Cup-shaped container

Abstract

To provide a cup-like container which can be inexpensively manufactured using a paper cup manufacturing facility, is excellent in long-term storage property of contents, is excellent in shape retention property between a body and a bottom body as a cup-like container that enables aseptic sterilization and retort sterilization, and enables heat fusion to a lid material without any hindrance.SOLUTION: A cup-like container 1 is composed of: a body 2 which is molded into a cylindrical shape by overlapping and joining both end edge parts of a blank 20A for a body, and has a flange part 23 folded outward on an upper opening edge; a bottom body molded so as to form a bottom part and a suspension part; and a laminate 20 composed of a metal foil layer and a heat fusible resin layer laminated on both surfaces thereof. The flange part has an upper surface part 23a extending outward in a radial direction from an upper end opening edge of the body, a lower surface part 23b that is folded downward from its tip and extends inward in a radial direction, and an intermediate interposed part 23c that is folded upward from the tip and extends outward in a radial direction between the upper surface part and the lower surface part, and is molded into a flat shape.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a cup-shaped container containing contents such as foods and beverages such as ice cream and yogurt.

Background Art

[0002] For example, as a container for filling and packaging semi-solid dairy products such as ice cream and yogurt, a paper cup-shaped container, that is, a paper cup, is generally used. A paper cup is usually formed by joining and integrating a body and a bottom body each made of a paper blank cut into a predetermined shape. More specifically, the body is formed into a cylindrical shape by overlapping and joining both end edges of a substantially fan-shaped body blank, and a folded-back portion folded inward is formed at the lower end opening edge, and a flange portion curled outward is formed at the upper end opening edge. The bottom body is a cross-sectionally substantially inverted U-shaped one formed by skirt-forming a substantially circular bottom body blank so that a hanging portion is formed on its outer peripheral portion. Then, the hanging portion of the bottom body is wrapped and joined to the folded-back portion of the body, whereby the body and the bottom body are integrated. Each of the body blank and the bottom body blank is made of a laminate having, for example, a paper layer made of general base paper, acid-resistant paper, coated paper, etc., and a polyethylene resin (PE) layer laminated on one or both sides of the paper layer (see, for example, Patent Document 1 below).

[0003] Also, as the material of each of the above blanks, a paper cup using a laminate formed by laminating a barrier layer made of aluminum foil or the like in addition to the paper layer and the polyethylene resin (PE) layer is also known (see, for example, Patent Document 2 below).

[0004] In addition, as a container for ice cream, yogurt, etc., those made of a plastic molded body such as polypropylene resin (PP) are also known (see, for example, Patent Document 3 below).

Prior Art Documents

Patent Documents

[0005] [Patent Document 1] Japanese Patent Application Publication No. 58-30955 [Patent Document 2] Japanese Patent Publication No. 2007-210639 [Patent Document 3] Japanese Patent Publication No. 2007-176505 [Overview of the Initiative] [Problems that the invention aims to solve]

[0006] However, while paper cups offer excellent productivity and can be manufactured cheaply, they have poor barrier properties and are not suitable for long-term storage of their contents. In the case of paper cups with a barrier layer such as aluminum foil, the long-term preservation of the contents is improved, but water can easily penetrate from the edges of the paper layer, making retort sterilization impossible. Furthermore, plastic containers incur high manufacturing costs and are not suitable for long-term storage of their contents.

[0007] To solve the above problems, the inventors previously proposed a cup-shaped container using a laminate consisting of a metal foil layer and a heat-sealable resin layer laminated on at least one of its two surfaces as the material for the blank for the body and the blank for the bottom (Japanese Patent Application No. 2019-106125). The cup-shaped container described above can be manufactured inexpensively using paper cup manufacturing equipment, offers excellent long-term storage for its contents, and can also be subjected to aseptic sterilization or retort sterilization.

[0008] In the case of the cup-shaped container described above, if the flange portion of the body does not have sufficient strength, the overall shape retention of the container will be insufficient, and there is a risk that problems may arise when heat-sealing the lid material to the upper surface of the flange portion. The objective of this invention is to provide a cup-shaped container that can be manufactured inexpensively using paper cup manufacturing equipment, has excellent long-term storage properties for its contents, can be subjected to aseptic sterilization and retort sterilization, has excellent shape retention, and can be heat-sealed to a lid without any problems. [Means for solving the problem]

[0009] To achieve the above objective, this invention comprises the following embodiments.

