Manufacturing method and device for manufacturing packaging material for pouch container

Abstract

This method for manufacturing packaging for a pouch container comprises: a first folding step P9 in which are used a first body sheet material 110, a second body sheet material 120, and a top-side sheet material 130; a first cutting step P11 in which the top-side sheet material 130, a second auxiliary region 1220, a first main region 1110, and a first auxiliary region 1120 are cut along a first cutting line CL that crosses from a portion where the top-side sheet material 130 and the second auxiliary region 1220 overlap across a first boundary line 1130 on the z-direction bottom side; a second folding step P12; and a second cutting step P14 in which the top-side sheet material 130, the first auxiliary region 1120, the first main region 1110, and a second main region 1210 are cut along a second cutting line CL2 that crosses from a portion where the top-side sheet material 130 and the first auxiliary region 1120 overlap across a second boundary line 1230 on the z-direction bottom side and that intersects a first outline OL1 formed in the first cutting step P11, whereby a top-side sheet 13 is formed from the top-side sheet material 130. Due to this configuration, the degree of freedom in forming a top-side sheet can be further enhanced.

Description

[Technical field]

[0001] The present invention relates to a method and an apparatus for manufacturing a packaging material for a pouch container. [Background technology]

[0002] Pouch containers are widely used as containers for storing contents such as various detergents, beverages, and foods. Generally, pouch containers are formed using a flexible synthetic resin sheet. Patent Document 1 discloses an example of a manufacturing method for a pouch container packaging material used in a conventional pouch container. In the manufacturing method disclosed in the document, a top sheet material is joined to a pair of main body sheet materials. The pair of main body sheet materials and the top sheet material are each long sheets, and it is intended to continuously manufacture a plurality of pouch container packaging materials. Then, a first cutting step is performed in which the top sheet material is partially cut while the pair of main body sheet materials are oriented along the vertical direction and the top sheet material is oriented along the horizontal direction. In this first cutting step, the general shape of the top sheet in the pouch container packaging material is formed, but the adjacent top sheets are still connected to each other. Next, a second cutting step is performed while the pair of main body sheet materials and the top sheet material are oriented along the vertical direction. In this second cutting step, the pair of main body sheet material and top sheet material are cut in the sheet feeding direction, and a plurality of pouch-container packaging materials are successively produced. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2014-193566 A Summary of the Invention [Problem to be solved by the invention]

[0004] Both ends of the top sheet of the conventional pouch container packaging material are cut in the second cutting process. In order to separate the pair of main sheet material and top sheet material connected in the feed direction, a straight line extending vertically is used as the cutting line in the second cutting process. This causes a problem that the shape of both ends of the top sheet is restricted.

[0005] The present invention was devised in light of the above-mentioned circumstances, and its object is to provide a method and an apparatus for manufacturing packaging material for pouch containers that enable greater freedom in the shape of the top sheet. [Means for solving the problem]

[0006] A method for producing a packaging material for pouch containers provided by a first aspect of the present invention includes a sheet joining step of joining a first main region of the first main body sheet material and a second main region of the second main body sheet material at a pair of side seal parts spaced apart from each other in a third direction perpendicular to both the first and second directions, using a first main body sheet material and a second main region of the second main body sheet material facing each other in a first direction, and a top sheet material arranged on the top sides of the first main body sheet material and the second main body sheet material in a second direction perpendicular to the first direction, and joining a first sub-region located on the top side of the first main region of the first main body sheet material in the second direction with a second sub-region located on the top side of the second main region of the second main body sheet material and the top sheet material at the top seal parts; and a step of valley-folding a first boundary line between the first main region and the first sub-region to form a first main region and a second main region of the second main body sheet material. a first folding step of cutting the top side sheet material, the second sub-region, the first main region and the second main region along a first cutting line that crosses the first boundary line from the overlapping portion of the top side sheet material and the second sub-region to the bottom side in the second direction; a second folding step of valley-folding the second boundary line between the second main region and the second sub-region to overlap the second main region and the second sub-region; and a second cutting step of cutting the top side sheet material, the first sub-region, the first main region and the second main region along a second cutting line that crosses the second boundary line from the overlapping portion of the top side sheet material and the first sub-region to the bottom side in the second direction and intersects with the first outline line formed in the first cutting step, thereby forming a top side sheet from the top side sheet material.

[0007] In a preferred embodiment of the present invention, after the second cutting step, a third cutting step is further provided in which the first main region and the second main region are cut along a pair of third cutting lines reaching the second outline formed in the second cutting step and the bottom ends in the second direction of the first main region and the second main region, thereby forming a first main sheet from the first main sheet material and a second main sheet from the second main sheet material.

[0008] In a preferred embodiment of the present invention, in the third cutting step, the third cutting line smoothly connects with a second outer shape line formed by cutting along the second cutting line in the second cutting step.

[0009] In a preferred embodiment of the present invention, the first main body sheet material, the second main body sheet material and the top sheet material are a single original sheet.

[0010] In a preferred embodiment of the present invention, the method further includes, before the sheet joining step, a step of preparing a laminated sheet of a first structural sheet material and a second structural sheet material having a filler filling portion formed therein, which is a joined area for sealing in a filler, and in the sheet joining step, the first structural sheet material and the second structural sheet material are joined to the outside of the first main body sheet material, the second main body sheet material and the top sheet material, and in the first folding step, the first cutting step, the second folding step and the second cutting step, the first structural sheet material and the second structural sheet material are folded and cut together with the first main body sheet material, the second main body sheet material and the top sheet material.

[0011] A second aspect of the present invention provides an apparatus for manufacturing a packaging material for pouch containers, which uses a first main body sheet material and a second main body sheet material facing each other in a first direction, and a top sheet material arranged on the top sides of the first main body sheet material and the second main body sheet material in a second direction perpendicular to the first direction, and joins a first main region of the first main body sheet material and a second main region of the second main body sheet material at a pair of side seal parts spaced from each other in a third direction perpendicular to both the first and second directions, and joins a first sub-region located on the top side of the first main region of the first main body sheet material in the second direction with a second sub-region located on the top side of the second main region of the second main body sheet material and the top sheet material at a sheet joining part and a first boundary line between the first main region and the first sub-region, thereby producing the above-mentioned a first folding section that causes a first main region and a first sub-region to overlap with each other; a first cutting section that cuts the top sheet material, the second sub-region, the first main region, and the second main region along a first cutting line that crosses the first boundary line from an overlapping portion of the top sheet material and the second sub-region to the bottom side in the second direction; a second folding section that causes a second boundary line between the second main region and the second sub-region to be valley-folded so that the second main region and the second sub-region overlap with each other; and a second cutting section that forms a top sheet from the top sheet material by cutting the top sheet material, the first sub-region, the first main region, and the second main region along a second cutting line that crosses the second boundary line from an overlapping portion of the top sheet material and the first sub-region to the bottom side in the second direction and intersects with a first outline line formed in the first cutting section.

[0012] In a preferred embodiment of the present invention, a first main sheet is formed from the first main sheet material and a second main sheet is formed from the second main sheet material by cutting the first main region and the second main region along a pair of third cutting lines that reach the second outline formed in the second cutting section and the bottom ends of the first main region and the second main region in the second direction. Effect of the Invention

[0013] According to the present invention, the degree of freedom in the shape of the top sheet can be increased.

