Workpiece for container, tube container, and manufacturing method for workpiece for container

Abstract

The present invention suppresses unintended deformation of a cylindrical part during formation of an end sealing part.　A cylindrical part 10 in a workpiece 1 for a container is obtained by forming a sheet S into a cylindrical shape. A molded body 20 comprises a resin component including a polyester-based resin as the main component. The molded body 20 is joined to one end part 13 of the cylindrical part 10. The one end part 13 annularly extends when viewed in an axis direction DA. The other end part 14 is open. In a state in which no folding line is formed and no substantial effect by external force is present, the cylindrical part 10 extends such that the dimension L1 in a first direction D1 orthogonal to the axis direction DA increases toward the other end part 14, and extends such that the dimension L2 in a second direction D2 orthogonal to both of the axis direction DA and the first direction D1 decreases toward the other end part.

Description

Container workpiece, tube container, and method for manufacturing container workpiece

[0001] The present disclosure relates to a workpiece for a container, a tube container, and a method for manufacturing the workpiece for a container.

[0002] International Publication No. 2023 / 238800 (Patent Document 1) discloses a tube container. The tube container includes a cylindrical body and a pouring portion. The cylindrical body is made of a single sheet. The sheet includes a first base material layer, a second base material layer, and a third base material layer. The first base material layer, the second base material layer, and the third base material layer each include a polyester resin as a main component. The pouring portion is joined to one end of the cylindrical body in the axial direction. The other end of the cylindrical body in the axial direction is closed. At the other end, sheets facing each other in a direction perpendicular to the axial direction of the cylindrical body are welded to each other.

[0003] WO 2023 / 238800

[0004] The end seal portion is formed by welding the sheets facing each other in a direction perpendicular to the axial direction of the tubular portion. When forming the end seal portion, the tubular portion is pressed in a direction perpendicular to the axial direction.

[0005] A molded body made of a resin composition containing a polyester resin as a main component has relatively high rigidity and is not easily bent. When such a molded body is joined to one end of a cylindrical part, the cylindrical part may be difficult to deform in a portion of the cylindrical part near the part where the molded body is joined.

[0006] Therefore, when the cylindrical portion is pressed to form the end seal, stress is concentrated in the vicinity of the portion where stress relief due to deformation is difficult. If the stress is concentrated excessively, the cylindrical portion may be unintentionally deformed, such as by being dented or bent.

[0007] The present disclosure has been made in consideration of the above-mentioned problems, and aims to provide a workpiece for a container that can suppress unintended deformation of the tubular portion when forming the end seal portion.

[0008] A container workpiece according to the present disclosure comprises a tubular portion and a molded body. The tubular portion is formed by forming a sheet into a tubular shape. The tubular portion includes one end in the axial direction of the tubular portion and another end located opposite the one end. The molded body is made of a resin composition containing a polyester-based resin as a main component. The molded body is joined to one end of the tubular portion. The one end extends in an annular shape when viewed from the axial direction. The other end is open. The tubular portion does not have a fold line and, in a state where there is no substantial action of external force, extends so that its dimension in a first direction perpendicular to the axial direction increases toward the other end, and its dimension in a second direction perpendicular to both the axial direction and the first direction decreases.

[0009] According to the present disclosure, unintended deformation of the tubular portion can be suppressed when the end seal portion is formed.

[0010] 1. A perspective view showing a container workpiece according to embodiment 1. A perspective view showing the container workpiece according to embodiment 1 from another direction. A front view showing the container workpiece according to embodiment 1. A side view showing the container workpiece according to embodiment 1. A plan view of the container workpiece according to embodiment 1 as viewed from one direction. A plan view of the container workpiece according to embodiment 1 as viewed from another direction. An exploded perspective view of the container workpiece according to embodiment 1. A schematic cross-sectional view of the container workpiece of FIG. 1 as viewed in the direction of the arrows VIII-VIII. A partial cross-sectional view enlarging region IX of FIG. 8. A partial cross-sectional view enlarging region X of FIG. 8. A partial cross-sectional view of the container workpiece of FIG. 1 as viewed in the direction of the arrows XI-XI. A partial cross-sectional view of the container workpiece of FIG. 1 as viewed in the direction of the arrows XII-XII. A partial cross-sectional view showing an enlarged region XIII in FIG. 12. A flow diagram showing a manufacturing method of a container workpiece according to embodiment 1. A schematic view showing sheets in a superposing process and a welding process. 18. FIG. 19 is a diagram showing a state immediately before a core jig is placed inside a cylindrical body in the deformation process of embodiment 1. FIG. 20 is a diagram showing a state immediately after a core jig is placed inside a cylindrical body in the deformation process of embodiment 1. FIG. 21 is a schematic cross-sectional view showing a tubular portion in a state immediately before insert molding is performed in the molded body joining process of embodiment 1. FIG. 22 is a partial cross-sectional view showing an enlarged view of region IXX in FIG. 18. FIG. 23 is a diagram showing a schematic state of a removal process of embodiment 1. FIG. 24 is a perspective view showing a tubular container according to embodiment 1. FIG. 25 is a flow diagram showing a manufacturing method for a tubular container according to embodiment 1. FIG. 26 is a perspective view showing a container workpiece according to a comparative example. FIG. 27 is a perspective view showing a tubular container according to embodiment 2. FIG. 28 is a side view showing a container workpiece according to embodiment 2. FIG. 29 is a partial cross-sectional view showing a first region of one end portion and its vicinity in embodiment 2. FIG. 29 is a flow diagram showing a manufacturing method for a container workpiece according to embodiment 2. FIG. 21 is a perspective view showing a container workpiece according to embodiment 3. FIG. 22 is a side view showing a container workpiece according to embodiment 3.

[0011] Hereinafter, a container workpiece and a manufacturing method thereof, as well as a tube container and a manufacturing method thereof according to each embodiment of the present disclosure will be described with reference to the drawings. In the following description of each embodiment, the same or corresponding parts in the drawings will be designated by the same reference numerals, and the description thereof will not be repeated.

[0012] Furthermore, in this specification, a component containing a polyester-based resin as a main component can mean that the content of the polyester-based resin in the component is 85% by mass or more, 90% by mass or more, 95% by mass or more, or 99% by mass or more.

[0013] (Embodiment 1) <Container workpiece> Fig. 1 is a perspective view showing a container workpiece according to embodiment 1. Fig. 2 is a perspective view showing the container workpiece according to embodiment 1 from another direction. Fig. 3 is a front view showing the container workpiece according to embodiment 1. Fig. 4 is a side view showing the container workpiece according to embodiment 1. Fig. 5 is a plan view of the container workpiece according to embodiment 1 as seen from one direction. Fig. 6 is a plan view of the container workpiece according to embodiment 1 as seen from another direction.

[0014] 1 to 6, a container workpiece 1 according to a first embodiment of the present disclosure includes a tubular portion 10 and a molded body 20. The tubular portion 10 includes a sheet base 11, a welded portion 12, one end portion 13, and the other end portion 14.

[0015] Fig. 7 is an exploded perspective view of the container workpiece according to the first embodiment. Fig. 8 is a schematic cross-sectional view of the container workpiece of Fig. 1 as viewed in the direction of the arrows VIII-VIII. As shown in Figs. 7 and 8, the tubular portion 10 is formed by forming a sheet S containing a polyester-based resin as a main component into a cylindrical shape. This increases the recyclability of the tubular portion 10. Specifically, the sheet S as a whole preferably contains 85% by mass or more of polyester-based resin, and more preferably 90% by mass or more.

[0016] The sheet base 11 is located between a first side edge SE1 in the surface direction DP of one sheet S and a second side edge SE2 of the sheet S located opposite the first side edge SE1. The welded portion 12 is formed by curving or bending the sheet S and welding the first side edge SE1 and the second side edge SE2 to each other in the thickness direction of the sheet S. The thickness direction is a direction perpendicular to the surface direction DP of the sheet S.

[0017] Thus, in this embodiment, the cylindrical portion 10 is made of one sheet S. First, the sheet S will be described in detail.

[0018] The sheet S before the first side end portion SE1 and the second side end portion SE2 are welded to each other has a rectangular outer shape when viewed in the thickness direction of the sheet S. Fig. 9 is an enlarged partial cross-sectional view of region IX in Fig. 8. That is, Fig. 9 shows a cross section of the sheet S that constitutes the tubular portion 10.

[0019] The sheet S includes a first base layer SL1, a second base layer SL2, and one or more reinforcing layers RL.

[0020] The first substrate layer SL1 is located toward the center of the tubular portion 10 in the radial direction of the tubular portion 10. In other words, the first substrate layer SL1 is the innermost layer of the tubular portion 10. The second substrate layer SL2 is located radially outward of the first substrate layer SL1 in the seat base 11 of the tubular portion 10. The second substrate layer SL2 can have the same configuration as the first substrate layer SL1. However, the second substrate layer SL2 may have a different configuration from the first substrate layer SL1. Hereinafter, when the configuration of "each of the first substrate layer SL1 and the second substrate layer SL2" is described, at least one of the first substrate layer SL1 and the second substrate layer SL2 may have that configuration.

[0021] Each of the first substrate layer SL1 and the second substrate layer SL2 contains a polyester-based resin as a main component. This improves the recyclability of the tube container when the container workpiece 1 is processed into the tube container. The polyester-based resin content of each of the first substrate layer SL1 and the second substrate layer SL2 is preferably 95% by mass or more, or 99% by mass or more. The polyester-based resin contained in the first substrate layer SL1 and the second substrate layer SL2 is not particularly limited as long as it can be used for the tubular portion 10. Examples of polyester-based resins include polyethylene terephthalate, polyethylene naphthalate, glycol-modified polyethylene terephthalate (PETG, polyethylene terephthalate in which a portion of the glycol component is modified with cyclohexanedimethanol (CHDM) or neopentyl glycol, etc.), polylactic acid, etc. Preferably, the first substrate layer SL1 contains only polyester-based resin as a resin component.

[0022] From the viewpoint of the recyclability of the tube container when the container workpiece 1 is processed into a tube container, the polyester-based resin in each of the first base layer SL1 and the second base layer SL2 is preferably homopolyethylene terephthalate, or polyethylene terephthalate such as copolymerized polyethylene terephthalate obtained by copolymerizing ethylene glycol, terephthalic acid, and a third component, or glycol-modified polyethylene terephthalate, and more preferably homopolyethylene terephthalate.

[0023] Furthermore, the polyester-based resin in the first base layer SL1 and the second base layer SL2 is preferably an amorphous polyester-based resin (such as amorphous polyethylene terephthalate or glycol-modified polyethylene terephthalate) from the viewpoints of welding the sheets S together at the welding portion 12 with relatively low energy and of efficiently transmitting ultrasonic vibrations. In particular, it is most preferable that each of the first base layer SL1 and the second base layer SL2 be amorphous homopolyethylene terephthalate from the viewpoints of both the recyclability of the tubular portion 10 and the adhesiveness of the sheets S at the welding portion 12 and the end seal portion described below.

