Method for manufacturing a tube container filled with contents, and a shape correction and holding device for a workpiece for a tube container.

Abstract

This enables the manufacture of tube containers containing contents, regardless of the shape of the body of the workpiece material. [Solution] The method for manufacturing a tube container filled with contents comprises the steps of: preparing a workpiece 2A for a tube container having a body 3 and a dispensing part 4, which is unfilled with contents and has no seal portion formed; holding the workpiece 2A in an upright position; filling the workpiece 2A with contents; and forming a seal portion. When the inner dimensions of the body 3 in two orthogonal axes perpendicular to the axial direction of the body 3 are defined as the first dimension D1 and the second dimension D2, the workpiece 2A for the tube container has a shape in which the first dimension D1 gradually increases and the second dimension D2 gradually decreases as the body 3 moves from one end to the other. In the step of filling the workpiece 2A with contents, the shape of the body 3 is corrected so that the difference between the first dimension D1 and the second dimension D2 at each position along the axial direction of the body 3 decreases, and the workpiece 2A is filled with contents.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a tube container containing a content, and also relates to a shape correction holder capable of holding a work material for a tube container, which is a material for manufacturing the tube container containing a content, while correcting the shape thereof.

Background Art

[0002] Generally, when manufacturing a tube container containing a content, a work material for a tube container is prepared in advance. This work material for a tube container has a hollow cylindrical body portion and a pouring portion located on one end side in the axial direction of the body portion, and in this work material for a tube container, the other end in the axial direction of the body portion is open.

[0003] The content is filled into the work material for a tube container prepared in advance through the opening located on the other end side of the body portion described above, and then, a sealing process is performed on the other end of the body portion provided with the opening, whereby the other end of the body portion is sealed. Thus, a tube container containing a content in which the inside of the tube container is filled with the content is manufactured.

[0004] Normally, the body portion of the work material for a tube container is formed in a substantially cylindrical shape, and in the above-described sealing process, the other end in the axial direction of the body portion is flattened and crushed, and then sealed by heat welding or the like.

[0005] Here, in this specification, when the body portion is referred to as "cylindrical", it means a case where the cross-sectional shape of the body portion orthogonal to the axial direction is a perfect circle with the same diameter at any position in the axial direction, and when the body portion is referred to as "non-cylindrical", it means a case where the cross-sectional shape of the body portion orthogonal to the axial direction is a shape other than a perfect circle (for example, an ellipse, an ellipse with a bent portion in part, a polygon, etc.) at least at any position in the axial direction.

[0006] Japanese Patent Publication No. 2011-121342 (Patent Document 1) discloses a workpiece for a tube container having a cylindrical resin body, and describes that distortion of the body that may occur during molding can be corrected by blowing steam onto the body of the workpiece for the tube container after molding. [Prior art documents] [Patent Documents]

[0007] [Patent Document 1] Japanese Patent Publication No. 2011-121342 [Overview of the project] [Problems that the invention aims to solve]

[0008] Here, as described in Patent Document 1 above, unintended distortion may occur in the body of the pre-prepared workpiece for tube containers. In addition, there are cases in which workpieces for tube containers are prepared in which the body is formed into a non-cylindrical shape by intentionally shaping it beforehand. In these cases, various shapes can be envisioned for the body, but since a dispensing part is already provided at one end of the body, it is usually the case that the one end is perfectly round while the other end is deformed into an elliptical shape, or is shaped in that way.

[0009] In that case, during the process of filling the aforementioned contents into the workpiece for the tube container, there is a risk that the nozzle or other device used to discharge the contents may come into contact with the other end of the elliptical body where the opening is formed, which could cause malfunctions in that process.

[0010] In this regard, if the method for correcting the body of the tube disclosed in Patent Document 1 is adopted, as described above, it is possible to correct the shape of the body of the workpiece for the tube container by blowing steam onto it after molding. However, this not only complicates the work process and lengthens the cycle time, but also necessitates strict hygiene control due to moisture adhering to the workpiece for the tube container, which puts pressure on manufacturing costs.

[0011] Therefore, the present invention has been made to solve the above-mentioned problems, and aims to provide a method for manufacturing a tube container filled with contents that can be manufactured in a simple manner regardless of the shape of the body of the workpiece for the tube container, and a shape correction and holding device for the workpiece for the tube container that can be suitably used in the method for manufacturing the tube container filled with contents. [Means for solving the problem]

[0012] A method for manufacturing a tube container filled with contents according to the present invention comprises the steps of: preparing a workpiece for a tube container having the body and the dispensing part, but not filled with contents and not having the seal part formed; holding the workpiece for the tube container in an upright position with one end of the body positioned downwards and the other end of the body positioned upwards; filling the workpiece for the tube container with contents through the other end of the body which is open because the seal part is not formed; and forming the seal part by closing the other end of the body while the workpiece for the tube container is held. In the method for manufacturing a tube container filled with contents according to the present invention described above, two orthogonal axial directions perpendicular to the axial direction of the body are designated as the first and second directions, respectively, and the inner dimension of the body in the first direction is designated as the first dimension, and the inner dimension of the body in the second direction is designated as the second dimension. In the step of preparing the workpiece for the tube container, the workpiece for the tube container is prepared having a shape in which the first dimension gradually increases and the second dimension gradually decreases as the body moves from one end to the other. In the step of filling the contents into the storage space, the contents are filled while maintaining a state in which the shape of the body is corrected so that the difference between the first dimension and the second dimension at each position along the axial direction of the body decreases.

