Patent Grant
10947001
The present invention relates to a delaminatable container having an inner layer delaminated from an outer layer and shrunk with a decrease in the contents.
Conventionally, delaminatable containers are known that inhibit entrance of air inside the container by an inner layer delaminated from an outer layer and shrunk with a decrease in the contents (e.g., PTLs 1 and 2). Such delaminatable container is provided with an inner bag composed of the inner layer and an outer shell composed of the outer layer.
A container body of such delaminatable container is generally manufactured by blow molding using a cylindrical laminated parison. The container body has a bottom equipped with a sealing portion when an end of the laminated parison is welded. Since the sealing portion is not resistant to impact, it is provided to protrude from a bottom surface of the container to increase the strength. In PTL 1, to increase the strength of the sealing portion even more, welded layers in the sealing portion are welded to be engaged with each other by a plurality of penetration portions.
(First Aspect)
To achieve the composition of PTL 1, a die has to be provided with a pin to press the parison welding layer, resulting in a complex die structure, which increases production costs. It is therefore desired to reinforce the sealing portion with simpler configuration.
A first aspect of the present invention has been made in view of such circumstances, and it is to provide a delaminatable container excellent in productivity.
(Second Aspect)
A delaminatable container is normally used with a cap mounted in a mouth. To prevent leakage of the contents from a gap between the cap and the mouth, a cap provided with an inner ring that closely adheres to an inner surface of the mouth is used.
When the present inventors repeatedly performed an experiment of mounting a cap to a delaminatable container, it is found that the inner ring is caught on the inner layer of the mouth to bend the inner layer, and in the worst case, the inner layer sometimes delaminates completely from the outer layer in the mouth, causing the inner bag to fall out in the outer shell.
A second aspect of the present invention has been made in view of such circumstances, and it is to provide a delaminatable container that inhibits inner layer delamination in a mouth of the delaminatable container.
(First Aspect)
According to the first aspect of the present invention, a delaminatable container is provided that includes: a container body having an outer shell and an inner bag, the inner bag delaminating from the outer shell and being shrunk with a decrease in contents, wherein
the container body includes a bottom seal protrusion protruding from a bottom surface of a storage portion to store the contents, and
the bottom seal protrusion is a sealing portion of, in blow molding using a cylindrical laminated parison provided with an outer layer constituting the outer shell and an inner layer constituting the inner bag, the laminated parison and is bent.
Based on intensive examinations, the present inventors found that a sealing portion is reinforced by a simple configuration of bending a bottom seal protrusion protruding from a bottom surface of a storage portion of a container body and thus have come to complete the present invention.
Various embodiments in the first aspect of the present invention are exemplified below. The embodiments described below may be combined with each other.
It is preferred that the bottom seal protrusion includes, in order from a side of the bottom surface, a thinner portion and a thicker portion having a thickness greater than that of the thinner portion.
It is preferred that the bottom seal protrusion is bent in the thinner portion.
It is preferred that the bottom surface includes a concave region and a peripheral region provided surrounding the concave region, and the bottom seal protrusion is provided in the concave region.
It is preferred that the bottom seal protrusion is configured not to protrude from a plane defined by the peripheral region in a state of being bent.
It is preferred that the concave region is provided across the entire bottom surface in a longitudinal direction of the bottom seal protrusion.
According to another aspect, the present invention is a method of manufacturing the above delaminatable container, and it is to provide a method of manufacturing the delaminatable container, that includes bending the bottom seal protrusion by softening by blowing hot air after blow molding.
(Second Aspect)
According to the second aspect of the present invention, a delaminatable container is provided that includes a container body provided with a storage portion to store contents and a mouth to deliver the contents from the storage portion, the storage portion and the mouth having an outer layer and an inner layer, the inner layer delaminating from the outer layer and being shrunk with a decrease in the contents, wherein
the mouth includes an enlarged diameter portion provided at an end of the mouth and an inner layer support portion provided in a position closer to the storage portion than the enlarged diameter portion and inhibiting slip down of the inner layer.
According to intensive review by the present inventors, it is found that a conventional delaminatable container has a mouth in an approximately cylindrical shape, and when the mouth has an inner diameter smaller than the outer diameter of the inner ring due to variations in manufacturing and the like, the end of the inner ring sometimes enters between the inner layer and the outer layer at the end of the mouth. Based on such finding, they have come up with the idea of providing an enlarged diameter portion in the end of the mouth and actually produced a delaminatable container having such configuration. The entrance of the inner ring between the inner layer and the outer layer is inhibited and inner layer delamination in the mouth of the delaminatable container is inhibited.
Although this method prevents the phenomenon that the inner bag falls out in the outer shell, a phenomenon possibly occurs that the inner layer delaminates due to friction between the inner layer and the inner ring and the inner bag falls out in the outer shell. To prevent such phenomenon more securely, as a result of further review, they have come up with the idea of providing an inner layer support portion to inhibit slip down of the inner layer in a position closer to the body side than the enlarged diameter portion and thus have come to complete the present invention.
Various embodiments in the second aspect of the present invention are exemplified below. The embodiments described below may be combined with each other.
It is preferred that the storage portion includes a main portion having an approximately constant cross-sectional shape in longitudinal directions of the storage portion and a shoulder portion linking the main portion to the mouth, the shoulder portion or a boundary between the shoulder portion and the main portion includes a bent portion, and the bent portion has a bending angle of 140 degrees or less and has a radius of curvature of 4 mm or less on a side of a container inner surface in the bent portion.
It is preferred that the bending angle is120 degrees or less.
It is preferred that the radius of curvature is 2 mm or less.
It is preferred that the bent portion is provided in a position where a distance from a container center axis to the container inner surface in the bent portion is 1.3 times or more of a distance from the container center axis to the container inner surface in the mouth.
It is preferred that the mouth has a thickness from 0.45 to 0.50 mm, the bent portion has a thickness from 0.25 to 0.30 mm, and the main portion has a thickness from 0.15 to 0.20 mm.