[0024] From the viewpoint of reducing the environmental load, it is preferable that the polyester-based resin in each of the first substrate layer SL1 and the second substrate layer SL2 is made from recycled materials or biomass materials, but from the viewpoint of storing contents inside the tubular portion 10, it is also preferable that the polyester-based resin in the first substrate layer SL1 is made from virgin materials.

[0025] The first base layer SL1 may be a monolayer film or a part of a laminate film. The films (monolayer films or laminate films) constituting each of the first base layer SL1 and the second base layer SL2 are preferably unstretched films or uniaxially stretched films. This suppresses crystallization of the surfaces of the first base layer SL1 and the second base layer SL2, improving the weldability between the first base layer SL1 and the second base layer SL2 when performing ultrasonic welding (described later) to form the tubular portion 10. Furthermore, the adhesion between the sheets S in the tubular portion 10 and the end seal portion (described later), as well as the bond strength between the tubular portion 10 and the molded body 20, are improved.

[0026] From the viewpoint of improving the adhesiveness and bonding strength described above, it is particularly preferable that the films constituting each of the first base layer SL1 and the second base layer SL2 are unstretched films.

[0027] The one or more reinforcing layers RL may be two or more reinforcing layers RL, or may be three or more reinforcing layers RL. The one or more reinforcing layers RL are disposed between the first base material layer SL1 and the second base material layer SL2. By including one or more reinforcing layers RL in the sheet S, the drop strength of the tube container can be improved when the container workpiece 1 is processed into a tube container.

[0028] The reinforcing layer RL also contains a polyester-based resin as a main component. The polyester-based resin of the reinforcing layer RL is preferably homopolyethylene terephthalate, polyethylene terephthalate such as copolymerized polyethylene terephthalate obtained by copolymerizing ethylene glycol, terephthalic acid, and a third component, glycol-modified polyethylene terephthalate, or polybutylene terephthalate (PBT). It is also preferable that the reinforcing layer RL contains only a polyester-based resin or polybutylene terephthalate as a resin component.

[0029] From the standpoint of recyclability, the polyester resin of the reinforcing layer RL is preferably homopolyethylene terephthalate, or polyethylene terephthalate such as copolymerized polyethylene terephthalate obtained by copolymerizing ethylene glycol, terephthalic acid, and a third component, or glycol-modified polyethylene terephthalate, and more preferably homopolyethylene terephthalate.

[0030] From the viewpoint of reducing the environmental load, it is preferable that the polyester-based resin in the reinforcing layer RL is made from recycled or biomass raw materials, but from the viewpoint of reducing the cost of forming the tubular portion 10 and the end seal portion described later, it is also preferable that the polyester-based resin in the reinforcing layer RL is made from virgin raw materials.

[0031] From the viewpoint of further reducing the drop strength of the tube container obtained by processing the container workpiece 1, it is also preferable that the polyester-based resin of the reinforcing layer RL is polybutylene terephthalate. Polybutylene terephthalate has higher impact strength than polyethylene terephthalate. Therefore, by using polybutylene terephthalate as the polyester-based resin of the reinforcing layer RL, the recyclability of the tube container can be improved while further reducing breakage of the tube container when dropped. Furthermore, films containing polybutylene terephthalate have superior refraction resistance compared to films containing polyethylene terephthalate. Therefore, including polybutylene terephthalate as the polyester-based resin of the reinforcing layer RL can reduce the formation of pinholes in the tube container when forming fold lines by squeezing the tube container, for example. Furthermore, films containing polybutylene terephthalate have higher rigidity (specifically, tensile modulus, etc.) compared to films containing polyamide. Therefore, by including polybutylene terephthalate in the reinforcing layer RL rather than a polyamide-based resin, hot air welding for forming the end seal portion is facilitated.

[0032] The film constituting the reinforcing layer RL is preferably a biaxially stretched film. This allows the radial thickness of the tubular portion 10 to be thinner while maintaining its strength. In addition, when the reinforcing layer RL is a biaxially stretched film, the formation of the end seal portion becomes easier. Furthermore, when the sheet S includes a barrier layer BL described below, the film constituting the reinforcing layer RL is a biaxially stretched film, which can suppress cracking of the barrier layer BL. At least one layer of the multiple reinforcing layers RL may be a biaxially stretched film. However, it is preferable that each of all of the reinforcing layers RL is a biaxially stretched film.

[0033] The reinforcing layer RL may be part of a laminate film. When the reinforcing layer RL is part of a laminate film, the reinforcing layer RL may be configured as one layer of the laminate film together with the first base layer SL1 or the second base layer SL2, or may be laminated directly on the first base layer SL1 or the second base layer SL2 without an adhesive layer or the like interposed therebetween.

[0034] In this embodiment, the one or more reinforcing layers RL include a first reinforcing layer RL1, a second reinforcing layer RL2, and a third reinforcing layer RL3. The first reinforcing layer RL1 is located closest to the first base layer SL1 among the multiple reinforcing layers RL. The second reinforcing layer RL2 is located closest to the second base layer SL2 among the multiple reinforcing layers RL. The third reinforcing layer RL3 is located between the first reinforcing layer RL1 and the second reinforcing layer RL2.

[0035] From the viewpoint of achieving a balanced improvement in recyclability, drop strength, and refraction resistance, it is preferable that the polyester-based resin of each of the first reinforcing layer RL1 and the third reinforcing layer RL3 be homopolyethylene terephthalate, or polyethylene terephthalate such as copolymerized polyethylene terephthalate obtained by copolymerizing ethylene glycol, terephthalic acid, and a third component, or glycol-modified polyethylene terephthalate, and the polyester-based resin of the second reinforcing layer RL2 be polybutylene terephthalate. It is most preferable that the polyester-based resin of each of the first reinforcing layer RL1 and the third reinforcing layer RL3 be homopolyethylene terephthalate, and the polyester-based resin of the second reinforcing layer RL2 be polybutylene terephthalate.

[0036] In this embodiment, the sheet S further includes a barrier layer BL. The barrier layer BL may be located on the first base layer SL1 side as viewed from the reinforcing layer RL, or may be located on the opposite side of the reinforcing layer RL from the first base layer SL1. Specifically, the barrier layer BL may be located between the second base layer SL2 and the reinforcing layer RL. The sheet S does not necessarily include the barrier layer BL.

[0037] The material constituting the barrier layer BL is not particularly limited. Examples of the barrier layer BL include a ceramic barrier layer such as a silica barrier layer or an alumina barrier layer, and a metal barrier layer such as an aluminum barrier layer. The ceramic barrier layer may be a transparent vapor-deposited layer. In this embodiment, the barrier layer BL is laminated on the reinforcing layer RL by vapor deposition. Specifically, the barrier layer BL is laminated on the first reinforcing layer RL1 by vapor deposition. The sheet S may include multiple barrier layers BL. The multiple barrier layers BL may be laminated on multiple reinforcing layers RL by vapor deposition, respectively. In this embodiment, the sheet S includes only one barrier layer BL.

[0038] The sheet S further includes a plurality of adhesive layers AL. The plurality of adhesive layers AL are located between the first base layer SL1 and the barrier layer BL, between the second base layer SL2 and the second reinforcing layer RL2, and between the second base layer SL2 and the third base layer SL3. More specifically, the plurality of adhesive layers AL bond the first base layer SL1 and the barrier layer BL, bond the second base layer SL2 and the third reinforcing layer RL3, bond the first reinforcing layer RL1 and the second reinforcing layer RL2, and bond the second reinforcing layer RL2 and the third reinforcing layer RL3. The adhesive constituting the adhesive layers AL is not particularly limited, but it is preferable to use a dry lamination adhesive. Conventional dry lamination adhesives can be used.

[0039] The sheet S may further include a printed layer for improving design. The printed layer may be located between any layers as long as it is located radially outward from the first base layer SL1, which is the innermost layer of the tubular portion 10. For example, the printed layer may be located between the first base layer SL1 and the reinforcing layer RL, between the second base layer SL2 and the reinforcing layer RL, or between the reinforcing layers RL. The printed layer is preferably located on the opposite side of the reinforcing layer RL from the second base layer SL2.

[0040] It is also preferable that the sheet S does not include a printed layer in the welded portion 12. This prevents the printed layer from melting when the welded portion 12 is formed, thereby preventing the cosmetic appearance of the container workpiece from being reduced. It is also preferable that the sheet S does not include a printed layer in the other end 14 of the tubular portion 10. This prevents the printed layer from melting when the other end 14 is formed into an end seal portion, thereby preventing the cosmetic appearance of the tube container from being reduced.

[0041] The print layer is made of, for example, ink, such as oil-based ink (including solvent-based ink using an organic solvent as a solvent), water-based ink (including water-dispersed emulsion ink), or UV-curable ink.

[0042] The sheet S may further include an anchor coat layer. The anchor coat layer is located between the printed layer and another layer. The anchor coat layer increases the adhesion between the printed layer and another layer. The anchor coat layer can be formed using a conventionally known anchor coating agent, etc. When the sheet S includes a printed layer, a transparent protective layer may be further laminated on the printed layer. The transparent protective layer may be, for example, a resin film such as a polypropylene film, or a layer made of transparent ink.

[0043] The sheet S may further include a heat insulating layer. The heat insulating layer may be disposed between the first base layer SL1 and the second base layer SL2. This prevents heat applied to the first base layer SL1 during the formation of the end seal portion from being transferred to the second base layer SL2. The heat insulating layer may be disposed between the first base layer SL1 and the reinforcing layer RL. This prevents the heat from being transferred to the reinforcing layer RL. The heat insulating layer preferably has a thermal conductivity lower than that of the first base layer SL1. This effectively prevents the heat from being transferred to the second base layer SL2, etc., even if the heat insulating layer is relatively thin. The heat insulating layer may be a metal layer such as aluminum, but from the viewpoint of effectively suppressing heat conduction as described above, it is preferable that the heat insulating layer be made of a foam material made of a resin component such as polyethylene terephthalate.

[0044] The total thickness of the sheet S is preferably, for example, 12 μm or more and 250 μm or less from the viewpoint of forming the sheet S into a cylindrical shape and from the viewpoint of the handleability of the tube container obtained by processing the container workpiece 1. This makes it possible to impart good squeezability to the tube container obtained by processing the container workpiece 1. Squeezability refers to the property of being able to pour out the contents contained in the container by squeezing them out from the outside of the container.

