Method for manufacturing blank materials and packaging containers

Abstract

To provide a packaging container formed from a sheet material and having a desired planar shape.SOLUTION: A packaging container has a box type body made of a first sheet material, having a bottom and side faces, with one face opened, a flat flange made of a ring type second sheet material different from the first sheet material, extended outward from the circumference of an opening of the body, and a liner material sealed by an inner face of the body and an outer face of the flange, and integrating the body and the flange.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a packaging container formed of a sheet material, a blank material used for manufacturing the packaging container, and a method for manufacturing the packaging container.

Background Art

[0002] In recent years, from the viewpoints of environmental protection and resource conservation, reduction of the resin usage amount in packaging containers has been demanded, and various packaging containers using paper have been studied. For example, Patent Document 1 describes a paper container mainly made of paper, which includes a paper container body assembled with one blank and an internal protective film layer.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Since the paper container described in Patent Document 1 is composed of one blank, it has been difficult to manufacture a packaging container having a shape other than a quadrangle. <庸

[0005] Therefore, an object of the present invention is to provide a packaging container having a desired planar shape formed using a sheet material, a blank material used for manufacturing the packaging container, and a method for manufacturing the packaging container.

Means for Solving the Problems

[0007] The blank material according to the present invention is used in the manufacture of a packaging container having a box-shaped main body having a bottom and side portions and one side open, a flat flange portion extending outward from the periphery of the opening of the main body, and a liner material that seals to the inner surface of the main body and the outer surface of the flange portion, integrating the main body and the flange portion. The blank material comprises a first sheet material in which a portion corresponding to the bottom and a portion corresponding to the side portion are integrally formed, and a second sheet material which is ring-shaped and corresponds to the flange portion and is separate from the first sheet material, with the surface of the first sheet material that becomes the inner surface of the main body and the surface of the second sheet material that becomes the back surface of the flange portion being detachably bonded together.

[0008] The method for manufacturing a packaging container according to the present invention uses the blank material described above and comprises the steps of: separating a first sheet material and a second sheet material; forming a box-shaped main body with one side open from the first sheet material; arranging the second sheet material so that its inner periphery aligns with the periphery of the opening of the main body; and integrating the main body and the flange by sealing a liner material to the inner surface of the main body and the outer surface of the flange. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a packaging container having a desired planar shape formed using a sheet material, a blank material used in the manufacture of a packaging container, and a method for manufacturing a packaging container. [Brief explanation of the drawing]

[0010] [Figure 1] Perspective view of a packaging container according to an embodiment [Figure 2] Cross-sectional view along the line II-II shown in Figure 1 [Figure 3] Figure 1 is a plan view showing the blank material used in the manufacture of the packaging container. [Figure 4] A schematic cross-sectional view illustrating the manufacturing method of the packaging container shown in Figure 1. [Figure 5] Perspective view of the packaging container according to Modification 1 [Figure 6]Figure 5 is a plan view showing the blank material used in the manufacture of the packaging container. [Figure 7] Perspective view of the packaging container according to modified example 2 [Figure 8] Figure 7 is a plan view showing the blank material used in the manufacture of the packaging container. [Modes for carrying out the invention]

[0011] Figure 1 is a perspective view of a packaging container according to an embodiment, and Figure 2 is a cross-sectional view along the line II-II shown in Figure 1.

[0012] The packaging container 100 comprises a main body 1, a flange 2, and a liner material 3.

[0013] The main body 1 has a box-like shape with one side open, and comprises a bottom 5 and four side sections 6a to 6d connected to the bottom 5. The bottom 5 and the side sections 6a to 6d are integrally constructed by folding a single first sheet material into a box shape.

[0014] The flange portion 2 is composed of a ring-shaped (frame-shaped) second sheet material and is provided to extend outward from the periphery of the opening (open surface) of the main body portion 1. The outer surface of the flange portion 2 (the upper surface in Figures 1 and 2) is formed flat, making it possible to seal a cover material (not shown) or the like. The second sheet material constituting the flange portion 2 is a separate component from the first sheet material constituting the main body portion 1.

[0015] The first and second sheet materials are preferably made of paper-based materials. For example, the base material for the first and second sheet materials may have a basis weight of 100 to 500 g / m². 2 Paperboard can be used. The basis weight of the paperboard used as the base material should be 190-400 g / m². 2If so, it is more preferable because it has excellent processability. The first sheet material and the second sheet material may have one or more layers as needed, such as a resin film, a barrier layer, a sealant layer, a paper protective layer, an ink layer (printing layer), or an overcoat varnish layer. However, in order to reduce the amount of resin used, it is preferable that the proportion of paper in each of the first and second sheet materials is 50% by mass or more. The layer configurations of the first and second sheet materials may be the same or different. Of the two sides of each of the first and second sheet materials, the side to which the liner material 3 described later is sealed is made of two sides that have welding properties to the liner material 3.