[0014] Other features and advantages of the present invention will become more apparent from the following detailed description taken in conjunction with the accompanying drawings. [Brief description of the drawings]

[0015] [Figure 1] 1 is a perspective view of a main portion showing a method and an apparatus for producing a packaging material for pouch containers according to a first embodiment of the present invention. FIG. [Diagram 2] FIG. 2 is a front view of a main portion showing a structural seal forming step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Diagram 3] 1 is a front view of a main portion showing a method and an apparatus for producing a packaging material for a pouch container according to a first embodiment of the present invention. [Figure 4] FIG. 2 is a front view of a main portion showing an auxiliary seal forming step and a spout hole forming step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Diagram 5] FIG. 4 is a cross-sectional view taken along line VV in FIG. [Figure 6] 1 is a front view of a main portion showing a method and an apparatus for producing a packaging material for a pouch container according to a first embodiment of the present invention. [Figure 7] FIG. 2 is a plan view of a main portion showing a sheet bonding step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Figure 8] FIG. 2 is a front view of a main portion showing a sheet bonding step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Figure 9] FIG. 9 is a cross-sectional view taken along line IX-IX in FIG. [Figure 10] FIG. 2 is a front view of a main portion showing a first point seal forming step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Figure 11] 11 is a cross-sectional view taken along line XI-XI in FIG. [Figure 12] 1 is a front view of a main portion showing a method and an apparatus for producing a packaging material for a pouch container according to a first embodiment of the present invention. [Figure 13] FIG. 2 is a front view of a main portion showing a first cutting step in the method for producing a packaging material for pouch containers according to the first embodiment of the present invention. [Figure 14] FIG. 14 is a cross-sectional view taken along line XIV-XIV in FIG. [Figure 15] FIG. 2 is a front view of a main part showing a state after a first cutting step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Figure 16] FIG. 2 is an enlarged front view of a main part showing a state after a first cutting step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Figure 17] 1 is a front view of a main portion showing a method and an apparatus for producing a packaging material for a pouch container according to a first embodiment of the present invention. [Figure 18] FIG. 2 is a front view of a main portion showing a second point sealing step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Figure 19] FIG. 2 is an enlarged front view of a main portion showing a second point sealing step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Figure 20] FIG. 2 is a front view of a main portion showing a second cutting step in the method for producing a packaging material for pouch containers according to the first embodiment of the present invention. [Figure 21] FIG. 2 is a rear view of a main portion showing a second cutting step in the method for producing a packaging material for pouch containers according to the first embodiment of the present invention. [Figure 22] 4 is an enlarged rear view of a main portion showing a second cutting step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. FIG. [Figure 23] FIG. 23 is a cross-sectional view taken along line XXIII-XXIII in FIG. 20. [Figure 24] FIG. 2 is a front view of a main portion showing a third cutting step in the method for producing a packaging material for pouch containers according to the first embodiment of the present invention. [Diagram 25]FIG. 4 is a rear view of a main part showing a third cutting step in the method for producing a packaging material for pouch containers according to the first embodiment of the present invention. [Figure 26] FIG. 26 is a cross-sectional view taken along line XXVI-XXVI in FIG. 24. [Figure 27] 3 is a front view of a main part showing a state after a third cutting step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. FIG. [Figure 28] 3 is a rear view of a main part showing a state after a third cutting step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. FIG. [Figure 29] FIG. 2 is an enlarged rear view of a main part showing a state after a third cutting step in the manufacturing method for a pouch-container packaging material according to the first embodiment of the present invention. [Diagram 30] 1 is a perspective view seen from the front side showing an example of a pouch-container packaging material manufactured by a pouch-container packaging material manufacturing method and pouch-container packaging material manufacturing apparatus according to a first embodiment of the present invention. FIG. [Diagram 31] 1 is a perspective view seen from the rear side, showing an example of a pouch-container packaging material manufactured by a pouch-container packaging material manufacturing method and pouch-container packaging material manufacturing apparatus according to a first embodiment of the present invention. FIG. [Diagram 32] 31 is a cross-sectional view taken along line XXXII-XXXII in FIG. 30. [Diagram 33] 31 is a cross-sectional view taken along line XXXIII-XXXIII in FIG. 30. [Diagram 34] FIG. 2 is a perspective view seen from the rear side, illustrating a process of filling a filler into a pouch-container packaging material manufactured by the pouch-container packaging material manufacturing method and pouch-container packaging material manufacturing apparatus according to the first embodiment of the present invention. [Diagram 35] 35 is a cross-sectional view taken along line XXXV-XXXV in FIG. 34. [Diagram 36] FIG. 2 is a perspective view seen from the rear side, illustrating a process of sealing a filler-enclosing portion of a pouch-container packaging material manufactured by the pouch-container packaging material manufacturing method and pouch-container packaging material manufacturing apparatus according to the first embodiment of the present invention. [Figure 37]FIG. 1 is a front perspective view showing a pouch container and a pouch-container package manufactured using a pouch-container packaging material manufactured by a pouch-container packaging material manufacturing method and a pouch-container packaging material manufacturing apparatus according to a first embodiment of the present invention. [Figure 38] 38 is a cross-sectional view taken along line XXXVIII-XXXVIII in FIG. 37. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the drawings.

[0017] The terms "first," "second," "third," etc. in this disclosure are used merely as labels and are not necessarily intended to dictate any ordering of their objects.

[0018] 1, 3, 6, 12, and 17 show a method and an apparatus for manufacturing a pouch-container packaging material according to a first embodiment of the present invention. The method for manufacturing a pouch-container packaging material of this embodiment includes a structural seal forming step P1, an auxiliary seal forming step P2, a spout hole forming step P3, a folding line forming step P4, a first preliminary folding step P5, a spout fitting step P6, a second preliminary folding step P7, a sheet joining step P8, a first folding step P9, a first point seal forming step P10, a first cutting step P11, a second folding step P12, a second point sealing step P13, a second cutting step P14, and a third cutting step P15. The pouch-container packaging manufacturing apparatus S1 of this embodiment includes a structural seal forming section U1, an auxiliary seal forming section U2, a spout hole forming section U3, a folding line forming section U4, a first preliminary folding section U5, a spout mounting section U6, a second preliminary folding section U7, a sheet joining section U8, a first folding section U9, a first point seal forming section U10, a first cutting section U11, a second folding section U12, a second point sealing section U13, a second cutting section U14, and a third cutting section U15. The pouch-container packaging manufacturing method and pouch-container packaging manufacturing apparatus S1 of this embodiment are configured to continuously manufacture a plurality of pouch-container packaging materials A1. In this embodiment, a case will be described in which each process is performed in a state in which the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 described below are maintained in a belt-like connected form in the structural seal forming section U1 to the third cutting section U15. Unlike this embodiment, each process may be performed in a state in which the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are appropriately divided. As a means for conveying the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 connected in a belt-like form in the x direction, various conventionally known conveying mechanisms (not shown) can be appropriately adopted. For example, in this embodiment, a mechanism is assumed that clamps between the parts of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 that will become the pouch container packaging material A1 and pulls them in the x direction. In this embodiment, a conveying section U21 is provided for conveying the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 in the second cutting section U14 and the third cutting section U15.

[0019] The configuration of the pouch container packaging material manufacturing method and pouch container packaging material manufacturing device according to the present invention is not limited in any way. For example, the structural seal forming step P1 and the auxiliary seal forming step P2 may be completed in advance in separate steps, in which case the device may be configured without the structural seal forming unit U1 and the auxiliary seal forming unit U2. Furthermore, the spout hole forming step P3, the folding line forming step P4, the first preliminary folding step P5, the spout mounting step P6, the second preliminary folding step P7, and the sheet joining step P8 may be completed in advance in separate steps, in which case the device may be configured without the spout hole forming unit U3, the folding line forming unit U4, the first preliminary folding unit U5, the spout mounting unit U6, the second preliminary folding unit U7, and the sheet joining unit U8.

[0020] Furthermore, the pouch-container packaging material A1 manufactured by the pouch-container packaging material manufacturing method and pouch-container packaging material manufacturing apparatus of this embodiment has a configuration including a first structural sheet 15 and a second structural sheet 16 in addition to a first main body sheet 11, a second main body sheet 12, a top sheet 13 and a bottom gusset sheet 14, as described later with reference to Figures 30 to 33, but may not include the first structural sheet 15 and the second structural sheet 16. Also, for example, the bottom gusset sheet 14 may not be included.

