Patent Grant
10213846
The present invention relates to a method of machining a workpiece and a boring drill. This method is preferably applied to a procedure of forming a fresh air inlet in an outer shell of a delaminatable container.
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., PTL 1). Such delaminatable container is provided with an inner bag composed of an inner layer and an outer shell composed of an outer layer.
The outer shell of the delaminatable container is provided with a fresh air inlet to enable shrinkage of the inner bag. The fresh air inlet is generally formed using a punch cutter or the like from outside the container where it is not easy to securely form a fresh air inlet in the outer shell without damaging the inner bag.
[PTL 1] Japanese Patent No. 3455606
In PTL 1, the fresh air inlet is formed in the mouth from the mouth outer surface side by, in a state of causing a bearer to abut on the mouth inner surface, bringing the cutter blade at the end of the punch cutter in proximity to the bearer. Then, by setting a gap between the bearer and the cutter blade not to be in a predetermined distance or less, it is prevented that the cutter blade damages the inner bag of the delaminatable container.
However, the method in PTL 1 has a problem that it is difficult to form a fresh air inlet in a portion other than the mouth of the container.
The present invention has been made in view of such circumstances, and it is to provide a method of machining a workpiece that is capable of forming a fresh air inlet in an arbitrary position of the outer shell of the container.
According to the present invention, a method of machining a workpiece is provided that includes: machining to form a round hole in a workpiece using a boring drill having a tubular end portion, the end portion provided with a flat surface and a notch, and having a blade on a side of the notch by pressing the flat surface against the workpiece while rotating the drill to contact the blade with the workpiece.
In the present invention, a workpiece is machined using a boring drill having a tubular end portion, the end portion provided with a flat surface and a notch, and having a blade on a side of the notch. When the workpiece has certain stiffness and is readily deformed, the drill thus configured slightly digs in the workpiece at the end by pressing the flat surface against the workpiece while rotating the drill. As a result, entrance of the workpiece into the notch causes the blade to contact with the workpiece to form a round hole in the workpiece.
The outer shell of a general delaminatable container has certain stiffness and is readily elastically deformed. A round hole is thus readily formed by the method of the present invention. Meanwhile, when the flat surface of the drill is pressed on the inner bag of the delaminatable container, the inner bag is separated from the outer shell to be deformed towards the inside of the delaminatable container. The flat surface thus does not dig in the inner bag. The blade, therefore, does not make contact with the inner bag not to damage the inner bag. According to the present invention, a round hole is thus readily formed only in the outer shell of the delaminatable container. The round hole is applicable as a fresh air inlet to introduce fresh air between the outer shell and the inner bag.
Various embodiments of the present invention are exemplified below. The embodiments described below may be combined with each other.
Preferably, the workpiece is a delaminatable container including an outer shell and an inner bag, the inner bag delaminating from the outer shell to be shrunk with a decrease in the contents, and the machining includes forming a fresh air inlet in the outer shell by pressing the flat surface against the outer shell to contact the blade with the outer shell.
Preferably, the end portion of the drill has a C-shaped cross section.
Preferably, the flat surface has a radial width from 0.1 to 0.2 mm.
Preferably, the end portion has an inner surface provided with a tapered surface widening towards an end.
According to another aspect of the present invention, a boring drill is provided that includes: a tubular end portion; a flat surface and a notch provided in the end portion; and a blade on a side of the notch.
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 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 formed with a larger thickness than the inner layer 13 so as to increase the restorability thereof.
The outer layer 11 is formed of, for example, low-density polyethylene, linear low-density polyethylene, high-density polyethylene, polypropylene, ethylene-propylene copolymer, or a mixture thereof, or the like. The outer layer 11 consists of a single layer or multiple layers, and at least one of the innermost and outermost layers thereof contains a lubricant. If the outer layer 11 consists of a single layer, that single layer serves as both innermost and outermost layers. Accordingly, that layer only has to contain a lubricant. If the outer layer 11 consists of two layers, the layer closer to the inside of the container serves as the innermost layer, and the layer closer to the outside of the container serves as the outermost layer. Accordingly, at least one of these layers only has to contain a lubricant. If the outer layer 11 consists of three layers, the layer closest to the inside of the container serves as the innermost layer, and the layer closest to the outside of the container serves as the outermost layer. As shown in
The lubricant may be any type of commercially available common lubricant. The lubricant may be one of a hydrocarbon-based lubricant, a fatty acid-based lubricant, an aliphatic amide-based lubricant, a metal soap-based lubricant, and a combination of two or more thereof. Examples of the hydrocarbon-based lubricant include liquid paraffin, paraffin wax, and synthesized polyethylene wax. Examples of the fatty acid-based lubricant include stearic acid and stearyl alcohol. Examples of the aliphatic amide-based lubricant include fatty amides, such as stearamide, oleic amide, and erucic acid amide, and alkylene fatty amides, such as methylene bis(stearamide) and ethylene bis(stearamide).