[0010] 1) A cup-shaped container comprising a body formed into a cylindrical shape by overlapping and joining the edges of both ends of a blank for the body, and having a flange portion bent outward at the upper opening edge, and a bottom body formed by shaping a blank for the bottom so that a bottom portion and a hanging portion extending downward from the outer peripheral edge of the bottom portion are formed, wherein the body and the bottom body are integrated by joining the outer surface of the hanging portion of the bottom body to the inner surface of the lower end of the body, The fuselage blank is formed from a laminate consisting of a metal foil layer and a heat-sealable resin layer laminated on at least one of the two surfaces of the metal foil layer that faces the inside of the fuselage, and the edges of both ends of the fuselage blank are joined by heat-sealing the heat-sealable resin layers that make up these overlapping surfaces. The blank for the base is formed from a laminate consisting of a metal foil layer and a heat-sealable resin layer laminated on at least one of the surfaces of the metal foil layer that is on the upper side of the base, and the inner surface of the lower end of the body and the outer surface of the hanging part of the base are joined by heat-sealing the heat-sealable resin layers that make up these surfaces. A cup-shaped container in which the flange portion has an upper surface portion extending radially outward from the upper end opening edge of the body, a lower surface portion folded downward from the tip of the upper surface portion and extending radially inward, and an intermediate intervening portion folded upward from the tip of the lower surface portion and extending radially outward between the upper surface portion and the lower surface portion, and is formed in a flattened shape.

[0011] 2) The upper surface portion, lower surface portion, and intermediate intervening portion of the flange portion are joined by heat-sealing the heat-sealing resin layers of the blank for the body that form surfaces that overlap each other, the cup-shaped container of 1) above.

[0012] 3) The cup-shaped container of 1) or 2) above, wherein the radial length of the intermediate intervening portion of the flange portion is 0.5 to 1 times the radial length of the lower surface portion.

[0013] 4) The cup-shaped container of any one of 1) to 3) above, wherein the intermediate intervening portion of the flange portion is formed so as to entirely or partially overlap the sealing region with the lid material on the upper surface of the flange portion when viewed from the plane.

[0014] 5) The blank for the body has an inner heat-sealing resin layer laminated on the surface on the inner side of the body among both surfaces of the metal foil layer, and an outer heat-sealing resin layer laminated on the surface on the outer side of the body among both surfaces of the metal foil layer, the thickness of the inner heat-sealing resin layer is 30 to 120 μm, and the thickness of the outer heat-sealing resin layer is 20 to 100 μm, the cup-shaped container of any one of 1) to 4) above.

Advantages of the Invention

[0015] According to the cup-shaped container of 1) above, the flange portion of the body has a three-layer structure composed of an upper surface portion, a lower surface portion, and an intermediate intervening portion, and its strength is enhanced, so that excellent shape retention is obtained as a whole container, and heat-sealing with the lid material can be performed without any trouble.

[0016] According to the cup-shaped containers of 2) to 5) above, the effects of the cup-shaped container of 1) above are more surely achieved.

Brief Description of the Drawings

[0017] [Figure 1] It is a perspective view of the cup-shaped container according to an embodiment of this invention. [Figure 2]A vertical cross-sectional view taken along line II-II of FIG. 1. In the figure, the portion surrounded by the dashed-dotted line A is an enlarged view of the portion surrounded by the dashed-dotted line a, and the portion surrounded by the dashed-dotted line B is an enlarged view of the portion surrounded by the dashed-dotted line b. [Figure 3] (a) is an enlarged cross-sectional view showing the layer structure of the laminate used as the material for the body blank, and (b) is an enlarged cross-sectional view showing the layer structure of the laminate used as the material for the bottom blank. [Figure 4] A horizontal cross-sectional view showing an enlarged view of the overlapping portion of the body in the cup-shaped container. [Figure 5] A vertical cross-sectional view showing an enlarged view of the flange portion of the body in the cup-shaped container. [Figure 6] (a) is a plan view of the body blank, and (b) is a perspective view of the body formed from the body blank. [Figure 7] (a) is a plan view of the bottom blank, and (b) is a perspective view of the bottom formed from the bottom blank. [Figure 8] A vertical cross-sectional view sequentially showing the forming process of the flange portion of the body in the cup-shaped container. [Figure 9] A vertical cross-sectional view showing a part of the manufacturing process of the cup-shaped container. [Figure 10] It shows the main part of the cup-shaped container of Example 2, and is a vertical cross-sectional view corresponding to FIG. 5. [Figure 11] It shows the main part of the cup-shaped container of Comparative Example 1, and is a vertical cross-sectional view corresponding to FIG. 5.

Embodiments for Carrying Out the Invention

[0018] Hereinafter, embodiments of this invention will be described with reference to FIGS. 1 to 11. In the following explanation, "top and bottom" refers to the top and bottom of the cup-shaped container, body, or base (for example, the top and bottom of Figures 2, 5, and 8-11), "inside" refers to the side of the cup-shaped container, body, or base closer to the center (for example, the top of Figure 4, and the right side of Figures 5, 8-11), and "outside" refers to the side of the cup-shaped container, body, or base further from the center (for example, the bottom of Figure 4, and the left side of Figures 5, 8-11).

