Molded pulp container and manufacturing method thereof

Abstract

To provide a pulp-molded container as compact as possible.SOLUTION: A pulp-molded container comprises a storage part 12 for inserting and storing a commodity and an outer periphery part 14 surrounding the storage part 12. The storage part 12 and the outer periphery part 14 are made of a pulp mold, respectively, and the storage part 12 has a storage recessed part 20 for inserting and storing the commodity and a flange part 22 spreading from an edge part of the storage recessed part 20 to the side. The shape and size of a circumference of the flange part 22 are approximately the same as the shape and size of an upper edge of the outer periphery part 14. The circumference of the flange part 22 is overlapped with the upper edge of the outer periphery part 14. The whole or a part of the outer periphery part 14 is close to or in contact with the storage recessed part 20.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a pulp molded container produced by pulp molding and a method for producing the same. [Background technology]

[0002] Home appliances and other products are sold in plastic packaging. After the appliances and other products are removed from the plastic packaging, it becomes waste. Waste plastic packaging is either incinerated or reused as plastic resources, but much of it is dumped and ends up in the ocean.

[0003] Plastic packaging that has washed up into the ocean floats for a long time without decomposing, polluting the ocean and coastlines. In addition, plastic packaging that has washed up into the ocean is mechanically broken down by the force of waves, turning into microplastics, which worsens the environment for living organisms.

[0004] Therefore, there is a demand for the development of packaging that decomposes easily in nature and does not harm the environment, and three-dimensional paper packaging made by pulp molding has been proposed. These three-dimensional paper packages (pulp molded containers) are gradually replacing plastic packaging. Here, pulp molding refers to a method in which pulp slurry made by dispersing plant fibers in water is filtered through a three-dimensional mesh mold, and the resulting molded product is shaped and dried to obtain a three-dimensional paper package (paper container).

[0005] In the case of a package for containing a home appliance or the like, if the distance between the wall of the recess for storing the appliance or the like and the wall of the package is narrow, a sufficient amount of pulp slurry may not enter between the wall of the recess and the wall of the package during pulp molding, or they may compete for the pulp slurry, resulting in an insufficient supply of pulp slurry to the areas where the wall of the recess and the wall of the package face each other, causing these areas to be formed unevenly or to be damaged.

[0006] Therefore, when making a package for a home appliance or the like from pulp molding, it is necessary to leave a considerable gap between the wall of the recess for storing the home appliance or the like and the wall of the package. However, leaving a considerable gap between the wall of the recess for storing the home appliance or the like and the wall of the package causes a problem that the overall size of the pulp molded container becomes larger than that of a conventional plastic container. For this reason, there has been a demand for a small pulp molded container of about the same size as a conventional plastic package, and a method for manufacturing the same. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Japanese Patent Application Publication No. 10-226999 [Patent Document 2] JP 2001-55698 A [Patent Document 3] JP 2001-55699 A [Patent Document 4] Utility Model Registration No. 3136227 Summary of the Invention [Problem to be solved by the invention]

[0008] The problem that this invention aims to solve is that when attempting to make a compact pulp-molded container having a storage section for storing a product and an outer periphery surrounding the storage section, a sufficient amount of pulp slurry does not enter the gap between the outer periphery and the storage section, causing the opposing portions of the outer periphery and the storage section to become thin, uneven, or missing. [Means for solving the problem]

[0009] The pulp-molded container of the present invention comprises a storage section for inserting and storing a product and an outer peripheral section surrounding the storage section, the storage section and the outer peripheral section being each formed from pulp mold, and all or part of the outer peripheral section being adjacent to or in contact with the storage section.

[0010] In addition, the method for manufacturing a pulp-molded container according to the present invention is a method for manufacturing a pulp-molded container which has a storage recess for inserting and storing a product and an outer peripheral portion surrounding the storage recess, with all or part of the outer peripheral portion being adjacent to or in contact with the storage recess, and includes a storage recess forming step of forming the storage recess with a pulp mold, an outer peripheral portion forming step of forming the outer peripheral portion with a pulp mold, and an assembly step of assembling the storage recess and the outer peripheral portion to obtain the pulp-molded container.

