U.S. patent application number 15/266686 was filed with the patent office on 2017-01-05 for packaging container and packaged product contained in said packaging container, and manufacturing method and manufacturing apparatus for said packaging container.
The applicant listed for this patent is CHOKOKU PLAST CORPORATION, Hiromichi INAGAKI. Invention is credited to Hiromichi INAGAKI, Sakaru TAKAHASHI.
Application Number | 20170001787 15/266686 |
Document ID | / |
Family ID | 50278142 |
Filed Date | 2017-01-05 |
United States Patent
Application |
20170001787 |
Kind Code |
A1 |
INAGAKI; Hiromichi ; et
al. |
January 5, 2017 |
PACKAGING CONTAINER AND PACKAGED PRODUCT CONTAINED IN SAID
PACKAGING CONTAINER, AND MANUFACTURING METHOD AND MANUFACTURING
APPARATUS FOR SAID PACKAGING CONTAINER
Abstract
The purpose of the present invention is to provide: a packaging
container that can be industrially mass-produced, that can be used
as Modified Atmosphere Packaging (MAP) while ensuring sealing
performance, and that allows contents to be displayed in a
three-dimensional manner; a packaged product contained in the
packaging container; and a manufacturing method and manufacturing
apparatus for the packaging container. This packaging container
has: a container main body having a bottom face part and sidewall
parts, and having a flange at the upper end part periphery of the
sidewall parts; and a lid material heat-sealed to the flange. The
lid material is made of a film or sheet. A pair of opposing
sidewall parts has the same shape, and upper end parts of the pair
of side wall parts are at least positioned higher than the upper
end parts of another pair of opposing sidewall parts.
Inventors: |
INAGAKI; Hiromichi;
(Inuyama-shi, JP) ; TAKAHASHI; Sakaru; (Tokyo,
JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
INAGAKI; Hiromichi
CHOKOKU PLAST CORPORATION |
Inuyama-shi
Osaka |
|
JP
JP |
|
|
Family ID: |
50278142 |
Appl. No.: |
15/266686 |
Filed: |
September 15, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14425959 |
Mar 4, 2015 |
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PCT/JP2013/073499 |
Sep 2, 2013 |
|
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15266686 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 51/10 20130101;
B65D 11/10 20130101; B65D 81/34 20130101; B65B 61/065 20130101;
B65D 21/023 20130101; B65D 77/2024 20130101; B65D 51/1638 20130101;
B65D 81/2076 20130101; B65D 81/3446 20130101; B65D 81/3453
20130101; B65D 1/34 20130101; B65B 31/028 20130101; B65D 43/0233
20130101; B65D 21/0233 20130101; B65B 7/164 20130101 |
International
Class: |
B65D 81/34 20060101
B65D081/34; B65D 6/00 20060101 B65D006/00; B65D 21/02 20060101
B65D021/02; B65B 51/10 20060101 B65B051/10; B65D 51/16 20060101
B65D051/16; B65B 7/16 20060101 B65B007/16; B65B 31/02 20060101
B65B031/02; B65D 1/34 20060101 B65D001/34; B65D 43/02 20060101
B65D043/02 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 14, 2012 |
JP |
2012-203147 |
Nov 21, 2012 |
JP |
2012-254923 |
Jul 29, 2013 |
JP |
2013-156975 |
Claims
1. A manufacturing method for a packaging container, comprising the
steps of arranging and conveying a plurality of container main
bodies, each of which has a bottom face part, sidewall parts, and a
flange formed at an upper end part periphery of the sidewall parts,
and serially heat-sealing a lid material to the flanges of the
container main bodies, wherein in each of the container main
bodies, a pair of opposing sidewall parts have an identical shape,
and upper end parts of the pair of sidewall parts are at least
partly positioned higher than another pair of opposing sidewall
parts; the container main bodies are arranged and conveyed in such
a manner that the pair of opposing sidewall parts of each of the
container main bodies are positioned perpendicular to a conveyance
direction of the container main bodies; the lid material formed of
a flat film or sheet is reeled out from a reel roll and forwarded
through a dancer roll; and a plate having substantially the same
shape as an upper end contour shape of the pair of opposing
sidewall parts is brought into abutment with the lid material and
the lid material is heat-sealed to the flange of each of the
container main bodies by using a heat-seal block.