[0045] Furthermore, since the sheet S contains a polyester resin as a main component, the total thickness of the sheet S is 12 μm or more and 250 μm or less, and therefore fold lines extending in the axial direction DA can be easily formed in the tube container obtained by processing the container workpiece 1. This allows the tube container to have even better squeezability.

[0046] From the viewpoint of ensuring the desired drop strength, the total thickness of the sheet S is preferably 100 μm or more, and more preferably 120 μm or more.

[0047] The first base layer SL1 and the second base layer SL2 are welded to each other when the welded portion 12 is formed. Therefore, it is preferable that each of the first base layer SL1 and the second base layer SL2 is thicker than at least each of the reinforcing layers RL. This reduces the influence of the resin component contained in the reinforcing layer RL on the strength of the weld between the sheets S when the welded portion 12 is formed. To further reduce this influence, the thickness of each of the first base layer SL1 and the second base layer SL2 is preferably 1.2 times or more, more preferably 3 times or more, and even more preferably 5 times or more, the thickness of the reinforcing layer RL. At least one of the first base layer SL1 and the second base layer SL2, or both, may be the thickest layers in the sheet S. In this specification, the thickness of the sheet S and its constituent layers refers to the sheet S and its constituent thickness in a state before the tubular portion 10 is formed, and corresponds to the radial thickness of the layer constituting the extension portion 113 (described in detail below) in the sheet base 11.

[0048] The thickness of each of the first base layer SL1 and the second base layer SL2 is preferably, for example, 10 μm or more, more preferably 60 μm or more, and may be, for example, 50 μm, 60 μm, 70 μm, 80 μm, 90 μm, or 100 μm.

[0049] The first base layer SL1 and the second base layer SL2 may have the same thickness. This allows the second base layer SL2 to be made of the same film as the film that forms the first base layer SL1. The thickness of the second base layer SL2 may be different from the thickness of the first base layer SL1.

[0050] The thickness of each of the reinforcing layers RL is preferably, for example, 5 μm or more and 200 μm or less, and more preferably 5 μm or more and 100 μm or less. From the viewpoint of reducing the total thickness of the sheet S, the thickness of each of the reinforcing layers RL may be, for example, 5 μm or more and 25 μm or less. The thickness of each of the reinforcing layers RL may be, for example, 12 μm, 15 μm, or 25 μm. When a barrier layer BL is vapor-deposited on the reinforcing layer RL, the total thickness of the reinforcing layer RL and the barrier layer BL may be, for example, 5 μm or more and 25 μm or less. The total thickness of the reinforcing layer RL and the barrier layer BL may be, for example, 12 μm, 15 μm, or 25 μm.

[0051] Next, the details of the sheet base 11 and the welded portion 12 will be described. Fig. 10 is an enlarged partial cross-sectional view of region X in Fig. 8. As shown in Figs. 8 and 10, the sheet base 11 has a first base end portion 111, a second base end portion 112, and an extension portion 113. The first base end portion 111 is a portion of the sheet S that is continuous with the second side end portion SE2. The second base end portion 112 is a portion of the sheet S that is continuous with the first side end portion SE1. The first base end portion 111 and the second base end portion 112 each extend from one end portion 13 to the other end portion 14 of the tubular portion 10 along the welded portion 12 (see Fig. 1, etc.).

[0052] The average thickness of the first base end 111 and the second base end 112 is different from the thickness (radial thickness of the extending portion 113) of the sheet S before the tubular portion 10 is formed. The first base end 111 and the second base end 112 may have both a portion that is thicker and a portion that is thinner in the radial direction than the thickness of the sheet S before the tubular portion 10 is formed, or may be composed of only the thick portion or only the thin portion.

[0053] 10, the radial thickness of the first base end 111 is thicker than the thickness of the sheet S (the radial thickness of the extending portion 113) before the cylindrical portion 10 is formed. The second base end 112 has a portion where the radial thickness is thinner than the thickness of the sheet S (the radial thickness of the extending portion 113) before the cylindrical portion 10 is formed, and a portion where the radial thickness is thicker than the thickness of the sheet S (the radial thickness of the extending portion 113).

[0054] The extending portion 113 is a portion located between the first base end portion 111 and the second base end portion 112 in the planar direction DP of the sheet S (the circumferential direction DC of the tubular portion 10) (see FIG. 8). The extending portion 113 has a substantially C-shaped outer shape when viewed in the axial direction DA of the tubular portion 10. The thickness of the extending portion 113 in the radial direction of the tubular portion 10 is equal to the thickness of the sheet S before the tubular portion 10 is formed.

[0055] The welded portion 12 is formed by curving or bending the sheet S, and welding the first side end portion SE1 and the second side end portion SE2 to each other while overlapping them in the thickness direction of the sheet S. In this embodiment, the outer peripheral surface of the first side end portion SE1 and the inner peripheral surface of the second side end portion SE2 are welded to each other (see FIG. 8).

[0056] The welded portion 12 has a band-like outer shape and extends along the axial direction DA of the tubular portion 10 when viewed from a first direction D1 perpendicular to the axial direction DA (see FIG. 4 ). The welded portion 12 extends continuously from one end 13 to the other end 14.

[0057] As shown in FIG. 10 , the welded portion 12 has a first leading edge 121, a second leading edge 122, a welded portion outer peripheral surface 123, and a welded portion inner peripheral surface 124. The first leading edge 121 is the leading edge of the first side end portion SE1 in the circumferential direction DC of the tubular portion 10. The first leading edge 121 is joined to the first base end portion 111. This increases the area of ​​the welded interface of the welded portion 12 relatively. Consequently, when peeling stress is applied to the welded portion 12, the stress is dispersed. This improves the weld strength of the welded portion 12. Note that in this embodiment, there is a boundary between the first base layer SL1 of the first side end portion SE1 and the first base layer SL1 of the first base end portion 111 at the first leading edge 121, but this boundary need not be present. That is, the first base material layer SL1 of the first side end portion SE1 and the first base material layer SL1 of the first base end portion 111 may be fused to each other and continuous in the circumferential direction DC.

[0058] Furthermore, the first leading edge 121 is located within the thickness of the first base end 111 when viewed along the circumferential direction DC. This reduces the chance of the first leading edge 121 coming into contact with an external object. In particular, in this embodiment, the outer peripheral surface of the first side end SE1 and the inner peripheral surface of the second side end SE2 are welded to each other to form the welded portion 12 (see FIG. 8 ). Therefore, since the first leading edge 121 is located within the thickness of the first base end 111 when viewed along the circumferential direction DC, this reduces the chance of the contents of the tube container obtained by processing the container workpiece 1 coming into contact with the first leading edge 121. In this case, it is sufficient that at least a portion of the first leading edge 121 is located within the thickness of the first base end 111 when viewed along the circumferential direction DC. However, as shown in FIG. 10, it is most preferable that the entire first tip edge 121 is located within the thickness of the first base end portion 111 when viewed in the circumferential direction DC.

[0059] Furthermore, the first interlayer portion SB1 between the first base material layer SL1 and one or more reinforcing layers RL at the first side end portion SE1 contacts the first base end portion 111 within the thickness of the first base end portion 111 when viewed in the circumferential direction DC. This makes it less likely that the contents of the tube container obtained by processing the container workpiece 1 will come into contact with the first interlayer portion SB1 between the first base material layer SL1 and one or more reinforcing layers RL at the first side end portion SE1.

[0060] 8, it is shown that a boundary surface is formed between the first side end portion SE1 and the second side end portion SE2. However, in this embodiment, as shown in FIG. 10, the second base material layer SL2 of the first side end portion SE1 and the first base material layer SL1 of the second side end portion SE2 are fused together to form an integral layer ML. Therefore, the first side end portion SE1 and the second side end portion SE2 do not clearly form a boundary surface, at least along the circumferential direction DC. Details of the integral layer ML will be described later.

[0061] The first leading edge 121 extends from one end 13 to the other end 14 in the axial direction DA of the tubular portion 10 (see FIG. 4). When viewed from the first direction D1, the first leading edge 121 is located at the center of the tubular portion 10 in the second direction D2. This positions the welded portion 12 at the side end of the tubular portion 10 when viewed from the second direction D2, thereby improving the design of the tubular container obtained by processing the container workpiece 1. The second direction D2 is perpendicular to both the axial direction DA and the first direction D1.

[0062] The second leading edge 122 is the leading edge of the second side end SE2 in the circumferential direction DC. The second leading edge 122 is joined to the second base end 112. This relatively increases the area of ​​the welded interface of the welded portion 12. Consequently, when peeling stress is applied to the welded portion 12, this stress is dispersed. Note that in this embodiment, there is a boundary between the second base material layer SL2 of the second side end SE2 and the second base material layer SL2 of the second base end 112 at the second leading edge 122, but this boundary does not have to be present. In other words, the second base material layer SL2 of the second side end SE2 and the second base material layer SL2 of the second base end 112 may be fused to each other and continuous in the circumferential direction DC.

[0063] Furthermore, the second leading edge 122 is located within the thickness of the second base end portion 112 when viewed along the circumferential direction DC. This reduces the chance of the second leading edge 122 coming into contact with an external object. In this case, it is sufficient that at least a portion of the second leading edge 122 is located within the thickness of the second base end portion 112 when viewed along the circumferential direction DC. However, as shown in FIG. 10 , it is most preferable that the entire second leading edge 122 is located within the thickness of the second base end portion 112 when viewed along the circumferential direction DC.

[0064] Furthermore, the second interlayer portion SB2 between the one or more reinforcing layers RL and the second base layer SL2 at the second side end portion SE2 is in contact with the second base end portion 112 within the thickness of the second base end portion 112 when viewed in the direction along the circumferential direction DC. This makes it difficult for other objects located outside the tubular portion 10 to come into contact with the second interlayer portion SB2, and ultimately makes it possible to suppress the occurrence of interlayer delamination between the one or more reinforcing layers RL and the second base layer SL2 due to the other objects coming into contact with the second interlayer portion SB2.

[0065] The second tip edge 122 extends from one end 13 to the other end 14 in the axial direction DA of the tubular portion 10 (see FIG. 4).

[0066] Next, the integrated layer ML will be described. As shown in Fig. 10, the integrated layer ML is formed as a single layer by fusing the second base layer SL2 of the first side end portion SE1 and the first base layer SL1 of the second side end portion SE2 together. Therefore, the first side end portion SE1 and the second side end portion SE2 are firmly connected to each other.

[0067] The integral layer ML is welded to the first base material layer SL1 of the first base end 111. Specifically, the integral layer ML does not form a boundary with the first base material layer SL1 of the first base end 111, and is continuous with the first base material layer SL1 of the first base end 111 in the circumferential direction DC. This allows the integral layer ML to be firmly connected to the first base material layer SL1 of the first base end 111.