Among the Examples described later, a first experimental example relates to a shape of a valve member, a second experimental example relates to a shape of a mounting portion of a valve member, a third experimental example relates to effects of using a random copolymer for the outer layer, and a fourth experimental example relates to effects of making an innermost layer of an inner layer as an EVOH layer. The third experimental example relates to the first aspect of the present invention and the fourth experimental example relates to the second aspect of the present invention.
Embodiments of the present invention are described below. Various characteristics in the embodiments described below may be combined with each other. Each characteristic is independently inventive.
As illustrated in
As illustrated in
As illustrated in
The mouth 9 is also provided with an inner layer support portion 9c to inhibit slip down of the inner layer 13 in a position closer to the storage portion 7 than the abutment portion 9e. The inner layer support portion 9c is formed by providing a narrow part in the mouth 9. Even when the mouth 9 is equipped with the enlarged diameter portion 9b, the inner layer 13 sometimes delaminates from the outer layer 11 due to friction between the inner ring 25 and the inner layer 13. In the present embodiment, even in such case, the inner layer support portion 9c inhibits slip down of the inner layer 13, and thus it is possible to inhibit falling out of the inner bag 14 in the outer shell 12.
As illustrated in
Although the lower limit of bending angle α is not particularly defined, it is preferably 90 degrees or more for ease of manufacture. Although the lower limit of the radius of curvature is not particularly defined, it is preferably 0.2 mm or more for ease of manufacture. In order to prevent delamination of the inner layer 13 from the outer layer 11 in the mouth 9 more securely, the bending angle α is preferably 120 degrees or less and the radius of curvature is preferably 2 mm or less. Specifically, the bending angle α is, for example, 90, 95, 100, 105, 110, 115, 120, 125, 130, 135, and 140 degrees or it may be in a range between any two values exemplified here. Specifically, the radius of curvature is, for example, 0.2, 0.4, 0.6, 0.8, 1, 1.2, 1.4, 1.6, 1.8, and 2 mm or it may be in a range between any two values exemplified here.
As illustrated in
To give an example, the thickness in the mouth 9 is from 0.45 to 0.50 mm, the thickness in the bent portion 22 is from 0.25 to 0.30 mm, and the thickness of the main portion 19 is from 0.15 to 0.20 mm. The thickness in the bent portion 22 is thus sufficiently less than the thickness in the mouth 9, thereby effectively exhibiting functions of the bent portion 22.
As illustrated in
The lid 5c is configured to substantially close the fresh air inlet 15 when the outer shell 12 is compressed and shaped to have a smaller cross-sectional area as coming closer to the axis 5a. The locking portion 5b is configured to be capable of introducing air in the intermediate space 21 when the outer shell 12 is restored after compression. When the outer shell 12 is compressed, the pressure in the intermediate space 21 becomes higher than external pressure and the air in the intermediate space 21 leaks outside from the fresh air inlet 15. The pressure difference and the air flow cause the lid 5c to move toward the fresh air inlet 15 to close the fresh air inlet 15 by the lid 5c. Since the lid 5c has a shape with a smaller cross-sectional area as coming closer to the axis 5a, the lid 5c readily fits into the fresh air inlet 15 to close the fresh air inlet 15.
When the outer shell 12 is further compressed in this state, the pressure in the intermediate space 21 is increased, and as a result, the inner bag is compressed to deliver the contents in the inner bag 14. When the compressive force to the outer shell 12 is released, the outer shell 12 attempts to restore its shape by the elasticity of its own. At this point, the lid 5c is separated from the fresh air inlet 15 and the closure of the fresh air inlet 15 is released to introduce fresh air in the intermediate space 21. Not to cause the locking portion 5b to close the fresh air inlet 15, the locking portion 5b is equipped with projections 5d in a portion abutting on the outer shell 12. The projections 5d abut on the outer shell 12 to provide gaps between the outer shell 12 and the locking portion 5b. Instead of providing the projections 5d, closure of the fresh air inlet 15 by the locking portion 5b may be prevented by providing grooves in the locking portion 5b.
The valve member 5 is mounted to the container body 3 by inserting the lid 5c into the intermediate space 21 while the lid 5c presses and expands the fresh air inlet 15. The lid 5c, therefore, preferably has an end in a tapered shape. Since such valve member 5 can be mounted only by pressing the lid 5c from outside the container body 3 into the intermediate space 21, it is excellent in productivity.
After the valve member 5 is mounted, the storage portion 7 is covered with a shrink film. At this point, not to allow the valve member 5 to interfere with the shrink film, the valve member 5 is mounted to a valve member mounting recess 7a provided in the storage portion 7. Not to seal the valve member mounting recess 7a with the shrink film, an air circulation groove 7b extending from the valve member mounting recess 7a in the direction of the mouth 9 is provided.
The valve member mounting recess 7a is provided in the shoulder portion 17 of the outer shell 12. The shoulder portion 17 is an inclined surface, and a flat region FR is provided in the valve member mounting recess 7a. Since the flat region FR is provided approximately in parallel with the inclined surface of the shoulder portion 17, the flat region FR is also an inclined surface. Since the fresh air inlet 15 is provided in the flat region FR in the valve member mounting recess 7a, the fresh air inlet 15 is provided in the inclined surface. When the fresh air inlet 15 is provided in, for example, a vertical surface of the main portion 19, there is a risk that the once delaminated inner bag 14 makes contact with the valve member 5 to interfere with movement of the valve member 5. In the present embodiment, since the fresh air inlet 15 is provided in the inclined surface, there is no such risk and smooth movement of the valve member 5 is secured. Although not particularly limited, an inclination angle of the inclined surface is preferably from 45 to 89 degrees, more preferably from 55 to 85 degrees, and even more preferably from 60 to 80 degrees.
