JP7578935B2 - Manufacturing apparatus and method for laminated container - Google Patents

Description

The present invention relates to an apparatus and method for manufacturing laminated containers in which a resin layer is formed and integrated onto the inner surface of a paper container.

Conventionally, laminated containers have been known as cup-shaped containers in which a resin layer is formed on the inside of a paper container to improve water resistance (see, for example, Patent Document 1). In Patent Document 1, a resin layer is formed on the inside of a paper container by stretch blow molding. That is, a preform made of a thermoplastic resin is heated, and the paper container is set in a stretch blow mold, and the preform placed in the paper container is stretch blow molded inside the paper container to adhere to the inner surface of the paper container, making it possible to integrate the resin layer with the paper container.

JP 2009-208402 A

However, in the case of a laminated container consisting of a paper container and a resin layer, the outside is paper and the inside is resin, so they are made of different materials, and when discarding them, it is necessary to remove the resin layer from the paper container and dispose of them separately.

However, because the purpose of Patent Document 1 is to increase the adhesive strength between the paper container and the resin layer to firmly integrate them, no consideration is given to the separate disposal of the paper container and the resin layer. Therefore, it is thought that separate disposal cannot be easily performed by users.

The present invention was made in consideration of these points, and its purpose is to make it possible to easily separate and dispose of laminated containers in which a resin layer is formed on the inside of a paper container, while preventing the paper container and the resin layer from accidentally separating during use.

To achieve the above objective, in the present invention, a resin sheet that has been heated and sufficiently softened is molded by adhering it to the inner surface of a paper container using vacuum and pressure molding.

The first invention is a laminated container manufacturing device in which a resin layer made of a resin different from the resin coating layer is formed on the inside of a paper container having a resin coating layer, the device being characterized by comprising a sheet heating unit that heats and softens the resin sheet that becomes the resin layer, an upper mold that is placed on the resin sheet heated by the sheet heating unit and has a recess that holds the paper container with air passage holes formed in an open position downward, a vacuum device connected to a suction hole formed on the inner surface of the recess of the upper mold, a lower mold that is placed under the resin sheet heated by the sheet heating unit, a mold drive device that drives at least one of the upper mold and the lower mold in a direction toward and away from each other, and a compressed air introduction device that introduces compressed air into the lower mold when the mold is in a closed state.

According to this configuration, by opening the upper and lower dies, it is possible to hold a paper container having a resin coating layer in the recess of the upper die. On the other hand, a resin sheet made of a resin different from the resin coating layer is heated by the sheet heating unit and sufficiently softened, and is placed under the paper container, i.e., facing the open part of the paper container. In this state, when the upper and lower dies are closed and negative pressure is applied to the suction hole by the vacuum device, the paper container has air passage holes, so that the inside of the paper container becomes negative pressure, and the softened resin sheet is molded in close contact with the inner surface of the paper container. At this time, compressed air is introduced into the lower die by the compressed air introduction device, so that the resin sheet is pressed against the inner surface of the paper container by the compressed air. In other words, by vacuum and pressure molding the resin sheet, a resin layer is formed inside the paper container by strongly adhering it to the inner surface of the paper container. Since the resin sheet has a strong adhesion to the paper container during molding, the resin layer is less likely to come off the paper container during use. On the other hand, because the resin layer and the resin coating layer of the paper container are made of different resins, the adhesive strength is not very high, making it easy to separate them when disposing of them.

The second invention is characterized in that the lower mold has a plug that is inserted into the recess of the upper mold.

With this configuration, the plug can be inserted into the recess of the upper mold while the upper and lower molds are closed. This makes it easier to actively push the resin sheet up into the paper container and make it adhere to the inner surface of the paper container.

The third invention is characterized in that it includes a plug drive device that switches the plug between a molding position where it protrudes from the upper surface of the lower mold and a storage position where it is stored in the lower mold, and the plug drive device is configured to set the plug to the molding position when the resin sheet is molded and to set it to the storage position after molding.

With this configuration, the plug protrudes only when the resin sheet is being molded, and can be stored in the lower die after molding, so the plug does not get in the way after molding.

The fourth invention is characterized in that it includes a sheet feed section that feeds the resin sheet, and the sheet heating section is disposed away from the upper mold on the upstream side in the feed direction of the resin sheet.

With this configuration, the sheet heating section is separated from the upper mold, so the resin coating layer of the paper container held in the recess of the upper mold can be prevented from melting due to the heat of the sheet heating section. As a result, the resin constituting the resin coating layer of the paper container and the resin constituting the resin layer do not mix, so the adhesive strength between the paper container and the resin layer does not increase more than necessary, and separation workability at the time of disposal can be improved.

The fifth invention is a method for manufacturing a laminated container in which a resin layer made of a different resin from the resin coating layer is formed on the inside of a paper container having a resin coating layer, and is characterized by comprising a sheet heating step of heating and softening the resin sheet that becomes the resin layer, a holding step of holding the paper container with air passage holes formed in a recess of an upper mold placed on the resin sheet in an open-down position, and a molding step of closing the upper mold and a lower mold placed below the upper mold after the sheet heating step and the holding step, applying negative pressure to the inner surface of the recess of the upper mold, and introducing compressed air into the lower mold to mold the resin sheet into close contact with the inner surface of the paper container.

According to the present invention, when a resin layer is formed on the inside of a paper container having a resin coating layer using a resin sheet made of a resin different from the resin coating layer, the resin sheet softened by heating can be integrated into the paper container by vacuum and pressure forming. This prevents the paper container and the resin layer from accidentally separating during use, and allows for easy separation when discarding.