[0021] In the following figures, the y direction corresponds to the first direction in the present invention, the z direction corresponds to the second direction in the present invention, and the x direction corresponds to the third direction in the present invention. The z direction may coincide with the vertical direction. The x direction is the feed direction of the sheet material in the pouch-container packaging material manufacturing method and in the pouch-container packaging material manufacturing apparatus S1. Note that the z direction in Figures 1 to 3 does not necessarily correspond to the second direction in the present invention, at least in the section until the first pre-folding step P5 in the first pre-folding unit U5 described later is completed.

[0022] <Structural seal forming process P1, structural seal forming section U1> As shown in Fig. 1, a first structural sheet material 150 and a second structural sheet material 160 are prepared. The first structural sheet material 150 and the second structural sheet material 160 are capable of forming a plurality of the first structural sheets 15 and the second structural sheets 16 of the pouch-container packaging material A1, and are strip-shaped synthetic resin sheet materials extending long in the x-direction. The illustrated packaging material outline 19 is an imaginary line showing the outline of the pouch-container packaging material A1, and is depicted for ease of understanding.

[0023] Assuming the following manufacturing method, both sides of the first structural sheet material 150 are made of sealant film layers, and the inner surface (the surface facing the first structural sheet material 150) of the second structural sheet material 160 is made of a sealant film layer, and the outer surface (the surface opposite the first structural sheet material 150) is made of a base film layer. The first structural sheet material 150 may be a structure in which a base film layer is sandwiched between two sealant film layers, or a co-extruded film having heat seal layers on both sides and a polyamide layer or the like in the middle. Furthermore, when high gas barrier properties and light blocking properties are required for the first structural sheet material 150 and the second structural sheet material 160, a structure further having a barrier layer, barrier resin, vapor deposition layer, or colored layer is preferable.

[0024] Here, examples of the constituent materials of the base film layer, the sealant film layer, and the barrier layer are given below. The lamination of each of these layers can be performed by a conventional lamination method, such as coextrusion lamination, dry lamination using an adhesive, or thermal lamination in which a thermal adhesive layer is sandwiched between the layers and bonded by heat.

[0025] Examples of films constituting the base film layer include one or more layered stretched or unstretched films, preferably biaxially stretched films, made of polyester (polyethylene terephthalate (PET), polyethylene naphthalate (PEN), polybutylene terephthalate (PBT), polycarbonate (PC), etc.), polyolefin (polyethylene (PE), polypropylene (PP), etc.), polyamide (nylon-6, nylon-66, etc.), etc.

[0026] Examples of films that constitute the sealant film layer include single-layer or two or more layer films composed of low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), ethylene-propylene copolymer (EP), unoriented polypropylene (CPP), ethylene-olefin copolymer, ethylene-acrylic acid copolymer (EAA), ethylene-methacrylic acid copolymer (EMAA), ethylene-vinyl acetate copolymer (EVA), etc.

[0027] Examples of the barrier layer include a metal foil such as aluminum, a film or resin such as polyvinylidene chloride (PVDC) or ethylene-vinyl alcohol copolymer (EVOH), or a film in which aluminum, aluminum oxide, silica or other inorganic oxide is vapor-deposited (or sputtered) onto any synthetic resin film (which may be, for example, a base film layer).

[0028] The second structural sheet material 160 has a plurality of sealing through-holes 169 and a plurality of filling holes 58 formed in advance. The plurality of sealing through-holes 169 are provided for joining the first structural sheet materials 150 together in a sheet joining process P8 described below. The filling holes 58 are used for filling a filler 59 described below in a filler enclosing section 5 described below. After the first structural sheet material 150 and the second structural sheet material 160 are overlapped, a structural seal forming process P1 is performed in a structural seal forming section U1. The structural seal forming process P1 is a process for joining a portion of the first structural sheet material 150 and the second structural sheet material 160 together, and the joining is performed using heat sealing.

[0029] 2 is a plan view of a main part of the first structural sheet material 150 and the second structural sheet material 160 in the x direction. The illustrated first structural sheet material 150 and the second structural sheet material 160 are large enough to form one pouch container packaging material A1. As shown in FIG. 2, the first structural sheet material 150 is folded in a process described below, and has a first main region 1510, a first sub-region 1520, a second main region 1540, a second sub-region 1550, a top region 1570, and a bottom region 1580 in anticipation of the folding. The second structural sheet material 160 has a first main region 1610, a first sub-region 1620, a second main region 1640, a second sub-region 1650, a top region 1670, and a bottom region 1680. In the structural seal forming step P1, a portion of each of first structural sheet material 150 and second structural sheet material 160 is heat sealed to form structural seal portion 4 and filler encapsulation portion 5.

[0030] In the illustrated example, the structural seal portion 4 has a first structural seal portion 41, a second structural seal portion 42, a top structural seal portion 43, a bottom structural seal portion 44, and an extended structural seal portion 45. The first structural seal portion 41 is a portion where the first main region 1510 and the first sub-region 1520 of the first structural sheet material 150 and the first main region 1610 and the first sub-region 1620 of the second structural sheet material 160 are heat-sealed. In the illustrated example, the first structural seal portion 41 is in a substantially double annular shape. The second structural seal portion 42 is a portion where the second main region 1540 and the second sub-region 1550 of the first structural sheet material 150 and the second main region 1640 and the second sub-region 1650 of the second structural sheet material 160 are heat-sealed. In the illustrated example, the second structural seal portion 42 is in a substantially double annular shape.

[0031] The top structural seal portion 43 is a portion where the top region 1570 of the first structural sheet material 150 and the top region 1670 of the second structural sheet material 160 are heat-sealed. In the illustrated example, the top structural seal portion 43 is in the shape of a substantially single ring. The bottom structural seal portion 44 is a portion where the bottom region 1580 of the first structural sheet material 150 and the bottom region 1680 of the second structural sheet material 160 are heat-sealed. In the illustrated example, the bottom structural seal portion 44 is in the shape of a substantially double ring. The extended structural seal portion 45 is a portion where the first sub-region 1520 of the first structural sheet material 150 and the first sub-region 1620 of the second structural sheet material 160 are heat-sealed. In the illustrated example, the extended structural seal portion 45 is a pair of strip-shaped portions extending in the z-direction.

[0032] The filler-enclosing portion 5 is for maintaining the outer shape of the pouch container formed using the pouch-container packaging material A1 and promoting its self-supporting by being filled with a filler 59 described below. In the illustrated example, the filler-enclosing portion 5 has a first filler-enclosing portion 51, a second filler-enclosing portion 52, a top-side filler-enclosing portion 53, a bottom-side filler-enclosing portion 54, and an extending filler-enclosing portion 55.

[0033] The first filler encapsulation portion 51 is the space between the first major region 1510 and the first minor region 1520 of the first structural sheet material 150 and the first major region 1610 and the first minor region 1620 of the second structural sheet material 160, and is a portion defined by the first structural seal portion 41. The second filler encapsulation portion 52 is the space between the second major region 1540 and the second minor region 1550 of the first structural sheet material 150 and the second major region 1640 and the second minor region 1650 of the second structural sheet material 160, and is a portion defined by the second structural seal portion 42.

[0034] The top filler encapsulation portion 53 is a space between the top region 1570 of the first structural sheet material 150 and the top region 1670 of the second structural sheet material 160, and is a portion partitioned by the top structural seal portion 43. The bottom filler encapsulation portion 54 is a space between the bottom region 1580 of the first structural sheet material 150 and the bottom region 1680 of the second structural sheet material 160, and is a portion partitioned by the bottom structural seal portion 44. The extended filler encapsulation portion 55 is a space between the first sub-region 1520 of the first structural sheet material 150 and the first sub-region 1620 of the second structural sheet material 160, and is a portion partitioned by the extended structural seal portion 45. A filling port 58 is connected to the extended filler encapsulation portion 55. In this embodiment, the filling port 58 is an opening portion between the z-direction ends of the first sub-region 152 and the first sub-region 162.

[0035] The structural seal forming portion U1 is a portion that functions to form the structural seal portion 4 in the first structural sheet material 150 and the second structural sheet material 160. The specific configuration of the structural seal forming portion U1 is not limited in any way, and may appropriately include, for example, a conventionally known sealing die with a built-in heater, a cooling portion that cools the portion sealed by the sealing die, or the like.