2. The manufacturing method for a packaging container according to
claim 1, wherein: the flange of each of the container main bodies
and the lid material are heat-sealed to each other in a vacuum
chamber, the vacuum chamber having a chamber main body and a
chamber lid abutting therewith, and the upper end contour shape of
the pair of opposing sidewall parts of each of the container main
bodies being similar to an upper end contour shape of sidewall
parts of the chamber main body corresponding to the pair of
opposing sidewall parts; a support base for the container main
bodies is provided at the chamber main body side; the lid material
has a width greater than a width of the container main body and
narrower than a width of the vacuum chamber; the container main
bodies are mounted on the support base; the vacuum chamber is
tightly sealed by sandwiching the lid material between the chamber
lid and the chamber main body, the lid material being brought into
contact with the plate and deformed into the upper end contour
shape of the pair of opposing sidewall parts; after deaerating the
vacuum chamber, the vacuum chamber is filled with filler gas, and a
pressure in the vacuum chamber is adjusted; then the flange of each
of the container main bodies and the lid material are heat-sealed
to each other by means of a heat-seal block provided at the chamber
lid side; and the lid material on the outside of the flange of each
of the packaging containers is removed.
3. A manufacturing method for a packaging container, comprising the
steps of arranging and conveying a plurality of container main
bodies, each of which has a bottom face part, sidewall parts, and a
flange formed at an upper end part periphery of the sidewall parts,
and serially heat-sealing a lid material to the flanges of the
container main bodies, wherein in each of the container main
bodies, a pair of opposing sidewall parts have an identical shape,
and upper end parts of the pair of sidewall parts are at least
partly positioned higher than another pair of opposing sidewall
parts: the container main bodies are arranged and conveyed in such
a manner that the pair of opposing sidewall parts of each of the
container main bodies are positioned parallel to a conveyance
direction of the container main bodies; the lid material formed of
a flat film or sheet is reeled out from a reel roll and forwarded
through a dancer roll; and the lid material is heat-sealed to the
flange of each of the container main bodies by using a heat-seal
block while correcting and adjusting a sag of the lid material that
occurs between reeling out the lid material and heat-sealing the
lid material to the flange of each of the container main bodies by
using the dancer roll or another dancer roll different from that
dancer roll, so that the lid material follows the contour shape of
the upper end parts of the pair of opposing sidewall parts.
4. The manufacturing method for a packaging container according to
claim 3, wherein: the flange of each of the container main bodies
and the lid material are heat-sealed to each other in a vacuum
chamber, the vacuum chamber having a chamber main body and a
chamber lid abutting therewith, and an abutment face between the
chamber lid and the chamber main body being a horizontal plane; a
support base for the container main bodies is provided at the
chamber main body side; the lid material has a width greater than a
width of the container main body and narrower than a width of the
vacuum chamber; the container main bodies are mounted on the
support base; the vacuum chamber is tightly sealed by sandwiching
the lid material between the chamber lid and the chamber main body;
after deaerating the vacuum chamber, the vacuum chamber is filled
with filler gas, and a pressure in the vacuum chamber is adjusted;
then the flange of each of the container main bodies and the lid
material are heat-sealed to each other by means of a heat-seal
block provided at the chamber lid side; and the lid material on the
outside of the flange of each of the packaging containers is
removed.
5. The manufacturing method for a packaging container according to
claim 1, wherein the heat-seal block is capable of being divided
and joined.
6. The manufacturing method for a packaging container according to
claim 3, wherein the heat-seal block is capable of being divided
and joined.
Description
[0001] This is a divisional of prior U.S. application Ser. No.
14/425 959, which was the national stage of International
Application No. PCT/JP2013/073499, filed Sep. 2, 2013.
TECHNICAL FIELD
[0002] The present invention relates to packaging containers for
containing various types of food products such as packaged lunches
("bento" in Japanese language), noodles and side dishes, the
packaging container being formed of a main body and a base
material.
BACKGROUND ART
[0003] A packaging container for containing food items such as
packaged lunches, noodles and side dishes uses a lid material
formed of a transparent sheet or film to enable visibility of the
contents thereof.