1 is a side view of a stacked container manufacturing apparatus according to an embodiment of the present invention. FIG. 2 is a vertical cross-sectional view of a laminated container. FIG. 2 is a vertical cross-sectional view of a paper container. FIG. 2 is a perspective view showing a state in which a plurality of stacked containers are connected together. FIG. 4 is a side view of the mold drive device, the upper mold, and the lower mold in a closed state. FIG. 5 is a view equivalent to FIG. 4 and shows the mold in an open state. FIG. 4 is a cross-sectional view of the upper and lower molds, showing the molds in an open state. FIG. 7 is a view corresponding to FIG. 6 according to a modified example of the embodiment. FIG. FIG. 7 is a view equivalent to FIG. 6 and shows the mold in a closed state. FIG. 7 is a view equivalent to FIG. 6 showing the plug in a molding position. FIG. 7 is a view equivalent to FIG. 6 and shows a state in which a resin sheet is adhered to the inner surface of a paper container by air pressure. 7 is a view equivalent to FIG. 6 showing the state in which the mold is open after molding of the laminated container. 7 is a view equivalent to FIG. 6 and showing a state in which the stacked container is placed on a container placement member. FIG. 7 is a view equivalent to FIG. 6 and shows a state in which the container mounting member on which the stacked containers are mounted is switched to the upper position. 7 is a view equivalent to FIG. 6 and illustrating a state in which the stacked container placed on the container placement member is sucked by the suction portion and transported. FIG.

The following describes in detail an embodiment of the present invention with reference to the drawings. Note that the following description of the preferred embodiment is essentially merely an example and is not intended to limit the present invention, its applications, or its uses.

Figure 1 is a side view of a manufacturing apparatus 1 for a laminated container according to an embodiment of the present invention. The manufacturing apparatus 1 is an apparatus for manufacturing a laminated container 100 as shown in Figures 2A and 2B. In explaining this embodiment, before explaining the manufacturing apparatus 1, the structure of the laminated container 100 will be explained based on Figures 2A and 2B. The laminated container 100 is composed of a paper container 101 and a resin layer 102. The laminated container 100 may be a container for storing liquid, such as a cup, or a container for storing various foods, and its shape is not particularly limited. The laminated container 100 may be a bowl, a box, etc. other than a cup.

The size of the laminated container 100 is not particularly limited, but may be, for example, about 5 cm to 15 cm in depth and about 5 cm to 10 cm in diameter. The resin layer 102 of the laminated container 100 having such a depth can be obtained by drawing or deep drawing a resin sheet S (shown by phantom lines in FIG. 1) which is the material of the resin layer 102. The resin sheet S may be any sheet that has been conventionally used for drawing, and may be, for example, a sheet made of polypropylene or a sheet in which multiple types of resin are laminated. Such a resin sheet S has a length of several tens of meters or more, and can be supplied to the manufacturing device 1 in a coiled state.

As shown in FIG. 2B, the paper container 101 is a cup-shaped container that opens upward and has a bottom wall portion 101a and a peripheral wall portion 101b. An air passage hole 101c is formed in the bottom wall portion 101a. There may be one or more air passage holes 101c, which penetrate the bottom wall portion 101a in the vertical direction. The inside of the paper container 101 communicates with the outside through the air passage hole 101c. The air passage hole 101c may be a hole such as a so-called pinhole formed by penetrating the bottom wall portion 101a with a thin needle, for example, or may be a hole formed by punching out a part of the bottom wall portion 101a with a punch or the like. Forming the air passage hole 101c with a needle is preferable because it makes the air passage hole 101c less noticeable. The air passage holes 101c may be provided only on the periphery of the bottom wall 101a, only on the center of the bottom wall 101a, or on the entire bottom wall 101a. The periphery of the bottom wall 101a is the part that joins with the peripheral wall 101b and is bent downward.

The peripheral wall portion 101b is formed so that its diameter increases as it approaches the upper end. The lower end portion of the peripheral wall portion 101b is the portion that joins with the bottom wall portion 101a, and is bent upward so as to sandwich the peripheral portion of the bottom wall portion 101a. The peripheral portion of the bottom wall portion 101a and the lower end portion of the peripheral wall portion 101b may be glued or crimped. Although not shown, the peripheral wall portion 101b may be provided with air passage holes.

As shown in FIG. 2B, a resin coating layer 101d is provided on the inner surface of the paper container 101. The resin coating layer 101d can be provided on both the inner surface of the bottom wall portion 101a and the inner surface of the peripheral wall portion 101b, but may be provided on only one of the inner surfaces. Examples of resins that constitute the resin coating layer 101d include polyethylene (PE) and polyvinyl acetate (PVCA). The resin coating layer 101d is firmly attached to the inner surface of the paper container 101. An adhesive component may be applied instead of the resin coating layer 101d.

The bottom wall 101a and the peripheral wall 101b that make up the paper container 101 are made of separate materials, so there is a risk of liquid leaking from the joints between them. To prevent this, a resin layer 102 is provided as shown in FIG. 2A. The resin layer 102 is a water-impermeable layer formed on the inside of the paper container 101 that has the resin coating layer 101d, and is formed integrally with the bottom wall 101a and the peripheral wall 101b so as to cover them, and is continuous from the bottom wall 101a side to the upper end of the paper container 101. The thickness of the resin layer 102 is set to be thicker than the thickness of the resin coating layer 101d.

By providing the resin layer 102, the laminated container 1 can be made water-resistant, and various liquids do not leak to the outside. The resin layer 102 is made of a resin different from the resin constituting the resin coating layer 101d, and an example of such a resin is polypropylene (PP). While the resin coating layer 101d is firmly attached to the inner surface of the paper container 101, the resin layer 102 is not firmly attached to the resin coating layer 101d, and for example, when the laminated container 100 is disposed of, the resin layer 102 can be easily peeled off from the resin coating layer 101d with a finger. In other words, the adhesion strength between the resin layer 102 and the resin coating layer 101d is set lower than the adhesion strength between the resin coating layer 101d and the paper container 101. This is because the resin layer 102 is made of a resin different from the resin coating layer 101d, the adhesive strength of one layer to the other is low, and the resin coating layer 101d is not melted when the resin layer 102 is molded, as described later.

On the other hand, the adhesive strength between the resin layer 102 and the resin coating layer 101d is set so that they do not peel off during normal use of the laminated container 100. Such adhesive strength can be obtained by vacuum and pressure molding the resin layer 102, as described below.

The resin layer 102 and the resin coating layer 101d may be made of different resins, and may be made of a resin other than polyethylene or polypropylene. Any combination of resins may be used as long as the adhesive strength of the resin layer 102 to the resin coating layer 101d is such that the resin layer 102 can be easily peeled off when disposed of, as described above, but is strong enough not to be easily peeled off during normal use.