[0013] The shape-correcting holder for a workpiece for a tube container according to the present invention is capable of holding a workpiece for a tube container, which has a hollow cylindrical body with a storage space inside capable of accommodating contents, and a dispensing portion located on one axial end of the body that enables dispensing of the contents to the outside, with the other axial end of the body being open, while correcting the shape of the body. The holder comprises a main body into which the portion of the body near the one end can be inserted, and a shape-correcting portion capable of correcting the shape of the body. The main body includes a positioning portion that positions the body in the axial direction when the workpiece for the tube container is inserted into the main body. The shape-correcting portion has a substantially annular inner circumferential surface that can contact the outer circumferential surface of the portion of the body excluding the one end, by positioning itself so as to surround at least a portion of the body excluding the one end in the circumferential direction when the body has been positioned by the positioning portion, and the inner circumferential surface of the shape-correcting portion is made of an elastically deformable member. [Effects of the Invention]

[0014] According to the present invention, it is possible to provide a method for manufacturing a tube container filled with contents, which allows for the production of a tube container filled with contents by a simple method, regardless of the shape of the body of the workpiece for the tube container, and a shape-correcting and holding device for the workpiece for the tube container that can be suitably used in the method for manufacturing the tube container filled with contents. [Brief explanation of the drawing]

[0015] [Figure 1] This is a schematic diagram showing the shape of a tube container with contents manufactured according to the manufacturing method for a tube container with contents according to the embodiment, and the shape of the workpiece for the tube container as a material used in the manufacturing method for the tube container with contents. [Figure 2] This is a flow chart showing a method for manufacturing a tube container filled with contents according to an embodiment. [Figure 3] Figure 2 is a schematic diagram illustrating one step in the manufacturing flow shown. [Figure 4] It is a schematic diagram for explaining one step of the manufacturing flow shown in FIG. 2. [Figure 5] It is a schematic diagram for explaining one step of the manufacturing flow shown in FIG. 2. [Figure 6] It is a schematic diagram for explaining one step of the manufacturing flow shown in FIG. 2. [Figure 7] It is a partially broken perspective view showing the structure of the shape correction retainer according to the embodiment. [Figure 8] It is a schematic diagram showing how the shape of the body portion of the workpiece for the tube container is corrected by the shape correction retainer shown in FIG. 7. [Figure 9] It is a schematic diagram showing how the shape of the body portion of the workpiece for the tube container is corrected by the shape correction retainer shown in FIG. 7. [Figure 10] It is a schematic diagram showing how the shape of the body portion of the workpiece for the tube container is corrected by the shape correction retainer shown in FIG. 7. [Figure 11] It is a schematic cross-sectional view showing one configuration example of the inner peripheral surface of the elastic holding portion of the shape correction retainer shown in FIG. 7.

Embodiments for Carrying Out the Invention

[0016] Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. In the embodiments shown below, the same or common parts are denoted by the same reference numerals in the drawings, and the description thereof will not be repeated.

[0017] <Embodiment> In the following embodiments, as an example, a case is illustrated in which a material for a tube container, which is a material for a tube container with contents, is used, in which the body portion is formed in a non-cylindrical shape by intentionally giving a warp in advance. The reason for intentionally giving a warp to the body portion in advance is, for example, when forming the body portion of the material for the tube container using a so-called firm material, due to the sealing process of the material for the tube container that is carried out after filling the contents, a predetermined portion of the body portion is flattened and crushed, etc., stress concentration occurs in a part of the body portion, and an undesirable deformation occurs in the said part of the body portion. To avoid this, etc.

[0018] FIG. 1 is a schematic view showing the shape of a tube container with contents manufactured according to the manufacturing method of a tube container with contents according to the embodiment, and the shape of the material for the tube container used as the material in the manufacturing method of the tube container with contents. Here, FIG. 1(A) shows the tube container with contents, and FIGS. 1(B) and 1(C) show the material for the tube container in a state where the shape of the body portion has not been corrected and in a state where this has been corrected, respectively. First, referring to this FIG. 1, the shape of the tube container with contents 1 manufactured by the manufacturing method of the tube container with contents according to the present embodiment, the shape of the material for the tube container (hereinafter, this is represented by reference numeral 2A) in a state where the shape of the body portion 3 has not been corrected, and the shape of the material for the tube container (hereinafter, this is represented by reference numeral 2B) in a state where the shape of the body portion 3 has been corrected will be described.

[0019] As shown in Figure 1(A), the tube container 1 containing contents comprises a tube container consisting of a body 3 and a dispensing section 4, and contents not shown in the figure contained inside the tube container. The body 3 has a hollow cylindrical shape with the axial direction in the X direction shown in the figure, and a storage space configured to accommodate the contents is located inside it. The dispensing section 4 is a part that allows the contents to be dispensed to the outside of the tube container and is connected to one end 3a in the axial direction of the body 3. The dispensing section 4 includes a molded body 4a that includes a shoulder and neck portion continuous with the body 3 and a mouth portion provided on the neck portion, and a cap body 4b that is attached to the molded body 4a and has a spout not shown in the figure.

[0020] A side seal 6 is provided at a predetermined position in the circumferential direction of the body portion 3, extending along the axial direction. This side seal 6 is a seal portion formed by rolling a sheet-like material, which is the material for the body portion 3, into a cylindrical shape, overlapping a pair of side edges located in the circumferential direction, and welding them together.

[0021] On the other hand, an end seal 7 is provided at the other axial end 3b of the body portion 3. This end seal 7 is a seal portion formed by flattening and welding the other end 3b in order to close the opening 5 located at the other end 3b of the body portion 3 (see Figures 1(A) and 1(B), etc.). This end seal 7 extends along the first direction (the Y direction shown in the figure), which will be described later.