[0036] <Auxiliary seal forming process P2, auxiliary seal forming unit U2> As shown in FIG. 1, after the structural seal forming process P1, the original sheet 10 is laminated so as to face the first structural sheet material 150. The original sheet 10 is a sheet that constitutes the first main body sheet material 110, the second main body sheet material 120, the top sheet material 130, and the bottom sheet material 140 described below. That is, in this embodiment, the first main body sheet material 110, the second main body sheet material 120, the top sheet material 130, and the bottom sheet material 140 are constituted by one original sheet 10. Note that, unlike this embodiment, all or any of the first main body sheet material 110, the second main body sheet material 120, the top sheet material 130, and the bottom sheet material 140 may be constituted by sheets separate from each other.

[0037] Next, the auxiliary seal forming process P2 is performed in the auxiliary seal forming section U2. In the auxiliary seal forming process P2, an auxiliary seal portion 39 is formed in the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160. The auxiliary seal portion 39 temporarily joins the original sheet 10 to the first structural sheet material 150 and the second structural sheet material 160. In this manufacturing method, both sides of the original sheet 10 are made of sealant film layers, and a base film layer and a barrier layer are appropriately provided between these sealant film layers.

[0038] The auxiliary seal forming unit U2 functions to form a plurality of auxiliary seals 39 in the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160. The specific configuration of the auxiliary seal forming unit U2 is not limited in any way, and may include, for example, a conventionally known sealing die with a built-in heater, a cooling unit for cooling the seal portion formed by the sealing die, or the like.

[0039] <Spout hole forming process P3, spout hole forming unit U3> After the auxiliary seal forming step P2 in the auxiliary seal forming unit U2, the spout hole forming step P3 is performed in the spout hole forming unit U3 as shown in Fig. 3. In the spout hole forming step P3, spout holes 137, 1571 and 1671 are formed in the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 as shown in Fig. 4. Fig. 4 is a plan view of the essential parts showing a portion of the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 in the x direction. The illustrated original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 are large enough to form one pouch container packaging material A1. Spout hole 137, spout hole 1571, and spout hole 1671 penetrate original sheet 10, first structural sheet material 150, and second structural sheet material 160, respectively, and are formed in top sheet material 130, top region 1570, and top region 1670 at positions surrounded by top structural seal portion 43. In the illustrated example, spout hole 137, spout hole 1571, and spout hole 1671 are aligned with each other.

[0040] Spout hole forming section U3 is a section that functions to form spout holes 137, spout holes 1571, and spout holes 1671 in original sheet 10, first structural sheet material 150, and second structural sheet material 160. The specific configuration of spout hole forming section U3 is not limited in any way, and for example, a conventionally known cutting blade, cutting die, laser, or the like may be used as appropriate, and a method using a cutting die with a punch and die is preferred from the viewpoint of durability.

[0041] <Bending line forming process P4, bending line forming unit U4> As shown in Fig. 3, a folding line forming step P4 is performed in a folding line forming section U4. In the folding line forming step P4, as shown in Fig. 4, folding lines 171, 172, 173, 174, 175, and 176 are formed in the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160. The folding lines 171, 172, 173, 174, 175, and 176 are provided to make it easier and more reliable to fold the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in the subsequent steps. Note that the folding line forming step P4 may be omitted in part or in whole, and the subsequent steps may be performed.

[0042] The fold lines 171 are provided at positions that divide the top sheet material 130, the top region 1570, and the top region 1670 from the second sub-region 1220, the second sub-region 1550, and the second sub-region 1650. The fold lines 172 are provided at positions that divide the second sub-region 1220, the second sub-region 1550, and the second sub-region 1650 from the second main region 1210, the second main region 1540, and the second main region 1640. The fold lines 173 are provided at positions that divide the second main region 1210, the second main region 1540, and the second main region 1640 from the bottom sheet material 140, the bottom region 1580, and the bottom region 1680. Fold line 175 is provided at a location separating bottom sheet material 140, bottom region 1580, and bottom region 1680 from first major region 1110, first major region 1510, and first major region 1610. Fold line 174 is provided between fold line 173 and fold line 175. Fold line 176 is provided at a location separating first major region 1110, first major region 1510, and first major region 1610 from first minor region 1120, first minor region 1520, and first minor region 1620.

[0043] The fold line forming section U4 functions to form fold lines 171, 172, 173, 174, 175 and 176 in the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160. The specific configuration of the fold line forming section U4 is not limited in any way, and for example, various configurations capable of imparting localized folds to the sheet material that are conventionally known may be used as appropriate.

[0044] <First preliminary folding process P5, first preliminary folding unit U5> Next, a first preliminary folding step P5 is performed in a first preliminary folding section U5. In the first preliminary folding step P5, the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are valley-folded at a folding line 171 so that the original sheet 10 is on the inside. Also, the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are mountain-folded at a folding line 172 so that the original sheet 10 is on the outside. The original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are valley-folded at a folding line 173 and a folding line 175 so that the original sheet 10 is on the inside, and the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are mountain-folded at a folding line 174 so that the original sheet 10 is on the outside. Furthermore, original sheet 10, first structural sheet material 150 and second structural sheet material 160 are mountain-folded at folding line 176 so that original sheet 10 is on the outside.

[0045] The first pre-folding unit U5 is a portion that performs the function of the first pre-folding step P5. The specific configuration of the first pre-folding unit U5 is not limited in any way, and for example, a conventionally known sheet folding mechanism may be appropriately used.

[0046] 5, by folding at folding line 171, top sheet material 130, top region 1570, and top region 1670 are defined in original sheet 10, first structural sheet material 150, and second structural sheet material 160. By folding at folding line 172, second main body sheet material 120, second main region 1540, second sub region 1550, second main region 1640, and second sub region 1650 are defined in original sheet 10, first structural sheet material 150, and second structural sheet material 160. By folding at folding lines 173 and 175, bottom sheet material 140, bottom region 1580, bottom region 1680, and first main body sheet material 110 are defined. Also, by folding at the folding line 176, the first main region 1110, the first sub-region 1120, the first main region 1510, the first sub-region 1520, the first main region 1610, and the first sub-region 1620 are partitioned. In FIG. 5, for the sake of convenience, the thickness of each sheet is depicted as a thickness that can be seen in the drawing, and is significantly thicker than the actual thickness. For this reason, the folding state and overlapping state of each sheet are depicted in some parts different from the actual state. This point is the same in the subsequent cross-sectional views.

[0047] Furthermore, by folding at folding line 172, second boundary lines 1230, 1560, and 1660 are formed in original sheet 10, first structural sheet material 150, and second structural sheet material 160. Second boundary lines 1230, 1560, and 1660 are boundaries between second major region 1210, 1540, and 1640 and second minor region 1220, 1550, and 1650. Furthermore, by folding at folding line 176, first boundary lines 1130, 1530, and 1630 are formed in original sheet 10, first structural sheet material 150, and second structural sheet material 160. The first boundary line 1130, the first boundary line 1530, and the first boundary line 1630 are boundaries between the first primary region 1110, the first primary region 1510, and the first primary region 1610 and the first sub-region 1120, the first sub-region 1520, and the first sub-region 1620.

[0048] <Spout installation process P6, spout installation part U6> Next, a spout mounting process P6 is performed in the spout mounting unit U6. In the spout mounting process P6, as shown in Fig. 5, the spout outlet 71 of the spout 7 is inserted into the spout hole 137, the spout hole 1571, and the spout hole 1671. Then, the top sheet material 130, the top region 1570, and the top region 1670 are heat-sealed to the flange portion 72 to form the spout seal portion 33. The flange portion 72 of the spout 7 is a molded product made of a heat-sealable resin, such as polyethylene or polypropylene.