Figure 3 shows a stacked container 200 that can be manufactured by the manufacturing apparatus 1. The stacked container 200 shown in Figure 3 is formed by connecting and integrating four containers 201. Each container 201 has a recess 201a and a flange 201b, and is composed of a paper container and a resin layer, similar to the stacked container 100 shown in Figure 2A. Reference numeral 202 indicates a linear weakened portion for dividing the container 201. The linear weakened portion 202 is designed to break when a bending force or the like is applied, allowing the container 201 to be divided into four.

The resin sheet S is fed from the left side to the right side of FIG. 1. On the left side of FIG. 1, the resin sheet S wound into a coil shape is shown by imaginary lines. On the right side of FIG. 1, the resin sheet S after molding into the container 100 is shown by imaginary lines in a wound (recovered) state. In the description of this embodiment, when defining the direction of the manufacturing device 1, the upstream side and downstream side are defined based on the feed direction of the resin sheet S. The upstream side is the left side of FIG. 1, and the downstream side is the right side of FIG. 1. In addition, when the manufacturing device 1 is viewed from the upstream side of the feed direction of the resin sheet S, the left side is referred to as the left of the manufacturing device 1, and the right side is referred to as the right of the manufacturing device 1. The left-right direction of the manufacturing device 1 is the width direction of the manufacturing device 1.

(Overall configuration of manufacturing apparatus 1)
The manufacturing device 1 includes a sheet feeding section 2, a sheet heating section 3, a forming section 4, a discharge section 5, an adsorption section 6, and a control panel 7. The resin sheet S fed by the sheet feeding section 2 is heated by the sheet heating section 3. When the heated and softened resin sheet S is fed to the forming section 4, it is molded by the forming section 4 so as to adhere to the inner surface of a paper container 101. The stacked container 100 obtained in this manner is automatically discharged to the discharge section 5 by the feeding operation of the resin sheet S, as described later. The stacked container 100 discharged to the discharge section 5 is adsorbed by the adsorption section 6 and transported to another location. The stacked containers 100 transported by the adsorption section 6 are stacked and accumulated in a predetermined location.

Upstream of the sheet feed section 2 of the manufacturing apparatus 1, an upstream support table 8 is provided that supports the coiled resin sheet S so that it can be unwound. Downstream of the discharge section 5 of the manufacturing apparatus 1, a downstream support table 9 is provided that supports the wound resin sheet S after the formation of the laminated container 100 has been completed. The upstream support table 8 and the downstream support table 9 are also components that constitute the manufacturing apparatus 1, but they may be omitted.

(Configuration of Sheet Feed Unit 2)
The manufacturing apparatus 1 includes a base 10 fixed to, for example, a floor surface 200 of a factory. The sheet feed unit 2 is disposed on the upstream side of the manufacturing apparatus 1, and in this embodiment, is located between the upstream support table 8 and the sheet heating unit 3. The sheet feed unit 2 is fixed to the upper part of the base 10, and is disposed at a higher position than the upstream support table 8. Therefore, the resin sheet S is set in the sheet feed unit 2 so as to extend upward from the upstream support table 8 toward the downstream side to the sheet feed unit 2.

The sheet feed section 2 is composed of a feed device for feeding the resin sheet S downstream. For example, there is a feed device that presses a roller rotated around a horizontal axis against the resin sheet S and feeds the resin sheet S by utilizing the friction between the outer circumferential surface of the roller and the surface of the resin sheet S, but this is not limited to this, and various feed devices can be used. The sheet feed section 2 is connected to a control panel 7 and is controlled by this control panel 7 to control the timing of starting and stopping the feeding of the resin sheet S and adjust the feeding speed of the resin sheet S. Although not shown, the manufacturing device 1 is provided with guide members that guide both ends of the resin sheet S in the width direction (left and right direction of the manufacturing device 1) in the horizontal direction, and the resin sheet S is fed from the upstream side to the downstream side in a posture extending in a substantially horizontal direction, as shown by the imaginary line in FIG. 4.

The sheet feed unit 2 does not have to be located upstream of the manufacturing device 1, but may be located, for example, in the middle or downstream of the manufacturing device 1 in the feed direction of the sheet S.

(Configuration of the seat heating unit 3)
The sheet heating unit 3 is disposed downstream of the sheet feeding unit 2. Specifically, the sheet heating unit 3 is located between the sheet feeding unit 2 and the molding unit 4, and is disposed away from the upper mold 40 on the upstream side in the feeding direction of the resin sheet S. In addition, the sheet heating unit 3 is fixed on the upper part of the base 10 on the downstream side of the sheet feeding unit 2, and is disposed at a position higher than the upstream support stand 8.

The sheet heating unit 3 includes a heater support member 3a, a lower heater 3c, and a heater lifting device 3d. The heater support member 3a is configured to protrude upward from the upper part of the base 10. The heater lifting device 3d is provided on the upper part of the heater support member 3a. The heater lifting device 3d includes a wire 3e, a pulley 3f around which the wire 3e is wound, and a motor (not shown) that rotates the pulley 3f forward and backward.

A lower heater 3c is fixed to one end of the wire 3e. The lower heater 3c is an electric heater that is disposed to face the lower surface of the resin sheet S and heats the resin sheet S from below. Meanwhile, the other end of the wire 3e is wound around a pulley 3f. When the pulley 3f is rotated, the wire 3e is advanced, and the advancement of the wire 3e causes the lower heater 3c to be raised and lowered.

As shown by the solid line in FIG. 1, by placing the lower heater 3c in the lowermost position, the lower heater 3c is separated from the resin sheet S and is in a retracted state. By rotating the pulley 3f and placing the lower heater 3c in the uppermost position as shown by the phantom line in FIG. 1, the lower heater 3c is brought close to the resin sheet S. In this embodiment, by raising and lowering the lower heater 3c, it is possible to switch between a state close to the resin sheet S and a state retracted from the resin sheet S, so that it is possible to prevent the width of the manufacturing device 1 from becoming wider than when the heater is moved in the width direction of the manufacturing device 1.

The lower heater 3c of the sheet heating unit 3 and the motor for rotating the pulley 3f are connected to and controlled by the control panel 7. For example, the output of the lower heater 3c can be adjusted so that the temperature of the resin sheet S is suitable for molding, and the lower heater 3c can be moved away from the resin sheet S when heating is not required and moved close to the resin sheet S when heating is required.