[0022] The body portion 3 has two orthogonal axial directions perpendicular to its axial direction (the X direction shown in the figure), which are designated as the first direction (the Y direction shown in the figure) and the second direction (the Z direction shown in the figure), respectively. The internal dimension of the body portion 3 in the first direction is designated as the first dimension D1, and the internal dimension of the body portion 3 in the second direction is designated as the second dimension D2. The body portion 3 has a shape in which the first dimension D1 gradually increases and the second dimension D2 gradually decreases as it moves from one end 3a to the other end 3b.

[0023] In other words, when the tube container 1 containing the contents is cut along the two orthogonal axes described above, the cross-section of the body portion 3 changes in shape from one end 3a to the other end 3b in the axial direction. Specifically, in the portion near the one end 3a in the axial direction, the first dimension D1 and the second dimension are almost the same (D1=D2), and the cross-section of the body portion 3 in this portion is substantially circular. On the other hand, in the central part in the axial direction, the first dimension D1 is larger than the second dimension D2 (D1>D2), and the cross-section of the body portion 3 in this portion is elliptical. Furthermore, in the portion near the other end 3b in the axial direction, the first dimension D1 is even larger than the second dimension D2 (D1>>D2), and the cross-section of the body portion 3 in this portion is an even flatter ellipse than the shape in the central part in the axial direction.

[0024] Here, the material of the body 3 is not particularly limited, but in this embodiment, the body 3 is made of a sheet-like resin material mainly composed of polyester resin. By making the body 3 of a sheet-like resin material mainly composed of polyester resin in this way, recyclability is improved, but the body 3 becomes rigid.

[0025] The polyester resin content in the sheet-like member is not particularly limited, but is preferably 95% by mass or more, and more preferably 99% by mass or more. Examples of polyester resins include polyethylene terephthalate, polyethylene naphthalate, glycol-modified polyethylene terephthalate (PETG, polyethylene terephthalate in which part of the glycol component is modified with cyclohexanedimethanol (CHDM) or neopentyl glycol, etc.), and polylactic acid.

[0026] Furthermore, the body 3 may include, in addition to the base layer mainly composed of polyester resin, a reinforcing layer, a barrier layer, an adhesive layer, a printed layer, an anchor coat layer, an insulating layer, etc. Also, as mentioned above, the body 3 does not necessarily have to be composed of a sheet-like resin member mainly composed of polyester resin, but may be composed of a sheet-like resin member mainly composed of other types of resin.

[0027] The thickness of the body portion 3 described above is not particularly limited, but if the body portion 3 is made of a sheet-like resin material mainly composed of polyester resin, its thickness is, for example, 12 μm or more and 250 μm or less.

[0028] As shown in Figures 1(B) and 1(C), the workpieces 2A and 2B for the tube container, which are the material for the tube container 1 containing contents, have the body portion 3 and dispensing portion 4 described above. However, compared to the tube container 1 containing contents, their structure differs in that they are not filled with contents and the end seal 7 is not formed. In particular, because the end seal 7 is not formed on the body portion 3, an opening 5 is located at the other end 3b of the body portion 3.

[0029] Here, as shown in Figure 1(B), in the workpiece 2A for the tube container, when the shape of the body portion 3 is not corrected, it has a shape similar to the tube container 1 with contents described above, where the first dimension D1 gradually increases and the second dimension D2 gradually decreases as you move from one end 3a to the other end 3b of the body portion 3. This is because, as described above, in this embodiment, the body portion 3 of the workpiece 2A for the tube container has been pre-formed.

[0030] In other words, when the workpiece 2A for the tube container is cut along the two orthogonal axes described above while the shape of the body 3 is not corrected, the cross-section of the body 3 changes in shape from one end 3a to the other end 3b in the axial direction. Specifically, in the part near the one end 3a in the axial direction, the first dimension D1 and the second dimension are almost the same (D1=D2), and the cross-section of the body 3 in this part is substantially circular. On the other hand, in the central part in the axial direction, the first dimension D1 is larger than the second dimension D2 (D1>D2), and the cross-section of the body 3 in this part is elliptical. Furthermore, in the part near the other end 3b in the axial direction, the first dimension D1 is even larger than the second dimension D2 (D1>>D2), and the cross-section of the body 3 in this part is an even flatter ellipse than the shape in the central part in the axial direction.

[0031] On the other hand, as shown in Figure 1(C), in the workpiece 2B for the tube container in the state where the shape of the body 3 has been corrected, the shape of the body 3 is corrected to have a substantially cylindrical shape by using the shape correction holder 10 (see Figures 3 to 10, etc.), which will be described later.

[0032] In other words, when the workpiece 2B for the tube container, with the shape of the body 3 corrected, is cut along the two orthogonal axes described above, the cross-section of the body 3 will be substantially the same shape at any position from one end 3a to the other end 3b in the axial direction. Specifically, at any position in the axial direction, the first dimension D1 and the second dimension are substantially the same (D1=D2), and as a result, the cross-section of the body 3 is substantially circular at any position in the axial direction.

[0033] Figure 2 is a flow chart showing the manufacturing method of a tube container with contents according to this embodiment, and Figures 3 to 6 are schematic diagrams illustrating one step of the manufacturing flow shown in Figure 2. Here, Figures 3(A) and 3(B) are schematic diagrams specifically illustrating the process flow of step ST2, which will be described later, and Figures 4(A) to 4(C) are schematic diagrams specifically illustrating the process flow of step ST3, which will be described later. Furthermore, Figures 5(A) to 5(C) are schematic diagrams specifically illustrating the process flow of step ST4, which will be described later, and Figures 6(A) and 6(B) are schematic diagrams specifically illustrating the process flow of step ST5, which will be described later. Next, the manufacturing method of a tube container with contents according to this embodiment will be described with reference to Figures 2 to 6.