As illustrated in
According to an experiment (Second Experimental Example) by the present inventors, it is found that a wider flat region FR on an outer surface side of the outer shell 12 causes a larger radius of curvature on an inner surface of the outer shell 12, and when the flat region FR is provided across the range of 3 mm or more surrounding the fresh air inlet 15 on the outer surface side of the outer shell, the radius of curvature on the inner surface of the outer shell 12 is sufficiently large, and as a result, the close adherence between the outer shell 12 and the valve member 5 is improved. The radius of curvature on the inner surface of the outer shell 12 is preferably 200 mm or more in a range of 2 mm surrounding the fresh air inlet 15 and even more preferably 250 mm or more or 300 mm or more. This is because, when the radius of curvature has such value, the inner surface of the outer shell 12 substantially becomes flat and the close adherence between the outer shell 12 and the valve member 5 is good.
As illustrated in
Immediately after blow molding, as illustrated in
The base portion 27d is provided on the bottom surface 29 side closer than the thinner portion 27a and is an area thicker than the thinner portion 27a. Although the base portion 27d does not have to be provided, the impact resistance of the bottom seal protrusion 27 is further improved by providing the thinner portion 27a on the base portion 27d.
As illustrated in
The layer structure of the container body 3 is described below in further detail. The container body 3 is provided with the outer layer 11 and the inner layer 13.
The outer layer 11 is composed of, for example, low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, an ethylene-propylene copolymer, a mixture thereof, and the like. The outer layer 11 may have a multilayer structure. For example, it may have a structure where a reproduction layer has both sides sandwiched by polypropylene layers. Here, the reproduction layer refers to a layer using burrs produced while molding a container by recycling. The outer layer 11 is formed thicker than the inner layer 13 for better restorability.
In the present embodiment, the outer layer 11 includes a random copolymer layer containing a random copolymer of propylene and another monomer. The outer layer 11 may be a single layer of the random copolymer layer or may be a multilayer structure. For example, it may have a structure where a reproduction layer has both sides sandwiched by random copolymer layers. The outer layer 11 is composed of a random copolymer of specific composition to improve shape restorability, transparency, and heat resistance of the outer shell 12.
The random copolymer has a content of a monomer other than propylene of less than 50 mol % and preferably from 5 to 35 mol %. Specifically, this content is, for example, 5, 10, 15, 20, 25, and 30 mol % or it may be in a range between any two values exemplified here. The monomer to be copolymerized with propylene may be one that improves impact resistance of the random copolymer compared with a homopolymer of polypropylene, and ethylene is particularly preferred. In the case of a random copolymer of propylene and ethylene, the ethylene content is preferably from 5 to 30 mol %. Specifically, it is, for example, 5, 10, 15, 20, 25, and 30 mol % or it may be in a range between any two values exemplified here. The random copolymer preferably has a weight average molecular weight from 100 thousands to 500 thousands, and even more preferably from 100 thousands to 300 thousands. Specifically, the weight average molecular weight is, for example, 100 thousands, 150 thousands, 200 thousands, 250 thousands, 300 thousands, 350 thousands, 400 thousands, 450 thousands, and 500 thousands or it may be in a range between any two values exemplified here.
The random copolymer has a tensile modulus of elasticity preferably from 400 to 1600 MPa and more preferably from 1000 to 1600 MPa. This is because the shape restorability is particularly good with a tensile modulus of elasticity in such range. Specifically, the tensile modulus of elasticity is, for example, 400, 500, 600, 700, 800, 900, 1000, 1100, 1200, 1300, 1400, 1500, and 1600 Mpa or it may be in a range between any two values exemplified here.
Since an excessively hard container impairs feeling of using the container, the outer layer 11 may be composed by, for example, mixing a softening material, such as linear low density polyethylene, to the random copolymer. Note that, in order not to severely interfere with effective properties of the random copolymer, the material to be mixed with the random copolymer is preferably mixed to be less than 50 weight % based on the entire mixture. For example, the outer layer 11 may be composed of a material in which the random copolymer is mixed with linear low density polyethylene at a weight ratio of 85:15.
As illustrated in
The EVOH layer 13a is a layer containing an ethylene-vinyl alcohol copolymer (EVOH) resin and is obtained by hydrolysis of a copolymer of ethylene and vinyl acetate. The EVOH resin has an ethylene content, for example, from 25 to 50 mol %, and from the perspective of oxygen barrier properties, it is preferably 32 mol % or less. Although not particularly defined, the lower limit of the ethylene content is preferably 25 mol % or more because the flexibility of the EVOH layer 13a is prone to decrease when the ethylene content is less. The EVOH layer 13a preferably contains an oxygen absorbent. The content of an oxygen absorbent in the EVOH layer 13a further improves the oxygen barrier properties of the EVOH layer 13a. The EVOH resin preferably has a modulus of elasticity in bending of 2350 MPa or less and even more preferably 2250 MPa or less. Although not particularly defined, the lower limit of the modulus of elasticity in bending of the EVOH resin is, for example, 1800, 1900, or 2000 MPa. The modulus of elasticity in bending is measured in a test method in accordance with ISO 178. The testing speed is 2 mm/min.
The EVOH resin preferably has a melting point higher than the melting point of the random copolymer contained in the outer layer 11. The fresh air inlet 15 is preferably formed in the outer layer 11 using a thermal perforator, and when the fresh air inlet 15 is formed in the outer layer 11, the inlet is prevented from reaching the inner layer 13 by the EVOH resin having a melting point higher than the melting point of the random copolymer. From this perspective, a greater difference of (Melting Point of EVOH)−(Melting Point of Random Copolymer Layer) is desired, and it is preferably 15° C. or more and particularly preferably 30° C. or more. The difference in melting points is, for example, from 5 to 50° C. Specifically, it is, for example, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50° C. or it may be in a range between any two values exemplified here.
The inner surface layer 13b is a layer to make contact with the contents of the delaminatable container 1. It contains, for example, polyolefin, such as low density polyethylene, linear low density polyethylene, high density polyethylene, polypropylene, an ethylene-propylene copolymer, and a mixture thereof, and preferably low density polyethylene or linear low density polyethylene. The resin contained in the inner surface layer 13b preferably has a tensile modulus of elasticity from 50 to 300 MPa and more preferably from 70 to 200 MPa. This is because the inner surface layer 13b is particularly flexible when the tensile modulus of elasticity is in such range. Specifically, the tensile modulus of elasticity is, for example, specifically for example, 50, 100, 150, 200, 250, and 300 Mpa or it may be in a range between any two values exemplified here.