The heating temperature of the resin sheet S by the sheet heating unit 3 can be set arbitrarily depending on the resin. In this embodiment, the heating temperature is set so that the resin sheet S is sufficiently softened, and as a result, the resin sheet S is deformed so that it sags significantly downward compared to before heating. In other words, it is preferable to adjust the heating temperature so that the resin sheet S sags significantly.

In addition, the sheet heating unit 3 can be covered with a shielding member and placed in a closed space to improve heating efficiency.

(Configuration of molding portion 4)
The forming section 4 is provided downstream of the sheet heating section 3, and includes an upper mold (upper mold) 40, a lower mold (lower mold) 41, and a mold drive device 42. The upper mold 40 is disposed on the resin sheet S. As shown in FIG. 6, the upper mold 40 is formed with a holding recess 40a that opens downward for holding a paper container 101 (shown in FIG. 2B) that constitutes the outside of the laminated container 100. The paper container 101 with air passage holes 101c formed therein is held in a position that opens downward. Note that FIG. 6 shows only a part of the forming section 4.

A plurality of suction holes 40c are formed on the inner surface of the holding recess 40a. A vacuum suction pipe 4a is connected to these suction holes 40c. There may be only one suction hole 40c. A vacuum device 4c (shown only in FIG. 6) is connected to the vacuum suction pipe 4a. The vacuum device 4c is a device equipped with a conventionally known vacuum pump, etc., and is connected to and controlled by the control panel 7. By operating the vacuum suction device 4c, a negative pressure is applied to the suction hole 4c through the vacuum suction pipe 4a. For example, the vacuum pressure is applied to the suction hole 40c only during molding of the laminated container 100, or from holding the paper container 101 until before demolding, and it can be controlled not to act when demolding the laminated container 100, which can be controlled by the control panel 7. In addition, an upper cut blade 40b is continuously formed on the lower surface of the upper mold 40 so as to surround the lower end opening of the holding recess 40a.

The lower die 41 has a plug 41b and is positioned directly below the upper die 40, i.e., below the resin sheet S. The lower die 41 is formed with a plug accommodating recess 41a that accommodates the plug 41b and is recessed downward. The plug accommodating recess 41a is open upward, and the upper end opening of this plug accommodating recess 41a and the lower end opening of the holding recess 40a of the upper die 40 are approximately aligned.

A plurality of air discharge holes 41d are formed on the inner surface of the plug receiving recess 41a. An inlet pipe 4b for introducing compressed air is connected to the air discharge hole 41d. There may be only one air discharge hole 41d. A compressed air introduction device 4d (shown only in FIG. 6) is connected to the inlet pipe 4b. The compressed air introduction device 4d is a device equipped with a conventionally known air compression pump, etc., and is connected to and controlled by the control panel 7. By operating the compressed air introduction device 4d, air pressure is applied to the air discharge hole 41d through the inlet pipe 4b. For example, air pressure is applied to the air discharge hole 41d only during molding of the resin layer 102, and it is possible to prevent air pressure from acting when the laminated container 100 is demolded after molding, which can be controlled by the control panel 7.

The compressed air introduction device 4d may be configured as a switching valve device connected to the factory air piping, and the switching valve device can be controlled by the control panel 7 to switch between a state in which air pressure is applied to the air discharge hole 41d and a state in which it is not applied.

The manufacturing device 1 according to this embodiment is a vacuum/compressed air molding machine capable of molding the resin layer 102 using the vacuum pressure of the upper mold 40 and the compressed air of the lower mold. Depending on the conditions of the molded product, molding may be performed using only one of the vacuum pressure of the upper mold 40 and the compressed air of the lower mold.

On the upper surface of the lower mold 41, the lower cutter blade 41c is continuously formed so as to surround the upper end opening of the plug receiving recess 41a. For example, as shown in FIG. 9, when the upper mold 40 and the lower mold 41 are closed, the lower cutter blade 41c and the upper cutter blade 40b apply a shear force to the resin sheet S, and this shear force can cut the portion of the resin sheet S that will become the peripheral portion of the laminated container 100. In other words, when the upper mold 40 and the lower mold 41 are driven in a direction approaching each other and the molds are closed, the cutter blade of one mold cuts the portion of the resin sheet S that will become the peripheral portion of the container 100 together with the cutter blade of the other mold.

In addition, since it is sufficient to apply a shear force capable of cutting the resin sheet S, only one of the lower cutting blade 41c and the upper cutting blade 40b may be provided, and the peripheral portion of the container 100 may be cut by that cutting blade and the edge portion of the mold. The structure and shape of the cutting blade are not particularly limited.

Below the lower mold 41, a plug drive device 43 is provided to drive the plug 41b in the vertical direction. The plug drive device 43 can be configured, for example, with a fluid pressure cylinder or a feed screw device, and is connected to and controlled by a control panel 7. The lower part of the plug 41b is fixed to the upper part of the plug drive device 43. The plug 41b has a shape close to a cylinder. The upper surface of the plug 41b is curved so as to protrude upward. The shape of the plug 41b is not limited to the shape shown in the figure, and can be changed as appropriate depending on the shape of the stacked container 100, etc.

The plug drive device 43 is for switching the plug 41b between a molding position (shown in FIG. 10) where the plug 41b protrudes from the upper surface of the lower mold 41 and is inserted into the holding recess 40a of the upper mold 40, and a storage position (shown in FIG. 6, FIG. 7, etc.) where the plug 41b is stored in the plug storage recess 41a of the lower mold 41. The plug drive device 43 is configured to set the plug 41b to the molding position when the resin sheet S is molded (when the resin layer 102 is molded), and to set the plug 41b to the storage position when the resin sheet S is sent, for example, after molding. The upper surface of the plug 41b in the molding position is pressed against the resin sheet S from below, so that the resin sheet S is stretched upward and approaches the inner surface of the holding recess 40a of the upper mold 40, i.e., the inner surface of the paper container 101. The movement of the plug 41b can be controlled so that the plug 41b is stored when the resin sheet S is sent. The manufacturing device 1 of this embodiment is a plug-assisted type manufacturing device because it is equipped with the plug 41b pressed against the resin sheet S.