[0049] The spout fitting part U6 is a part that performs the function of fitting the spout 7 in the spout fitting process P6. The specific configuration of the spout fitting part U6 is not limited in any way, and may appropriately include, for example, a conventionally known conveying mechanism for inserting the spout 7, a sealing die with a built-in heater for heat sealing, and a cooling part for cooling the portion sealed by the sealing die.

[0050] <Second preliminary folding process P7, second preliminary folding unit U7> 6, a second pre-folding step P7 is performed in a second pre-folding unit U7. In the second pre-folding step P7, the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are folded at the folding line 171 so that the top sheet material 130, the top region 1570, and the top region 1670 are aligned along the x and y directions. As a result, the top sheet material 130, the top region 1570, and the top region 1670 are aligned along the x and y directions together with the first sub-region 1120, the first sub-region 1520, and the first sub-region 1620, and the second sub-region 1220, the second sub-region 1550, and the second sub-region 1650.

[0051] The second pre-folding section U7 is a section that performs a folding function in the spout attachment step P6. The specific configuration of the second pre-folding section U7 is not limited in any way, and for example, a conventionally known sheet folding mechanism may be appropriately used.

[0052] <Sheet joining process P8, sheet joining part U8> Next, a sheet joining step P8 is performed at a sheet joining portion U8. In the sheet joining step P8, as shown in Figs. 7, 8 and 9, a portion each of the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 is joined to form a sealed portion 30. Figs. 7 and 8 are plan views of the main portions of the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 in the x direction. The illustrated original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 are large enough to form one pouch container packaging material A1.

[0053] The sealed portion 30 is a portion in which each of the first main body sheet material 110, the second main body sheet material 120, the top sheet material 130, the bottom sheet material 140, the first structural sheet material 150, and the second structural sheet material 160 are appropriately joined together, and in this embodiment, they are joined together by heat sealing. The sealed portion 30 has a pair of side seal portions 310 and a top seal portion 320.

[0054] The pair of side seal portions 310 are portions where both ends in the x direction of the first main body sheet material 110, the second main body sheet material 120, the bottom sheet material 140, the first structural sheet material 150, and the second structural sheet material 160 are joined together. In the illustrated example, the pair of side seal portions 310 are formed so as to overlap the outer side or a part of the first structural seal portion 41 in the x direction. The pair of side seal portions 310 overlap the pair of sealing through holes 169, respectively. The sealing through holes 169 constitute an area where the bottom side region 1680 does not exist, and the bottom side regions 1580 are joined together by heat sealing through the sealing through holes 169. The portions of the bottom side region 1680 other than the sealing through holes 169 are not heat sealed to each other, so a gusset structure is formed.

[0055] The top seal portion 320 is a portion where the top sheet material 130, the top region 1570, and the top region 1670, the first sub-region 1120, the first sub-region 1520, and the first sub-region 1620, and the second sub-region 1220, the second sub-region 1550, and the second sub-region 1650 are joined together. In the illustrated example, the top seal portion 320 is formed so as to overlap the outside or a portion of the top structural seal portion 43.

[0056] The sheet joining section U8 is a section that performs a heat sealing function in the sheet joining step P8. The specific configuration of the sheet joining section U8 is not limited in any way, and may include, for example, a sealing die with a built-in heater for performing a conventionally known heat sealing, a cooling section for cooling the portion sealed by the sealing die, or the like.

[0057] <First folding process P9, first folding unit U9> Next, as shown in Fig. 6, a first folding step P9 is performed at a first folding unit U9. In the first folding step P9, the first main body sheet material 110, the first structural sheet material 150, and the second structural sheet material 160 are folded at the first boundary line 1130, the first boundary line 1530, and the first boundary line 1630 shown in Fig. 9. This causes the second main body sheet material 120 to be aligned along the z direction, as shown in Fig. 11. Also, the first main region 1110, the first main region 1510, and the first main region 1610 and the first sub-region 1120, the first sub-region 1520, and the first sub-region 1620 overlap each other in a posture along the z direction. In addition, on the opposite side of the first main region 1110, the first main region 1510 and the first main region 1610, the top sheet material 130, the top region 1570 and the top region 1670 are aligned in the z direction, sandwiching the first sub-region 1120, the first sub-region 1520 and the first sub-region 1620 in the y direction.

[0058] The first folding unit U9 is a portion that performs the folding function in the first folding step P9. The specific configuration of the first folding unit U9 is not limited in any way, and for example, a conventionally known sheet folding mechanism may be appropriately used.

[0059] <First point seal forming process P10, first point seal forming unit U10> Next, as shown in FIG. 6, a first point seal forming step P10 is performed in a first point seal forming unit U10. In the first point seal forming step P10, a plurality of first reinforcing seal parts 391 are formed at appropriate positions of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in a state in which the first folding step P9 has been completed. The plurality of first reinforcing seal parts 391 are formed for the purpose of partially enhancing the joining function of the sealing unit 30. As shown in FIG. 10, in the illustrated example, the plurality of first reinforcing seal parts 391 include first reinforcing seal parts 391a, 391b, and 391c. FIG. 10 is a plan view of a main part showing a portion of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in the x direction. The illustrated original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are large enough to form one pouch container packaging material A1.

[0060] The first reinforcing seal portion 391a is formed at a position overlapping the first boundary line 1130, the second boundary line 1230, the first boundary line 1530, the second boundary line 1560, the first boundary line 1630, and the second boundary line 1660, and both ends in the x direction of the packaging outline 19. The first reinforcing seal portion 391b is formed at a position overlapping the mountain folds of the bottom sheet material 140, the bottom region 1580, and the bottom region 1680, and both ends in the x direction of the packaging outline 19. The first reinforcing seal portion 391c is formed at a position overlapping the sealing through hole 169.

[0061] The first point seal forming unit U10 is a unit that performs the heat sealing function in the first point seal forming step P10. The specific configuration of the first point seal forming unit U10 is not limited in any way, and may include, for example, a sealing die with a built-in heater for performing conventional heat sealing, a cooling unit for cooling the portion sealed by the sealing die, or the like.

[0062] <First cutting process P11, first cutting part U11> Next, as shown in Fig. 12, a first cutting step P11 is performed in a first cutting section U11. In the first cutting step P11, the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 after the first folding step P9 (and the first point seal forming step P10) are cut along a first cutting line CL1. As shown in Fig. 13, the first cutting line CL1 extends from the portion where the top sheet material 130, the top region 1570, and the top region 1670 overlap with the second sub-region 1220, the second sub-region 1550, and the second sub-region 1650 (the portion on the top side in the z direction from the first boundary line 1130, the second boundary line 1230, the first boundary line 1530, the second boundary line 1560, the first boundary line 1630, and the second boundary line 1660) to the bottom side in the z direction beyond the first boundary line 1130, the first boundary line 1530, and the first boundary line 1630. In the illustrated example, two first cutting lines CL1 are set on both sides in the x direction. The top structural seal portion 43, the top filler enclosing portion 53, and the spout 7 are located between the two first cutting lines CL1 in the x direction. Fig. 13 is a plan view of the essential parts showing a portion of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in the x direction. The illustrated original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are large enough to form one pouch container packaging material A1.

[0063] The first cutting unit U11 is a part that performs the cutting function in the first cutting step P11. The specific configuration of the first cutting unit U11 can be a cutting blade, a cutting die, a laser, etc., and is not limited in any way. As a specific configuration for realizing the cutting function of the first cutting unit U11, a cutting blade, a so-called Thomson blade, is suitable for cutting a laminated film for forming a packaging material for a pouch container, and is preferable in that it is easy to change the shape of the cut shape, etc. In this embodiment, as shown in FIG. 14, it has a receiving portion 811 and a cutting portion 812. The receiving portion 811 is located on one side of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in the y direction, and is a portion that receives the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 to be cut. The cutting section 812 is a section for cutting the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160, and in the illustrated example, has a support section 813, a cutting blade 815, and a drive cylinder 816. The support section 813 is a section for supporting the cutting blade 815. The cutting blade 815 is a blade for cutting the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160, and has a shape that coincides with the first cutting line CL1 shown in FIG. 14 when viewed from the y direction. The drive cylinder 816 is a drive source for moving the support section 813 and the cutting blade 815 forward and backward relative to the receiving section 811. In addition, the support section 813 is provided with a through hole 814. The through hole 814 is for accommodating the spout 7 when the support section 813 and the cutting blade 815 advance toward the receiving section 811, thereby avoiding interference.

