短い方が好ましい。間隔が長すぎると紙基材から水分が抜けて、ポリエチレンが発泡し難くなるためである。 After the polyethylene A layer is provided on one side of the paper base material, the polyethylene B layer is provided on the surface opposite to the polyethylene A layer. Specifically, extrusion laminating is performed from the T die, and the molten polyethylene B is applied to the paper base material on the opposite side of the polyethylene A layer. The surface coated with the polyethylene B layer is cooled by a chilled roller to provide the polyethylene B layer. As a result, a laminate in which polyethylene layers are provided on both sides of the paper base material can be obtained. The thickness of the polyethylene B layer is preferably 25 to 80 μm. In this embodiment, polyethylene A is applied first, but polyethylene B may be applied first. Further, it is preferable that the (time) interval in which the polyethylene A layer and the polyethylene B layer are provided is short. This is because if the interval is too long, water will escape from the paper base material and it will be difficult for polyethylene to foam.
得られた積層体のポリエチレンＡ層表面には印刷を行うこともできる。印刷を行うことで装飾を付与することができ、美観が良くなる。印刷は未発泡層に対して行うのが好ましい。未発泡層であれば印刷が行いやすい。 Printing can also be performed on the surface of the polyethylene A layer of the obtained laminate. By printing, decoration can be added and the appearance is improved. Printing is preferably performed on the unfoamed layer. If it is an unfoamed layer, printing is easy.
次に、本実施形態にかかる成形容器の製造方法について説明する。ここでは真空成形を例に説明する。まず、印刷を施した上述の積層体を所定の形状に打ち抜く。打ち抜いた積層体は、印刷面を外側に向けて端部と端部を接着すると、丼型容器の側面と一致する形状となる。 Next, a method for manufacturing a molded container according to the present embodiment will be described. Here, vacuum forming will be described as an example. First, the printed laminate is punched into a predetermined shape. When the end portions are bonded to each other with the printed surface facing outward, the punched laminate has a shape that matches the side surface of the bowl-shaped container.
まず、端部と端部を接着した積層体を、真空成形装置の金型内に配置する。続いて、加熱したポリプロピレンシートを金型の上部に配置し、金型に表面に設けられた吸引口からポリプロピレンシートを吸引する。ポリプロピレンシートは吸引によって金型に密着することで変形し、所定の容器本体形状となる。また、ポリプロピレンシートが吸引によって変形するとき、積層体の内側面と容器本体の胴部とが当接する。積層体の内側面にはポリプロピレンが含まれているため、加熱されたポリプロピレンシートが積層体の内側面に当接すると、積層体とポリプロピレンシートとが接着して一体化する。これにより、接着剤を用いなくても積層体と容器本体とを一体化することができる。なお、ポリプロピレンシートを真空成形する際に、冶具でポリプロピレンシートを押してもよい。冶具を用いることにより、より確実にポリプロピレンシートを所望の容器本体形状に近づけることができる。また、冶具で押さえることにより、積層体とポリプロピレンシートとの接着を確実ならしめることができる。 First, the laminate with the ends bonded to each other is placed in the mold of the vacuum forming apparatus. Subsequently, the heated polypropylene sheet is placed on the upper part of the mold, and the polypropylene sheet is sucked from the suction port provided on the surface of the mold. The polypropylene sheet is deformed by being brought into close contact with the mold by suction, and has a predetermined container body shape. Further, when the polypropylene sheet is deformed by suction, the inner side surface of the laminate and the body of the container body come into contact with each other. Since polypropylene is contained in the inner surface of the laminate, when the heated polypropylene sheet comes into contact with the inner surface of the laminate, the laminate and the polypropylene sheet are adhered and integrated. As a result, the laminate and the container body can be integrated without using an adhesive. When vacuum forming the polypropylene sheet, the polypropylene sheet may be pressed with a jig. By using a jig, the polypropylene sheet can be more reliably brought close to the desired container body shape. Further, by pressing with a jig, the adhesion between the laminate and the polypropylene sheet can be ensured.