[0019] Figures 1 and 2 show the overall structure of a cup-shaped container (1) according to an embodiment of the present invention, the container (1) is formed by joining together a body (2) molded from a body blank (20A) and a bottom (3) molded from a bottom blank (30A). The fuselage (2) is tapered and cylindrical, and as shown in Figure 6, it is formed by overlapping and joining the edges of both ends of a fan-shaped fuselage blank (20A). Therefore, the fuselage (2) has an overlapping portion (21) that extends along its height. Preferably, the upper corners of the outer edges of the fuselage blank (20A) that are on the outside of the fuselage (2) are rounded (20c) portions. This makes it possible to reduce the thickness of the upper end portion of the overlapping portion (21) of the fuselage (2), and facilitates the formation of the flange portion (23), which will be described later. A folded portion (22) is formed at the lower end opening edge of the fuselage (2), which is folded inward. Furthermore, a flange portion (23) that is bent outward is provided at the upper opening edge of the fuselage (2). Details of the flange portion (23) will be described later. The base (3) has a roughly inverted U-shaped cross-section, with a circular horizontal base (31) and a hanging portion (32) extending downward from the outer peripheral edge of the base (31). As shown in Figure 7, it is formed by drawing a circular base blank (30A) so that the hanging portion (32) is formed on its outer peripheral edge. Then, the outer surface of the hanging portion (32) of the base (3) is joined to the inner surface of the lower end (2a) of the body (2), and the folded portion (22) of the body (2) is joined to the inner surface of the hanging portion (32), thereby integrating the body (2) and the base (3) (see Figures 2 and 9).

[0020] Although not shown in the diagram, it is also possible to integrate the body (2) and the base (3) by a connecting structure in which the outer surface of the hanging portion (32) of the base (3) is joined only to the inner surface of the lower end (2a) of the body (2), without forming a folded portion (22) at the lower end opening edge of the body (2). With this configuration, even if there are some wrinkles in the hanging portion (32) when the base (3) is molded, the lower end (2a) of the body (2) and the hanging portion (32) of the base (3) can be reliably sealed without introducing air or other contaminants.

[0021] As shown in Figure 3(a), the fuselage blank (20A) consists of a metal foil layer (201), an inner heat-sealable resin layer (202) laminated on the inner side of the metal foil layer (2) that faces the fuselage (2), and the metal foil layer It is formed from a laminate (20) consisting of an outer heat-sealable resin layer (203) laminated on the outer surface of the body (2) of (201), and does not have a paper layer. Furthermore, as shown in Figure 3(b), the blank for the base (30A) is formed from a laminate (30) consisting of a metal foil layer (301), an upper heat-sealable resin layer (302) laminated on the upper side of the metal foil layer (301) that is the upper side of the base (3), and a lower heat-sealable resin layer (303) laminated on the lower side of the metal foil layer (301) that is the lower side of the base (3), and does not have a paper layer. The thickness of each laminate (20)(30) is preferably less than 250 μm, and more preferably less than 200 μm. By setting the thickness of each laminate (20)(30) within the above range, the step in the part of the flange portion (23) of the body (2) that is composed of the overlap portion (21) will not become too large, as is the case with paper cups that use a laminate with a thickness of about 250 to 400 μm as the blank material, and the lower end (2a) and folded portion (22) of the body (2) and the hanging part of the bottom (3) (32) Problems such as unstable connections are reliably avoided.

[0022] The metal foil layers (201) and (301) function as barrier layers to protect the contents from gas, water vapor, light, etc. As the metal foil constituting the metal foil layers (201)(301), aluminum foil, iron foil, stainless steel foil, copper foil, etc., can be used, but aluminum foil is preferably used. In the case of aluminum foil, either pure aluminum foil or aluminum alloy foil is acceptable, and either soft or hard is acceptable, but for example, annealed soft material (O material) of the A8000 series (especially A8079H and A8021H) classified in JIS H4160 is preferably used because it has excellent formability. Furthermore, when hard material (H material) is applied as the aluminum foil constituting the metal foil layer (201) (especially the metal foil layer (201) of the blank (20A) for the body), the strength of the flange portion (23) is increased, deformation of the flange portion (23) due to unexpected impacts is suppressed, and furthermore, the shape retention of the cup-shaped container (1) as a whole is considered to be improved. Both sides of the metal foil layers (201) and (301) are subjected to surface treatment such as chemical conversion treatment as necessary. Specifically, for example, on the surface of the degreased metal foil, 1) Phosphate and, Chromic acid and, An aqueous solution of a mixture containing at least one compound selected from the group consisting of metal salts of fluorides and nonmetal salts of fluorides. 2) Phosphate and, At least one resin selected from the group consisting of acrylic resins, chitosan derivative resins, and phenolic resins, An aqueous solution of a mixture containing at least one compound selected from the group consisting of chromic acid and chromium(III) salts. 3) Phosphate and, At least one resin selected from the group consisting of acrylic resins, chitosan derivative resins, and phenolic resins, At least one compound selected from the group consisting of chromic acid and chromium(III) salts, An aqueous solution of a mixture containing at least one compound selected from the group consisting of metal salts of fluorides and nonmetal salts of fluorides. After applying an aqueous solution of any of the above 1) to 3), a chemical conversion treatment is performed by drying to form a film. The coating formed on the surface of the metal foil layers (201) and (301) by the above chemical conversion treatment has a chromium deposition amount (per side) of 0.1 mg / m². 2 ~50mg / m 2 It is preferable to do so, and in particular, 2 mg / m² 2 ~20mg / m 2 It is preferable to do so. The thickness of the metal foil layers (201)(301) is preferably 40 to 200 μm, and more preferably 80 to 160 μm. By setting the thickness of the metal foil layers (201)(301) within the above range, sufficient barrier properties and formability can be obtained.