[0068] Furthermore, the integral layer ML is welded to the second base material layer SL2 of the second base end 112. Specifically, the integral layer ML does not form a boundary with the second base material layer SL2 of the second base end 112, and is continuous with the second base material layer SL2 of the second base end 112 in the circumferential direction DC. This allows the integral layer ML and the second base material layer SL2 of the second base end 112 to be firmly connected to each other.

[0069] The welded portion outer peripheral surface 123 faces radially outward from the tubular portion 10. The welded portion outer peripheral surface 123 is configured by the second side end portion SE2. The welded portion outer peripheral surface 123 is unevenly formed. That is, the second side end portion SE2 has unevenness formed on the radially outer side. The unevenness formed on the welded portion outer peripheral surface 123 not only improves tactile identifiability but also makes it less likely for the tube container obtained by processing the container workpiece 1 to slip off when gripped. In the welded portion 12, unevenness is formed over the entire circumferential direction DC of the welded portion outer peripheral surface 123 from one end 13 to the other end 14 of the tubular portion 10.

[0070] In the welded portion 12 (second side end portion SE2), the second interlayer portion SB2 between one or more reinforcing layers RL and the second base material layer SL2 extends so as to follow the uneven shape of the welded portion outer peripheral surface 123. Concave or convex portions may be formed in a grid pattern on the welded portion outer peripheral surface 123. Note that, although the uneven shape is formed on the welded portion outer peripheral surface 123 in this embodiment, the uneven shape may also be formed on the welded portion inner peripheral surface 124.

[0071] Figure 11 is a partial cross-sectional view of the container workpiece of Figure 1, as viewed in the direction of the arrows XI-XI. Figure 12 is a partial cross-sectional view of the container workpiece of Figure 1, as viewed in the direction of the arrows XII-XII. As shown in Figures 1 to 6, 11, and 12, one end 13 is an end located on one side of the axial direction DA of the tubular portion 10. One end 13 extends in an annular shape as viewed in the axial direction DA (see Figure 5). One end 13 is joined to the molded body 20. Specifically, an inner surface 13S of one end 13 and the molded body 20 are joined to each other (see Figures 11 and 12).

[0072] The one end portion 13 is composed of one end portion of the seat base portion 11 in the axial direction DA and one end portion of the welded portion 12. In the one end portion 13 as well, the first tip edge 121 (see FIG. 10 ) is preferably located within the thickness of the first base end portion 111 when viewed in the circumferential direction DC. This makes the inner surface 13S of the one end portion 13 relatively smooth, allowing the inner surface 13S of the one end portion 13 to be easily joined to the molded body 20. In this embodiment, the inner circumferential surface 124 of the welded portion (see FIG. 10 ) is also smooth in the circumferential direction DC. This makes it easy to join the inner surface 13S of the one end portion 13 to the molded body 20.

[0073] The one end portion 13 includes a pair of first regions 131 and a pair of second regions 132 (see FIG. 1, etc.). The pair of first regions 131 are regions of the one end portion 13 located at both ends in the first direction D1. FIG. 13 is a partial cross-sectional view showing an enlarged view of region XIII in FIG. 12. As shown in FIGS. 12 and 13, the inner surface 13S of each of the pair of first regions 131 is inclined toward the center of the tubular portion 10 as it approaches an edge 131E of the first region 131 of the one end portion 13. The edge 131E is also an edge of the sheet S.

[0074] In the first region 131 of one end portion 13, the entire edge of the first base layer SL1 of the edge 131E is joined to the molded body 20. In the first region 131 of one end portion 13, at least a portion of the edge of the second base layer SL2 of the edge 131E is joined to the molded body 20. In the present embodiment, in the first region 131 of one end portion 13, the entire edge of the second base layer SL2 of the edge 131E is joined to the molded body 20. That is, in the first region 131 of one end portion 13, the entire edge 131E is joined to the molded body 20.

[0075] As shown in FIG. 1 and other figures, the pair of second regions 132 are regions of the one end portion 13 located at both ends in the second direction D2. When viewed from the second direction D2, the edge 132E of each of the pair of second regions 132 is convexly curved toward the other end portion 14 in the axial direction DA (see FIG. 3). The inner surfaces 13S of the pair of second regions 132 extend substantially parallel to the axial direction DA (see FIG. 11). At least a portion of the edge 132E of the second region 132 is joined to the molded body 20. The entire edge 132E of the second region 132 may be joined to the molded body 20. The edge 132E is also an edge of the sheet S.

[0076] The length along the axial direction DA of one end 13 joined to molded body 20 is, for example, preferably 3 mm or more, and more preferably 4 mm or more. From the viewpoint of relatively increasing the volume of the tubular container obtained by processing container workpiece 1, the inner diameter of one end 13 as viewed in the axial direction DA is preferably 40 mm or more. There is no particular upper limit to the inner diameter of one end 13, but the inner diameter of one end 13 may be 75 mm or less, or 60 mm or less.

[0077] 1 to 16, the other end 14 is an end of the tubular portion 10 that is located opposite to the one end 13. The other end 14 is open.

[0078] When no fold line is formed in the tubular portion 10 and when the tubular portion 10 is not substantially subjected to an external force, the other end 14 extends elliptically when viewed from the axial direction DA. Hereinafter, this state may be referred to simply as the "unloaded state." Note that the portion of the welded portion 12 where the sheet S is plastically deformed during the formation of the welded portion 12 is not included in the "fold line." Furthermore, the above-mentioned "no substantial external force acting on the tubular portion 10" includes a state in which no object other than the molded body 20 is in contact with the tubular portion 10 under atmospheric conditions at room temperature and normal pressure. In this specification, when the container workpiece 1 is described without specifically describing the state of the tubular portion 10, the container workpiece 1 when the tubular portion 10 is in an unloaded state is described.

[0079] In the no-load state, the major axis of the elliptical other end 14 extends along the first direction D1, and the minor axis of the elliptical other end 14 extends along the second direction D2.

[0080] In an unloaded state, the cylindrical portion 10 extends such that its dimension L1 in a first direction D1 perpendicular to the axial direction DA increases and its dimension L2 in a second direction D2 perpendicular to both the axial direction DA and the first direction D1 decreases toward the other end 14. Furthermore, in an unloaded state, the cylindrical portion 10 extends so that its entirety is curved in the circumferential direction relative to the axial direction DA. When viewed from the axial direction DA, the cylindrical portion 10 extends elliptically with respect to the axial direction DA, except for one end 13. The major axis of the elliptical cylindrical portion 10, excluding one end 13, extends along the first direction D1. The minor axis of the elliptical cylindrical portion 10, excluding one end 13, extends along the second direction D2.

[0081] In the unloaded state, the dimension L2 of the other end 14 in the second direction D2 is preferably at least 0.4 times the overall length along the circumferential direction of the other end 14. This allows the amount of deformation of the tubular portion 10 to be relatively small when the other end 14 is molded into the end seal portion.

[0082] As shown in Figures 1 to 7 and Figures 11 to 13, the molded body 20 is joined to one end 13 of the tubular portion 10. The molded body 20 is joined to the inner surface 13S of one end 13 of the tubular portion 10. The molded body 20 may close one end 13 of the tubular portion 10. In this embodiment, the contents contained in the tubular container obtained by processing the container workpiece 1 can be poured out from a pouring outlet formed in the molded body 20. If the molded body 20 does not have a pouring outlet, the contents may be taken out by cutting a part of the tubular portion 10 of the tubular container.

[0083] The molded body 20 includes a spout 21, a shoulder portion 22, and an extension portion 23. The spout 21 is capable of pouring out the contents accommodated in the tubular portion 10. The spout 21 is provided in the molded body 20 so as to face the side opposite the tubular portion 10 in order to pour out the contents. The spout 21 extends along the axial direction DA of the tubular portion 10 and has a generally cylindrical outer shape. The outer peripheral surface of the spout 21 may be configured to be engageable with a cap portion, which will be described later. The outer peripheral surface of the spout 21 may have a male thread-like outer shape, or may have a ridge portion extending circumferentially relative to the axial direction DA.

[0084] The shoulder portion 22 extends radially from the spout 21, centered at the spout 21, as viewed in the axial direction DA. The shoulder portion 22 extends from the spout 21 at an angle relative to the axial direction DA. The shoulder portion 22 has a frustum-shaped outer shape, more specifically, a truncated cone-shaped outer shape. The shoulder portion 22 may also have a flat plate-like outer shape extending perpendicular to the axial direction DA. The average thickness of the shoulder portion 22 is 1 mm or more. If the average thickness of the shoulder portion 22 is 1 mm or more, the rigidity of the molded body 20 is relatively high, thereby improving the drop strength of the container workpiece 1 and the tube container obtained by processing the container workpiece 1. The average thickness of the shoulder portion 22 is more preferably 1.1 mm or more, and even more preferably 1.2 mm or more. The thickness of the shoulder portion 22 at any point on the inner surface of the shoulder portion 22 is the shortest distance from that point to the outer surface of the shoulder portion 22. The average thickness of the shoulder portion 22 may be the thickness of the portion extending from the spout 21 to the extension portion 23 so as to be approximately uniform in thickness.

[0085] The extending portion 23 extends from the shoulder portion 22 along the axial direction DA and is joined to one end 13 of the tubular portion 10. Specifically, the extending portion 23 extends from the outer peripheral end of the shoulder portion 22. One end 13 of the extending portion 23 is joined to the outer peripheral surface of the extending portion 23 in the axial direction DA. The extending portion 23 extends in the opposite direction from the spout 21 side.

[0086] The maximum radial thickness of the extension portion 23 is 1 mm or more. The extension portion 23 has the greatest radial thickness at a portion facing the second region 132 of the one end portion 13 (see FIG. 11 ). Furthermore, the extension portion 23 has the greatest radial thickness at a portion facing the second region 132 of the one end portion 13 that connects to the shoulder portion 22. The maximum radial thickness of the extension portion 23 is more preferably 1.1 mm or more, and even more preferably 1.2 mm or more.

[0087] The molded body 20 is a molded body made of a resin composition containing a polyester-based resin as a main component. The polyester-based resin in the molded body 20 can be the same as the polyester-based resin in the first base layer SL1. From the viewpoint of recyclability of the tube container obtained by processing the container workpiece 1, it is preferable that the resin composition constituting the molded body 20 contains only a polyester-based resin as a resin component. The resin composition constituting the molded body 20 may further contain a conventionally known additive. Furthermore, in order to increase the flexibility of the molded body 20, the resin composition may contain a polybutylene terephthalate resin. Specifically, the resin composition may contain both a polyester-based resin similar to the polyester-based resin in the first base layer SL1 and a polybutylene terephthalate resin.