[0016] The liner material 3 is made of a resin film. The liner material 3 is sealed to the inner surface of the main body 1 (the inside of the box shape) and the outer surface of the flange 2, integrating the main body 1 and the flange 2 and providing strength to the entire packaging container 100. The material of the liner material 3 is not particularly limited, but a thermoplastic resin film with water resistance, airtightness, and heat sealability can be suitably used. The liner material 3 may be a single-layer film, or a laminated film in which multiple resin layers are laminated by extrusion or via an adhesive layer. Examples of thermoplastic resins that can be used for the liner material 3 include polyethylene (PE), polypropylene (PP), polyamide, polyester, ethylene-vinyl acetate copolymer (EVOH), ethylene-acrylic acid copolymer, polyvinyl alcohol, ethylene-vinyl alcohol copolymer, polybutene, polyvinylidene chloride, and polystyrene. For example, as the liner material 3, a polyethylene-based barrier multilayer film having a layer structure of PE (20 μm) / adhesive layer / EVOH (10 μm) adhesive layer / PE (20 μm) or a polypropylene-based barrier multilayer film having a layer structure of CPP (unoriented polyethylene, 20 μm) / adhesive layer / EVOH / adhesive layer / CPP can be used.

[0017] The liner material 3 may be sealed to the entire inner surface of the main body portion 1 and the entire outer surface of the flange portion 2. However, when the liner material 3 is configured to be separable from the main body portion 1, it is preferable to seal the liner material 3 to the entire outer surface of the flange portion 2 while sealing it partially to the inner surface of the main body portion 1. When the liner material 3 is sealed to the entire outer surface of the flange portion 2 and partially to a part of the inner surface of the main body portion 1, the flange portion 2 can be grasped and the liner material 3 can be peeled off from the main body portion 1, which is excellent in the disposability of the liner material 3 made of a resin film and the recyclability of the first sheet (main body portion 1) mainly made of paper. Incidentally, when a lid material or the like is sealed to the outer surface of the flange portion 2 of the packaging container 100, the sealing strength between the lid material or the like and the flange portion 2 is set to be smaller than the sealing strength between the liner material 3 and the flange portion 2.

[0018] Figure 3 is a plan view showing a blank material used for manufacturing the packaging container shown in Figure 1. More specifically, Figure 3(a) shows a first sheet material for forming the main body portion, Figure 3(b) shows a second sheet material for forming the flange portion, and Figure 3(c) shows a blank material in a state where the first sheet material and the second sheet material are detachably bonded.

[0019] As shown in Figure 3(a), the first sheet material 11 is a single member having a portion 13 for forming the bottom portion 5 shown in Figure 1 and portions 14a to 14d for forming the side surface portions 6a to 6d shown in Figure 1, respectively. The short dashed lines shown in Figure 3(a) represent the positions of the folding lines. A ruled line may be provided at the positions of the folding lines indicated by the short dashed lines. By folding the portions 14a to 14d in a valley fold at the positions of the short dashed lines in Figure 3(a), a box-shaped main body portion 1 having a bottom portion 5 and side surface portions 6a to 6d is formed.

[0020] As shown in Figure 3(b), the second sheet material 12 is a ring-shaped (frame-shaped) member having the same shape as the flange portion 2 shown in Figure 1.

[0021] The blank material 15 shown in Figure 3(c) is formed by placing the second sheet material 12 shown in Figure 3(b) on top of the first sheet material 11 shown in Figure 3(a) and applying a weak seal. That is, in the blank material 15, the inner surface of the main body portion 1 of the first sheet material 11 and the back surface (bottom surface in Figures 1 and 2) of the flange portion 2 of the second sheet material 12 are separated and bonded together. The method of bonding the first sheet material 11 and the second sheet material 12 is not particularly limited, and heat sealing, adhesive, heat sealing varnish, etc., can be used. However, the seal strength of the first sheet material 11 and the second sheet material 12 is preferably 5N / 15mmN / 15mm, and more preferably 3N / 15mm or less, so that they can be easily separated. By weakly sealing the first sheet material 11 and the second sheet material 12 in advance, the process of setting the first sheet material 11 and the second sheet material 12 into the mold during the manufacturing of the packaging container 100 can be easily performed. Furthermore, the weak seal allows the second sheet material 12 to be positioned in advance relative to the first sheet material 11, making the box-shape forming process easier.