[0034] As shown in Figure 2, when manufacturing a tube container filled with contents according to this embodiment, first, in step ST1, a workpiece for the tube container is prepared. In this step ST1, a workpiece for the tube container is prepared that has been shaped such that the first dimension D1 gradually increases and the second dimension D2 gradually decreases from one end 3a to the other end 3b of the body portion 3 (i.e., a workpiece for the tube container 2A having the shape shown in Figure 1(B) above).

[0035] This deformation can be achieved, for example, when joining a molded body 4a, which is part of the dispensing section 4, to a sheet-like member that is formed in a cylindrical shape by the provision of the side seal 6 described above, by joining one end of the sheet-like member to the molded body 4a in a state where the axial end of the sheet-like member (more specifically, the axial end that will become the other end 3b of the workpiece 2A for the tube container) is shaped to be elliptical. This deformation is intended to prevent stress concentration from occurring in a part of the body 3 and causing undesirable deformation of that part of the body 3, as described above, during the sealing process of the workpiece for the tube container (i.e., step ST4) which is performed after the contents are filled.

[0036] Next, as shown in Figure 2, step ST2 involves holding the workpiece for the tube container. Specifically, as shown in Figure 3(A), the workpiece 2A for the tube container is inserted into a concave portion 12 provided on the main body 11 of the shape-correcting holder 10, which is capable of holding the workpiece 2A while correcting its shape.

[0037] More specifically, the workpiece 2A for the tube container has one end 3a in its axial direction inserted into a concave portion 12 provided on the main body 11 of the shape correction holder 10. Here, since the dispensing portion 4, consisting of the molded body 4a and the cap body 4b described above, is already attached to one end 3a of the body 3 of the workpiece 2A for the tube container, the overall shape is a bottomed cylindrical shape with an open top.

[0038] As shown in Figure 3(B), when the workpiece 2A for the tube container is inserted into the shape-correcting holder 10, the workpiece 2B for the tube container is held by the shape-correcting holder 10 in an upright position with one end 3a of the body 3 positioned downwards and the other end 3b of the body 3 positioned upwards. When the workpiece 2B for the tube container is held by the shape-correcting holder 10, the portion of the workpiece 2B for the tube container, excluding the portion of the body 3 near one end 3a, is exposed to the outside of the shape-correcting holder 10.

[0039] Furthermore, at this time, the insertion of the workpiece 2A for the tube container into the shape-correcting holder 10 positions the workpiece 2B for the tube container in the axial direction of its body portion 3 relative to the shape-correcting holder 10. In addition, at this time, the shape of the body portion 3 of the workpiece 2B for the tube container is corrected and held by the shape-correcting holder 10. The positioning of the workpiece 2B for the tube container and the correction of the shape of the body portion 3 of the workpiece 2B for the tube container will be described in detail later.

[0040] Next, as shown in Figure 2, step ST3 involves filling the workpiece for the tube container with its contents. Specifically, as shown in Figure 4(A), while the workpiece for the tube container 2B is held in a state where its body 3 is corrected by the shape correction holder 10, the nozzle 20 of the filling device is inserted into the opening 5 located at the other end 3b of the body 3 of the workpiece for the tube container 2B. As shown in Figure 4(B), the contents are discharged from the nozzle 20 in this state, thereby filling the storage space of the workpiece for the tube container 2B with its contents. As shown in Figure 4(C), after the filling of the storage space of the workpiece for the tube container 2B is complete, the nozzle 20 of the filling device is withdrawn from the other end 3b of the body 3 of the workpiece for the tube container 2B.

[0041] At this time, the shape of the body portion 3 of the workpiece 2B for the tube container is corrected by the shape correction holder 10 (i.e., the cross-sectional shape at the other end 3b of the body portion 3 is substantially corrected to a perfect circle), so that the portion of the workpiece 2B for the tube container near the other end 3b of the body portion 3 does not come into contact with the nozzle 20 or various mechanisms of the filling device (not shown) installed around it. As a result, defects in this process (defects such as bending of the workpiece 2B for the tube container or leakage of contents) can be prevented.

[0042] Next, as shown in Figure 2, step ST4 involves sealing the workpiece for the tube container. Specifically, as shown in Figure 5(A), a pair of welding heads 30A and 30B of the sealing device are positioned facing the outer circumferential surface of the other end 3b of the body 3 of the workpiece 2B for the tube container, which is filled with contents. As shown in Figure 5(B), in this state, the other end 3b of the body 3 is sandwiched between these welding heads 30A and 30B, thereby sealing the other end 3b of the body 3 of the workpiece 2B for the tube container. Subsequently, as shown in Figure 5(C), the pair of welding heads 30A and 30B move away from the other end 3b of the body 3, forming the end seal 7 described above on the other end 3b of the body 3. This closes the opening 5 located at the other end of the body 3, thereby sealing the workpiece 2B for the tube container.

[0043] The sealing process of the workpiece 2B for the tube container may be carried out following step ST3 described above, while the shape of the body 3 has been corrected by the shape correction holder 10 (i.e., the cross-sectional shape at the other end 3b of the body 3 has been corrected to a substantially circular shape). In this way, the positioning of the other end 3b of the body 3 with respect to the pair of welding heads 30A and 30B can be reliably performed, and the sealing process can be carried out with high precision.