[0088] Furthermore, from the viewpoint of reducing the environmental load, it is preferable that the polyester-based resin in the resin composition is made from recycled materials or raw materials derived from biomass, but from the viewpoint of reducing the manufacturing costs of the molded body 20, it is also preferable that the polyester-based resin in the resin composition is made from virgin raw materials.

[0089] In this embodiment, the molded body 20 is an injection-molded member made of the resin composition. Specifically, the molded body 20 is an insert-molded member that is joined to one end 13 of the tubular portion 10 by injecting the resin composition. The molding method for the molded body 20 will be described in detail below.

[0090] The intrinsic viscosity (IV) value of the polyester resin material used to form the molded body 20 may be, for example, 0.60 or more and 0.90 or less when measured in accordance with JIS standard (K7390-1:2015). If the IV value is 0.60 or more and 0.90 or less, the molding of the molded body 20 becomes easy.

[0091] <Method of manufacturing the container workpiece> Next, a method of manufacturing the container workpiece 1 according to the first embodiment of the present disclosure will be described. Fig. 14 is a flow chart showing the method of manufacturing the container workpiece according to the first embodiment.

[0092] As shown in Figure 14, the manufacturing method for container workpiece 1 according to embodiment 1 of the present disclosure includes a cylindrical body forming process S1, a deformation process S2, a molded body joining process S3, and a removal process S4, in this order.

[0093] In the cylindrical body forming step S1, the sheet S is formed into a cylindrical shape to form a cylindrical body CB (see FIG. 16 described later). The cylindrical body forming step S1 includes a sheet preparation step S11, a stacking step S12, and a welding step S13.

[0094] In the sheet preparation step S11, a sheet S is prepared by laminating multiple layers together. For example, a first substrate layer SL1 made of a single-layer film and a reinforcing layer RL on which a barrier layer BL is vapor-deposited may be joined by an adhesive layer AL by dry lamination, and the reinforcing layer RL and a second substrate layer SL2 made of a single-layer film may be joined by an adhesive layer AL by dry lamination to prepare the sheet S. A commercially available laminated film including the first substrate layer SL1, the reinforcing layer RL, and the second substrate layer SL2 may also be prepared. When the sheet S includes multiple reinforcing layers RL, these multiple reinforcing layers may be joined by an adhesive layer AL by dry lamination.

[0095] Fig. 15 is a schematic diagram showing the sheet S in the overlapping step and the welding step. Fig. 15 shows the sheet S from a direction corresponding to the cross-sectional view direction similar to that of Fig. 8. As shown in Fig. 15, in the overlapping step S12, the prepared sheet S is curved into a cylindrical shape, and the first side end SE1 and the second side end SE2 are overlapped with each other.

[0096] In the welding step S13, the first side end SE1 and the second side end SE2 are sandwiched between an ultrasonic horn 5 positioned on one of the radially inner and outer sides of the cylindrically curved sheet S and an anvil 6 positioned on the other of the radially inner and outer sides, and ultrasonically welded together to form a cylindrical body CB having a welded portion corresponding to the welded portion 12 of the tubular portion 10. Note that in this specification and in the drawings, the same reference numerals are used to denote portions of the cylindrical body CB that are the same as or equivalent to those of the tubular portion 10, and the cylindrical body CB may be described.

[0097] In the welding process S13, the first side end portion SE1 and the second side end portion SE2 are vibrated by ultrasonic waves from the ultrasonic horn 5 and pressed in the thickness direction of the sheet S by the ultrasonic horn 5 and the anvil 6. In this embodiment, the ultrasonic horn 5 is located radially outside the sheet S, and the anvil 6 is located radially inside the sheet S. Alternatively, the ultrasonic horn 5 may be located radially inside the sheet S, and the anvil 6 may be located radially outside the sheet S. In this embodiment, the convex portions 511 of the concave-convex shape 51 locally press the second side end portion SE2 into the first side end portion SE1 at multiple locations. This facilitates mutual melting of the resin components of the first side end portion SE1 and the second side end portion SE2 at the welded portion 12 (see FIGS. 8 and 10 ). Consequently, the first side end portion SE1 and the second side end portion SE2 are firmly welded to each other. More specifically, the integral layer ML is easily formed at the welded portion 12 .

[0098] Fig. 16 is a diagram showing a state immediately before a core jig is placed inside a cylindrical body in the deformation process of embodiment 1. Fig. 17 is a diagram showing a state immediately after a core jig is placed inside a cylindrical body in the deformation process of embodiment 1.

[0099] 16(A) and 17(A) show the respective states as viewed from diagonally above, 16(B) and 17(B) show the states as viewed from the second direction D2, and 16(C) and 17(C) show the states as viewed from the first direction D1.

[0100] 16 and 17 , in the deformation step S2, a core jig 70 is placed inside the cylindrical body CB, thereby deforming the cylindrical body CB into a tubular portion 10 that extends so that the dimension L1 in the first direction D1 increases and the dimension L2 in the second direction D2 decreases toward the other end 14. The core jig 70 is inserted into the cylindrical body CB from the other end side of the cylindrical body CB. Hereinafter, the state of the core jig 70 when the cylindrical body CB is deformed into the tubular portion 10 as a result of inserting the core jig 70 may be referred to as the "internal arrangement state." Furthermore, hereinafter, when the configuration of the core jig 70 is described without describing the positional relationship between the core jig 70 and the tubular portion 10, the configuration of the core jig 70 in the internal arrangement state will be described.

[0101] The core jig 70 includes a first support portion 71, a second support portion 72, and an intermediate portion 73. In the internal arrangement state, the first support portion 71 is arranged to support the tubular portion 10 from the inner surface side. The first support portion 71 has a circular outer shape when viewed from the axial direction DA. The first support portion 71 has an outer diameter that is approximately the same as the inner diameter of the cylindrical body CB. The first support portion 71 is arranged to support the vicinity of one end portion 13 from the inner surface side.

[0102] The second support portion 72 is positioned apart from the first support portion 71 in the axial direction DA. The second support portion 72 is provided at a position farthest from the one end portion 13 so as to support the tubular portion 10 from the outer surface side. The second support portion 72 has an elliptical outer shape when viewed from the axial direction DA. The outer peripheral length of the second support portion 72 is approximately the same as the inner peripheral length of the cylindrical body CB. The major axis of the second support portion 72 extends along the first direction D1. The minor axis of the second support portion 72 extends along the second direction D2. In this embodiment, the second support portion 72 is provided so as to support the other end portion 14 or the vicinity of the other end portion 14 from the inner surface side.

[0103] The intermediate portion 73 connects the first support portion 71 and the second support portion 72 to each other. The intermediate portion 73 is provided so as to be spaced apart from the tubular portion 10 in the second direction D2 (see FIG. 17C). Both side surfaces of the intermediate portion 73 facing the second direction D2 extend in a narrowed manner toward the center in the second direction D2. In this embodiment, the intermediate portion 73 is also provided so as to be spaced apart from the tubular portion 10 in the first direction D1 (see FIG. 17B). In this embodiment, both side surfaces of the intermediate portion 73 facing the first direction D1 extend in a narrowed manner toward the center in the first direction D1.

[0104] In the molded body joining step S3, the molded body 20 is joined to the tubular portion 10 with the core jig 70 disposed therein. In this embodiment, the molded body 20 is joined to the tubular portion 10 by so-called insert molding.

[0105] 18A and 18B are schematic cross-sectional views showing the tubular portion 10 immediately before insert molding in the molded body joining step of embodiment 1. Fig. 18A shows a cross-sectional view taken along the center of the tubular portion 10 and in the first direction D1. Fig. 18B shows a cross-sectional view taken along the center of the tubular portion 10 and in the second direction D2.

[0106] 18 , the core jig 70 further includes a core mold part 74. The core mold part 74 protrudes from the first support part 71. The core mold part 74 is located opposite the intermediate part 73 when viewed from the first support part 71. The core mold part 74 may be arranged in the molded body joining step S3 as a separate part from the core jig 70. In the molded body joining step S3, first, a cavity mold 80 is arranged so as to cover the one end part 13 and the core mold part 74 from the outside.

[0107] FIG. 19 is a partial cross-sectional view showing an enlarged view of region IXX in FIG. 18 . As shown in FIGS. 18 and 19 , a portion of the tubular portion 10 adjacent to one end 13 is sandwiched between the first support portion 71 and the cavity mold 80. This results in the first support portion 71 being inserted into the space. Within the space formed by the core mold portion 74 and the cavity mold 80, the inner surfaces 13S of each of the pair of first regions 131 are inclined toward the center of the tubular portion 10 as they approach the edge 131E of the first region 131 at one end 13. Then, by filling the space with a molten resin composition, the molded body 20 is injection-molded onto the tubular portion 10. This substantially fixes the shape of the tubular portion 10 with the core jig 70 disposed therein.

[0108] In this way, when the molded body 20 is joined to one end portion 13, the first support portion 71 is provided so as to support the tubular portion 10 from the inner surface side at the position closest to the molded body 20. At this time, the second support portion 72 is provided so as to support the tubular portion 10 from the inner surface 131S side at the position farthest from the molded body 20. Furthermore, at this time, the intermediate portion 73 is provided so as to be separated from the tubular portion 10 in the second direction D2.

[0109] 20A and 20B are diagrams schematically illustrating the removal step of the first embodiment. Fig. 20A shows a view from diagonally above. Fig. 20B shows a view from the second direction D2. Fig. 20C shows a view from the first direction D1. As shown in Fig. 20, in the removal step S4, the core jig 70 is removed from the other end 14 of the tubular portion 10 to which the molded body 20 is joined.

[0110] During the process of removing the core jig 70 from the other end 14 of the tubular portion 10 (hereinafter sometimes referred to as the “removal process”), the first support portion 71 of the core jig 70 pushes open the tubular portion 10, which has a smaller dimension L2 in the second direction D2 than the cylinder CB, from the inside. As a result, during the removal process, the tubular portion 10 tends to shrink toward the intermediate portion 73 of the core jig 70 due to a reaction force from being pushed open. If no gap was formed between the intermediate portion 73 in the internal arrangement state and the tubular portion 10 in the second direction D2, the tubular portion 10 would stick to the intermediate portion 73, making it difficult to remove the core jig 70. For this reason, as described above, in this embodiment, a gap is provided in advance between the intermediate portion 73 in the internal arrangement state and the tubular portion 10 in the second direction D2 (see FIGS. 17 and 18 ). This prevents the tubular portion 10 from sticking to the intermediate portion 73 during the removal process. As a result, the core jig 70 can be easily removed from the other end 14 of the cylindrical portion 10.

[0111] The container workpiece 1 according to this embodiment is manufactured by the above-described steps. Next, a tubular container manufactured by processing this container workpiece 1 will be described.