[0011] Here, the storage section has a storage recess into which the product is inserted and stored, and a flange section extending laterally from the upper edge of the storage recess. The shape and size of the outer peripheral edge of the flange section and the shape and size of the upper edge of the outer peripheral section are substantially the same. The peripheral edge of the flange section and the upper edge of the outer peripheral section overlap when assembled into a pulp molded container.

[0012] The entire or part of the outer periphery is in close proximity to or in contact with the storage recess in the state of a pulp-molded container. Here, "close" refers to a distance at which it becomes difficult to neatly and integrally form the opposing outer periphery and storage recess by pulp molding, i.e., a distance of 1 to 1.5 times the depth of the storage recess. Note that even if the distance is greater than this, it is not excluded when the outer periphery and the storage recess are manufactured separately as in the present invention.

[0013] The outer peripheral portion and the storage portion may be fitted and integrated, or may be bonded and integrated. The outer peripheral portion and the storage portion may each have an overlapping portion. When the outer peripheral portion and the storage portion are bonded and integrated, the connection between the outer peripheral portion and the storage portion is strengthened by bonding the overlapping portions. The storage portion and the outer peripheral portion may be punched using a press die, or punched using NC.

[0014] The pulp molded article according to the present invention may have a bottom and a lid separately formed by a pulp molding method, in addition to the storage portion and the outer periphery. Effect of the Invention

[0015] In the present invention, since the storage section and the outer peripheral portion are each formed from pulp mold, there is no need to form the outer peripheral portion large in order to widen the space between the storage section and the outer peripheral portion in consideration of interference such as competition for pulp slurry between the storage section and the outer peripheral portion when filtering the pulp slurry, and the outer peripheral portion can be formed as small as possible, thereby having the effect of enabling the production of a compact pulp-molded container by forming the outer peripheral portion small.

[0016] In addition, in the present invention, since the storage section and the outer peripheral section are each formed from pulp mold, there is no need to form a large taper on the outer peripheral section in order to widen the space between the storage section and the outer peripheral section in consideration of interference such as competition for pulp slurry between the storage section and the outer peripheral section when filtering the pulp slurry, and the taper of the outer peripheral section can be made small, thereby having the effect of making it possible to manufacture a pulp-molded container with an inconspicuous taper by forming the taper of the outer peripheral section small.

[0017] In addition, according to the present invention, since the storage section and the outer peripheral section are each formed from pulp mold, when the pulp slurry is filtered, there is no interference between the storage section and the outer peripheral section, such as a struggle for the pulp slurry, and the opposing portions of the storage section and the outer peripheral section are not damaged or formed unevenly, thereby having the effect of producing a clean pulp molded container without any defects.

[0018] In addition, the present invention has the effect of making it possible to manufacture a pulp-molded container with a sense of unity, since the shape and size of the peripheral edge of the flange portion is approximately the same as the shape and size of the upper edge of the outer periphery, the peripheral edge of the flange portion and the upper edge of the outer periphery are positioned to overlap with the upper edge of the pulp-molded container, and the peripheral edge of the flange portion and the upper edge of the outer periphery are not noticeable.

[0019] In addition, the present invention has the effect of making it easy to manufacture pulp-molded containers, since when the storage portion and the outer peripheral portion are capable of being fitted together, they can be assembled by simply using the simple method of fitting the storage portion and the outer peripheral portion together. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 is a cross-sectional view of one embodiment of a molded pulp container according to the present invention. [Diagram 2] FIG. 2 is an exploded cross-sectional view of one embodiment of a molded pulp container according to the present invention. [Diagram 3] FIG. 3 is a process diagram showing the manufacturing process of a pulp molded container according to the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] The present invention achieves the object of producing a pulp-molded container that is as compact as possible by using a normal pulp-molded manufacturing process and without partially damaging the pulp-molded container. EXAMPLES

[0022] FIG. 1 is a cross-sectional view of one embodiment of a pulp-molded container according to the present invention, and FIG. 2 is an exploded cross-sectional view of one embodiment of a pulp-molded container according to the present invention.