[0022] Figure 4 is a schematic cross-sectional view illustrating the manufacturing method of the packaging container shown in Figure 1.

[0023] First, as shown in Figure 4(a), a blank material 15, as shown in Figure 3(c), is placed between a mold 21 having a recess complementary to the outer surface shape of the main body 1 and a mold 22 having a convex portion complementary to the inner surface shape of the main body 1. The blank material 15 is arranged such that the first sheet material 11 faces the mold 21 side and the second sheet material 12 faces the mold 22 side.

[0024] Next, the mold 22 is moved toward the mold 21, and the protrusion of the mold 21 is brought into contact with the second sheet material through the opening of the first sheet material 11, pressing the first sheet material 11 (part 13 shown in Figure 3(c)) and pushing the first sheet material 11 into the recess of the mold 21. During this process, the weak seal portion of the first sheet material 11 and the second sheet material 12 separates. As shown in Figure 4(b), when the protrusion of the mold 21 is fully fitted into the recess of the mold 22, the first sheet material 11 is bent along the recess of the mold 21 to form a box-shaped main body 1. The second sheet material 12 is positioned so that its entire surface is on the same plane, and its inner periphery (the inner periphery of the ring-shaped portion) substantially coincides with the periphery of the opening of the main body 1.

[0025] Next, as shown in Figure 4(c), the heated liner material 3 is placed, and as shown in Figure 4(d), the liner material is welded onto the main body 1 and flange 2 by pressure forming or vacuum forming.

[0026] The packaging container 100 can be manufactured through the above process.

[0027] As described above, the packaging container 100 according to this embodiment has excellent strength at the connection between the bottom 5 and the side portions 6a to 6d because the bottom 5 and side portions 6a to 6d are made of a single sheet material.

[0028] Furthermore, by forming a blank material 15 with the first sheet material 11 and the second sheet material 12 pre-sealed, the process of setting the first sheet material 11 and the second sheet material 12 into the mold during the manufacturing of the packaging container 100 can be easily performed. In addition, the pre-sealing allows the second sheet material 12 to be positioned relative to the first sheet material 11, making the box-shape molding process easier.

[0029] (Variation 1) Figure 5 is a perspective view of the packaging container according to Modification 1.

[0030] Figures 1 to 4 illustrate packaging containers with a rectangular planar shape, but the present invention is also applicable to packaging containers with shapes other than rectangular. For example, the packaging container 101 shown in Figure 5 is a packaging container with a circular planar shape, comprising a main body 1 having a bottom 5 and side parts 6, and an annular, flat flange 2 extending outward from the periphery of the opening of the main body 1. Similar to the packaging container 100 shown in Figures 1 to 4, the main body 1 and the flange 2 are integrated by a liner material 3.

[0031] Figure 6 is a plan view showing the blank material used in the manufacture of the packaging container shown in Figure 5. More specifically, Figure 6(a) shows the first sheet material for forming the main body, Figure 6(b) shows the second sheet material for forming the flange, and Figure 6(c) shows the blank material with the first and second sheet materials peelably bonded together.

[0032] As shown in Figure 6(a), the first sheet material 11 is a single member having a circular portion 18 for forming the bottom portion 5 shown in Figure 7 and a portion 19 for forming the side portion 6 shown in Figure 5. The dashed lines shown in Figure 6(b) indicate the positions of the folding lines. Scratch lines may be provided at the positions of the folding lines indicated by the dashed lines. By folding portion 19 in a valley fold at the positions of the dashed lines in Figure 6(a), a box-shaped main body portion 1 having a bottom portion 5 and side portions 4 is formed. In addition, as in the modified example 2, if the outer edge of the bottom portion 5 is not straight, the bottom portion 5 and side portions 4 can be formed by drawing with a mold for forming the main body portion 1.

[0033] As shown in Figure 6(b), the second sheet material 12 is an annular (frame-shaped) member with the same shape as the flange portion 2 shown in Figure 5.

[0034] The blank material 20 shown in Figure 6(c) is obtained by placing the second sheet material 12 shown in Figure 6(b) on top of the first sheet material 11 shown in Figure 6(a) and applying a weak seal. The weak sealing method and preferred seal strength for the first sheet material 11 and the second sheet material 12 are as described above. Furthermore, the method for manufacturing the packaging container 101 using the blank material 20 shown in Figure 6(c) is the same as that described in Figure 4, so a repeated explanation will be omitted.