[0112] <Tube container> Fig. 21 is a perspective view showing a tube container according to embodiment 1. As shown in Fig. 21, a tube container 1C according to this embodiment is formed by processing a container workpiece 1 (see Figs. 1 to 13). The tube container 1C includes a body portion 10C, a molded body 20, an end seal portion 30C, and a cap portion 40C. The molded body 20 in the tube container 1C has the same configuration as the molded body 20 in the container workpiece 1.

[0113] The body 10C is configured to be able to accommodate contents together with the molded body 20 and the end seal portion 30C. The body 10C is formed by deforming the tubular portion 10 except for the other end 14 due to the formation of the end seal portion 30C. However, one end 13 of the tubular portion 10 is not deformed. One end 13C of the body 10C has the same configuration as one end 13 of the tubular portion 10.

[0114] The trunk portion 10C further includes a main body portion 15C. The main body portion 15C is the portion of the trunk portion 10C excluding one end portion 13C. The one end portion 13C is formed by deforming the tubular portion 10 excluding one end portion 13 and the other end portion 14 due to the formation of the end seal portion 30C. The main body portion 15C is connected to the end seal portion 30C on the side opposite to the one end portion 13C. As the main body portion 15C extends toward the end seal portion 30C, its dimension in the first direction D1 increases and its dimension L2 in the second direction D2 decreases.

[0115] The end seal portion 30C is formed by welding together the inner surfaces 14S (see FIG. 2) of the other ends 14 of the tubular portion 10 that face each other in the second direction D2. The end seal portion 30C has a plate-like outer shape and extends along the first direction D1. The end seal portion 30C closes the side of the body portion 10C opposite the one end 13C.

[0116] 21 shows a tube container 1C containing a content. The content of the tube container 1C is not particularly limited, and may be a content contained in a conventional tube container. Examples of the content include cosmetics, foods, pharmaceuticals, and oral compositions. The content may contain at least one of an oil-soluble compound adsorbable to a polyolefin resin, an oily component, a volatile oily component, a flavoring, or a sweetener, or a surfactant.

[0117] In the tube container 1C according to this embodiment, the resin (first base layer SL1) that comes into direct contact with the contents is a polyester resin, which relatively prevents the components adsorbable to polyolefin resins from being adsorbed onto the tube container 1C, and prevents the tube container 1C from absorbing these components and swelling. Furthermore, because the welded portion 12 is firmly joined, it is possible to prevent the surfactant from leaking out of the tube container 1C from the portion corresponding to the welded portion 12.

[0118] Examples of oil-soluble compounds include tocopherols such as DL-α-tocopherol, D-δ-tocopherol, DL-α-tocopherol acetate, DL-α-tocopherol succinate, DL-α-tocopherol nicotinate, and DL-α-tocopherol linoleate; 3-methyl-4-isopropylphenol (also known as isopropylmethylphenol); and the like. For example, oil-soluble compounds are contained in the contents when the contents are pharmaceuticals, foods, or cosmetics. The tocopherols are known as vitamin E and its derivatives, and are incorporated into the contents in the hopes of anti-aging effects, peripheral vasodilating effects, and promoting blood circulation. 3-methyl-4-isopropylphenol is incorporated as a disinfectant and preservative into cosmetics such as acne cosmetics and pharmaceuticals.

[0119] Examples of oily components include triacylglycerol; diacylglycerol; natural oils and fats such as rapeseed oil, rapeseed oil, sesame oil, sunflower oil, corn oil, rice oil, grape oil, camellia oil, macadamia nut oil, olive oil, castor oil, safflower oil, soybean oil, tea seed oil, cocoa butter, coconut oil, hardened coconut oil, palm oil, Japan wax, hardened castor oil, beeswax, candelilla wax, carnauba wax, lanolin, liquid lanolin, jojoba wax, hard lanolin, polyoxyethylene lanolin alcohol ether, and polyoxyethylene cholesterol ether; hydrocarbon oils and fats such as liquid paraffin, ozokerite, squalene, paraffin, ceresin, petrolatum, and microcrystalline wax; isopropyl myristate, octyldodecyl myristate, and isopropyl palmitate. Examples of suitable oil-based ingredients include synthetic oil components such as ethanol, cholesteryl 12-hydroxystearate, ethylene glycol di-2-ethylhexyl, dipentaerythritol fatty acid ester, pentaerythritol tetra-2-ethylhexyl, glycerin tri-2-ethylhexyl, trimethylolpropane triisostearate, cetyl-2-ethylhexanoate, and castor oil fatty acid methyl ester; and linear polysiloxanes such as dimethylpolysiloxane, methylphenylpolysiloxane, and methylhydrogenpolysiloxane; cyclic polysiloxanes such as decamethylpolysiloxane, dodecamethylpolysiloxane, and tetramethyltetrahydrogenpolysiloxane; silicone resins capable of forming a three-dimensional network structure; and silicones such as silicone rubber. These oil-based ingredients are contained in the contents, for example, when the contents are foods such as mayonnaise or cosmetics.

[0120] Examples of volatile oily components include relatively low molecular weight silicone oils, relatively low molecular weight hydrocarbon oils, ether oils, etc. Silicone oils include linear silicones and cyclic silicones. Specific examples of silicone oils include linear dimethylpolysiloxanes and cyclic dimethylpolysiloxanes. The linear dimethylpolysiloxanes may be either linear or branched, and linear ones include dimethylpolysiloxane (1.5cs), dimethylpolysiloxane (2cs), etc., while branched ones include methyltrimethicone, tris(trimethylsilyl)methylsilane, tetrakis(trimethylsilyl)silane, etc. Cyclic dimethylpolysiloxanes include octamethylcyclotetrasiloxane, decamethylcyclopentasiloxane, dodecamethylcyclohexasiloxane, etc. Examples of hydrocarbons include isododecane, isotridecane, isohexadecane, light isoparaffin, light liquid isoparaffin, etc. Examples of ether oils include ethyl perfluorobutyl ether, etc. These volatile oily components are mainly contained in the contents when the contents are cosmetics such as sunscreen oil-in-water emulsion cosmetics.

[0121] Examples of fragrances include peppermint oil, spearmint oil, anise oil, eucalyptus oil, wintergreen oil, cassia oil, clove oil, thyme oil, sage oil, lemon oil, orange oil, mint oil, cardamom oil, coriander oil, mandarin oil, lime oil, lavender oil, rosemary oil, laurel oil, chamomile oil, caraway oil, marjoram oil, bay oil, lemongrass oil, origanum oil, pine needle oil, neroli oil, rose oil, jasmine oil, grapefruit oil, sweetie oil, yuzu oil, cinnamon bark oil, perilla oil, wintergreen oil, clove oil, and pi Natural fragrances such as menthol oil, tea tree oil, taban oil, star anise oil, fennel oil, diatomaceous oil, basil oil, iris concrete, peppermint absolute, rose absolute, orange flower, and nutmeg, or fragrances obtained by processing these natural fragrances (such as front-end cutting, back-end cutting, fractional distillation, liquid-liquid extraction, essence preparation, and powdered fragrance preparation); camphor, menthol, carvone, benzyl succinate, anethole, cineole, methyl salicylate, cinnamic aldehyde, eugenol, methyleugenol, 3-l-menthoxy Propane-1,2-diol, thymol, linalool, linalyl acetate, limonene, menthone, menthyl acetate, N-substituted-paramenthan-3-carboxamide, pinene, octyl aldehyde, citral, pulegone, carbeth acetate, anisaldehyde, ethyl acetate, ethyl butyrate, allyl cyclohexane propionate, methyl anthranilate, ethyl methylphenylglycidate, vanillin, undecalactone, hexanal, butanol, isoamyl alcohol, hexenol, dimethyl sulf Examples of flavorings include single flavorings such as methyl acrylate, cyclotene, furfural, trimethylpyrazine, ethyl lactate, ethyl thioacetate, ocimene, n-decyl alcohol, methyl acetate, citronellyl acetate, ethyl linalool, vanillin, and benzaldehyde; and compound flavorings such as strawberry flavor, apple flavor, banana flavor, pineapple flavor, grape flavor, mango flavor, butter flavor, milk flavor, fruit mix flavor, and tropical fruit flavor.These flavors are contained in the contents when the contents are oral compositions, for example.Flavors may also be contained in the contents as aroma components of foods such as wasabi, mustard, and the like.

[0122] Examples of sweeteners include saccharin, saccharin sodium, acesulfame potassium, stevia extract, stevioside, neohesperidyl dihydrochalcone, glycyrrhizin, perillartine, thaumatin, aspartylphenylalanine methyl ester, methoxycinnamic aldehyde, palatinose, palatinit, erythritol, maltitol, xylitol, lactitol, etc. These sweeteners are contained in the contents when the contents are, for example, an oral composition.

[0123] Examples of surfactants include anionic surfactants, cationic surfactants, amphoteric surfactants, and nonionic surfactants. Examples of anionic surfactants include fatty acid soaps, higher alkyl sulfates, alkyl ether sulfates, N-acylsarcosinic acid, higher fatty acid amide sulfonates, phosphate salts, sulfosuccinates, alkylbenzene sulfonates, higher fatty acid ester sulfates, N-acylglutamates, sulfated oils, POE-alkyl ether carboxylic acids, POE-alkyl allyl ether carboxylates, α-olefin sulfonates, higher fatty acid ester sulfonates, secondary alcohol sulfates, higher fatty acid alkylolamide sulfates, sodium lauroyl monoethanolamide succinate, N-palmitoyl aspartic acid ditriethanolamine, and sodium caseinate. Examples of cationic surfactants include alkyltrimethylammonium salts, alkylpyridinium salts, distearyldimethylammonium chloride, dialkyldimethylammonium salts, poly(N,N'-dimethyl-3,5-methylenepiperidinium) chloride, alkyl quaternary ammonium salts, alkyldimethylbenzylammonium salts, alkylisoquinolinium salts, dialkylmorphonium salts, POE-alkylamines, alkylamine salts, polyamine fatty acid derivatives, amyl alcohol fatty acid derivatives, benzalkonium chloride, and benzethonium chloride. Examples of amphoteric surfactants include imidazoline-based amphoteric surfactants and betaine-based surfactants. Examples of nonionic surfactants include polyoxyethylene hydrogenated castor oil, polyoxyethylene alkyl ethers, sucrose fatty acid esters, alkyl glycosides, polyoxyethylene-polyoxypropylene block copolymers, polyoxyethylene ethers of glycerin esters, fatty acid alkylolamides, and glycerin fatty acid esters.

[0124] <Method for manufacturing a tube container> Next, a method for manufacturing a tube container 1C will be described. As described above, the tube container 1C is formed by processing the container workpiece 1 (see FIGS. 1 to 13, etc.). Fig. 22 is a flow chart showing a method for manufacturing a tube container according to embodiment 1. As shown in Fig. 22, the method for manufacturing a tube container 1C according to embodiment 1 includes, in this order, a cap attachment step S5, a content filling step S6, and an end seal formation step S7.