The adhesion layer 13c is a layer having a function of adhering the EVOH layer 13a to the inner surface layer 13b, and it is, for example, a product of adding acid modified polyolefin (e.g., maleic anhydride modified polyethylene) with carboxyl groups introduced therein to polyolefin described above or an ethylene-vinyl acetate copolymer (EVA). An example of the adhesion layer 13c is a mixture of acid modified polyethylene with low density polyethylene or linear low density polyethylene.
As illustrated in
The internal EVOH layer 13d contains an ethylene-vinyl alcohol copolymer (EVOH) resin. According to an experiment (Fourth Experimental Example) by the present inventors, it is found that, when the innermost layer of the inner layer 13 is the internal EVOH layer 13d, adsorption or absorption of limonene in the container inner surface is inhibited, and as a result, the reduction of the citrus aroma emitted by a citrus-based liquid condiment is inhibited.
Since EVOH resins have relatively high rigidity, such EVOH resin is normally used by adding a softening agent to the EVOH resin for use as a material for the inner layer 13 to improve the flexibility. There is a risk, however, in adding a softening agent to the EVOH resin contained in the internal EVOH layer 13d as the innermost layer of the inner layer 13 of eluting the softening agent in the contents. Therefore, as the EVOH resin contained in the internal EVOH layer 13d, one that does not contain a softening agent has to be used. Meanwhile, since the EVOH resin not containing a softening agent has high rigidity, a problem occurs that, when the internal EVOH layer 13d is too thick, the inner bag 14 is not prone to be shrunk smoothly at delivery of the contents. When the internal EVOH layer 13d is too thin, the internal EVOH layer 13d is not formed uniformly and there are problems that the adhesion layer 13c is exposed to the container inner surface and a pinhole is prone to be formed in the internal EVOH layer 13d. From such perspective, the internal EVOH layer 13d preferably has a thickness from 10 to 20 μm.
The EVOH resin contained in the internal EVOH layer 13d has an ethylene content, for example, from 25 to 50 mol %. Since a greater ethylene content facilitates improvement in flexibility of the internal EVOH layer 13d, the ethylene content is preferably higher than that of the EVOH resin contained in the external EVOH layer 13e and it is preferred to be 35 mol % or more. In other words, the EVOH resin contained in the internal EVOH layer 13d preferably has an ethylene content set to have a tensile modulus of elasticity of the EVOH resin of 2000 MPa or less.
The external EVOH layer 13e also contains an ethylene-vinyl alcohol copolymer (EVOH) resin similar to the internal EVOH layer 13d. Note that, since the external EVOH layer 13e does not make contact with the contents, the flexibility may be increased by adding a softening agent, and for that purpose, the external EVOH layer 13e may have a thickness thicker than that of the internal EVOH layer. Although not particularly limited, the external EVOH layer 13e has a thickness, for example, from 20 to 30 μm. A problem occurs that the gas barrier properties of the inner layer 13 become insufficient when the external EVOH layer 13e is too thin, and another occurs that the flexibility of the inner layer 13 becomes insufficient when the external EVOH layer 13e is too thick, causing the inner bag 14 not prone to be shrunk smoothly at delivery of the contents. Although not particularly limited, a ratio of thicknesses of the external EVOH layer 13e/internal EVOH layer 13d is, for example, from 1.1 to 4 and preferably from 1.2 to 2.0. Specifically, the ratio is, for example, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, 2, 2.1, 2.2, 2.3, 2.4, 2.5, 3, and 4 or it may be in a range between any two values exemplified here. By providing the external EVOH layer 13e as the outermost layer of the inner layer 13, it is possible to improve the delamination properties of the inner layer 13 from the outer layer 11.
The EVOH resin contained in the external EVOH layer 13e has an ethylene content, for example, from 25 to 50 mol %, and from the perspective of oxygen barrier properties, it is preferably 32 mol % or less. Although not particularly defined, the lower limit of the ethylene content is preferably 25 mol % or more because a less ethylene content causes a decrease in flexibility of the external EVOH layer 13e.
It is preferred that an amount of adding the softening agent to the EVOH resin contained in the external EVOH layer 13e and the ethylene content of the EVOH resin are set in such a manner that the EVOH resin has a tensile modulus of elasticity of 2000 MPa or less. Composition of both the internal EVOH layer 13d and the external EVOH layer 13e by EVOH resins having a tensile modulus of elasticity of 2000 MPa or less enables smooth shrinking of the inner bag 14. The external EVOH layer 13e preferably contains an oxygen absorbent. By containing an oxygen absorbent in the external EVOH layer 13e, it is possible to further improve the oxygen barrier properties of the external EVOH layer 13e.
The EVOH resin contained in the external EVOH layer 13e preferably has a melting point higher than the melting point of the random copolymer contained in the outer layer 11. The fresh air inlet 15 is preferably formed in the outer layer 11 using a thermal perforator, and when the fresh air inlet 15 is formed in the outer layer 11, the inlet is prevented from reaching the inner layer 13 by the EVOH resin having a melting point higher than the melting point of the random copolymer. From this perspective, a greater difference of (Melting Point of EVOH)−(Melting Point of Random Copolymer Layer) is desired, and it is preferably 15° C. or more and particularly preferably 30° C. or more. The difference in melting points is, for example, from 5 to 50° C. Specifically, it is, for example, 5, 10, 15, 20, 25, 30, 35, 40, 45, and 50° C. or it may be in a range between any two values exemplified here.