[0023] The heat-sealable resin layers (202)(203)(302)(303) constitute the inner and outer surfaces of the container (1) and serve to protect the metal foil layers (201)(301) and to provide moldability to the laminates (20)(30). They also function as heat-sealable layers when joining the edges of both ends of the body blank (20A) and when joining the lower end (2a) and folded portion (22) of the body (2) to the hanging portion (32) of the bottom (3). The heat-sealable resin layers (202)(203)(302)(303) are composed of, for example, general-purpose films such as heat-sealable polypropylene (PP) film or polyethylene (PE) film, or composite films made by laminating these, but unoriented polypropylene film (CPP), which has excellent heat resistance and draw-molding properties, is particularly preferred. In addition, the heat-sealable resin layers (202)(203)(302)(303) may be formed by coating layers such as maleic acid-modified polyethylene, maleic acid-modified polypropylene, ethylene vinyl acetate, epoxy resin, or shellac resin instead of the above films.

[0024] The thickness of the inner heat-sealable resin layer (202) of the fuselage blank (20A) is preferably 30 to 120 μm, more preferably 40 to 80 μm, and the thickness of the outer heat-sealable resin layer (203) is preferably 20 to 100 μm, more preferably 30 to 70 μm. The thickness of the upper heat-sealable resin layer (302) of the bottom blank (30A) is preferably 30 to 120 μm, more preferably 40 to 80 μm, and the thickness of the lower heat-sealable resin layer (303) is preferably 20 to 100 μm, more preferably 30 to 70 μm. By setting the thickness of the heat-fusible resin layers (202), (203), (302), and (303) within the above range, sufficient adhesive strength can be obtained at the joints between the edges of both ends of the fuselage blank (20A), and at the joints between the lower end (2a) and folded portion (22) of the fuselage (2) and the hanging portion (32) of the bottom body (3). In addition, the step difference in the portion of the upper surface of the flange portion (23) of the fuselage (2) that is composed of the overlap portion (21) can be made gentler, resulting in good sealing performance when sealed with the lid material. Furthermore, by setting the thickness of the inner heat-fusible resin layer (202) and the outer heat-fusible resin layer (203) of the fuselage blank (20A) within the above range, the strength of the flange portion (23) can be increased.

[0025] The lamination of the metal foil constituting the metal foil layers (201)(301) and the film constituting the heat-fusible resin layers (202)(203)(302)(303) is carried out, for example, by a dry lamination method via an adhesive layer (not shown). For the adhesive layer, for example, a two-component curing type polyester-polyurethane adhesive or a polyether-polyurethane adhesive is used. Due to the presence of the adhesive layer described above, even if the heat-sealable resin layers (202)(203) at both ends of the fuselage blank (20A) at the overlap portion (21) of the fuselage (2) thin out due to heat fusion, contact between the metal foil layers (201) is avoided, thus maintaining sealing performance. Furthermore, with the presence of the adhesive layer described above, even if the contents that permeate the heat-sealable resin layers (202)(203)(302)(303) are filled into the container (1), corrosion of the metal foil layers (201)(301) and leakage of the contents can be avoided.

[0026] In addition, the laminate (20) that constitutes the fuselage blank (20A) and the laminate (30) that constitutes the bottom blank (30A) are usually the same, but they may be made of different materials and / or have different thicknesses.

[0027] As shown in detail in Figure 5, the flange portion (23) of the body (2) has an upper surface portion (23a) extending radially outward from the upper end opening edge of the body (2), a lower surface portion (23b) that is folded downward from the tip of the upper surface portion (23a) and extends radially inward, and an intermediate intervening portion (23c) that is folded upward from the tip of the lower surface portion (23b) and extends radially outward between the upper surface portion (23a) and the lower surface portion (23b), and is formed in a flattened shape overall. With the above configuration, the strength of the flange portion (23) is increased, and consequently the shape retention of the container (1) as a whole is increased, and heat sealing with the lid material (4) that closes the opening of the container (1) can be performed without any problems. If the intermediate intervening portion (23c) is absent, the thickness of the flange portion (23) will be too thin, resulting in insufficient strength. Furthermore, the flange portion (23) may not be horizontal, or it may bend during molding, causing a wave-like phenomenon. Preferably, the upper portion (23a), the lower portion (23b), and the intermediate intervening portion (23c) are joined by heat-sealing the heat-fusible resin layers (202) and (203) of the fuselage blank (20A) that constitute their overlapping surfaces. This further increases the strength of the flange portion (23). The radial length (L1) of the intermediate intervening portion (23c) is preferably 0.5 to 1 times the radial length (L2) of the lower surface portion (23b), and more preferably 0.7 to 1 time (see Figures 5 and 10). If the radial length (L1) of the intermediate intervening portion (23c) is less than 0.5 times the radial length (L2) of the lower surface portion (23b), the effect of increasing the strength of the flange portion (23) may not be sufficiently obtained. Furthermore, the radial length of the gap between the upper surface portion (23a) and the lower surface portion (23b) will be longer, which may cause the radially outer portion of the flange portion (23) to deform during molding, resulting in a narrower seal width with the lid material and potentially insufficient seal strength with the lid material. Note that the radial lengths (L1) and (L2) mentioned above do not include the curved folded portion, and refer to the lengths of the horizontal portions of the intermediate intervening portion (23c) and the lower surface portion (23b) (see Figures 5 and 10). Furthermore, it is preferable that at least a portion of the intermediate intervening portion (23c) is formed so as viewed from above, it overlaps with the sealing region (231) between the flange portion (23) and the lid material (4) on the upper surface. More preferably, as shown in Figures 5 and 10, the intermediate intervening portion (23c) is formed so that its entirety overlaps with the sealing region (231) as viewed from above. With the above configuration, for example, heat sealing using hot plates (S1) and (S2) can be reliably performed to ensure good thermal fusion between the flange portion (23) and the lid material (4).