[0125] In the cap attachment step S5, a preformed cap 40C is attached to the molded body 20 of the container workpiece 1 (see FIGS. 1, 2, and 21). In the content filling step S6, the contents are filled into the tubular portion 10 from the other end 14 side with one end 13 facing downward. Then, in the end seal formation step S7, the inner surfaces 14S (see FIG. 2) of the other end 14 of the tubular portion 10 facing each other in the second direction D2 are welded together to form the end seal portion 30C.

[0126] The specific method for forming the end seal portion 30C is not particularly limited. The end seal portion 30C may be formed, for example, by butting the inner surfaces 14S of the other end portion 14 of the tubular portion 10 together in the second direction D2 while being heated with hot air, thereby welding the first base material layers SL1 at the other end portion 14 together (see, for example, Figures 8 to 10 ). The end seal portion 30C may also be formed by ultrasonically welding the inner surfaces 14S of the other end portion 14 of the tubular portion 10 together. The tube container 1C is manufactured using the above manufacturing method.

[0127] Here, in order to further explain the features of the container workpiece 1 and the tubular container 1C according to this embodiment, a container workpiece and a tubular container according to a comparative example will be described below.

[0128] <Comparative example of container workpiece and tube container> Figure 23 is a perspective view showing a comparative example of a container workpiece. As shown in Figure 23, the cylindrical portion 910 of the comparative example of a container workpiece 901 has a constant dimension L1 in the first direction D1 and a constant dimension L2 in the second direction D2 from one end 913 to the other end 914. The cylindrical portion 910 of the comparative example of a container workpiece 901 has a cylindrical outer shape in an unloaded state. More specifically, the comparative example of a container workpiece 901 is formed by joining the cylindrical body CB of embodiment 1 to the molded body 20 while maintaining its shape.

[0129] Fig. 24 is a perspective view showing a tube container according to a comparative example. As shown in Fig. 24, the tube container 901C according to the comparative example is a tube container obtained by processing the container workpiece 901 according to the comparative example using the same method as the tube container manufacturing method according to embodiment 1. In the barrel portion 910C of the tube container 901C according to the comparative example, a recess DE is formed in a portion of the main body portion 915C located near one end portion 913C. The recess DE may be formed unintentionally on both sides of the main body portion 915C in the first direction D1.

[0130] The recess DE is formed during the end seal portion forming process in the comparative example. The reason for the formation of the recess DE is thought to be as follows. First, in the end seal portion forming process in the comparative example, the other end 914 (see FIG. 23 ) of the tubular portion 910 of the container workpiece 901 is butted in the second direction D2. Here, the tubular portion 910 is cylindrical. Therefore, when the other end 914 of the tubular portion 910 is butted against each other, the deformation amount of the tubular portion 910 is greater than the deformation amount in the first embodiment. Furthermore, since the sheet S contains a polyester-based resin as a primary component, it has a higher elastic modulus than sheets containing a polyolefin-based resin such as polyethylene as a primary component. The tubular portion 910 is formed by forming this high-elasticity sheet S into a cylindrical shape. Furthermore, since the molded body 920 contains a polyester-based resin as a primary component, it is a molded body made of a resin composition with a relatively high rigidity. Therefore, the extension portion 923 joined to the one end 913 is relatively difficult to bend. Therefore, due to the reaction caused by the expansion of the other end 914 of the cylindrical portion 910 and the surrounding area in the first direction D1, excessive stress is concentrated in the area near one end 913 of the cylindrical portion 910, compressing the cylindrical portion 910 toward the center in the first direction D1. This is thought to result in the unintentional formation of a recess DE (see FIG. 24 ).

[0131] Note that if the inner diameter of one end 913 is 40 mm or greater, the amount of deformation of the tubular portion 910 becomes particularly large, making it easier for the recess DE to be formed. Furthermore, if the average thickness of the shoulder portion 922 is 1 mm or greater, the extension portion 923 joined to the one end 913 becomes particularly difficult to bend relative to the shoulder portion 922. This causes the stress to concentrate more excessively, making it easier for the recess DE to be formed. Furthermore, if the maximum radial thickness of the extension portion 923 is 1 mm or greater, it becomes harder for the extension portion 923 to deform. This causes the stress to concentrate more excessively, making it easier for the recess DE to be formed.

[0132] <Configuration and effects of container workpiece according to embodiment 1> In contrast to the container workpiece 901 according to the comparative example, the tubular portion 10 in the container workpiece 1 according to embodiment 1 of the present disclosure has no fold lines and, in a state where there is no substantial action from external forces, extends so that the dimension L1 in a first direction D1 perpendicular to the axial direction DA increases toward the other end 14, and so that the dimension L2 in a second direction D2 perpendicular to both the axial direction DA and the first direction D1 decreases.

[0133] Because the tubular portion 10 has the above configuration when in the above state (i.e., in an unloaded state), the amount of deformation when the tubular portion 10 is pressed in the second direction D2 to deform the tubular portion 10 during the formation of the end seal portion 30C can be kept small. Consequently, unintended deformation of the tubular portion 10 can be suppressed when the tubular portion 10 is pressed in the second direction D2 to form the end seal portion 30C.

[0134] In this embodiment, the average thickness of the shoulder portion 22 is 1 mm or more, and the maximum thickness of the extension portion 23 in the radial direction is 1 mm or more.

[0135] Because molded body 20 is a molded body made of a resin composition containing polyester resin as a main component, shoulder portion 22 and extension portion 23 have the above-described configuration, making molded body 20 even less likely to bend even when an external force is applied. However, in this embodiment, tubular portion 10 extends so that dimension L1 in first direction D1 increases and dimension L2 in second direction D2 decreases toward other end 14. Therefore, even if molded body 20 has the above-described configuration that makes it less likely to bend, unintended deformation of tubular portion 10 can be suppressed by pressing tubular portion 10 in second direction D2 during formation of end seal portion 30C.

[0136] In this embodiment, the molded body 20 is joined onto an inner surface 13S of one end 13 of the tubular portion 10. The one end 13 includes a pair of first regions 131 located at both ends in the first direction D1. The inner surfaces 13S of each of the pair of first regions 131 are inclined toward the center of the tubular portion 10 as they approach an edge 131E of the first region 131 of the one end 13.

[0137] According to the above configuration, the cylindrical portion 10 can easily maintain an extending form in which the dimension L1 in the first direction D1 increases toward the other end 14 .

[0138] In this embodiment, the one end 13 includes a pair of second regions 132 located at both ends in the second direction D2. When viewed from the second direction D2, the edge 132E of each of the pair of second regions 132 is curved convexly toward the other end 14 in the axial direction DA.

[0139] According to the above configuration, the cylindrical portion 10 can easily maintain an extending form in which the dimension L1 in the first direction D1 increases toward the other end 14 .

[0140] The tube container 1C according to this embodiment is formed by processing the container workpiece 1. The tube container 1C includes an end seal portion 30C formed by welding together inner surfaces 14S of the other end portions 14 that face each other in the second direction D2.

[0141] The tube container 1C described above can improve its manufacturing efficiency because unintended deformation of the tubular portion 10 of the container workpiece 1 is suppressed during the formation of the end seal portion 30C. Furthermore, the tube container 1C as a whole contains a polyester-based resin as its main component, which can further improve the recyclability of the tube container 1C. The tube container 1C according to this embodiment is in line with the sustainable circular economy sought by the SDGs (Sustainable Development Goals) and can greatly contribute to reducing plastic waste.

[0142] In addition, the manufacturing method of the container workpiece according to this embodiment is a manufacturing method of the container workpiece 1, and includes forming a sheet S into a cylindrical shape to form a cylindrical body CB, placing a core jig 70 inside the cylindrical body CB to deform the cylindrical body CB into a tubular portion 10 that extends so that the dimension L1 in the first direction D1 increases and the dimension L2 in the second direction D2 decreases as it extends toward the other end 14, and joining a molded body 20 to one end 13 of the tubular portion 10 with the core jig 70 placed inside.

[0143] According to the above configuration, when molding the cylindrical portion 10 having the above-described special shape, the cylindrical portion 10 can be easily formed by performing each of the relatively simple steps in the stated order.

[0144] The method for manufacturing a container workpiece according to this embodiment further includes removing the core jig 70 from the other end 14 of the tubular portion 10 to which the molded body 20 is joined. The core jig 70 includes a first support portion 71, a second support portion 72, and an intermediate portion 73. The first support portion 71 is provided to support the tubular portion 10 from the inner surface side at a position closest to the molded body 20 when the molded body 20 is joined to the one end 13. The second support portion 72 is provided to support the tubular portion 10 from the inner surface 131S side at a position farthest from the molded body 20 when the molded body 20 is joined to the one end 13. The intermediate portion 73 connects the first support portion 71 and the second support portion 72 to each other. The intermediate portion 73 is provided to be separated from the tubular portion 10 in the second direction D2 when the molded body 20 is joined to the one end 13.

[0145] When removing the core jig 70 from the other end 14 of the tubular portion 10, the first support portion 71 of the core jig 70 pushes the tubular portion 10, which has a smaller dimension L2 in the second direction D2 than the cylindrical body CB, from the inside. This causes the tubular portion 10 to shrink toward the intermediate portion 73 of the core jig 70 due to a reaction force. If no gap was formed between the intermediate portion 73 and the tubular portion 10 in the second direction D2, the tubular portion 10 would stick to the intermediate portion 73, making it difficult to remove the core jig 70. Therefore, by providing a gap between the intermediate portion 73 and the tubular portion 10 in the second direction D2 as described above, the tubular portion 10 can be prevented from sticking to the intermediate portion 73. This ultimately makes it easier to remove the core jig 70 from the other end 14 of the tubular portion 10.

[0146] (Embodiment 2) Hereinafter, a container workpiece according to embodiment 2 of the present disclosure will be described. The container workpiece according to embodiment 2 of the present disclosure differs from the container workpiece 1 according to embodiment 1 of the present disclosure in the configuration of one end of the tubular portion. Note that the same configurations and effects as those of the container workpiece 1 according to embodiment 1 of the present disclosure may not be described repeatedly.

[0147] Fig. 25 is a front view showing a container workpiece according to embodiment 2. Fig. 26 is a side view showing a container workpiece according to embodiment 2. As shown in Figs. 25 and 26 , in the container workpiece 1a according to embodiment 2 of the present disclosure, the tubular portion 10a also has no fold lines and extends such that the dimension L1 in the first direction D1 increases and the dimension L2 in the second direction D2 decreases toward the other end 14 in a state in which there is no substantial action of an external force.