[0023] In these figures, reference numeral 10 denotes a pulp-molded container, which comprises a storage section 12 for storing products such as home appliances, a roughly cylindrical outer peripheral portion 14 that surrounds the periphery of storage section 12, a bottom portion 16 that closes the bottom of outer peripheral portion 14, and a lid portion 18 that fits into the upper portion of outer peripheral portion 14 to cover storage section 12 from above.

[0024] The storage section 12 is composed of one or more storage recesses 20 into which products such as home appliances are inserted and stored, and a flange portion 22 that expands laterally from the upper edge of the storage recesses 20. The storage recesses 20 are recesses into which products such as home appliances are inserted and stored, and are formed slightly larger than the size of the home appliances to be stored. When there are two or more storage recesses 20, the two or more storage recesses 20 are connected by the flange portion 22.

[0025] The shape and size of the outer peripheral edge of flange portion 22 are substantially the same as the shape and size of the upper edge of outer peripheral portion 14. The outer peripheral edge of flange portion 22 and the upper edge of outer peripheral portion 14 are bonded and integrated with an adhesive, but the outer peripheral edge of flange portion 22 and the upper edge of outer peripheral portion 14 may simply be left overlapping, or may be fitted together and integrated.

[0026] The shape and size of the outer peripheral edge of the bottom portion 16 are substantially the same as the shape and size of the lower edge of the outer peripheral portion 14. The outer peripheral edge of the bottom portion 16 and the lower edge of the outer peripheral portion 14 are bonded and integrated with an adhesive, but the outer peripheral edge of the bottom portion 16 and the lower edge of the outer peripheral portion 14 may simply be fitted together.

[0027] A step 24 is formed around the entire periphery of the upper portion of the outer periphery 14, being slightly smaller than the lower portion. The lid 18 is cup-shaped with one open end. The edge of the open side of the lid 18 fits into the upper portion of the outer periphery 14 up to the height of the step 24. The outer periphery of the lid 18 and the outer periphery of the outer periphery 14 (the surface below the step 24) are flush with each other in the vicinity of the step 24.

[0028] All or a part of the outer periphery 14 is in close proximity to or in contact with the storage recess 20. The width of the flange portion 22 at the same longitude as the longitude at which the outer periphery 14 and the storage recess 20 are in close proximity to or in contact with each other is formed narrow. Here, narrow means that the width of the flange portion 22 is shorter than 1 to 1.5 times the depth of the storage recess 20. The storage portion 12 and the outer periphery 14 are formed separately by pulp molding and then assembled, so that the distance (back groove width) between the storage recess 20 and the outer periphery 14 can be made narrower than that which cannot be formed by pulp molding.

[0029] An overlapping area (not shown) that overlaps with the flange portion 22 of the storage portion 12 may be formed on the upper edge of the outer circumferential portion 14 in a state where it protrudes inward while avoiding the storage recess 20. When an overlapping area (not shown) is formed on the upper edge of the outer circumferential portion 14, the storage portion 12 and the outer circumferential portion 14 can be firmly bonded and integrated.

[0030] Next, the manufacturing process of the pulp molded container according to the present invention will be described with reference to the process diagram in Fig. 3. The dies used in the immersion / decompression step, dehydration step, shaping step, compression / drying step, and processing step described below correspond to the shapes of the pulp molded bodies (storage section 12, outer peripheral section 14, bottom section 16, and lid section 18) to be manufactured.

[0031] Pulp slurry preparation step: A pulp slurry is prepared in advance by dispersing organic fibers and other materials in water, and this pulp slurry is stored in a slurry tank.