[0028] Next, an example of a method for forming a cup-shaped container (1) using the above laminates (20) and (30) will be described. First, the laminate (20) is punched out into a predetermined size fan shape to form a blank for the fuselage (20A) (see Figure 6(a)). Furthermore, the laminate (30) is punched out into a circular shape of a predetermined size to form a blank for the base (30A) (see Figure 7(a)), and this blank (30A) is formed by drawing using a mold (not shown) to create a base (3) with a roughly inverted U-shaped cross-section, consisting of a bottom (31) and a hanging part (32) (see Figure 7(b)). The resulting base (3) is wrinkle-free. Also, the corner portion between the bottom (31) and the hanging part (32) on the outer surface of the base (3) has a sharp corner. Then, the bottom body (3) is set on the top surface of a roughly frustoconical mold (not shown) so that the upper surface of its bottom (31) overlaps, and then the blank for the body (20A) is wrapped around the outer circumference of the mold, overlapping both ends, and then the inner heat-sealable resin layer (202) and the outer heat-sealable resin layer (203) that make up the overlapping surfaces of the overlapping portion (21) are heat-sealed to form a tapered cylindrical body (2). The means for heat-sealing the overlapping portion (21) may be heat sealing using a hot plate, high-frequency sealing, ultrasonic sealing, etc. Here, heat sealing is preferably performed under the following conditions: when the inner heat-fusible resin layer (202) and the outer heat-fusible resin layer (203) are made of unoriented polypropylene film (CPP), the sealing temperature is 160-220°C, the load is 80-200 kgf, and the sealing time is 1-5 seconds. Also, when the inner heat-fusible resin layer (202) and the outer heat-fusible resin layer (203) are made of polyethylene film (PE), the sealing is preferably performed under the following conditions: the sealing temperature is 140-220°C, the load is 80-200 kgf, and the sealing time is 1-5 seconds. In other words, in the case of heat sealing, it is preferable to heat both ends of the overlapped body blank (20A) from both sides at a temperature 20-40°C higher than the melting point of the resin constituting the heat-fusible resin layers (202) and (203). Furthermore, high-frequency sealing is preferably performed under conditions such as, for example, output: 0.5~1.5kW, sealing time: 3~5 seconds, distance from coil: 0.5~15mm, and load: 100~200kgf. Next, as shown in Figure 9, the lower end opening edge of the body (2) is folded inward, and the folded portion (22) is pressed against the hanging portion (32) of the base (3) using a disc-shaped rotating mold (not shown). Then, the inner heat-sealable resin layer (202), which forms the overlapping surface between the lower end (2a) of the body (2) and the folded portion (22) and the hanging portion (32) of the base (3), is heat-sealed to the upper heat-sealable resin layer (302) and the lower heat-sealable resin layer (303), thereby joining and integrating the body (2) and the base (3). The heat sealing of these heat-sealable resin layers (202), (302), and (303) is usually performed by heat sealing using a hot plate or the like, but it may also be performed by high-frequency sealing or ultrasonic sealing. The preferred conditions for heat sealing and high-frequency sealing are the same as those for heat fusion of the overlapping portion (21) of the body (2). Furthermore, as shown in Figure 8, the upper opening edge of the body (2) is curled outward using a predetermined curl molding die (not shown), and then the flange portion (23) is formed by heating it at a predetermined temperature using a hot plate (not shown) and applying pressure in the vertical direction with a predetermined load to form a flattened shape consisting of an upper portion (23a), a lower portion (23b), and an intermediate intervening portion (23c). Here, the heating temperature during flange portion (23) formation is set to 150-250 kgf, as softening the resin constituting the overlapping inner heat-fusible resin layer (202) and / or outer heat-fusible resin layer (203) of the flange portion (23) and press-molding it improves the adhesion between the upper surface (23a), lower surface (23b), and intermediate intervening portion (23c) and increases strength. However, exceeding the melting point of the resin will roughen the surface of the flange portion (23). Therefore, the temperature is preferably set to 10-20°C lower than the melting point of the resin, i.e., 120-150°C. Furthermore, the pressurizing load during flange portion (23) formation is preferably set to 150-250 kgf, as too low a load weakens the adhesion between the three layers (23a), (23b), and (23c), while too high a load causes significant damage to the aluminum foil, etc., constituting the metal foil layer (201). In this way, the cup-shaped container (1) shown in Figures 1 and 2 is obtained.