The mold driving device 42 is a device for driving the upper mold 40 and the lower mold 41 in a direction to move them toward and away from each other, and is connected to the control panel 7 and controlled by the control panel 7. The mold driving device 42 includes an upper mold driving device 44 that drives the upper mold 40 in the vertical direction, and a lower mold driving device 45 that drives the lower mold 41 in the vertical direction. The upper mold driving device 44 moves the upper mold 40 upward, and the lower mold driving device 45 moves the lower mold 41 downward to open the mold, and the upper mold driving device 44 moves the upper mold 40 downward, and the lower mold driving device 45 moves the lower mold 41 upward to close the mold. The upper mold driving device 44 and the lower mold driving device 45 are controlled by the control panel 7 and are synchronized.

That is, the upper die driving device 44 is composed of, for example, a fluid pressure cylinder, a feed screw device, etc., or a combination of these, and is fixed to the base 10 via a support member or the like (not shown) so as not to move. The upper die 40 is connected to the lower part of the upper die driving device 44, and the upper die 40 descends when the upper die driving device 44 performs an extending operation (shown in FIG. 9), while the upper die 40 ascends when the upper die driving device 44 performs a contracting operation (shown in FIG. 6). The timing at which the upper die driving device 44 starts operating and the amount of operation are determined by a signal from the control panel 7.

As shown in Figures 4 and 5, the lower die driving device 45 includes an electric motor 45a, a reducer 45b, a driving lever 45c, a driving link 45d, a first driven lever 45e, a second driven lever 45f, and a connecting rod 45h. The electric motor 45a is connected to a control panel 7 and is controlled by the control panel 7. The output of the electric motor 45a is input to the reducer 45b. The driving lever 45c is fixed to the output shaft of the reducer 45b (a shaft extending in the width direction and horizontal direction of the manufacturing device 1) and is adapted to rotate around a horizontal axis by the rotational force of the output shaft. One end of the driving link 45d is connected to the tip of the driving lever 45c so as to be rotatable around the horizontal axis.

On the other hand, the first driven lever 45e and the second driven lever 45f are integrated via a shaft 45g so that they do not rotate relative to each other. The shaft 45g extends horizontally and is supported rotatably with respect to the base 10. Therefore, the first driven lever 45e and the second driven lever 45f rotate together around the horizontal axis. The other end of the drive link 45d is connected to the tip of the first driven lever 45e so as to be rotatable around the horizontal axis.

One end of the connecting rod 45h is connected to the tip of the second driven lever 45f so as to be rotatable around a horizontal axis. The other end of the connecting rod 45h is connected to a connecting member 41e that connects the lower die 41 and the connecting rod 45h so as to be rotatable around a horizontal axis. The lower die 41, the plug 41b, and the plug driver 43 are integrated and move up and down together.

When the electric motor 45a rotates, the drive lever 45c rotates, and the drive link 45d moves in the left-right direction in FIG. 1. The moving force of the drive link 45d is transmitted to the first driven lever 45e, and the first driven lever 45e and the second driven lever 45f rotate around a horizontal axis. When the second driven lever 45f rotates, the connecting rod 45h moves up and down, and the lower die 41 to which the connecting rod 45h is connected via the connecting member 41e moves up and down. The lower die 41 can be raised or lowered depending on the rotation direction of the electric motor 45a. The rotation direction, rotation speed, start and stop of the electric motor 45a can be controlled by a signal from the control panel 7, and the operation start timing and operation amount of the lower die 41 are determined. The state shown in FIG. 4 is a state in which the lower die 41 is located at the upper end, and the state shown in FIG. 5 is a state in which the lower die 41 is located at the lower end.

The configuration of the lower die drive device 45 described above is an example, and is not limited to the above configuration. For example, the lower die drive device 45 can be configured using a fluid pressure cylinder, etc.

The compressed air introduction device 4d is controlled by the control panel 7 to introduce compressed air into the lower die 41 when the upper die 40 and the lower die 41 are closed, and not to introduce compressed air when the upper die 40 and the lower die 41 are open. Similarly, the vacuum drawing device 4c is controlled by the control panel 7 to draw a vacuum when the upper die 40 and the lower die 41 are closed, and not to draw a vacuum when the upper die 40 and the lower die 41 are open.

The mold drive device 42 is configured to lower the lower mold 41 when the sheet feed unit 2 feeds the resin sheet S, compared to when the resin sheet S is molded. That is, as shown in FIG. 6, when the sheet feed unit 2 feeds the resin sheet S, the lower mold drive device 45 is operated so that the upper surface of the lower mold 41 is positioned below the trajectory (shown by a virtual line) of the resin sheet S. As a result, a predetermined gap is formed between the upper surface of the lower mold 41 and the lower surface of the resin sheet S. Note that a predetermined gap does not need to be formed between the upper surface of the lower mold 41 and the lower surface of the resin sheet S, and in this case, the degree of interference with the lower surface of the resin sheet S can be reduced by the amount that the upper surface of the lower mold 41 is lowered. After that, when the feeding operation of the resin sheet S stops, the lower mold drive device 45 is operated so that the upper surface of the lower mold 41 comes into contact with the lower surface of the resin sheet S when the resin sheet S is molded, as shown in FIG. 9 to FIG. 11.

When the sheet feed unit 2 stops feeding the resin sheet S, the lower die drive unit 45 of the die drive unit 42 raises the lower die 41 to a position higher than when the resin sheet S was being fed (see FIG. 9). At this time, the upper surface of the lower die 41 is on the trajectory of the resin sheet S, i.e., in a position that contacts the lower surface of the resin sheet S, so that the heated and loosened resin sheet S can be supported from below.

The upper mold 40 and the lower mold 41 may be arranged in multiple rows in the feed direction of the resin sheet S, or in multiple rows in the left-right direction of the manufacturing device 1. In addition, multiple holding recesses 40a may be formed in one upper mold 40, and multiple plug-accommodating recesses 41a may be formed in one lower mold 41.

As shown in FIG. 6, the molding section 4 has an in-mold suction section 49. The in-mold suction section 49 is a section that suctions the paper container 101. A vacuum piping (not shown) is connected to the in-mold suction section 49, so that negative pressure acts on the lower end of the in-mold suction section 49.

The in-mold suction section 49 moves up and down by a drive device not shown, and the position shown by the solid line in FIG. 6 is the raised position, and the position shown by the virtual line is the lowered position. By moving the in-mold suction section 49 to the lowered position by the drive device, the paper container 101 can be adsorbed and held by the in-mold suction section 49. By moving the in-mold suction section 49 holding the paper container 101 to the raised position by the drive device, the paper container 101 can be contained and held within the upper mold 40, as shown by the solid line in FIG. 6.