[0004] For instance, a lid material formed of a sheet or the like
is internally or externally fitted into an opening part of a
container main body, and the container main body and the lid
material are wrapped with a shrink film. For this type of packaging
container, there is a case in which the container main body and the
lid material are wrapped entirely by a shrink film or partially by
a strip of a shrink film. There is also a case in which the
container main body and the lid material are fixed to each other by
an adhesive tape in place of the shrink film.
[0005] The shape of the opening part of the container main body of
such a packaging container is not particularly limited; thus, a
quadrangular shape, an elliptical shape, a round shape, and any
other shape can be employed. The lid material matches the shape of
the opening part of the container main body and is provided to the
opening part by means of internal fitting or external fitting, and
the container main body and the lid material are fixed to each
other with the above-mentioned shrink film or adhesive tape.
[0006] Although the packaging container described above has its
container main body and lid material fixed to each other with a
shrink film or adhesive tape, when the contents thereof include a
liquid content, the liquid content spills when the packaging
container is tilted, because the lid material is fitted into the
container main body. Especially when the entire packaging container
is wrapped with the shrink film, the liquid matter leaks into the
gap between the packaging container and the shrink film,
significantly deteriorating the aesthetic appearance of the
packaging container.
[0007] In addition, the ability to ensure sealing performance of
the packaging container significantly affects food hygiene and the
expiration date of the contained food product, and is therefore
crucial for the packaging container. Unfortunately, sealing
performance of the above-mentioned packaging container has not yet
been ensured. Although the use of a shrink film to wrap entirely
the container main body and the lid material appears to be able to
achieve sealing performance, sealing performance is, in fact, not
ensured due to the air holes which are formed in the shrink film in
order to let air out when heat-shrinking the shrink film.
[0008] In order to enhance the sealing performance of a packaging
container, there is proposed a technique of providing a flange part
to the periphery of an opening part of a container main body and
then heat-sealing a lid material formed of a film to the flange
part (see Patent Document 1 and the like, for example).
PRIOR ART DOCUMENTS
Patent Document
[0009] Patent Document 1: Japanese Patent Application Publication
No. 2000-344224
SUMMARY OF INVENTION
Problems that the Invention is to Solve
[0010] Incidentally, in view of improving the appearance of
contents of a packaging container, a way to display the contents in
a three-dimensional manner has been devised in recent years.
However, only a flat-shaped packaging container is known as a
packaging container capable of ensuring the sealing performance
described above. In other words, although a quadrangular shape, an
elliptical shape, a round shape, and any other shape can be
employed as the shape of the opening part of the container main
body of such a packaging container, this type of packaging
container is in a flat tray-like shape with a constant distance
between the bottom face of the container main body and the flange
part. The reason of this configuration is because the flange part
needs to be formed in the same plane in order to heat-seal a lid
material formed of a film to the flange part.
[0011] Therefore, an object of the present invention is to provide
a packaging container that can be industrially mass-produced and
allows contents thereof to be displayed in a three-dimensional
manner while ensuring sealing performance, a packaged product that
is contained in the packaging container, and a manufacturing method
and a manufacturing apparatus for manufacturing the packaging
container.
Means for Solving the Problems
[0012] As a result of a series of dedicated studies to solve the
foregoing problems, the inventors of the present invention have
discovered that, in a packaging container in which a lid material
formed of a film or sheet is heat-sealed to a flange formed at an
upper end part periphery on sidewall parts of a container main
body, positioning at least a part of upper end parts of sidewall
parts higher than upper end parts of the other sidewall parts can
solve the problems described above.
[0013] As the shape of such a packaging container, for example, the
shapes shown in FIGS. 12(A), 13(A) and 14(A) are considered. A
packaging container shown in FIG. 12(A) has a bottom face part (91)
formed into a quadrangular shape, one of sidewall parts (92) into a
triangular roof, and the rest of the sidewall parts into a
rectangular shape. In a packaging container shown in FIG. 13(A), a
bottom face part (101) is formed into a semi-elliptical shape, and
a sidewall (102) standing upright from the linear portion of the
bottom face part is formed into a triangular roof, and the
remaining sidewall standing upright from the ellipse portion of the
bottom face part is configured to have a constant height. A
packaging container shown in FIG. 14(A) has a bottom face part
(111) formed into a circle, a part of which is cut into a fan
shape. In this packaging container, sidewall parts (112) standing
upright from the linear portion of the fan shape are sloped
gradually from the center of the circle toward the circumference,
with the portions of the sidewall parts at the center of the circle
being the tallest, and the height of a sidewall standing upright
from the circumferential portion of the remaining bottom face part
is made constant.