[0029] Referring to Figure 4, in the overlap portion (21) of the body (2) of the cup-shaped container (1), the total thickness (T1) of the inner heat-sealable resin layer (202) and the outer heat-sealable resin layer (203) that are heat-sealed to each other at both ends of the body blank (20A) is preferably 8 to 150 μm, and more preferably 16 to 80 μm. If the total thickness (T1) is less than 8 μm, the sealing performance of the overlap portion (21) may be insufficient. On the other hand, if the total thickness (T1) exceeds 150 μm, the barrier performance of the overlap portion (21) may be impaired. Furthermore, in the overlap portion (21) of the fuselage (2), the overlap width (W1) of the metal foil layers (201) (201) at both ends of the fuselage blank (20A), as viewed from the thickness direction, is preferably 2 to 10 mm, and more preferably 4 to 8 mm. If the above overlap width (W1) is less than 2 mm, the barrier properties of the overlap portion (21) may be impaired, and the seal width may become too small, resulting in insufficient sealing. On the other hand, if the above overlap width (W1) exceeds 10 mm, the width of the overlap portion (21) becomes unnecessarily large, leading to increased costs. In addition, due to the difference in stress between the inner portion (one end edge of the fuselage blank (20A)) and the outer portion (the other end edge of the fuselage blank (20A)) of the overlap portion (21), cosmetic defects such as wrinkles may occur in the inner portion of the overlap portion (21). In addition to joining the ends of the blank body (20A) in the overlapping manner described above, the ends of the blank body (20A) may also be joined by overlapping them in a gusset shape. In this case, the outer heat-sealable resin layer (203) of the blank body (20A) can be omitted. Furthermore, it is preferable that the gusset portion is folded to one side so as to overlap with the outer surface of the body (2) and joined to that outer surface, so as not to get in the way when holding the body (2) by hand or when drinking the liquid filled in the container (1) from the upper opening edge of the body (2). The width (overlap) of the gusset portion of the body (2) is preferably 5 to 20 mm, more preferably 10 to 18 mm. If the above width is less than 5 mm, it may become difficult to seal the gusset portion. On the other hand, if the above width exceeds 20 mm, the width of the joint becomes unnecessarily large, leading to increased costs. Furthermore, when the joint is folded to one side so that it overlaps with the outer surface of the body (2) and joined to the outer surface, there is a risk of cosmetic defects such as wrinkles forming in the joint.

[0030] Furthermore, as shown in Figure 4, it is preferable that the inner end surface of the fuselage blank (20A) located inside the fuselage (2) is covered by an inner resin reservoir (R1) formed when the inner heat-sealable resin layer (202) and the outer heat-sealable resin layer (203), which constitute the overlapping surfaces of both ends of the fuselage blank (20A), are heat-sealed. Although not shown in the figure, the outer end surface of the fuselage blank (20A) located outside the fuselage (2) may also be covered by an outer resin reservoir formed when the inner heat-sealable resin layer (202) and the outer heat-sealable resin layer (203), which constitute the overlapping surfaces of both ends of the fuselage blank (20A), are heat-sealed. The inner resin reservoir (R1) and outer resin reservoir described above are formed when the overlapping edges of the fuselage blank (20A) are heat-sealed together. Parts of the inner heat-sealable resin layer (202) and outer heat-sealable resin layer (203) that make up these overlapping surfaces melt, and the molten resin is pushed out in the width direction of the overlapping portion (21) by the pressure applied during heat sealing. Furthermore, the inner resin reservoir (R1) is also formed by the inner heat-sealable resin layer (202) and outer heat-sealable resin layer (203) that constitute the inner end face (204) of the fuselage blank (20A), as well as by the molten resin of a portion of the inner heat-sealable resin layer (202) adjacent to the inner end face (204). The outer resin reservoir is also thought to be formed by the inner heat-sealable resin layer (202) and outer heat-sealable resin layer (203) that constitute the outer end face (205) of the fuselage blank (20A), as well as by the molten resin of a portion of the outer heat-sealable resin layer (203) adjacent to the outer end face (205). These resin reservoirs (R1) can be formed, for example, by controlling the sealing conditions during heat fusion (seal temperature, pressure, sealing time, sealing range, etc.) or by appropriately setting the configuration of the blank body (20A).