[0035] In Modification 1, a packaging container 101 with a circular planar shape was described. However, in the present invention, since the parts constituting the packaging container are divided into a first sheet material 11 for constituting the bottom 5 and side 6 and a second sheet material 12 for constituting the flange 2, it is easy to design the first sheet material 11 and the second sheet material 12 to correspond to the desired planar shape, and it becomes possible to manufacture packaging containers with planar shapes other than square or circular.

[0036] (Modification 2) Figure 7 is a perspective view of the packaging container according to Modification 2.

[0037] The packaging container 101 shown in Figure 7 further comprises flap portions 7a to 7d connected to the inner periphery of the flange portion 2. In the state of the packaging container 101, the flap portions 7a to 7d overlap with the side portions 6a to 6d of the main body portion 1, respectively. By overlapping the portion made of the first sheet material (part of the side portions 6a to 6d) with the portion made of a second sheet material different from the first sheet material (flap portions 7a to 7d), the rigidity near the opening of the packaging container 101 can be increased, thereby increasing the strength of the packaging container 101.

[0038] Figure 8 is a plan view showing the blank material used in the manufacture of the packaging container shown in Figure 7. More specifically, Figure 8(a) shows the first sheet material for forming the main body, Figure 8(b) shows the second sheet material for forming the flange, and Figure 8(c) shows the blank material with the first and second sheet materials peelably bonded together.

[0039] The first sheet material 11 shown in Figure 8(a) is the same as the one shown in Figure 3(a), and the second sheet material 12 shown in Figure 8(b) is a single member having a ring-shaped portion 20 for forming the flange portion 2 shown in Figure 1, and flap portions 7a to 7d connected to the inner periphery of portion 20. The short dashed lines shown in Figure 8(b) indicate the positions of the folding lines. Scratch lines may be provided at the positions of the folding lines indicated by the short dashed lines. The flap portions 7a to 7d are folded in a mountain fold at the positions of the short dashed lines in Figure 8(b) and overlapped with the side portions 6a to 6d formed by the first sheet material 11.

[0040] The blank material 16 shown in Figure 8(c) has a surface that will become the inner surface of the main body portion 1 on the first sheet material 11 shown in Figure 8(a), and a surface that will become the back surface (bottom surface in Figure 7) of the flange portion 2 on the second sheet material 12 shown in Figure 8(b), which are detachably bonded together. The weak sealing method and preferred sealing strength for the first sheet material 11 and the second sheet material 12 are as described above. By weakly sealing the first sheet material 11 and the second sheet material 12 in advance, the process of setting the first sheet material 11 and the second sheet material 12 in the mold during the manufacturing of the packaging container 101 can be easily performed. In addition, the weak sealing allows the second sheet material 12 to be positioned relative to the first sheet material 11 in advance, making the box-shape molding process easier. The method for manufacturing the packaging container 101 using the blank material 16 shown in Figure 8(c) is the same as that described in Figure 4, so a repeated explanation will be omitted.

[0041] The flap portion described in Modification 2 can also be provided when constructing a packaging container with a circular planar shape, as in Modification 1, or when constructing a packaging container with an irregular shape other than a square or circle, thereby improving the strength of the packaging container.

[0042] As explained above, since the bottom and side parts that constitute the main body and the flange part are made of separate sheet materials, it is possible to construct a packaging container with a circular, polygonal, or other irregular planar shape. [Industrial applicability]

[0043] This invention can be applied to packaging containers for packaging food and other articles. [Explanation of symbols]

[0044] 1. Main body 2 Flange section 3 Liner material 5 Bottom part 6, 6a~6d side part 11. First sheet material 12. Second sheet material 15, 16, 17 Blank material 100, 101, 102 Packaging containers

Claims

1. A blank material used in the manufacture of a packaging container having a box-shaped main body having a bottom and side portions and one side open, a flat flange portion extending outward from the periphery of the opening of the main body, and a liner material that seals the inner surface of the main body and the outer surface of the flange portion, and integrates the main body and the flange portion, A first sheet material having a portion corresponding to the bottom and a portion corresponding to the side portion integrally formed, It comprises a ring-shaped second sheet material that corresponds to the flange portion and is separate from the first sheet material, A blank material in which the inner surface of the main body portion of the first sheet material and the back surface of the flange portion of the second sheet material are detachably bonded together.

2. A method for manufacturing a packaging container using the blank material described in claim 1, A step of separating the first sheet material and the second sheet material, The process of forming a box-shaped main body with one side open from the first sheet material, The steps include: positioning the second sheet material such that its inner periphery lies along the periphery of the opening of the main body; A method for manufacturing a packaging container, comprising the step of integrating the main body portion and the flange portion by sealing a liner material to the inner surface of the main body portion and the outer surface of the flange portion.

Images