[0044] If the sealing process for the tube container material 2B were performed without any modifications, while the shape of the body portion 3 was still corrected, there is a risk that unintended deformation would occur in the body portion 3, potentially forming depressions or other defects on its surface. However, the shape-correcting holder 10 according to this embodiment, which will be described in detail later, is designed to allow deformation of the body portion 3 during the sealing process, and is configured to prevent the formation of such depressions. This point will be described in detail later.

[0045] Upon completion of this step ST4, the tube container 1 containing the contents is completed while remaining held in place by the shape correction holder 10.

[0046] After the contents-filled tube container 1 is completed, as shown in Figure 2, step ST5 is performed to release the contents-filled tube container (workpiece for tube container). Specifically, as shown in Figure 6(A), the contents-filled tube container 1 is held by the shape-correcting holder 10, and as shown in Figure 6(B), the contents-filled tube container 1 is pulled out from the shape-correcting holder 10, thereby releasing the contents-filled tube container 1.

[0047] By going through the above series of steps, the manufacturing of the contents-filled tube container 1 according to the manufacturing method of the contents-filled tube container according to this embodiment is completed.

[0048] Figure 7 is a partially broken perspective view showing the structure of the shape-correcting holder according to this embodiment. Next, the structure of the shape-correcting holder 10 according to this embodiment will be described with reference to Figure 7.

[0049] As shown in Figure 7, the shape correction holder 10 has a generally bottomed, approximately cylindrical shape and includes a main body 11 with a concave portion 12. The concave portion 12 in the main body 11 has a shape and size that can receive the portion near one end 3a of the body 3 of the workpiece 2A for the tube container and the dispensing portion 4. Below the concave portion 12 of the main body 11 is the bottom surface 13.

[0050] This bottom surface 13 is the part that contacts the lower end surface of the dispensing part 4 (i.e., the tip surface of the cap body 4b) when the workpiece 2A for the tube container is inserted into the main body 11. When the lower end surface of the dispensing part 4 contacts this bottom surface 13, the axial positioning of the body portion 3 of the workpiece 2A for the tube container is performed (the state in which this positioning has been performed is shown in Figure 10). In other words, the bottom surface 13 of the main body 11 constitutes a positioning part that positions the axial positioning of the body portion 3 of the workpiece 2A for the tube container.

[0051] A shape-correcting portion 14 is provided in the concave portion 12 of the main body 11. This shape-correcting portion 14 is a part that can correct the shape of the body portion 3 of the workpiece 2A for the tube container by contacting a predetermined position on the outer circumferential surface of the body portion 3 of the workpiece 2A that is received in the concave portion 12. The shape-correcting portion 14 consists of a cylindrical member that surrounds the above predetermined position on the body portion 3 in the circumferential direction and is attached to the inner circumferential surface of the concave portion 12 so as to protrude radially inward from the inner circumferential surface of the concave portion 12. This shape-correcting portion 14 is positioned a predetermined distance above the bottom surface 13 provided on the main body 11 as described above.

[0052] The main body portion 11 is not particularly limited in its material, but it is preferable that it be made of a relatively hard material. In contrast, the shape correction portion 14 is made of an elastically deformable material. By making the shape correction portion 14 of an elastically deformable material in this way, the body portion 3 of the workpiece 2A for the tube container inserted into the main body portion 11 can be elastically held by the shape correction portion 14.

[0053] In other words, by constructing the shape correction section 14 from an elastically deformable material, when the workpiece 2A for the tube container is inserted into the main body 11, the shape correction section 14 itself undergoes corresponding elastic deformation, thereby holding the body 3, which is made of a relatively soft material, without causing it to dent. Furthermore, this configuration also prevents damage to the body 3 when inserting or removing the workpiece 2A for the tube container from the main body 11.

[0054] With the above configuration, the shape correction holder 10 includes a main body portion 11 which includes a bottom surface 13 as a positioning portion for positioning the body portion 3 of the workpiece 2A for the tube container in the axial direction when the workpiece 2A for the tube container is inserted, and a shape correction portion 14 which is made of an elastically deformable member having a substantially annular inner circumferential surface 14A that can contact the outer circumferential surface of the outer circumferential surface of the part of the body portion 3 excluding one end 3a, when the body portion 3 is positioned by the bottom surface 13.

[0055] Here, suitable elastic deformable members constituting the shape correction section 14 described above include, for example, sponge materials made of elastomer or rubber, felt materials made of natural fibers or synthetic fibers or both, and resin members with a contact surface shaped like cilia. In particular, low-rebound sponge materials, continuously foamed sponge materials, and members with a cilia-like contact surface do not excessively compress the workpiece 2A for the tube container, thus suppressing unintended deformations such as dents in the body 3.

[0056] The inner diameter of the concave portion 12 provided in the main body portion 11 is preferably slightly larger than the outer diameter of the body portion 3 of the workpiece 2A for the tube container that is inserted, for example, it is preferable to have a margin of 2 mm to 15 mm. By configuring it in this way, insertion of the workpiece 2A for the tube container into the main body portion 11 is made easier, and a deformation margin for the shape correction portion 14 to elastically deform can be secured.

[0057] On the other hand, it is preferable that the inner diameter of the shape-correcting portion 14 is about 0.5 mm smaller than the outer diameter of the body portion 3 of the workpiece 2A for the tube container whose shape is corrected by the shape-correcting portion 14. With this configuration, the inner circumferential surface 14A of the shape-correcting portion 14 comes into contact with the body portion 3 around its entire circumference, thereby ensuring more reliable shape correction.