[0031] The cup-shaped container (1) of this embodiment provides the following effects. a) Since the blank for the body (20A) and the blank for the bottom (30A) are each formed from laminates (20) (30) consisting of a metal foil layer (201) (301) and heat-fusible resin layers (202) (203) (302) (303) laminated on both sides thereof, they can be manufactured inexpensively using paper cup manufacturing equipment. b) Since the laminates (20) and (30) used as the material for each blank (20A) and (30A) have metal foil layers (201) and (301), the contents have excellent long-term preservation properties. c) Compared to paper cups, the thickness of the blank for the body (20A) is smaller, so the step in the part of the upper surface of the flange portion (23) of the body (2) that is made up of the overlap portion (21) can be reduced, and therefore, sealing defects are less likely to occur when sealing the lid material (4) to the upper surface of the flange portion (23) of the container (1). In addition, when aseptic filling is performed, sterilizing solution is less likely to remain in the step on the upper surface of the flange portion (23). d) Since the bottom body (3) is formed by drawing a blank for the bottom body (30A), no wrinkles occur in the bottom body (3), and therefore, there is no risk of poor joining between the hanging part (32) of the bottom body (3) and the lower end (2a) and folded part (22) of the body (2), or of a decrease in barrier properties, as is the case with conventional paper cups. e) Compared to a paper cup, the thickness of the blank for the body (20A) and the blank for the bottom (30A) is smaller, so that the lower end (2a) and folded portion (22) of the body (2) and the hanging portion (32) of the bottom (3) can be stably joined. f) The corners between the bottom (31) and the hanging part (32) on the outer surface of the bottom body (3) can be made sharp, so when aseptic filling is performed, it is less likely that sterilizing solution will remain at the boundary between the upper surface of the bottom body (3) and the inner circumference of the body (2) of the cup-shaped container (1). g) Since the laminates (20) and (30) used as the material for each blank (20A) and (30A) do not have a paper layer, retort sterilization can be performed without any problems. h) The flange portion (23) of the body (2) has a three-layer structure consisting of an upper portion (23a), a lower portion (23b), and an intermediate intervening portion (23c), thereby increasing its strength and, consequently, improving the overall shape retention of the container (1), and also allowing for heat fusion with the lid material (4) that seals the opening of the container (1) without any problems. i) In the overlap portion (21) of the body (2), the inner end face of the body blank (20A) located inside the body (2) is covered by an inner resin reservoir (R1) formed when the heat-sealable resin layers (202) (203) at both ends of the body blank (2) are heat-sealed together, and is not exposed to the contents. Therefore, deterioration due to delamination and corrosion of the inner end face is effectively suppressed, and is also preferable from a hygienic standpoint. Furthermore, in the overlap portion (21) of the body (2), if the outer end face of the body blank (20A) located outside the body (2) is covered by an outer resin reservoir formed when the heat-sealable resin layers (202) (203) at both ends of the body blank (2) are heat-sealed together, deterioration due to delamination and corrosion of the outer end face is effectively suppressed. [Examples]

[0032] Next, specific embodiments of this invention will be described, but this invention is not limited to these embodiments.

[0033] <Example 1> Approximately 3g / m² of two-component curing urethane adhesive was applied to both sides of a 100μm thick aluminum foil (A8021H-O) that had undergone chemical conversion treatment. 2 The material was applied, and a 30 μm thick unoriented polypropylene film (CPP) was dry-laminated. Then, a predetermined aging treatment was performed to cure the adhesive, thereby obtaining a laminate. Next, the resulting laminate was punched out into predetermined shapes to form blanks for the fuselage and base (see Figures 6 and 7). Then, using the blanks for the body and the blanks for the bottom, a cup-shaped container as shown in Figures 1 and 2 was fabricated using the same process as in the embodiment described above, and this was designated as Example 1. The resulting cup-shaped container uses 100 μm thick aluminum foil, and is therefore a container with good barrier properties that has almost no permeability of oxygen or water vapor. The dimensions of the cup-shaped container were as follows: (Dimensions of the cup-shaped container) • Inner diameter of the opening at the top of the cup-shaped container: 65mm • Inner diameter of the bottom of the cup-shaped container: 50mm • Flange width: 4mm • Radial length (L1) of the intermediate intervening portion of the flange: 3.5 mm • Radial length (L2) of the lower surface of the flange: 3.8 mm • Height of cup-shaped container: 95mm • Height of the base (folded-over portion (22)) of the cup-shaped container: 6 mm • Width of the overlapping section of the fuselage (overlap allowance): 8mm

[0034] <Example 2> As shown in Figure 10, the radial length (L1) of the intermediate intervening portion (23c) of the flange portion (23) was set to 2.5 mm (approximately 0.7 times the radial length (L2) of the lower portion (23b)), and a cup-shaped container (1X) was manufactured in the same manner as in Example 1, and this was designated as Example 2.

[0035] <Comparative Example 1> As shown in Figure 11, the flange portion (23) was made without an intermediate intervening portion and consisted of a two-layer structure of an upper portion (23a) and a lower portion (23b). The cup-shaped container (10) was manufactured in the same manner as in Example 1, and this was designated as Comparative Example 1.