The adhesion layer 13c is a layer arranged between the internal EVOH layer 13d and the external EVOH layer 13e, and it is, for example, a product of adding acid modified polyolefin (e.g., maleic anhydride modified polyethylene) with carboxyl groups introduced therein to polyolefin described above or an ethylene-vinyl acetate copolymer (EVA). An example of the adhesion layer 13c is a mixture of acid modified polyethylene with low density polyethylene or linear low density polyethylene. The adhesion layer 13c may directly adhere the internal EVOH layer 13d to the external EVOH layer 13e or may indirectly adhere via another layer provided between the adhesion layer 13c and the internal EVOH layer 13d or between the adhesion layer 13c and the external EVOH layer 13e.
The adhesion layer 13c is a layer having rigidity per unit thickness less than that of any of the internal EVOH layer 13d and the external EVOH layer 13e, that is, a layer excellent in flexibility. Therefore, by thickening the adhesion layer 13c to increase the ratio of the thickness of the adhesion layer 13c to the thickness of the entire inner layer 13, the flexibility of the inner layer 13 is increased and the inner bag 14 readily shrinks smoothly at delivery of the contents. Specifically, the adhesion layer 13c preferably has a thickness greater than a total of the thickness of the internal EVOH layer 13d and the thickness of the external EVOH layer 13e. The ratio of thicknesses of Adhesion Layer 13c/(Internal EVOH Layer 13d+External EVOH Layer 13e) is, for example, from 1.1 to 8. Specifically, the ratio is, for example, 1.1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 7, and 8 or it may be in a range between any two values exemplified here.
Then, an example of a method of manufacturing the delaminatable container 1 in the present embodiment is described.
Firstly, as illustrated in
Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
The procedures of inner layer preliminary delamination and fresh air inlet opening may be in the following method.
Firstly, as illustrated in
When the tubular cutter penetrates the outer layer 11, as illustrated in
Then, as illustrated in
The procedures of inner layer preliminary delamination and fresh air inlet opening may be in the following method. Here, with reference to
Firstly, as illustrated in
The cutter blade 2a is coupled to a ventilation pipe 2e in communication with a hollow in the cutter blade 2a, and the ventilation pipe 2e is coupled to an air intake and exhaust system, not shown. This enables air suction from inside the cutter blade 2a and air blowing inside the cutter blade 2a. The heating device 2d is provided with a coil 2f formed of a conductive wire and configured to heat the cutter blade 2a by the principle of electromagnetic induction by applying an alternating current to the coil 2f. The heating device 2d is arranged in proximity to a blow molded article 1a and separate from the cutter blade 2a. Such structure simplifies wiring of the heating device 2d and enables efficient heating of the edge of the cutter blade 2a.
Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
When the edge of the cutter blade 2a reaches the boundary between the outer shell 12 and the inner bag 14, the outer shell 12 is hollowed out in the shape of the edge of the cutter blade 2a to form the fresh air inlet 15. A cut piece 15a that is hollowed out of the outer shell 12 is sucked in the hollow of the cutter blade 2a. The cutter blade 2a may stop the movement when the edge reaches the boundary between the outer shell 12 and the inner bag 14, whereas it may be moved until the edge of the cutter blade 2a is pressed against the inner bag 14 beyond the interface between the outer shell 12 and the inner bag 14 to form the fresh air inlet 15 more securely. At this point, to inhibit damage in the inner bag 14 by the cutter blade 2a, the shape of the edge of the cutter blade 2a is preferably a rounded shape as illustrated in
Then, as illustrated in
In the above procedures, formation of the fresh air inlet 15 in the outer shell 12 is completed.
Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
As the specific type of gas, a type of gas present in a less amount in the air (preferably a type of gas at 1% or less) is selected preferably and examples of it may include hydrogen, carbon dioxide, helium, argon, neon, and the like. The concentration of the specific type of gas in the inspection gas is not particularly limited, and the inspection gas may be composed only of the specific type of gas or may be a mixed gas of air and the specific type of gas.
Although not particularly limited, the injection pressure of the inspection gas is, for example, from 1.5 to 4.0 kPa. When the injection pressure is too low, the leakage of the specific type of gas is sometimes too little to sense the specific type of gas even though a pinhole is present. When the injection pressure is too high, the inner bag 14 expands and is pressed against the outer shell 12 immediately after injection of the inspection gas, resulting in a decrease in accuracy of check for a pinhole of the inner bag 14.
Although the sensor 37 is arranged outside the delaminatable container 1 in proximity to the fresh air inlet 15 in the present embodiment, the sensor 37 may be inserted into the intermediate space 21 through the fresh air inlet 15 to detect the specific type of gas in the intermediate space 21 as a modification. In this case, it is possible to sense the specific type of gas before diffusion of the specific type of gas passing through a pinhole in the inner bag 14, and thus the accuracy of sensing the specific type of gas is improved. As still another modification, the inspection gas containing the specific type of gas may be injected in the intermediate space 21 from the fresh air inlet 15 to sense the specific type of gas leaked to the inner bag 14 through a pinhole in the inner bag 14. In this case, the sensor 37 may be arranged outside the container in a position in proximity to the mouth 9 or the sensor 37 may be inserted into the inner bag 14 from the mouth 9.
The delaminatable container 1 after checked for a pinhole may be forwarded directly to a next procedure, whereas in a modification it may be forwarded to a next procedure after a procedure of expanding the inner bag 14 by blowing air into the inner bag 14. In the case of the latter, an air blowing procedure in
Then, as illustrated in
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Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
The order of various procedures described here may be switched appropriately. For example, the hot air bending procedure may be before the fresh air inlet opening procedure or may be before the inner layer preliminary delamination procedure. The procedure of cutting the upper tubular portion 31 may be before inserting the valve member 5 into the fresh air inlet 15.
Then, working principle of the product thus manufactured in use is described.