[0014] Furthermore, modifications of the packaging containers shown
in FIGS. 12(A), 13(A) and 14(A) are considered, in each of which a
top edge part of the sidewall having the high position and a bottom
edge part at the bottom face side are formed into substantially an
identical shape. These modified packaging containers are shown in
FIGS. 12(B), 13(B) and 14(B).
[0015] These packaging containers are capable of displaying
contents thereof in a three-dimensional manner while ensuring
sealing performance, but the problem is that these packaging
containers cannot easily be mass-produced industrially.
Specifically, in a manufacturing apparatus (120) for a conventional
packaging container, as shown in FIG. 15, when a film configuring a
lid material of the packaging container is heat-sealed to a flange
of the container main body of the packaging container, the film
forms wrinkles, deteriorating the appearance of the packaging
container.
[0016] As a result of a series of further studies, the inventors of
the present invention have discovered the effectiveness of the
following inventions, completing the present invention. The present
invention employs the following configurations for the purpose of
solving the foregoing problems.
[0017] (1) A packaging container, characterized by comprising:
[0018] a container main body that has a bottom face part, sidewall
parts, and a flange formed at an upper end part periphery of the
sidewall parts; and
[0019] a lid material that is heat-sealed to the flange,
wherein
[0020] the lid material is formed of a film or a sheet, and
[0021] a pair of opposing sidewall parts has an identical shape,
and upper end parts of the pair of sidewall parts are at least
partly positioned higher than upper end parts of another pair of
opposing sidewall parts.
[0022] (2) The packaging container according to the foregoing
aspect (1), wherein the lid material is in the form of a flat film
or sheet when reeled out from a raw material roll or fed as a piece
of a raw material sheet, is deformed so as to follow the shape of
an upper end edge of the container main body prior to or during
heat-sealing and then heat-sealed.
[0023] (3) The packaging container according to the foregoing
aspect (1) or (2), wherein upper end contours of the sidewall parts
whose upper end parts are at least partly positioned higher than
the upper end parts of the other sidewall parts are in the shape of
an upward arc, an upward triangle, or an upward trapezoid.
[0024] (4) The packaging container according to any one of the
foregoing aspects (1) to (3), wherein the top edge parts of the
sidewall parts having the higher upper end part and a bottom edge
part at the bottom face side are formed in substantially the same
shape.
[0025] (5) The packaging container according to any one of
foregoing aspects (1) to (3), wherein the bottom face part is
substantially flat and has projections projecting downward which
are provided at positions enabling stacking of the packaging
container on another packaging container.
[0026] (6) The packaging container according to the foregoing
aspect (5), wherein a bottom edge part of the projection is in
substantially the same shape as the top edge parts of the sidewall
parts corresponding to the bottom edge part.
[0027] (7) The packaging container according to any one of the
foregoing aspects (1) to (6), wherein the lid material has a
function of automatically opening a steam hole formed therein by a
pressure of steam generated when heating contents of the packaging
container in a microwave oven.
[0028] (8) The packaging container according to any one of the
foregoing aspects (1) to (6), wherein at least a part of the flange
of the container main body and at least a part of the lid material,
which are heat-sealed to each other, have weaker sealing strength
than the other parts and have a function of being separated and
opened by a pressure of steam generated when the contents of the
packaging container are heated in a microwave oven.
[0029] (9) A packaged product, characterized by comprising a food
product placed in the packaging container described in any one of
the foregoing aspects (1) to (8).
[0030] (10) A manufacturing method for a packaging container,
characterized by comprising the steps of arranging and conveying a
plurality of container main bodies, each of which has a bottom face
part, sidewall parts, and a flange formed at an upper end part
periphery of the sidewall parts, and serially heat-sealing a lid
material to the flanges of the container main bodies, wherein
[0031] in each of the container main bodies, a pair of opposing
sidewall parts has an identical shape, and upper end parts of the
pair of sidewall parts are at least partly positioned higher than
another pair of opposing sidewall parts;
[0032] the container main bodies are arranged and conveyed in such
a manner that the pair of opposing sidewall parts of each of the
container main bodies is positioned perpendicular to a conveyance
direction of the container main bodies;
[0033] the lid material formed of a flat film or sheet is reeled
out from a reel roll and forwarded through a dancer roll; and
[0034] a plate having substantially the same shape as an upper end
contour shape of the pair of opposing sidewall parts is brought
into abutment with the lid material and the lid material is
heat-sealed to the flange of each of the container main bodies by
using a heat-seal block.