Figure 7 shows a modified example of the molding section 4. In this modified example, two upper dies 40 and a lower die 41 are arranged side by side in the feed direction of the resin sheet S. This makes it possible to mold multiple stacked containers 100 simultaneously. Three or more upper dies 40 and lower dies 41 may be arranged side by side in the feed direction of the resin sheet S.

(Configuration of Supply Device 60)
As shown in Fig. 1, the manufacturing apparatus 1 includes a supply device 60 that supplies paper containers 101 to the upstream side of the forming unit 4. The upstream side is the upstream side in the feed direction of the resin sheet S. As shown in an enlarged view in Fig. 8, the manufacturing apparatus 1 includes a cylindrical storage unit 61 that stores the paper containers 101, a slider 62 that slides horizontally, and a slider drive device 63 that drives the slide member 62.

In the case of the modified example shown in FIG. 7, the storage section 61 can store the paper containers 101 arranged in two rows in the feed direction of the resin sheet S. The paper containers 101 are stored in a large number stacked one on top of the other with their open portions facing downwards. The storage section 61 may store only one row of paper containers 101.

A drop device (not shown) is provided below the storage section 61, which drops only the bottommost paper container 101 downward; the paper container 101 dropped by this drop device is shown in phantom lines. The slider 62 is driven in the feed direction of the resin sheet S by a slider drive device 63. The main body of the supply device 60 is transported together with the paper container 101 to the molding section 4 by the slider 62, and then the paper container 101 can be dropped onto the resin sheet S and positioned as shown by the solid line in FIG. 8. The structure of the supply device 60 described above is one example, and supply devices with other structures may be used.

(Configuration of the discharge section 5)
As shown in FIG. 1, the discharge section 5 is provided downstream of the molding section 4, and includes a support table 50, a container mounting member 51, and a mounting member drive device 52. The support table 50 is fixed to a floor surface 200. A mounting member drive device 52 is fixed to the upper surface of the support table 50. The container mounting member 51 is fixed to the mounting member drive device 52. The container mounting member 51 is provided downstream of the upper mold 40 and the lower mold 41 in the feed direction of the resin sheet S, and is disposed below the resin sheet S. The container mounting member 51 is close to the upper mold 40 and the lower mold 41, so that the stacked container 100 does not fall between the container mounting member 51 and the upper mold 40 and the lower mold 41.

The stacked container 100 is placed on the container mounting member 51 immediately after production when it is sent downstream together with the resin sheet S from between the upper mold 40 and the lower mold 41. The container mounting member 51 can be made of, for example, a plate material extending in the horizontal direction. The downstream end of the container mounting member 51 can be bent or inclined downward. This makes it easier for the stacked container 100 placed on the upper surface of the container mounting member 51 to move downstream from the upper surface of the container mounting member 51.

The mounting member drive device 52 is a device for moving the container mounting member 51 vertically to switch between a lower position and an upper position, and can be configured, for example, with a fluid pressure cylinder or a feed screw device. The mounting member drive device 52 is connected to the control panel 7 and is controlled by the control panel 7. The mounting member drive device 52 is configured to place the container mounting member 51 in the lower position (shown in Figures 12, 13, and 15) before the stacked container 100 is placed, and to switch it to the upper position (shown in Figure 14) after the stacked container 100 is placed.

When the container mounting member 51 is in the lower position, the upper surface of the container mounting member 51 is located below the path of the resin sheet S. This ensures that the stacked container 100 is securely mounted on the container mounting member 51 without getting caught on the container mounting member 51 when it is sent downstream together with the resin sheet S from between the upper mold 40 and the lower mold 41.

When the container mounting member 51 is in the upper position, the upper surface of the container mounting member 51 is positioned approximately at the same position as the path of the resin sheet S or above the path of the resin sheet S. This brings the upper end of the stacked container 100 closer to the suction portion 6, making it easier for the container 100 to be adsorbed by the suction portion 6.

(Configuration of Adsorption Part 6)
The suction unit 6 is disposed above and apart from the upper end of the stacked container 100 placed on the container placement member 51, and is a device for suctioning and transporting the stacked container 100. A vacuum suction pipe 6a is connected to the suction unit 6, and a negative pressure is applied to the lower end of the suction unit 6. The suction unit 6 has an arm 6b that is fixed to, for example, a transport device (not shown), and in a state where the arm 6b is fixed to the transport device, the stacked container 100 can be transported to an arbitrary location by the transport device. The transport device may be, for example, a robot.

(Configuration of control panel 7)
The control panel 7 is a control device that controls the sheet feeding unit 2, the sheet heating unit 3, the forming unit 4, the discharge unit 5, and the suction unit 6, and can be configured with, for example, a conventionally known microcomputer, sequencer, or the like. The control panel 7 is configured to store, as a program, the operation timing, operation speed, operation sequence, and the like of the sheet feeding unit 2, the sheet heating unit 3, the forming unit 4, the discharge unit 5, and the suction unit 6. The control panel 7 operates the sheet feeding unit 2, the sheet heating unit 3, the forming unit 4, the discharge unit 5, and the suction unit 6 as described below in accordance with the stored program.

(Production method)
Next, a method for manufacturing the laminated container 100 using the manufacturing apparatus 1 configured as described above will be described. The method described below can be realized by a program stored in the control panel 7, but may also be performed by an individual worker.

First, the resin sheet S is set in the sheet feed section 2. This is done by an operator. Then, when the operator operates the control panel 7, the sheet feed section 2 feeds the resin sheet S to a predetermined position. In addition, the lower heater 3c of the sheet heating section 3 is turned ON to start the current flow and, after preheating is complete, the lower heater 3c is moved to the uppermost position. This brings the lower heater 3c close to the resin sheet S and heats the resin sheet S to a predetermined temperature suitable for molding. The resin sheet S softens and slackens as a result of being heated by the lower heater 3c. This is the sheet heating process.