[0064] As shown in Fig. 15 and Fig. 16, when the first cutting step P11 is completed, a first outline OL1 is formed on the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160. The first outline OL1 straddles the first boundary line 1130, the first boundary line 1530, and the first boundary line 1630, and intersects with the first reinforcing seal portion 391a. Fig. 15 is a plan view of the main part showing a part of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in the x direction. The illustrated original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are large enough to form one pouch container packaging material A1.

[0065] <Second folding process P12, second folding unit U12> Next, as shown in FIG. 12, a second folding step P12 is performed in the second folding section U12. In the second folding step P12, the second boundary line 1230, the second boundary line 1560, and the second boundary line 1660 are valley-folded. As a result, as shown in FIG. 23, the first main body sheet material 110, the first main region 1510, the first sub-region 1520, the first main region 1610, and the first sub-region 1620 are aligned along the z direction. In addition, the second main region 1210, the second main region 1540, and the second main region 1640 are overlapped with the second sub-region 1220, the second sub-region 1550, and the second sub-region 1650 along the z direction. In addition, on the opposite side of the second main region 1210 across the second sub-region 1220, the second sub-region 1550, and the second sub-region 1650 in the y direction, the top sheet material 130, the top region 1570, and the top region 1670 are aligned along the z direction.

[0066] The second folding unit U12 is a portion that performs the folding function in the second folding step P12. The specific configuration of the second folding unit U12 is not limited in any way, and for example, a conventionally known sheet folding mechanism may be appropriately used.

[0067] <Second point sealing process P13, second point sealing section U13> Next, as shown in FIG. 17, a second point sealing step P13 is performed in the second point sealing section U13. In the second point sealing step P13, a plurality of second reinforcing seal parts 392 are formed at appropriate positions of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 after the second folding step P12. As shown in FIG. 18 and FIG. 19, the plurality of second reinforcing seal parts 392 are formed for the purpose of partially enhancing the joining function of the sealing section 30. FIG. 18 is a plan view of the main part showing a portion of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in the x direction. The illustrated original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are large enough to form one pouch container packaging material A1. 19, in the illustrated example, the second reinforcing seal portion 392 is formed across a portion of the top seal portion 320 that is surrounded by the packaging outline 19 and the first outline OL1 and a portion that extends from that portion beyond the packaging outline 19 to the top side in the z direction. However, the second reinforcing seal portion 392 does not reach the first outline OL1.

[0068] The second point sealing unit U13 is a unit that performs a heat sealing function in the second point sealing process P13. The specific configuration of the second point sealing unit U13 is not limited in any way, and may include, for example, a sealing die with a built-in heater for performing a conventionally known heat sealing, a cooling unit for cooling the sealed portion by the sealing die, or the like.

[0069] <Second cutting process P14, second cutting section U14> 17, a second cutting step P14 is performed in a second cutting unit U14. In the second cutting step P14, the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 after the second folding step P12 (and the second point sealing step P13) are cut along a second cutting line CL2. As shown in Figures 20, 21, 22 and 23, the second cutting line CL2 extends from the portion where the top sheet material 130, the top region 1570, and the top region 1670 overlap with the first sub-region 1120, the first sub-region 1520, and the first sub-region 1620 (the portion on the top side in the z direction of the first boundary line 1130, the second boundary line 1230, the first boundary line 1530, the second boundary line 1560, the first boundary line 1630, and the second boundary line 1660) to the bottom side in the z direction beyond the first boundary line 1130, the second boundary line 1230, the first boundary line 1530, the second boundary line 1560, the first boundary line 1630, and the second boundary line 1660 and intersects with the first outline line OL1. 20 and 21 are plan views of essential parts showing portions in the x direction of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160. The illustrated original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are each large enough to form one pouch-container packaging material A1.

[0070] In the illustrated example, as shown in Figs. 20 to 22, one second cutting line CL2 extends from the top side of the spout 7 in the z direction to both sides in the x direction and the bottom side in the z direction, and reaches the first outline OL1 while sandwiching the spout 7, the top structural seal portion 43, and the top filler encapsulation portion 53. As shown in Fig. 22, the second cutting line CL2 intersects with the second reinforcing seal portion 392. Furthermore, the second cutting line CL2 smoothly connects to the packaging outline 19. The second outline OL2 shown in Fig. 25 is formed by cutting along the second cutting line CL2. Then, the portion of the top sheet material 130 surrounded by the first outline OL1 and the second outline OL2 is divided into individual pieces as the top sheet 13.

[0071] The second cutting unit U14 is a part that performs the cutting function in the second cutting step P14. The specific configuration of the second cutting unit U14 can be a cutting blade, a cutting die, a laser, etc., and is not limited in any way. As a specific configuration for realizing the cutting function of the second cutting step P14, a cutting blade, a so-called Thomson blade, is suitable for cutting a laminated film for forming a packaging material for a pouch container, and is preferable in that it is easy to change the shape of the cut shape, etc. In this embodiment, as shown in FIG. 23, it has a receiving portion 821 and a cutting portion 822. The receiving portion 821 is located on one side of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in the y direction, and is a portion that receives the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 to be cut. The cutting section 822 is a section for cutting the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160, and in the illustrated example, has a support section 823, a cutting blade 825, and a drive cylinder 826. The support section 823 is a section for supporting the cutting blade 825. The cutting blade 825 is a blade for cutting the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160, and has a shape that coincides with the second cutting line CL2 shown in Figures 20 to 22 when viewed from the y direction. The drive cylinder 826 is a drive source for moving the support section 823 and the cutting blade 825 forward and backward relative to the receiving section 821. In addition, the support section 823 is provided with a through hole 824. The through hole 824 is for accommodating the spout 7 when the support section 823 and the cutting blade 825 advance toward the receiving section 821, thereby avoiding interference.

[0072] The original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 that have completed the second cutting step P14 by the second cutting unit U14 are transported to the third cutting unit U15 by the transport unit U21. As shown in Figures 24, 25, and 26, the transport unit U21 has a pair of clamping units 91. The pair of clamping units 91 can approach and move away from each other in the y direction, and by approaching each other, they clamp the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 across the upper part of the second outline OL2 in the z direction. In this state, the transport unit U21 can move the pair of 91 in the x direction. A motor, an air cylinder, or the like is appropriately used as a driving source for the transport unit U21.

[0073] <Third cutting process P15, third cutting part U15> Next, as shown in FIG. 17, a third cutting step P15 is performed at a third cutting section U15. In the third cutting step P15, the raw sheet 10, the first structural sheet material 150, and the second structural sheet material 160 that have been subjected to the second cutting step P14 are cut along a pair of third cutting lines CL3 while being clamped by a pair of clamping sections 91 so as to straddle the second outline OL2. As shown in FIG. 24 to FIG. 26, the third cutting line CL3 reaches the second outline OL2 and the bottom end of the first main region 1610 in the z direction and the bottom end of the second main region 1640 in the z direction. In the illustrated example, the third cutting line CL3 intersects with the first reinforcing seal portion 391b and the first reinforcing seal portion 391c. Furthermore, the third cutting line CL3 is smoothly connected to the second outline OL2. 24 and 25 are plan views of essential parts showing portions in the x direction of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160. The illustrated original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are each large enough to form one pouch-container packaging material A1.