[0058] Furthermore, although there are no particular limitations on the thickness of the shape-correcting portion 14, it is preferable that it be 5% to 20% of the outer diameter of the body portion 3 of the workpiece material 2A for the tube container, and more preferably 10% to 15%. For example, the thickness of the shape-correcting portion 14 is 1 mm to 7 mm, and more preferably 3 mm to 5 mm. By configuring it in this way, a deformation margin for the shape-correcting portion 14 can be secured.

[0059] Here, by ensuring sufficient elastic deformation of the shape correction section 14, it is possible to correct and hold the shape of the body 3 while the workpiece 2A for the tube container is held by the shape correction holder 10. Furthermore, even after the subsequent filling process and even after the subsequent sealing process, if deformation occurs in the body 3 due to these filling and sealing processes, the shape correction section 14 will deform in accordance with these deformations, thereby allowing deformation of the body 3 while the shape correction holder 10 can hold the workpiece 2B for the tube container or the tube container 1 with contents.

[0060] Figures 8 to 10 are schematic diagrams showing how the shape of the body of the workpiece for a tube container is corrected by the shape-correcting holder shown in Figure 7. Next, referring to Figures 8 to 10, the mechanism by which the shape of the body 3 of the workpiece for a tube container 2A is corrected by the shape-correcting holder 10 according to this embodiment will be explained. Figures 8 to 10 are diagrams showing the step-by-step process of inserting the workpiece for a tube container 2A into the main body 11 of the shape-correcting holder 10. Figures 8(A), 9(A), and 10(A) each show a cross-section along the XY plane at each stage, while Figures 8(B), 9(B), and 10(B) each show a cross-section along the XZ plane at each stage.

[0061] As shown in Figures 8(A) and 8(B), when the workpiece 2A for the tube container has not yet been inserted into the main body 11 of the shape correction holder 10, as described above, the workpiece 2A for the tube container has a shape in which the first dimension D1 gradually increases and the second dimension D2 gradually decreases as it moves from one end 3a to the other end 3b of the body 3.

[0062] As shown in Figures 9(A) and 9(B), when the workpiece 2A for the tube container is inserted into the main body 11 of the shape correction holder 10, one end 3a of the body 3 of the workpiece 2A and its vicinity are inserted into the shape correction part 14 provided on the shape correction holder 10. At this point, the outer circumferential surface 3A of the body 3 of the workpiece 2A inserted into the shape correction part 14 comes into contact with the inner circumferential surface 14A of the shape correction part 14. This contact causes the shape correction part 14 itself to deform slightly, and the elastic force of the shape correction part 14 causes deformation in the body 3 as well, thereby correcting the shape of the body 3.

[0063] At this time, the first dimension D1 of the body portion 3 in contact with the shape correction portion 14 is larger than the second dimension D2 of the body portion 3 in contact with the shape correction portion 14. As a result, the shape change that occurs in the body portion 3 is such that the difference between the first dimension D1 and the second dimension D2 is reduced. Therefore, in the body portion 3 inserted into the shape correction portion 14, the first dimension D1 and the second dimension become approximately the same (D1=D2), and the cross-section of the body portion 3 in that portion is corrected to be substantially circular.

[0064] Furthermore, as a result, deformation occurs in each part of the body 3 that has not yet been inserted into the shape correction section 14, such that the difference between the first dimension D1 and the second dimension D2 decreases. Consequently, the cross-sections of the body 3 in each of these parts change to a shape closer to a perfect circle than the cross-sections shown in Figures 8(A) and 8(A).

[0065] As shown in Figures 10(A) and 10(B), when the workpiece 2A for the tube container is fully inserted into the main body 11 of the shape correction holder 10, and the lower end surface of the cap body 4b contacts the bottom surface 13 of the main body 11, thereby positioning the body 3 in the axial direction, the outer circumferential surface 3A of the part of the body 3 of the workpiece 2B for the tube container near one end 3a will come into contact with the inner circumferential surface 14A of the shape correction part 14.

[0066] When the body portion 3 is positioned in the axial direction, the difference between the first dimension D1 and the second dimension D2 is reduced in the portion of the body portion 3 that is in contact with the shape correction portion 14. Not only is the shape corrected so that the cross-section of the body portion 3 in that portion becomes substantially circular, but because the position in which the shape correction portion 14 is provided is properly set, deformation occurs in each part of the body portion 3 that is not inserted into the shape correction portion 14 so that the difference between the first dimension D1 and the second dimension D2 is reduced. As a result, the first dimension D1 and the second dimension become almost the same (D1=D2), and the cross-section of the body portion 3 in each of these parts becomes substantially circular.

[0067] Therefore, by using the shape-correcting holder 10 according to this embodiment, when the workpiece 2B for the tube container is held by the shape-correcting holder 10, the shape of the body 3 is corrected so that the difference between the first dimension D1 and the second dimension D2 at each position along the axial direction of the body 3 of the workpiece 2B for the tube container is reduced. As a result, the cross-section of the other end 3b of the workpiece 2A for the tube container can be made approximately circular by the very simple operation of inserting the workpiece 2A for the tube container into the main body 11 provided on the shape-correcting holder 10, thereby preventing problems from occurring in the subsequent filling process of the contents and the sealing process of forming the end seal 7.