As illustrated in
The cap 23 has a built-in check valve, not shown, so that it is capable of delivering the contents in the inner bag 14 but not capable of taking fresh air in the inner bag 14. Therefore, when the compressive force applied to the outer shell 12 is removed after delivery of the contents, the outer shell 12 attempts to be back in the original shape by the restoring force of itself but the inner bag 14 remains deflated and only the outer shell 12 expands. Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
Then, with reference to
As illustrated in
The valve member mounting recess 7a is provided in the main portion 19 composed of an approximately vertical wall, and the valve member mounting recess 7a is equipped with a flat region FR. The flat region FR is an inclined surface at approximately 70 degrees. The flat region FR is provided with a fresh air inlet 15, and a width W of the flat region FR surrounding the fresh air inlet 15 is 3 mm or more same as in the first embodiment. The valve member mounting recess 7a has side walls 7c of tapered surfaces extending toward outside to facilitate a die to form the valve member mounting recess 7a to be taken away. As illustrated in
Then, with reference to
Specifically, the valve member 5 in the present embodiment has a locking portion 5b provided with a pair of foundation portions 5b1 and a bridge portion 5b2 disposed between the foundation portions 5b1. An axis 5a is provided on the bridge portion 5b2.
The lid 5c is configured to substantially close the fresh air inlet 15 when the outer shell 12 is compressed and is provided with a tapered surface 5d to have a smaller cross-sectional area as coming closer to the axis 5a. An inclination angle β of the tapered surface 5d illustrated in
As illustrated in
In this state, the lid 5c is only lightly pressed against the outer shell 12. However, when the outer shell 12 is compressed, the pressure in the intermediate space 21 becomes higher than external pressure and the pressure difference causes the lid 5c to be even stronger pressed against the fresh air inlet 15 to close the fresh air inlet 15 by the lid 5c. Since the lid 5c is equipped with the tapered surface 5d, the lid 5c readily fits into the fresh air inlet 15 to close the fresh air inlet 15.
When the outer shell 12 is further compressed in this state, the pressure in the intermediate space 21 is increased, and as a result, the inner bag 14 is compressed to deliver the contents in the inner bag 14. When the compressive force to the outer shell 12 is released, the outer shell 12 attempts to restore its shape by the elasticity of its own. The pressure in the intermediate space 21 is reduced with the restoration of the outer shell 12, thereby applying a force FI, as illustrated in
The valve member 5 in the present embodiment can be molded by injection molding or the like using a split die of a simple configuration that splits in an arrow X direction along a parting line L illustrated in
In the experimental example below, a delaminatable container having the outer layer 11 and the inner layer 13 was produced by blow molding, and the fresh air inlet 15 of ϕ4 mm was formed only in the outer layer 11 having a thickness of 0.7 mm using a thermal perforator. In addition, valve members 5 of first through fifth structural examples illustrated in
The valve members 5 in the first through fifth structural examples were evaluated in operability, moldability, tilt resistance, and transferability. The results are indicated in Table 1 below. The symbols X, Δ, and O in each evaluation point in Table 1 are relative evaluation results, where Δ denotes an evaluation result better than X and O denotes an evaluation result better than Δ.
The operability is evaluation of whether or not the fresh air inlet 15 is smoothly opened and closed by the valve member 5. In the first structural example where the axis 5a has a length shorter than a thickness of the outer layer 11, a slidable length was 0 and the fresh air inlet 15 remained closed. In the second structural example, although the fresh air inlet 15 was opened and closed by the valve member 5, the operation was sometimes not smooth. In contrast, in the third through fifth structural examples, the fresh air inlet 15 was smoothly opened and closed by the valve member 5. The reasons why the valve member 5 did not operate smoothly in the second structural example may include that the slidable length (length of axis 5a−thickness of outer layer 11) was 0.7 mm, which was not a sufficient length, and that the clearance to the fresh air inlet 15 (diameter of fresh air inlet 15−diameter of axis 5a) was 0.2 mm, which was not a sufficient size. In contrast, in the third through fifth structural examples, the slidable length was 1 mm or more, which was a sufficient length, and the clearance to the fresh air inlet 15 was 0.3 mm or more, which was a sufficient size, so that the valve member 5 operated smoothly. When the slidable length exceeds 2 mm, the valve member 5 is prone to interfere with the shrink film and the inner layer 13, and thus the valve member 5 preferably has a slidable length from 1 to 2 mm.
The moldability is evaluation of ease of molding the valve member 5 by injection molding. When the surface of the locking portion 5b on the axis 5a side was provided with the projections 5d as in the first structural example or four grooves 5e circumferentially at regular intervals as in the second structural example, the valve member 5 after molding had to be forcibly taken out of the split die or a split die with a special configuration had to be prepared, so that the moldability was poor. In contrast, when two grooves 5e were provided circumferentially at regular intervals as in the third through fifth structural examples, the valve member 5 was readily taken out of the split die and the moldability was excellent.
The tilt resistance is evaluation of whether or not a gap is prone to be formed in the fresh air inlet 15 when the valve member 5 is tilted in a state where the lid 5c is pressed against the fresh air inlet 15. When the shape at a boundary 5f between the lid 5c and the axis 5a was a curved shape depressing inside as in the first and second structural examples, a gap was prone to be formed in the fresh air inlet 15 when the valve member 5 was tilted. In contrast, when the shape of the boundary 5f between the lid 5c and the axis 5a was a curved shape bulged outside as in the third through fifth structural examples, a gap was not prone to be formed in the fresh air inlet 15 when the valve member 5 was tilted. In the third structural example, the clearance to the fresh air inlet 15 was 0.7 mm, which is too large, and the valve member 5 was tilted considerably and thus a gap was relatively prone to be formed. In contrast, in the fourth and fifth structural examples, the clearance to the fresh air inlet 15 was 0.6 mm or less, which was an adequate size, and an excessive tilt of the valve member 5 was inhibited. Considering both the operability and the tilt resistance, the clearance to the fresh air inlet 15 is preferably from 0.2 to 0.7 mm and even more preferably from 0.3 to 0.6 mm.
The transferability is evaluation of whether or not a large number of valve members 5 are readily transferred using a part feeder to hold the valve members 5 on two parallel rails at an interval slightly greater than the diameter of the lid 5c. The valve members 5 were inserted between the two rails with the lid 5c downward and held on the parallel rails by being caught on the parallel rails at the locking portion 5b. The transferability is further classified into anti-overlap properties and anti-fall properties.