[0074] The third cutting unit U15 is a part that performs the cutting function in the third cutting step P15. The specific configuration of the third cutting unit U15 can be a cutting blade, a cutting die, a laser, etc., and is not limited in any way. As a specific configuration for realizing the cutting function of the third cutting step P15, a cutting blade, a so-called Thomson blade, is suitable for cutting a laminated film for forming a packaging material for a pouch container, and is preferable in that it is easy to change the shape of the cut shape, etc. In this embodiment, as shown in FIG. 26, it has a receiving portion 831 and a cutting portion 832. The receiving portion 831 is located on one side of the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 in the y direction, and is a portion that receives the original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 to be cut. The cutting section 832 is a section for cutting the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160, and in the illustrated example, has a support section 833, a cutting blade 835 and a drive cylinder 836. The support section 833 is a section for supporting the cutting blade 835. The cutting blade 835 is a blade for cutting the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160, and has a shape that coincides with the third cutting line CL3 shown in Figures 24 and 25 when viewed from the y direction. The drive cylinder 836 is a drive source for moving the support section 833 and the cutting blade 835 forward and backward relative to the receiving section 831. In addition, the support section 833 is provided with a recess 837. The recess 837 is for avoiding interference with the spout 7 when the support section 833 and the cutting blade 835 advance toward the receiving section 831.

[0075] When cutting is performed along the third cutting line CL3 in the third cutting step P15, a third outline OL3 is formed, and the portion defined by the first outline OL1, the second outline OL2, and the third outline OL3 is completely divided into individual pieces. However, in this embodiment, the portion illustrated in Figs. 24 to 26 is clamped by a pair of clamping units 91 of the conveying unit U21 in the third cutting step P15. Therefore, the portion defined by the first outline OL1, the second outline OL2, and the third outline OL3 maintains the state taught by the pair of clamping units 91 together with the other portions even after cutting in the third cutting step P15.

[0076] Next, as shown in Fig. 27 to Fig. 29, the clamping by the pair of clamping parts 91 of the conveying part 21 is released. As a result, the parts of the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 defined by the first outline OL1, the second outline OL2 and the third outline OL3 are separated from the other parts, and the pouch-container packaging material A1 is obtained. Fig. 27 and Fig. 28 are plan views of the main parts showing parts of the original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 in the x direction. The illustrated original sheet 10, the first structural sheet material 150 and the second structural sheet material 160 are large enough to form one pouch-container packaging material A1.

[0077] <Pouch container packaging material A1> 30 to 33, the pouch-container packaging material A1 includes a first main body sheet 11, a second main body sheet 12, a top sheet 13, a bottom gusset sheet 14, a first structural sheet 15, and a second structural sheet 16, and is provided with a spout 7. The pouch-container packaging material A1 also includes a seal portion 3, a structural seal portion 4, a filler enclosing portion 5, and a content-accommodating portion 6.

[0078] The first main body sheet 11 has a first main region 111 and a first sub-region 112 defined by a first boundary line 113. The second main body sheet 12 has a second main region 121 and a second sub-region 122 defined by a second boundary line 123.

[0079] The first structural sheet 15 has a first main region 151 and a first sub-region 152 defined by a first boundary line 153, a second main region 154 and a second sub-region 155 defined by a second boundary line 156, a top region 157 and a bottom region 158.

[0080] The second structural sheet 16 has a first main region 161 and a first sub-region 162 defined by a first boundary line 163, a second main region 164 and a second sub-region 165 defined by a second boundary line 166, a top region 167 and a bottom region 168.

[0081] The seal portion 3 includes a pair of side seal portions 31 and a top seal portion 32. In the seal portion 3, the first main body sheet 11, the second main body sheet 12, the top sheet 13, the bottom gusset sheet 14, the first structural sheet 15, and the second structural sheet 16 are joined together at appropriate locations.

[0082] The configurations of the structural seal portion 4 and the filler sealing portion 5 are as described above.

[0083] The content-accommodating section 6 is a portion for accommodating the content 69 in the pouch-container package C1 produced using the pouch-container packaging material A1. The content-accommodating section 6 is a space surrounded by the inner surfaces of the first main body sheet 11, the second main body sheet 12, and the bottom gusset sheet 14. A spout 7 communicates with the content-accommodating section 6.

[0084] <Pouch container B1> 34 to 36 show the production of a pouch container B1 using a pouch container packaging material A1. First, as shown in FIG. 34, a filler 59 is filled from a filling port 58 into the filler encapsulation section 5 using, for example, a nozzle. As the filler 59, a fluid selected from a gas such as nitrogen or air, water, an aqueous solution, or an oil agent can be preferably used. Powder or granular material, resin, foaming material, etc. can also be used. The above-mentioned fluids, powder or granular material, etc. may be appropriately mixed and filled into the filler encapsulation section 5. As these fillers, gases such as nitrogen and air are more preferable from the viewpoint of ease of filling and weight reduction.

[0085] When air is used as the filler 59, when the air is blown in as the filler 59 from the filling port 58, the filler 59 is filled in the order of the extended filler encapsulation portion 55, the first filler encapsulation portion 51, the bottom filler encapsulation portion 54, the second filler encapsulation portion 52, and the top filler encapsulation portion 53. When the filler encapsulation portion 5 is filled with the filler 59, it becomes inflated and forms a strong structure. This completes the pouch container B1. It is preferable to seal the filler encapsulation portion 5 and cut the extended structure seal portion 45 and the extended filler encapsulation portion 55 as shown in FIG. 36 before filling the contents 69 described later. For example, after forming the encapsulation seal portion 34 so as to cross the top structural seal portion 43 and the connection portion between the first filler encapsulation portion 51 and the extended filler encapsulation portion 55, the first sub-region 112, the first sub-region 152 and the first sub-region 162 and the top sheet 13, the top region 157 and the top region 167 are cut so as to divide the encapsulation seal portion 34.

[0086] <Pouch container packaging C1> 37 and 38 show a pouch-container package C1 manufactured using a pouch container B1. In this manufacturing method, as shown in these figures, the contents 69 are filled. Specifically, a contents filling step is performed in which the contents 69, such as various detergents, beverages, and foods, are filled into the contents storage section 6 through the spout 7. After this, a step of closing the spout 7 with a cap 73 is performed, and the pouch-container package C1 consisting of the pouch container B1 filled with the filler 59 and the contents 69 is obtained.

[0087] Unlike the present embodiment, the pouch container packaging body C1 may be manufactured by performing a content filling step in which the content storage section 6 of the pouch container packaging material A1 is filled with content 69, and then performing a filler enclosing step in which the filler enclosing section 5 is filled with filler 59 after the content filling step.

[0088] Next, a method for producing the pouch-container packaging material A1 and the operation of the pouch-container packaging material producing apparatus S1 will be described.

[0089] According to this embodiment, the first cutting step P11 is performed after the first folding step P9, and then the second cutting step P14 is performed after the second folding step P12. In the first cutting step P11, as shown in FIG. 14, the raw sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are generally aligned along the z direction, so that they can be cut along the first cutting line CL1 that straddles the first boundary line 1130 as shown in FIG. 13. In addition, in the second cutting step P14, as shown in FIG. 20 to FIG. 22, they can be cut along the second cutting line CL2 that straddles the first boundary line 1130 and intersects with the first outline line OL1. As a result, when the second cutting step P14 is completed, the top sheet 13 can be cut into individual pieces from the top sheet material 130. That is, when a plurality of pouch container packaging materials A1 are continuously manufactured, the outer shape of the top sheet 13 is already completed by completing the second cutting step P14. However, the first main body sheet material 110 and the second main body sheet material 120 are still connected in the x direction. Therefore, there is no need to cut the top sheet material 130 when dividing the first main body sheet material 110 and the second main body sheet material 120 in the subsequent process. This allows for greater freedom in the shape of the top sheet 13.

[0090] In this embodiment, the first cutting line CL1 (first outer shape line OL1) and the second cutting line CL2 (second outer shape line OL2) cross obliquely at or near the first boundary line 1130. This allows both ends of the top sheet 13 in the x direction to have, for example, an acute corner rather than a shape having sides perpendicular to the x direction. In addition, in the first cutting process P11 and the second cutting process P14, the intersection of the first cutting line CL1 (first outer shape line OL1) and the second cutting line CL2 (second outer shape line OL2) overlaps the top seal portion 320. Therefore, it is not necessary to further seal both ends of the top sheet 13 in the x direction, which have been divided by the second cutting process P14, by heat sealing.