[0068] Furthermore, it is preferable that the shape-correcting portion 14 is positioned so as to contact the body portion 3 of the workpiece 2A for the tube container within a range of 70% of the total axial length of the body portion 3 from one end 3a side, and more preferably within a range of 20% to 50%. By configuring it in this way, the cross-sectional shape at each position along the axial direction of the body portion 3 of the workpiece 2A for the tube container can be made substantially circular, and the body portion 3 of the workpiece 2B for the tube container after shape correction can be made substantially cylindrical.

[0069] Furthermore, the axial length of the shape-correcting portion 14 should be at least 5% of the total axial length of the body portion 3 of the workpiece 2A for the tube container, and it is even preferable if it is 10% or more. By configuring it in this way, the cross-sectional shape at each position along the axial direction of the body portion 3 of the workpiece 2A for the tube container can be made substantially circular, and the body portion 3 of the workpiece 2B for the tube container after shape correction can be made substantially cylindrical.

[0070] For example, the shape correction section 14 is provided in a range of 0 mm to 50 mm along the axial direction of the body 3 of the workpiece 2A for the tube container, with reference to one end 3a of the body 3, and more preferably in a range of 20 mm to 30 mm.

[0071] As described above, by using the method for manufacturing a tube container filled with contents and the shape-correcting holder according to this embodiment, even if the body of the workpiece for the tube container is not formed in a cylindrical shape, various problems caused by this can be prevented in a very simple manner, making it possible to manufacture high-quality tube containers filled with contents at a low cost.

[0072] Here, Figure 11 is a schematic cross-sectional view showing one example of the configuration of the inner circumferential surface of the shape-correcting portion of the shape-correcting holder shown in Figure 7. As described above, suitable materials for the shape-correcting portion 14 provided on the shape-correcting holder 10 include, for example, a sponge material made of elastomer or rubber, a felt material made of natural fibers or synthetic fibers or both, and a resin member with a contact surface shaped like cilia. The shape-correcting portion 14 shown in Figure 11 is an example where it is made of a resin member with a contact surface shaped like cilia.

[0073] In one configuration example shown in Figure 11, the shape-correcting portion 14 is composed of a base portion 14a and a plurality of flexible protrusions 14b provided on the surface of the base portion 14a. These plurality of protrusions 14b are arranged to stand side by side on the surface of the base portion 14a, and the inner circumferential surface 14A of the shape-correcting portion 14 is formed by the tip surfaces of these plurality of protrusions 14b.

[0074] Here, the shape of the multiple protrusions 14b is not particularly limited, but it is preferable that each of the multiple protrusions 14b includes a rod-shaped portion 14b1 that protrudes from the surface of the base portion 14a and a spherical portion 14b2 provided at the tip of the rod-shaped portion 14b1.

[0075] With this configuration, the inner circumferential surface 14A of the shape-correcting portion 14 is made of a curved surface. As a result, when the shape-correcting portion 14 comes into contact with the body portion 3 of the workpiece 2A for the tube container, it is possible to hold the body portion 3, which is made of a relatively soft material, without denting it. Furthermore, it is possible to prevent damage to the body portion 3 when inserting or removing the workpiece 2A for the tube container from the main body portion 11.

[0076] The length of each of these multiple protrusions 14b is not particularly limited, but is preferably 4 mm to 6 mm. Furthermore, the density of these multiple protrusions 14b is preferably 200 to 500 per square inch. As a resin member with a contact surface shaped like cilia, for example, the hook side fastener of a commercially available hook fastener can be used, and if this is used, the shape correction holder 10 can be manufactured at a very low cost.

[0077] <Summary of disclosures in the embodiments> The characteristic configurations disclosed in the embodiments and modified examples described above can be summarized as follows:

[0078] [Note 1] A method for manufacturing a tube container filled with contents, comprising: a hollow cylindrical body having a storage space inside capable of containing contents; a dispensing portion located at one axial end of the body, enabling the contents to be dispensed to the outside; and a sealing portion that closes the other axial end of the body, wherein the storage space is filled with the contents, A step of preparing a workpiece for a tube container having the body and the dispensing portion, the contents being unfilled and the seal portion not yet formed, A step of holding the workpiece for the tube container such that it is in an upright position with one end of the body positioned downwards and the other end of the body positioned upwards, With the workpiece for the tube container held in place, the process involves filling the contents into the storage space through the other end of the body, which is open because the seal portion has not yet been formed. The process includes the step of forming the seal portion by closing the other end of the body portion when the contents are filled into the storage space, When the two orthogonal axial directions perpendicular to the axial direction of the torso are designated as the first and second directions, respectively, and the internal dimension of the torso in the first direction is designated as the first dimension, and the internal dimension of the torso in the second direction is designated as the second dimension, In the process of preparing the workpiece for the tube container, the workpiece for the tube container is prepared having a shape in which the first dimension gradually increases and the second dimension gradually decreases from one end to the other end of the body. A method for manufacturing a tube container containing contents, wherein, in the step of filling the storage space with the contents, the shape of the body is corrected so that the difference between the first dimension and the second dimension at each position along the axial direction of the body is reduced, while the contents are being filled.

[0079] [Note 2] A method for manufacturing a tube container containing contents as described in Appendix 1, wherein, in the step of forming the seal portion, the shape of the body portion is maintained in a corrected state while the seal portion is formed.