The anti-overlap properties are evaluation of probability of not overlapping the locking portions 5b of the valve member 5 with each other. In the first through fourth structural examples, the locking portion 5b had a thickness of 1 mm, which was not a sufficient thickness, and thus the locking portions 5b were prone to be overlapped with each other. In contrast, in the fifth structural example, the locking portion 5b had a thickness of not less than 1.2 mm, which was a sufficient thickness, and the locking portions 5b were not prone to be overlapped with each other.
The anti-fall properties are evaluation of whether or not the valve members 5 are appropriately held on the parallel rails without being dislocated and falling out of the parallel rails. In the first through fourth structural examples, the amount of the locking portion 5b sticking out (diameter of locking portion 5b−diameter of lid 5c) was 1.5 mm or less, which was too small, and the valve members 5 were prone to fall out of the parallel rails. In contrast, in the fifth structural example, the amount of the locking portion 5b sticking out was not less than 2 mm, and the valve members 5 did not fall out of the parallel rails and readily transferred using the parallel rails.
The valve member 5 in the fifth structural example, as illustrated in
In the experimental example below, a delaminatable container having the outer layer 11 and the inner layer 13 was produced by blow molding and the fresh air inlet 15 was formed only in the outer layer 11 having a thickness of 0.7 mm using a thermal perforator. By variously changing an inner capacity of the delaminatable container, a size of the fresh air inlet 15, and the width W surrounding the fresh air inlet 15 in the flat region FR in the valve member mounting recess 7a, delaminatable containers of sample No. 1 through 5 were formed. In addition, the valve member 5 in the shape illustrated in
As indicated in Table 2, samples No. 1 through 3 had low delivery performance for a small amount of the contents and samples No. 4 through 5 had high delivery performance for a small amount of the contents. To review reasons of such results, each sample was measured on a radius of curvature on the inner surface of the outer shell 12 in a range of 2 mm surrounding the fresh air inlet 15, and the results indicated in Table 2 were obtained. As indicated in Table 2, when the width W of the flat region FR on the outer surface of the outer shell 12 was 3 mm or more, it was found that the radius of curvature on the inner surface of the outer shell 12 became severely large and the inner surface of the outer shell 12 became approximately flat. In contrast, when the width W of the flat region FR on the outer surface of the outer shell 12 was less than 3 mm, it was found that the inner surface of the outer shell 12 did not become flat but curved. Then, it was found that the delivery performance for a small amount of the contents was lowered by air leakage from the fresh air inlet 15 because of the curved surface did not appropriately match the valve member 5.
In the experimental example below, various delaminatable containers having different layer structures were produced by blow molding for various types of evaluation, such as restorability, rigidity, impact resistance, heat resistance, transparency, gas barrier properties, moldability, and outer layer processability. The outer layer processability indicates ease of process of forming the fresh air inlet 15 only in the outer layer 11 using a thermal perforator.
In the first structural example, the layer structure was, in order from outside the container, random copolymer layer/EVOH layer/adhesion layer/LLDPE layer. For the random copolymer layer, a random copolymer of propylene and ethylene (model: NOVATEC EG7FTB, produced by Japan Polypropylene Corp., melting point of 150° C.) was used. For the EVOH layer, EVOH having a high melting point (model: Soarnol SF7503B, produced by Nippon Synthetic Chemical Industry Co., Ltd., melting point of 188° C., modulus of elasticity in bending of 2190 MPa) was used. According to the above various types of evaluation, excellent results were obtained in all evaluation categories.
In the second structural example, the layer structure was, in order from outside the container, random copolymer layer/reproduction layer/random copolymer layer/EVOH layer/adhesion layer/LLDPE layer. The reproduction layer is made from a material obtained by recycling burrs produced while molding a container and has composition very close to that of the random copolymer layer. The random copolymer layer and the EVOH layer were formed of materials same as those in the first structural example. According to the above various types of evaluation, excellent results were obtained in all evaluation categories.
In the third structural example, the layer structure was same as that in the first structural example while, for the EVOH layer, EVOH having a low melting point (model: Soarnol A4412, produced by Nippon Synthetic Chemical Industry Co., Ltd., melting point of 164° C.) was used. According to the above various types of evaluation, excellent results were obtained in all evaluation categories other than the outer layer processability. The outer layer processability was slightly worse than that in the first structural example. This result demonstrates that the difference of (melting point of EVOH)−(melting point of random copolymer layer) is preferably 15° C. or more.
In the first comparative structural example, the layer structure was, in order from outside the container, LDPE layer/EVOH layer/adhesion layer/LLDPE layer. According to the above various types of evaluation, at least the rigidity and the heat resistance were low.
In the second comparative structural example, the layer structure was, in order from outside the container, HDPE layer/EVOH layer/adhesion layer/LLDPE layer. According to the above various types of evaluation, at least the restorability and the transparency were low.
In the third comparative structural example, the layer structure was, in order from outside the container, polypropylene layer/EVOH layer/adhesion layer/LLDPE layer. For the material for the polypropylene layer, a homopolymer of propylene having a melting point of 160° C. was used. For the EVOH layer, the material same as that in the first structural example was used. According to the above various types of evaluation, at least the impact resistance was low. In addition, the outer layer processability was worse than that in the first structural example.
In the fourth comparative structural example, the layer structure was, in order from outside the container, block copolymer layer/EVOH layer/adhesion layer/LLDPE layer. According to the above various types of evaluation, at least the transparency and the impact resistance were low.
In the fifth comparative structural example, the layer structure was, in order from outside the container, PET layer/EVOH layer/adhesion layer/LLDPE layer. According to the above various types of evaluation, at least the moldability and the heat resistance were low.
In the sixth comparative structural example, the layer structure was, in order from outside the container, polyamide layer/EVOH layer/adhesion layer/LLDPE layer. According to the above various types of evaluation, at least the moldability was low.