[0148] Fig. 27 is a partial cross-sectional view showing the first region of one end and its vicinity in embodiment 2. Fig. 27 shows a cross section of the container workpiece 1a according to embodiment 2 in the same cross-sectional view as embodiment 1 in Fig. 13.

[0149] 26 and 27 , in the container workpiece 1a according to the second embodiment, one end 13a of the tubular portion 10a extends along the axial direction DA. That is, the pair of first regions 131a of the one end 13a also extend along the axial direction DA. In addition, in the container workpiece 1a according to the second embodiment, each edge 132Ea of the pair of second regions 132a of the one end 13a extends parallel to the axial direction DA.

[0150] Next, a method for manufacturing a container workpiece 1a according to the second embodiment of the present disclosure will be described. Fig. 28 is a flow diagram showing a method for manufacturing a container workpiece according to the second embodiment.

[0151] As shown in Figure 28, the manufacturing method of the container workpiece according to embodiment 2 of the present disclosure differs from the manufacturing method of the container workpiece according to embodiment 1 in that a deformation step S2a is included after the molded body joining step S3a and the extraction step S4a.

[0152] FIG. 29 is a perspective view schematically illustrating the state before and after the deformation process of the second embodiment. FIG. 29(A) shows the state immediately before the deformation process. FIG. 29(B) shows the state immediately after the deformation process. As shown in FIG. 29(A) , in the joining process of the second embodiment, the cylinder CB (see FIG. 16 ) is joined to the molded body 20 in its original state without being deformed. That is, the molded body 20 is joined to one end CB13 of the cylinder CB in the axial direction DA. In the second embodiment, the core jig may support the cylinder CB from the inside without deforming the cylinder CB. The core jig may not be used. That is, in the molded body joining process S3a, only a core mold for the cavity mold may be used instead of the core jig. In this case, the manufacturing method may not include the removal process S4a.

[0153] 29 , in the deformation step S2a in the second embodiment of the present disclosure, the joined cylinder CB and molded body 20 are heated while the cylinder CB is pressed from the outside to deform the cylinder CB. Specifically, the cylinder CB is deformed into a tubular portion 10a that extends toward the other end 14 so that the dimension L1 in the first direction D1 increases and the dimension L2 in the second direction D2 decreases. This allows the tubular portion 10a to be molded with a special shape without using a dedicated jig such as the core jig 70 in the first embodiment. The above-described steps produce the container workpiece 1a according to the second embodiment.

[0154] (Embodiment 3) Next, a method for manufacturing a container workpiece according to embodiment 3 of the present disclosure will be described. The container workpiece according to embodiment 3 of the present disclosure differs from the container workpiece 1a according to embodiment 2 of the present disclosure in the configuration of one end of the tubular portion and a part of the molded body. Note that the same configurations and effects as those of container workpiece 1a according to embodiment 2 of the present disclosure may not be described repeatedly.

[0155] Fig. 30 is a front view showing a container workpiece according to embodiment 3. Fig. 31 is a side view showing a container workpiece according to embodiment 3. As shown in Figs. 30 and 31 , in the container workpiece 1b according to embodiment 3 of the present disclosure, the tubular portion 10b also has no fold lines and extends such that the dimension L1 in the first direction D1 increases and the dimension L2 in the second direction D2 decreases toward the other end 14 in a state in which there is no substantial action of an external force.

[0156] As shown in FIG. 31 , in the container workpiece 1b according to the third embodiment, each of the pair of second regions 132b of the one end 13b is inclined toward the center of the tubular portion 10b as it moves away from the edge 132Eb. Furthermore, the outer peripheral surface of the portion of the extension 23b of the molded body 20b that is joined to the second region 132b is inclined toward the center of the tubular portion 10b as it moves away from the shoulder 22b. Furthermore, in the deformation step S2a (see FIG. 28 ) of the third embodiment, unlike the second embodiment (see FIG. 29 ), the molded body 20 and the joined cylinder CB are heated and pressed from the outside, thereby deforming the cylinder CB. The molded body 20 may also be heated while the cylinder CB is heated, as in the second embodiment. Furthermore, the molded body 20 may be pressed from the outside while the cylinder CB is pressed from the outside.

[0157] (Additional Notes) As described above, the embodiments of the present disclosure include the following disclosures.

[0158] <1> A processed material for a container, comprising: a tubular portion; and a molded body, wherein the tubular portion is formed by forming a sheet into a tubular shape, the tubular portion includes one end in an axial direction of the tubular portion and another end located opposite the one end, the molded body being made of a resin composition containing a polyester-based resin as a main component, the molded body being joined to the one end of the tubular portion, the one end extending in an annular shape when viewed from the axial direction, and the other end being open, the tubular portion having no fold lines and being in a state where it is not substantially acted upon by an external force, extends so that a dimension in a first direction perpendicular to the axial direction increases and a dimension in a second direction perpendicular to both the axial direction and the first direction decreases toward the other end.

[0159] <2> The molded body includes: a pouring outlet through which the contents accommodated in the cylindrical portion can be poured; a shoulder portion extending radially from the pouring outlet as viewed in the axial direction; and an extension portion extending from the shoulder portion along the axial direction and joined to the one end of the cylindrical portion, wherein the shoulder portion has an average thickness of 1 mm or more, and the extension portion has a maximum thickness in the radial direction of 1 mm or more.

[0160] <3> The processed container material according to <1> or <2>, wherein the molded body is joined onto the inner surface of the one end of the cylindrical portion, the one end includes a pair of first regions located at both ends in the first direction, and the inner surfaces of each of the pair of first regions are inclined toward the center of the cylindrical portion as they approach the edge of the first region of the one end.

[0161] <4> The container workpiece according to any one of <1> to <3>, wherein the one end portion includes a pair of second regions located at both ends in the second direction, and the edges of each of the pair of second regions are convexly curved toward the other end portion in the axial direction when viewed from the second direction.

[0162] <5> A tube container formed by processing the container workpiece according to any one of <1> to <4>, comprising an end seal portion formed by welding together inner surfaces of the other end portions that face each other in the second direction.

[0163] <6> A method for manufacturing a workpiece for a container according to any one of <1> to <4>, comprising: forming the sheet into a cylindrical shape to form a cylindrical body; disposing a core jig inside the cylindrical body to deform the cylindrical body into the tubular section that extends so that its dimension in the first direction increases and its dimension in the second direction decreases toward the other end; and joining the molded body to the one end of the tubular section with the core jig disposed inside.

[0164] <7> The method for manufacturing a processed material for a container according to <6>, further comprising removing the core jig from the other end of the tubular portion to which the molded body is joined, wherein the core jig includes: a first support portion provided to support the tubular portion from the inner surface side closest to the molded body when the molded body is joined to the one end; a second support portion provided to support the tubular portion from the inner surface side at a position farthest from the molded body when the molded body is joined to the one end; and an intermediate portion connecting the first support portion and the second support portion to each other and provided to be spaced apart from the tubular portion in the second direction when the molded body is joined to the one end.

[0165] The embodiments disclosed herein should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is defined by the claims, not by the above description, and is intended to include all modifications within the meaning and scope of the claims.

[0166] 1, 1a, 1b Container workpiece, 10, 10a, 10b Cylindrical portion, 11 Sheet base, 111 First base end, 112 Second base end, 113 Extension portion, 12 Welded portion, 121 First tip edge, 122 Second tip edge, 123 Welded portion outer circumferential surface, 124 Welded portion inner circumferential surface, 13, 13a, 13b One end, 13S Inner surface, 131, 131a Pair of first regions, 131E Edge, 131S Inner surface, 132, 132a, 132b Second regions, 132E, 132Ea, 132Eb Edge, 14 Other end, 14S Inner surface, 20, 20b Molded body, 21 Spout, 22, 22b Shoulder portion, 23, 23b Extension portion, 1C Tube container, 10C body portion, 13C one end portion, 15C main body portion, 30C end seal portion, 40C cap portion, 5 ultrasonic horn, 51 uneven shape, 511 convex portion, 6 anvil, 70 core jig, 71 first support portion, 72 second support portion, 73 middle portion, 74 core mold portion, 80 cavity mold, 901 container workpiece, 910 cylindrical portion, 913 one end portion, 914 other end portion, 920 molded body, 922 shoulder portion, 923 extension portion, 901C tube container, 910C body portion, 913C one end portion, 915C main body portion, AL adhesive layer, BL barrier layer, CB cylindrical body, CB13 one end portion, DE recessed portion, ML integrated layer, RL reinforcing layer, RL1 first reinforcing layer, RL2 Second reinforcing layer, RL3 third reinforcing layer, S sheet, SB1 first interlayer portion, SB2 second interlayer portion, SE1 first side end portion, SE2 second side end portion, SL1 first base material layer, SL2 second base material layer, SL3 third base material layer.

Claims

1. A processed material for a container, comprising: a tubular portion; and a molded body, wherein the tubular portion is formed by forming a sheet into a tubular shape, the tubular portion includes one end in the axial direction of the tubular portion and another end located opposite the one end, the molded body being made of a resin composition containing a polyester-based resin as a main component, the molded body being joined to the one end of the tubular portion, the one end extending in an annular shape when viewed from the axial direction, and the other end being open, the tubular portion having no fold lines and, in a state where there is no substantial action of an external force, extending so that its dimension in a first direction perpendicular to the axial direction increases toward the other end, and its dimension in a second direction perpendicular to both the axial direction and the first direction decreases.

2. The processed material for a container according to claim 1, wherein the molded body is joined onto the inner surface of the one end of the tubular portion, the one end includes a pair of first regions located at both ends in the first direction, and the inner surface of each of the pair of first regions is inclined toward the center of the tubular portion as it approaches the edge of the first region of the one end.

3. A tube container formed by processing the container workpiece according to claim 1 or 2, comprising an end seal portion formed by welding the inner surfaces of the other end portions that face each other in the second direction.

4. A method for manufacturing a processed material for a container as described in claim 1 or claim 2, comprising: forming the sheet into a cylindrical shape to form a cylindrical body; placing a core jig inside the cylindrical body to deform the cylindrical body into the tubular section that extends so that its dimension in the first direction increases toward the other end and so that its dimension in the second direction decreases toward the other end; and joining the molded body to the one end of the tubular section with the core jig placed inside.

5. A method for manufacturing a processed material for a container as described in claim 4, further comprising removing the core jig from the other end of the tubular portion to which the molded body is joined, wherein the core jig includes: a first support portion provided to support the tubular portion from the inner surface side at the position closest to the molded body when the molded body is joined to the one end; a second support portion provided to support the tubular portion from the inner surface side at the position farthest from the molded body when the molded body is joined to the one end; and an intermediate portion connecting the first support portion and the second support portion to each other and provided to be spaced apart from the tubular portion in the second direction when the molded body is joined to the one end.

Images