[0036] <Verification of the seal suitability of the flange section> Approximately 3 g / m² of two-component curing urethane adhesive is applied to one side of a 12 μm thick aluminum foil (A8021H-O) that has been chemically treated on both sides. 2 After coating, a 12 μm thick polyethylene terephthalate (PET) film is dry-laminated, and approximately 3 g / m² of a two-component curing urethane adhesive is applied to the other side of the aluminum foil. 2 The material was applied, and a 30 μm thick easy-peel film for PP containers (Okamoto Co., Ltd., product name: TP-9) was dry-laminated onto it. Then, a predetermined aging treatment was performed to cure the adhesive, and a laminate was obtained. Next, the obtained laminate was punched out into a predetermined shape to produce a lid material with tabs. Five cup-shaped containers each of Examples 1 and 2 and Comparative Example 1 were prepared, and the lid material was heat-sealed to the flange portion of each container under the following sealing conditions: heating temperature of 190°C, pressure of 120 kgf, and sealing time of 1.5 seconds. Next, each cup-shaped container was held in place by hand at a 45° angle on a support stand, and the tabs of the lids were clamped with a tensile testing machine clamp and pulled straight up at a speed of 100 mm / min to open the lids. The degree of deformation (lift) of the flange portion at that time was then measured. In the case of the cup-shaped container of Example 1, the container was opened when the periphery of the flange portion was lifted by 1 mm or less relative to the horizontal plane. In the case of the cup-shaped container of Example 2, the container was opened when the periphery of the flange portion was lifted by 3 mm or less relative to the horizontal plane. In contrast, in the case of the cup-shaped container of Comparative Example 1, the container was opened after the periphery of the flange portion deformed by 5 mm or more relative to the horizontal plane, and the upper part of the body connected to the flange portion also deformed. [Industrial applicability]

[0037] This invention can be suitably used, for example, as a cup-shaped container for liquid foods, beverages, and the like. [Explanation of Symbols]

[0038] (1): Cup-shaped container (2): Torso (2a): Lower end of the fuselage (21): Overlapping section (23): Flange section (23a):Top part (23b): Bottom part (23c): Intermediate part (231): Sealing area with lid material (20A): Blank for fuselage (20 Set Laminate) (201): Metal foil layer (202): Inner heat-sealable resin layer (203):Outer heat-fusible resin layer (3): Bottom body (31):Bottom (32): Drooping part (30A): Blank for bottom body (30): Laminate (301):Metal foil layer (302): Upper heat-fusible resin layer (303): Lower heat-fusible resin layer (L1): Radial length of the intermediate intervening portion (L2): Radial length of the lower surface

Claims

1. A cup-shaped container comprising a body formed into a cylindrical shape by overlapping and joining the edges of both ends of a blank for the body, and having a flange portion bent outward at the upper opening edge, and a bottom body formed by shaping a blank for the bottom so that a bottom portion and a hanging portion extending downward from the outer peripheral edge of the bottom portion are formed, wherein the body and the bottom body are integrated by joining the outer surface of the hanging portion of the bottom body to the inner surface of the lower end of the body, The fuselage blank is formed from a laminate consisting of a metal foil layer and heat-sealable resin layers laminated on both sides of the metal foil layer, and does not have a paper layer. The edges of both ends of the fuselage blank are joined by heat-sealing the heat-sealable resin layers that make up these overlapping surfaces. The blank for the base is formed from a laminate consisting of a metal foil layer and a heat-sealable resin layer laminated on at least one of the surfaces of the metal foil layer that is on the upper side of the base, and the inner surface of the lower end of the body and the outer surface of the hanging part of the base are joined by heat-sealing the heat-sealable resin layers that make up these surfaces. The flange portion has an upper surface portion extending radially outward from the upper end opening edge of the body, a lower surface portion folded downward from the tip of the upper surface portion and extending radially inward, and an intermediate intervening portion folded upward from the tip of the lower surface portion and extending radially outward between the upper surface portion and the lower surface portion, and is formed in a flattened shape. A cup-shaped container in which the upper, lower, and intermediate flange portions are joined by heat-sealing the heat-sealable resin layers of the body blanks that make up these overlapping surfaces.

2. A cup-shaped container according to claim 1, wherein the radial length of the intermediate intervening portion of the flange is 0.5 to 1 times the radial length of the lower surface portion.

3. A cup-shaped container according to claim 1 or 2, wherein the intermediate intervening portion of the flange is formed such that, when viewed from a planar perspective, all or part of it overlaps with the sealing area with the lid material on the upper surface of the flange.

4. A cup-shaped container according to any one of claims 1 to 3, wherein the blank for the body has an inner heat-sealable resin layer laminated on the inner side of the metal foil layer, and an outer heat-sealable resin layer laminated on the outer side of the metal foil layer, the thickness of the inner heat-sealable resin layer is 30 to 120 μm, and the thickness of the outer heat-sealable resin layer is 20 to 100 μm.

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