[0091] By performing the third cutting step P15 after the second cutting step P14, the first main body sheet material 110 and the second main body sheet material 120 are still connected in the x direction when the second cutting step P14 is completed, and although the top sheet 13 is divided into individual pieces, it is fixed to the first main body sheet material 110 and the second main body sheet material 120. Therefore, by pulling the end portions of the first main body sheet material 110 and the second main body sheet material 120 in the x direction on the traveling direction side, the long original sheet 10, the first structural sheet material 150, and the second structural sheet material 160 can be appropriately fed along the x direction up to the third cutting section U15 where the third cutting step P15 is performed. This has the advantage that a complicated sheet holding mechanism can be omitted. In addition, in this embodiment, as can be understood from FIG. 24, FIG. 25, and FIG. 29, the third cutting line CL3 is smoothly connected to the second outer shape line OL2. This makes it possible to prevent the occurrence of unintended corners or the like at the boundary between the second outline OL2 and the third outline OL3 in the pouch-container packaging material A1.

[0092] In addition, in this embodiment, as shown in Figs. 24 to 26, when the third cutting step P15 is performed, the raw sheet 10, the first structural sheet material 150, and the second structural sheet material 160 are cut along the third cutting line CL3 while being clamped by a pair of clamping parts 91 of the conveying unit U21 so as to straddle the second outline line OL2. Therefore, even after the third outline line OL3 is formed, the portion partitioned by the first outline line OL1, the second outline line OL2, and the third outline line OL3 is cut into individual pieces, but is kept clamped by the pair of clamping parts 91. Therefore, it is possible to prevent the individual pieces (pouch-container packaging material A1) from unintentionally dropping at the time of completion of the third cutting step P15. In addition, for example, after moving to a product storage unit or the like set further downstream in the x direction from the third cutting unit U15, the clamping by the pair of clamping parts 91 is released, so that the pouch-container packaging material A1 to be manufactured sequentially can be appropriately stored.

[0093] 22, the second reinforcing seal portion 392 intersects with the second cutting line CL2 but does not reach the first outline OL1. Therefore, even if a part of the sealant film layer is melted and spread by heat sealing in the second point sealing process P13 for forming the second reinforcing seal portion 392, it is possible to prevent the melted part from leaking out from the first outline OL1. In addition, since the second reinforcing seal portion 392 reliably reaches the second outline OL2, it is possible to reliably increase the seal strength in the vicinity of the intersection of the first outline OL1 and the second outline OL2.

[0094] 34 to 38, a pouch-container B1 formed using the pouch-container packaging material A1 is provided with a filler-enclosing section 5 filled with a filler 59. This allows the pouch-container B1 to maintain its outer shape and keep a shape that allows it to stand on its own even if the contents 69 are reduced as the contents 69 are used in the pouch-container package C1.

[0095] According to the pouch-container packaging material manufacturing method and pouch-container packaging material manufacturing apparatus S1 of this embodiment, manufacturing can be efficiently and reliably performed using the first structural sheet material 150 and the second structural sheet material 160 in addition to the original sheet 10. Providing the first reinforcing seal portion 391 and the second reinforcing seal portion 392 is preferable for improving the seal strength.

[0096] The method and apparatus for producing a pouch-container packaging material according to the present invention are not limited to the above-described embodiment. The specific configurations of the method and apparatus for producing a pouch-container packaging material according to the present invention can be freely designed in various ways.

Claims

1. A first main body sheet material and a second main body sheet material facing each other in a first direction, and a top sheet material arranged on the top side of the first main body sheet material and the second main body sheet material in a second direction perpendicular to the first direction, a sheet joining process in which a first main region of the first main body sheet material and a second main region of the second main body sheet material are joined at a pair of side seal portions spaced apart from each other in a third direction perpendicular to both the first and second directions, and a first sub-region located on the top side in the second direction with respect to the first main region of the first main body sheet material, a second sub-region located on the top side in the second direction with respect to the second main region of the second main body sheet material, and the top sheet material are joined at the top seal portions; a first folding step of folding a first boundary line between the first main region and the first sub-region in a valley manner so that the first main region and the first sub-region overlap each other; a first cutting step of cutting the top sheet material, the second sub-region, the first main region, and the second main region along a first cutting line that crosses the first boundary line from an overlapping portion of the top sheet material and the second sub-region to a bottom side in the second direction; a second folding step of folding a second boundary line between the second main region and the second sub-region in a valley manner so that the second main region and the second sub-region overlap each other; a second cutting step of forming a top sheet from the top sheet material by cutting the top sheet material, the first sub-region, the first main region and the second main region from the overlapping portion of the top sheet material and the first sub-region along a second cutting line that crosses the second boundary line to the bottom side in the second direction and intersects with the first outline line formed in the first cutting step.

2. 2. The method for manufacturing a pouch container packaging material according to claim 1, further comprising, after the second cutting step, a third cutting step of forming a first main sheet from the first main sheet material and a second main sheet from the second main sheet material by cutting the first main region and the second main region along a pair of third cutting lines that reach a second outline formed in the second cutting step and bottom ends in the second direction of the first main region and the second main region.

3. 3. The method for manufacturing a pouch container packaging material according to claim 2, wherein in the third cutting step, the third cutting line smoothly connects to a second outline formed by cutting along the second cutting line in the second cutting step.

4. 4. The method for manufacturing a pouch-container packaging material according to claim 1, wherein the first main body sheet material, the second main body sheet material and the top sheet material are a single original sheet.

5. The method further includes, before the sheet joining step, a step of preparing a laminated sheet of a first structural sheet material and a second structural sheet material, the laminated sheet having a filler filling portion formed therein, the filler filling portion being a joining region for sealing in a filler; In the sheet joining step, the first structural sheet material and the second structural sheet material are joined to the outer sides of the first main body sheet material, the second main body sheet material and the top sheet material, 5. A method for manufacturing a packaging material for a pouch container as described in any one of claims 1 to 4, wherein in the first folding process, the first cutting process, the second folding process and the second cutting process, the first structural sheet material and the second structural sheet material are folded and cut together with the first main body sheet material, the second main body sheet material and the top sheet material.

6. A first main body sheet material and a second main body sheet material facing each other in a first direction, and a top sheet material arranged on the top side of the first main body sheet material and the second main body sheet material in a second direction perpendicular to the first direction, a sheet joining portion which joins a first main region of the first main body sheet material and a second main region of the second main body sheet material at a pair of side seal portions spaced from each other in a third direction perpendicular to both the first and second directions, and which joins a first sub-region located on the top side in the second direction with respect to the first main region of the first main body sheet material, a second sub-region located on the top side in the second direction with respect to the second main region of the second main body sheet material, and the top sheet material at a top seal portion; a first folding portion that folds a first boundary line between the first main region and the first sub-region so that the first main region and the first sub-region overlap each other; a first cutting section that cuts the top sheet material, the second sub-region, the first main region, and the second main region along a first cutting line that crosses the first boundary line from the overlapping portion of the top sheet material and the second sub-region to the bottom side in the second direction; a second folding portion that folds a second boundary line between the second main region and the second sub-region in a valley manner so that the second main region and the second sub-region overlap each other; a second cutting unit that forms a top sheet from the top sheet material by cutting the top sheet material, the first sub-region, the first main region, and the second main region from the overlapping portion of the top sheet material and the first sub-region along a second cutting line that crosses the second boundary line to the bottom side in the second direction and intersects with a first outline line formed in the first cutting unit.

7. 7. The pouch container packaging material manufacturing apparatus according to claim 6, further comprising a third cutting unit that forms a first main body sheet from the first main body sheet material and a second main body sheet from the second main body sheet material by cutting the first main region and the second main region along a pair of third cutting lines that reach a second outline formed in the second cutting unit and bottom ends of the first main region and the second main region in the second direction.

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