[0080] [Note 3] A shape-correcting and holding device capable of holding a workpiece for a tube container, which has a hollow cylindrical body with a storage space inside capable of accommodating contents, and a dispensing portion located at one end of the body in the axial direction, enabling the contents to be dispensed to the outside, with the other end of the body in the axial direction being open, while correcting the shape of the body, The main body portion into which the part of the torso near one end can be inserted, It includes a shape-correcting part that can correct the shape of the torso, The main body includes a positioning portion that positions the body in the axial direction when the workpiece for the tube container is inserted into the main body. The shape-correcting portion is positioned so as to surround at least a portion of the body excluding one end in the circumferential direction when the body is positioned by the positioning portion, and has a substantially annular inner circumferential surface that can abut along the circumferential direction against the outer circumferential surface of the portion of the body excluding one end. A shape-correcting and holding device for a workpiece for a tube container, wherein the inner circumferential surface of the shape-correcting portion is made of an elastically deformable member.

[0081] [Note 4] The shape-correcting and holding device for a workpiece for a tube container as described in Appendix 3, wherein the inner circumferential surface is composed of the tip surfaces of each of a plurality of flexible protrusions arranged to stand side by side.

[0082] <Other forms, etc.>

[0083] In the above-described embodiment, the example described was one in which the shape of the body of the workpiece for the tube container is corrected during the filling process, and furthermore, the shape of the body of the workpiece for the tube container is maintained during the subsequent sealing process. However, the correction of the shape of the body of the workpiece for the tube container may be released once the filling of the contents is complete.

[0084] Furthermore, in the embodiments described above, the example described was one in which the shape of the body of the workpiece for the tube container is corrected using a shape-correcting holder. However, it is not always necessary to correct the shape of the body of the workpiece for the tube container using such a shape-correcting holder, and the shape of the body of the workpiece for the tube container may be corrected by other means. For example, the shape of the body of the workpiece can be corrected by holding the workpiece for the tube container with a holder that does not have a function to correct the shape of the body of the workpiece, and then clamping the body of the workpiece with, for example, a movable arm.

[0085] Furthermore, in the embodiments described above, the example given was the case in which a tube container filled with contents is manufactured using a workpiece for a tube container whose body shape has been pre-formed as the material. However, even when using a workpiece for a tube container whose body shape has not been pre-formed and which should ideally have a substantially cylindrical body, the present invention can also be applied when unintended deformation occurs in the body during the molding of the workpiece for the tube container as a preceding process, and as a result, correction of the shape of the body becomes necessary.

[0086] Thus, the embodiments disclosed herein are illustrative in all respects and not restrictive. The technical scope of the present invention is defined by the claims and includes all modifications within the meaning and scope of equivalents to the claims. [Explanation of Symbols]

[0087] 1 Tube container with contents, 2A, 2B Workpiece for tube container, 3 Body, 3A Outer surface, 3a One end, 3b Other end, 4 Dispensing part, 4a Molded body, 4b Cap body, 5 Opening, 6 Side seal, 7 End seal, 10 Shape correction holder, 11 Main body, 12 Concave part, 13 Bottom surface, 14 Shape correction part, 14A Inner surface, 14a Base, 14b Projection, 14b1 Rod-shaped part, 14b2 Spherical part, 20 Nozzle, 30A, 30B Welding head.

Claims

1. A method for manufacturing a tube container filled with contents, comprising: a hollow cylindrical body having a storage space inside capable of containing contents; a dispensing portion located at one axial end of the body, enabling the contents to be dispensed to the outside; and a sealing portion that closes the other axial end of the body, wherein the storage space is filled with the contents, A step of preparing a workpiece for a tube container having the body portion and the dispensing portion, the contents being unfilled and the seal portion not yet formed, A step of holding the workpiece for the tube container such that it is in an upright position with one end of the body positioned downwards and the other end of the body positioned upwards, With the workpiece for the tube container being held, the process involves filling the contents into the storage space through the other end of the body, which is open because the seal portion has not yet been formed. The process includes the step of forming the seal portion by closing the other end of the body portion when the contents are filled into the storage space, When the two orthogonal axial directions perpendicular to the axial direction of the torso are designated as the first and second directions, respectively, and the internal dimension of the torso in the first direction is designated as the first dimension, and the internal dimension of the torso in the second direction is designated as the second dimension, In the process of preparing the workpiece for the tube container, the workpiece for the tube container is prepared having a shape in which the first dimension gradually increases and the second dimension gradually decreases from one end to the other end of the body. A method for manufacturing a tube container containing contents, wherein, in the step of filling the storage space with the contents, the shape of the body is corrected so that the difference between the first dimension and the second dimension at each position along the axial direction of the body is reduced, while the contents are being filled.

2. A method for manufacturing a tube container containing contents according to claim 1, wherein, in the step of forming the seal portion, the shape of the body portion is maintained in a corrected state while the seal portion is formed.

3. A shape-correcting and holding device capable of holding a workpiece for a tube container, which has a hollow cylindrical body with a storage space inside capable of accommodating contents, and a dispensing portion located at one end of the body in the axial direction, enabling the contents to be dispensed to the outside, with the other end of the body in the axial direction being open, while correcting the shape of the body, The main body portion into which the part of the torso near one end can be inserted, It includes a shape-correcting part that can correct the shape of the torso, The main body includes a positioning portion that positions the body in the axial direction when the workpiece for the tube container is inserted into the main body. The shape-correcting portion is positioned so as to surround at least a portion of the body excluding one end in the circumferential direction when the body is positioned by the positioning portion, and has a substantially annular inner circumferential surface that can abut along the circumferential direction against the outer circumferential surface of the portion of the body excluding one end. A shape-correcting and holding device for a workpiece for a tube container, wherein the inner circumferential surface of the shape-correcting portion is made of an elastically deformable member.

4. The shape-correcting and holding device for a workpiece for a tube container according to claim 3, wherein the inner circumferential surface is composed of the respective tip surfaces of a plurality of flexible protrusions arranged to stand side by side.

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