In addition, as shown in FIG. 6, the molding section 4 is kept in a mold open state by the mold drive device 42. At this time, the upper mold 40 is moved upward by the upper mold drive device 44, and the lower mold 41 is moved downward by the lower mold drive device 45, so that the upper mold 40 and the lower mold 41 do not come into contact with the upper and lower surfaces of the resin sheet S. This makes it possible to prevent interference between the resin sheet S and the upper mold 40 and the lower mold 41 when feeding the resin sheet S. This is the retraction process.

Also, as shown in FIG. 8, the supply device 60 supplies the paper container 101 onto the resin sheet S. As the resin sheet S is fed, the paper container 101 is transported to directly below the upper mold 40 as shown in FIG. 6. After the in-mold suction section 49 is lowered to adsorb the paper container 101, the in-mold suction section 49 is raised to the upper position, and the paper container 101 is held in the holding recess 40a of the upper mold 40, which is in the raised position, with the paper container 101 open downward. The paper container 101 may be manually inserted into the holding recess 40a by an operator and held therein. This is the holding process.

The sheet heating process and the holding process may be performed in parallel, or one may be performed first. The lower heater 3c is located upstream and below the paper container 101 held in the holding recess 40a, so the resin coating layer 101d of the paper container 101 is not melted by the heat of the lower heater 3c.

After the sheet feed unit 2 stops feeding the resin sheet S, as shown in FIG. 9, the upper die 40 is moved downward by the upper die drive unit 44, and the lower die 41 is moved upward by the lower die drive unit 45 to close the die. This is the die closing process. The lower cut blade 41c and the upper cut blade 40b apply a shear force to the resin sheet S, and the peripheral portion of the resin layer 102 in the resin sheet S is completely cut by this shear force, so that the die closing process and the cutting process are performed simultaneously. At this time, the peripheral portion of the resin layer 102 can be sandwiched in the thickness direction between the peripheral portion of the holding recess 40a of the upper die 40 and the peripheral portion of the plug receiving recess 41a of the lower die 41. The timing for cutting the resin sheet S may be any time before the upper and lower dies 40 and 41 open, and cutting may not be performed until molding of the resin layer 102 is complete. Instead, after molding of the resin layer 102 is complete, the upper die 40 may be moved downward or the lower die 41 may be moved upward to apply a shear force to the resin sheet S to cut it.

After that, as shown in FIG. 10, the plug drive device 43 raises the plug 41b to a molding position protruding from the upper surface of the lower mold 41. As a result, the upper surface of the plug 41b stretches the resin sheet S upward and approaches the inner surface of the paper container 101.

At this time, negative pressure is applied to the holding recess 40a of the upper mold 40 through the vacuum piping 4a. As shown in FIG. 2A, the paper container 101 has an air passage hole 101c, so the paper container 101 is subjected to negative pressure through the air passage hole 101c, and the softened resin sheet S is molded by adhering it to the inner surface of the paper container 101. Since the resin coating layer 101d is not melted, the softened resin sheet S is adhered to the solidified resin coating layer 101d. At this time, compressed air is introduced into the lower mold 41 by the compressed air introduction device 4d, so that the resin sheet S is pressed against the inner surface of the paper container 101 by the compressed air. In other words, by vacuum and pressure molding the resin sheet S, the resin layer 102 is formed inside the paper container 101 by adhering it to the inner surface of the paper container 101 with strong force. Because the resin sheet S adheres strongly to the paper container 101 during molding, the resin layer 102 is less likely to come off the paper container 101, i.e., the resin coating layer 101d, during normal use. On the other hand, because the resin layer 102 and the resin coating layer 101d of the paper container 101 are made of different resins, their adhesive strength to each other is not very high, and they can be easily separated when disposing of the laminated container 100. This is the molding process. In this manner, the manufacture of the laminated container 100 is completed. Subsequent processes may be performed as necessary, or may be omitted.

12, the upper mold 40 is moved upward by the upper mold driving device 44, and the lower mold 41 is moved downward by the lower mold driving device 45 to open the mold. During this time, the laminated container 100 is gradually cooled, and the resin layer 102 hardens. When the mold is opened, the laminated container 100 can be released from the upper mold 40 by pushing it downward with a demolding pin or the like provided on the upper mold 40 as is well known in the art (not shown). The laminated container 100 released from the upper mold 40 is in a state where the lower end of the laminated container 100 (which becomes the upper end when the laminated container 100 is used) is placed on the upper surface of the lower mold 41 due to the weight of the laminated container 100, and the laminated container 100 is supported from below by the lower mold 41, preventing the laminated container 100 from falling. As described above, the lower mold 41 is lowered by the lower mold drive device 45 so that the upper surface of the lower mold 41 is positioned below the resin sheet S, and therefore the lower end of the stacked container 100 is positioned below the lower surface of the resin sheet S.

As shown in FIG. 12, holes S1 are formed in the resin sheet S at the cut marks from the laminated container 100. Since the lower end of the laminated container 100 is located below the lower surface of the resin sheet S, the height of the hole S1 is above the lower end of the laminated container 100, that is, the height corresponding to the peripheral wall portion (side portion) of the laminated container 100. Therefore, when the resin sheet S is subsequently fed by the sheet feeding unit 2, the peripheral wall portion of the laminated container 100 is hooked and engaged with the peripheral portion of the hole S1 of the resin sheet S, so that the laminated container 100 is fed downstream together with the resin sheet S. This makes it possible to easily remove the laminated container 100 from between the upper mold 40 and the lower mold 41 using the resin sheet S without providing a dedicated member or device for removing the laminated container 100. As described above, the height of the lower mold 41 when the mold is opened is set, so that the peripheral wall portion of the laminated container 100 and the peripheral portion of the hole S1 of the resin sheet S can be reliably engaged.

The stacked container 100 removed from between the upper die 40 and the lower die 41 by the operation of the sheet feed unit 2 is placed on the upper surface of the container placement member 51 as shown in FIG. 13. At this time, the container placement member 51 is in the lower position, and the upper end of the stacked container 100 (which becomes the lower end when the stacked container 100 is in use) and the lower end of the suction unit 6 are separated by a predetermined distance. This predetermined distance can be set depending on the weight of the stacked container 100 and the suction force exerted by the suction unit 6, and it is preferable to keep the stacked container 100 at a distance greater than the distance at which it is not suctioned by the suction unit 6. Specifically, if the stacked container 100 is heavy, the distance can be made shorter than when it is light, and if the suction force exerted by the suction unit 6 is large, the distance can be made longer than when it is small.