[0032] Immersion and decompression process: The mold is submerged in a slurry tank and the pressure inside the mold is reduced. The mold part of the mold is made of a mesh, and the pulp slurry is attracted to the mold part made of the mesh, and only the water in the pulp slurry passes through the mold and is discharged, while the fibers in the pulp slurry are caught by the mold, and a fiber mat of a specified thickness remains and is formed on the surface of the mold.

[0033] Dewatering process: The fiber mat remaining on the surface of the strainer mold is transferred to a draining mold. The fiber mat is compressed and dewatered in the draining mold.

[0034] Shaping process: The fiber mat that has been dewatered in the draining mold is transferred to a shaping mold, where it is pressed and shaped to form a wet pulp molded body.

[0035] Compression and drying process: The wet pulp molded body formed in the shaping mold is transferred to the hot press, where it is compressed, heated, and dried to become a thin, dense pulp molded body.

[0036] Processing step: The pulp molded body is punched with a press die or punched by NC to remove excess parts of the pulp molded body, thereby obtaining the storage section 12, the outer peripheral section 14, the bottom section 16, and the lid section 18.

[0037] Assembly process (1): An adhesive is applied in advance to the edge of the pulp molded body of the storage section 12 or the edge of the pulp molded body of the outer periphery 14. Then, the pulp molded body forming the storage section 12 is fitted into the pulp molded body forming the outer periphery 14. The pulp molded body forming the outer periphery 14 and the pulp molded body forming the storage section 12 are bonded together and integrated.

[0038] Assembly process (2): An adhesive is applied in advance to the lower edge of the pulp molded body forming the outer periphery 14 or the periphery of the pulp molded body forming the bottom 16. Then, the pulp molded body forming the bottom 16 is fitted to the lower edge of the pulp molded body forming the outer periphery 14. The pulp molded body forming the outer periphery 14 and the pulp molded body forming the bottom 16 are bonded together and integrated.

[0039] Assembly step (3): A pulp molded body forming the lid portion 18 is fitted onto the upper portion of the pulp molded body forming the outer peripheral portion 14. In this manner, a pulp molded container according to one embodiment of the present invention is completed.

[0040] The strainer mold, drainer mold, shaping mold, hot press mold, and press mold used in each of the above processes have shapes corresponding to the storage section 12, outer periphery 14, bottom section 16, and lid section 18 formed by the pulp mold. [Explanation of symbols]

[0041] 10 Molded pulp containers 12 Storage area 14 Outer periphery 16 Bottom 18 Lid 20 Storage recess 22 Flange 24 Step

Claims

1. A pulp-molded container comprising a storage section into which a product is inserted and stored and an outer peripheral section surrounding the storage section, the storage section and the outer peripheral section being each formed from pulp molding, the storage section having a storage recess into which a product is inserted and stored, and a flange section extending laterally from the upper edge of the storage recess, the outer peripheral section having an overlapping portion at its upper edge that protrudes inward, the shape and size of the periphery of the flange section being approximately the same as the shape and size of the upper edge of the outer peripheral section, the flange section overlapping the overlapping portion of the outer peripheral section and being bonded and integrated therewith, and all or part of the outer peripheral section being adjacent to the storage recess.

2. 2. The pulp-molded container according to claim 1, wherein the narrowest distance between said outer periphery and said storage recess is less than 1.5 times the depth of said storage recess.

3. 2. The pulp-molded container according to claim 1, wherein the narrowest distance between said outer periphery and said storage recess is narrower than the depth of said storage recess.

4. 2. The pulp molded container according to claim 1, wherein the storage portion and the outer peripheral portion are fitted together.

5. A pulp-molded container as described in any one of claims 1 to 4, characterized in that it has an approximately plate-shaped bottom portion that covers the bottom of the outer periphery.

6. A pulp molded container as described in any one of claims 1 to 5, characterized in that it has a lid portion that fits onto the upper part of the outer periphery.

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