The innermost layer of the outer layer 11 is a layer that makes contact with the inner layer 13. By containing the lubricant in the innermost layer of the outer layer 11, it is possible to improve delamination properties between the outer layer 11 and the inner layer 13 and to improve deliverability of the contents of the delaminatable container. Meanwhile, the outermost layer of the outer layer 11 is a layer that makes contact with a die during blow molding. By containing the lubricant in the outermost layer of the outer layer 11, it is possible to improve releasability.
One or both of the innermost layer and the outermost layer of the outer layer 11 may be formed with a random copolymer of propylene and another monomer. This enables improvement in 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, a mixture obtained by mixing a flexible material, such as linear low density polyethylene, with the random copolymer may be used. 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, a mixture obtained by mixing the random copolymer and linear low-density polyethylene at a weight ratio of 85:15 may be used.
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 melting point higher than the melting point of the resin contained in the outer layer 11. When the fresh air inlet 15 is formed in the outer layer 11 using a thermal perforator, 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 resin contained in the outer layer 11. From this perspective, a greater difference of (Melting Point of EVOH)−(Melting Point of the Resin from which the outer layer 11 is formed) 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.
A description is then given to an example of a method of manufacturing the delaminatable container 1 in the present embodiment.
First, as illustrated in
Next, as illustrated in
Then, as illustrated in
Then, as illustrated in
Then, as illustrated in
First, as illustrated in
The drill 30 is provided with a hollow 33 extending from the body portion 31 to the end portion 32 (see,
As illustrated in
The flat surface 34 has a radial width W preferably from 0.1 to 0.2 mm and more preferably from 0.12 to 0.18 mm. A too small width W causes easy damage of the inner bag 14 during perforation. A too large width W causes difficulty in contacting the blade 38 with the outer shell 12, making it difficult to perform smooth perforation. The notch 37 is provided in a range preferably from 60 to 120 degrees and more preferably from 75 to 105 degrees. The notch being provided in a too large range causes easy damage of the inner bag 14 during perforation, whereas the notch being provided in a too small range causes difficulty in smooth perforation. The blade 38 has an inclined plane P2 at an angle α to a circumscribed surface P1 preferably from 30 to 65 degrees and more preferably from 40 to 55 degrees. A too small angle α causes easy damage of the inner bag 14 during perforation, whereas a too large angle α causes difficulty in smooth perforation.
The end portion 32 has an inner surface 35 provided with a tapered surface 36 widening towards the end. This facilitates movement of a cut piece 15a (see,
Then, as illustrated in
When the flat surface 34 reaches the boundary between the outer shell 12 and the inner bag 14 and then the flat surface 34 is pressed against the inner bag 14, the inner bag 14 is delaminated from the outer shell 12 to be readily deformed towards inside the delaminatable container 1. The flat surface 34 thus does not dig in the inner bag 14 and the inner bag 14 does not make contact with the blade 38 to inhibit damaging of the inner bag 14.
In the present embodiment, the drill 30 is used without heating. This gives an advantage of not melting the edge of the fresh air inlet 15 to form the edge sharply. In order to inhibit influence due to heat generated by the friction between the boring drill 30 and the outer shell 12, the drill 30 is preferably form with a material having a high thermal conductivity (e.g., 35 W/(m·° C.) or higher at 20° C.). To facilitate the perforation more, the drill 30 may be heated. In this case, to keep the inner bag 14 from being melted by the heat of the drill 30, the resin contained in the outermost layer of the inner bag 14 preferably has a melting point higher than the melting point of the resin contained in the innermost layer of the outer shell 12.
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
Then, as illustrated in
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 41 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
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 |
|---|---|---|---|
| 2014-184552 | Sep 2014 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2015/073894 | 8/25/2015 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2016/039134 | 3/17/2016 | WO | A |
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| Number | Date | Country | |
|---|---|---|---|
| 20170259352 A1 | Sep 2017 | US |