After placing the stacked container 100 on the upper surface of the container mounting member 51, as shown in FIG. 14, the mounting member drive device 52 switches the container mounting member 51 to the upper position. As a result, the distance between the upper end of the stacked container 100 and the lower end of the adsorption section 6 becomes less than a predetermined distance, so that the stacked container 100 is adsorbed to the adsorption section 6. The distance between the upper end of the stacked container 100 and the lower end of the adsorption section 6 when in the upper position is set so that the upper end of the stacked container 100 is reliably adsorbed.

After that, as shown in FIG. 15, the mounting member drive device 52 switches the container mounting member 51 to the lower position without moving the suction unit 6. Because the upper end of the stacked container 100 is suctioned to the suction unit 6, the stacked container 100 is separated from the upper surface of the container mounting member 51. The transport device then transports the stacked container 100 to a desired location and accumulates it. Because the stacked container 100 is formed with the opening downwards, it can be stacked and stored in that state without having to be turned upside down.

(Effects of the embodiment)
As described above, according to the manufacturing device 1 of this embodiment, the resin sheet S softened by heating is vacuum- and pressure-molded to adhere strongly to the inner surface of the paper container 101, and the resin layer 102 can be integrally molded inside the paper container 101. The resin layer 102 is less likely to come off the paper container 101 during use because the resin sheet S has a strong adhesion to the paper container 101 during molding. On the other hand, since the resin layer 102 and the resin coating layer 101d of the paper container 101 are made of different resins, the adhesive strength is not so high, and they can be easily separated when discarded. Therefore, the paper container 101 and the resin layer 102 can be easily separated and disposed of when discarded, while preventing the paper container 101 and the resin layer 102 from being accidentally separated when used.

In the above embodiment, the resin coating layer 101d is provided on the inside of the paper container 101, but this resin coating layer 101d may be omitted and the resin layer 102 may be fixed to the paper of the paper container 101. In this case, the resin layer 102 is made of a different material from the paper, which makes it easier to separate and dispose of it. On the other hand, the resin layer 102 can be vacuum- and pressure-formed to adhere to the paper, which prevents the resin layer 102 from peeling off from the paper during normal use.

The above-described embodiments are merely illustrative in all respects and should not be interpreted as limiting. Furthermore, all modifications and variations within the scope of the claims are within the scope of the present invention.

In the above embodiment, the upper cutter blade 40b and the lower cutter blade 41c are used to cut the peripheral portion of the resin layer 102 in the resin sheet S, but this is not limited thereto. The upper cutter blade 40b and the lower cutter blade 41c may be omitted, and after the manufacturing process in the manufacturing device 1 is completed, the resin sheet S may be cut off separately using a trimming machine or the like.

As explained above, the present invention can be used, for example, when manufacturing laminated containers in which a resin layer is formed on the inner surface of a paper container to form an integrated structure.

1 Manufacturing device 2 Sheet feeding section 3 Sheet heating section 6 Adsorption section 40 Upper die (upper die)
40a Retaining recess 40b Upper cutting blade 41 Lower die (lower die)
41a Plug receiving recess 41b Plug 41c Lower cutter blade 42 Mold drive device 44 Upper die drive device 45 Lower die drive device 51 Container mounting member 52 Mounting member drive device 100 Laminated container 101 Paper container 101c Air passage hole 101d Resin coating layer 102 Resin layer S Resin sheet

Claims (5)

1. An apparatus for manufacturing a laminated container, comprising: a paper container having a resin coating layer; and a resin layer made of a different resin from the resin coating and thicker than the resin coating layer formed on the inside of the paper container in a manner that allows the resin layer to be peeled off from the resin coating layer;
a sheet heating section for heating and softening a resin sheet that will become the resin layer;
An upper mold having a recess that is placed on the resin sheet heated by the sheet heating unit and holds the paper container having the air passage hole in an open position downward;
a vacuum device connected to a suction hole formed on an inner surface of the recess of the upper mold;
a lower mold disposed under the resin sheet heated by the sheet heating unit;
a die drive device that drives at least one of the upper die and the lower die in a direction in which the upper die and the lower die are brought closer to or separated from each other;
a compressed air introducing device that introduces compressed air into the lower mold when the mold is in a closed state,
A laminated container manufacturing device characterized in that the resin layer is formed thicker than the resin coating layer by adhering the resin sheet, which has been heated and softened by the sheet heating section, to the resin coating layer using compressed air without melting the resin of the resin coating layer. The manufacturing apparatus for a laminated container according to claim 1,
13. An apparatus for manufacturing a laminated container, wherein the lower mold has a plug to be inserted into the recess of the upper mold. The manufacturing apparatus for a laminated container according to claim 2,
a plug driving device for switching the plug between a molding position where the plug protrudes from an upper surface of the lower die and a housing position where the plug is housed in the lower die,
13. The laminated container manufacturing apparatus, wherein the plug drive device is configured to move the plug to a molding position when the resin sheet is molded and to move the plug to a storage position after molding. In the manufacturing apparatus for a laminated container according to any one of claims 1 to 3,
a sheet feed unit for feeding the resin sheet,
The apparatus for manufacturing a laminated container, wherein the sheet heating section is disposed away from the upper mold on the upstream side in the feeding direction of the resin sheet. A method for manufacturing a laminated container, comprising forming, on the inside of a paper container having a resin coating layer, a resin layer made of a different resin than the resin coating layer and thicker than the resin coating layer so as to be peelable from the resin coating layer, comprising:
a sheet heating step of heating and softening a resin sheet that will become the resin layer;
A holding step of holding the paper container having the air passage hole formed therein in a recess of an upper mold placed on the resin sheet heated in the sheet heating step in an open-down position;
a molding step of, after the sheet heating step and the holding step, closing the upper mold and a lower mold disposed below the upper mold, applying negative pressure to the inner surface of the recess of the upper mold, and introducing compressed air into the lower mold, thereby closely adhering the resin sheet heated in the sheet heating step to the inner surface of the paper container and molding it;
A method for manufacturing a laminated container, characterized in that in the molding process, the resin layer is formed thicker than the resin coating layer by adhering the resin sheet, which has been heated and softened in the sheet heating process , to the resin coating layer using compressed air, without melting the resin of the resin coating layer.

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