In the sixth comparative structural example, the layer structure was, in order from outside the container, polypropylene layer/polyamide layer/adhesion layer/LLDPE layer. According to the above various types of evaluation, at least the gas barrier properties and the moldability were low.
<Bend Test>
For an EVOH resin used as the EVOH layer, a bend test was performed using a Gelbo Flex Tester in accordance with ASTM F392 (manufactured by Brugger, KFT-C—Flex Durability Tester). The test environment was at 23° C. and 50% RH.
Firstly, a sample made from a single layer film in 28 cm×19 cm×30 μm was prepared.
Then, a longer side of the sample was wound around a pair of mandrels (diameter of 90 mm) arranged at an interval of 180 mm for fixation of both ends of the sample to the pair of mandrels A and B.
Then, while the mandrel A remained fixed, the mandrel B was gradually brought closer while being twisted and the twist was stopped when the twisting angle was 440 degrees and the horizontal movement distance reached 9.98 cm. After that, the horizontal movement of the mandrel B was continued and the horizontal movement was stopped when the horizontal movement distance after stopping twisting reached 6.35 cm. After that, the mandrel B was returned to the initial state by an operation opposite to above. Such operation was performed 100 times, followed by check on the presence of a pinhole. The results are indicated in Table 3.
SF7503B in Table 3 is an EVOH resin used for the EVOH layer in the first structural example. Meanwhile, D2908 in Table 3 is Soarnol D2908 (model: Soarnol SF7503B, produced by Nippon Synthetic Chemical Industry Co., Ltd.), which is a general EVOH resin. Each EVOH resin was subjected to the test twice.
As indicated in Table 3, by the test above, many pinholes were created in D2908, whereas no pinhole was created at all in SF7503B and it was found that the latter was excellent in bending resistance more than a general EVOH resin.
In the experimental example below, various delaminatable containers having different layer structures were produced by blow molding and such container thus obtained was filled with citrus flavored soy sauce, followed by still standing for one week, and then the total amount of citrus flavored soy sauce in the container was delivered for sensory evaluation of the citrus aroma in the delivered citrus flavored soy sauce. In addition, the shape of the inner bag of the container when the citrus flavored soy sauce is delivered was visually evaluated.
In the first structural example, the layer structure was, in order from outside the container, random copolymer layer/external EVOH layer (thickness of 25 μm)/adhesion layer (thickness of 150 μm)/internal EVOH layer (thickness of 15 μm). The external EVOH layer was formed of an EVOH resin added to a softening agent and the internal EVOH layer was formed of an EVOH resin not added to a softening agent. The adhesion layer was formed of a mixture of linear low density polyethylene and acid modified polyethylene at a mass ratio of 50:50. According to the above evaluation, intensity of the citrus aroma emitted by the delivered citrus flavored soy sauce was barely different. In addition, when the inner bag shrunk with the delivery of the citrus flavored soy sauce, the inner bag shrunk smoothly without being folded.
In the second structural example, the layer structure was same as that in the first structural example other than changing the thickness of the internal EVOH layer to 5 μm. According to the above evaluation, the intensity of the citrus aroma emitted by the delivered citrus flavored soy sauce was slightly worse than that in the first structural example. In addition, when the inner bag shrunk with the delivery of the citrus flavored soy sauce, the inner bag shrunk smoothly without being folded.
In the third structural example, the layer structure was same as that in the first structural example other than changing the thickness of the internal EVOH layer to 25 μm. According to the above evaluation, the intensity of the citrus aroma emitted by the delivered citrus flavored soy sauce was at an equivalent level to that in the first structural example. In addition, when the inner bag shrunk with the delivery of the citrus flavored soy sauce, the inner bag was prone to be folded than in the first structural example.
In the fourth structural example, the layer structure was same as that in the first structural example other than changing the thickness of the external EVOH layer to 75 μm and the thickness of the adhesion layer to 80 μm. According to the above evaluation, the intensity of the citrus aroma emitted by the delivered citrus flavored soy sauce was at an equivalent level to that in the first structural example. In addition, when the inner bag shrunk with the delivery of the citrus flavored soy sauce, the inner bag was prone to be folded than in the first structural example.
In the first comparative structural example, the layer structure was same as that in the first structural example other than replacing the internal EVOH layer by a linear low density polyethylene layer (50 μm). According to the above evaluation, the intensity of the citrus aroma emitted by the delivered citrus flavored soy sauce was significantly worse than that in the first structural example. In addition, when the inner bag shrunk with the delivery of the citrus flavored soy sauce, the inner bag shrunk smoothly without being folded.
In the second comparative structural example, the layer structure was same as that in the first structural example other than replacing the internal EVOH layer by a polyamide layer (50 μm). According to the above evaluation, the intensity of the citrus aroma emitted by the delivered citrus flavored soy sauce was significantly worse than that in the first structural example. In addition, when the inner bag shrunk with the delivery of the citrus flavored soy sauce, the inner bag shrunk smoothly without being folded.
1: Delaminatable Container, 3: Container Body, 5: Valve Member, 7: Storage Portion, 9: Mouth, 11: Outer Layer, 12: Outer Shell, 13: Inner Layer, 14: Inner Bag, 15: Fresh Air Inlet, 23: Cap, 27: Bottom Seal Protrusion
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-245358 | Nov 2013 | JP | national |
| 2013-245374 | Nov 2013 | JP | national |
This application is a continuation of U.S. patent application Ser. No. 15/100,151, filed on May 27, 2016, which is the national phase application of International Application No. PCT/JP2014/080735, filed on Nov. 20, 2014, which claims priority to Japanese Application No. 2013-245374, filed on Nov. 27, 2013, and Japanese Application No. 2013-245358, filed on Nov. 27, 2013, the entire contents of which are hereby incorporated by reference.
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| Number | Date | Country | |
|---|---|---|---|
| 20190256239 A1 | Aug 2019 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 15100151 | US | |
| Child | 16383993 | US |