次に、積層体と容器本体とが一体化した成形容器を金型から外し、オーブン内へと搬送する。オーブン内は、ポリエチレンＡの融点以上ポリエチレンＢの融点未満に設定されている。これにより、積層体の外側面を加熱発泡させる。なお、加熱温度がポリエチレンＡの融点未満であると、発泡層を設けることができない。一方、加熱温度がポリエチレンＢの融点を超えると、積層体の内外面全てが発泡してしまったり、十分な発泡が得られなくなってしまったりするため好ましくない。また、容器本体の形状が歪む恐れもある。 Next, the molded container in which the laminate and the container body are integrated is removed from the mold and transported into the oven. The inside of the oven is set to be equal to or higher than the melting point of polyethylene A and lower than the melting point of polyethylene B. As a result, the outer surface of the laminate is heated and foamed. If the heating temperature is lower than the melting point of polyethylene A, the foam layer cannot be provided. On the other hand, if the heating temperature exceeds the melting point of polyethylene B, all the inner and outer surfaces of the laminate may foam, or sufficient foaming may not be obtained, which is not preferable. In addition, the shape of the container body may be distorted.
以上説明したように、本実施例にかかる真空成形容器は、コルゲート紙を巻いた容器よりも嵩張らず、しかも軽量である。また、積層体に印刷可能であるため、美観も優れる。さらに、新たな装置を用いなくても、容器本体と積層体とを一体化させることができるという極めて優れた効果を奏する。 As described above, the vacuum forming container according to the present embodiment is less bulky and lighter than the container wrapped with corrugated paper. Moreover, since it can be printed on the laminated body, it has an excellent aesthetic appearance. Further, it has an extremely excellent effect that the container body and the laminated body can be integrated without using a new device.
上記実施例では真空成形装置を用いたが、本発明は真空成形に限らず他の成形方法を用いても製造できる。例えば、真空成形装置の代わりに圧空成形装置を用いて行ってもよい。圧空成形装置を用いる場合、加熱した熱可塑性樹脂シートを金型の上に配置するまでは真空成形装置と同じである。圧空成形装置では、圧空BOXを用いて熱可塑性樹脂シートの上から圧力を加えることで、ポリプロピレンシートは金型に密着し、所定の容器本体形状となる。また、ポリプロピレンシートが圧力によって変形するとき、積層体の内側面と容器本体の胴部とが当接して一体化する。さらに、真空圧空成形装置を用いて製造することもできる。真空圧空成形装置の場合、金型からは吸引し、圧空BOXからは圧力を加える。 Although a vacuum forming apparatus was used in the above embodiment, the present invention can be produced not only by vacuum forming but also by using other molding methods. For example, a compressed air forming apparatus may be used instead of the vacuum forming apparatus. When the compressed air forming apparatus is used, it is the same as the vacuum forming apparatus until the heated thermoplastic resin sheet is placed on the mold. In the compressed air molding apparatus, by applying pressure from above the thermoplastic resin sheet using the compressed air BOX, the polypropylene sheet adheres to the mold and has a predetermined container body shape. Further, when the polypropylene sheet is deformed by pressure, the inner side surface of the laminated body and the body portion of the container body come into contact with each other to be integrated. Further, it can be manufactured by using a vacuum compressed air molding apparatus. In the case of a vacuum compressed air forming device, suction is applied from the mold and pressure is applied from the compressed air box.
Claims (3)
金型の内壁面に沿って逆錐台状または筒状に成形した発泡前の積層体を配置する配置工程と、
前記逆錐台状または筒状に成形した発泡前の積層体の内側に熱可塑性樹脂からなる容器が配置されるように、熱可塑性樹脂シートを真空および／または圧空加工する真空および／または圧空加工工程と、
積層体を加熱して、積層体の最外層を発泡させる発泡工程と、
を含む、真空および／または圧空成形容器の製造方法。 A method for manufacturing a vacuum and / or compressed air molded container having a foam layer on the side surface.
An arrangement step of arranging a laminated body before foaming formed in an inverted frustum shape or a cylindrical shape along the inner wall surface of the mold, and
Vacuum and / or pressure-pneumatic processing of the thermoplastic resin sheet so that the container made of the thermoplastic resin is arranged inside the laminated body before foaming, which is formed into an inverted frustum shape or a cylindrical shape. Process and
A foaming process that heats the laminate to foam the outermost layer of the laminate,
A method for manufacturing a vacuum and / or compressed air molded container, including.
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