[0035] (11) The manufacturing method for a packaging container
according to the foregoing aspect (10), wherein:
[0036] the flange of each of the container main bodies and the lid
material are heat-sealed to each other in a vacuum chamber, the
vacuum chamber having a chamber main body and a chamber lid
abutting therewith, and the upper end contour shape of the pair of
opposing sidewall parts of each of the container main bodies being
similar to an upper end contour shape of sidewall parts of the
chamber main body corresponding to the pair of opposing sidewall
parts;
[0037] a support base for the container main bodies is provided at
the chamber main body side;
[0038] the lid material has a width greater than the width of the
container main body and narrower than the width of the vacuum
chamber;
[0039] the container main bodies are mounted on the support
base;
[0040] the vacuum chamber is tightly sealed by sandwiching the lid
material between the chamber lid and the chamber main body, the lid
material being brought into contact with the plate and deformed
into the upper end contour shape of the pair of opposing sidewall
parts;
[0041] after deaerating the vacuum chamber, the vacuum chamber is
filled with filler gas, and the pressure in the vacuum chamber is
adjusted;
[0042] the flange of each of the container main bodies and the lid
material are heat sealed to each other by means of a heat-seal
block provided at the chamber lid side; and
[0043] the lid material on the outside of the flange of each of the
packaging containers is removed.
[0044] (12) A manufacturing method for a packaging container,
characterized by comprising the steps of arranging and conveying a
plurality of container main bodies, each of which has a bottom face
part, sidewall parts, and a flange formed at an upper end part
periphery of the sidewall parts, and serially heat-sealing a lid
material to the flanges of the container main bodies, wherein
[0045] in each of the container main bodies, a pair of opposing
sidewall parts has an identical shape, and upper end parts of the
pair of sidewall parts are at least partly positioned higher than
another pair of opposing sidewall parts:
[0046] the container main bodies are arranged and conveyed in such
a manner that the pair of opposing sidewall parts of each of the
container main bodies is positioned parallel to a conveyance
direction of the container main bodies;
[0047] the lid material formed of a flat film or sheet is reeled
out from a reel roll and forwarded through a dancer roll; and the
lid material is heat-sealed to the flange of each of the container
main bodies by using a heat-seal block while correcting and
adjusting a sag of the lid material that occurs between reeling out
the lid material and heat-sealing the lid material to the flange of
each of the container main bodies by using the dancer roll or
another dancer roll different from that dancer roll, so that the
lid material follows the contour shape of the upper end parts of
the pair of opposing sidewall parts.
[0048] (13) The manufacturing method for a packaging container
according to the foregoing aspect (12), wherein:
[0049] the flange of each of the container main bodies and the lid
material are heat-sealed to each other in a vacuum chamber, the
vacuum chamber having a chamber main body and a chamber lid
abutting therewith, and an abutment face between the chamber lid
and the chamber main body being a horizontal plane;
[0050] a support base for the container main bodies is provided at
the chamber main body side;
[0051] the lid material has a width greater than the width of the
container main body and narrower than the width of the vacuum
chamber;
[0052] the container main bodies are mounted on the support
base;
[0053] the vacuum chamber is tightly sealed by sandwiching the lid
material between the chamber lid and the chamber main body;
[0054] after deaerating the vacuum chamber, the vacuum chamber is
filled with filler gas, and the pressure in the vacuum chamber is
adjusted;
[0055] the flange of each of the container main bodies and the lid
material are heat-sealed to each other by means of a heat-seal
block provided at the chamber lid side; and
[0056] the lid material on the outside of the flange of each of the
packaging containers is removed.
[0057] (14) The manufacturing method for a packaging container
according to any one of the foregoing aspects (10) to (13), wherein
the heat-seal block is capable of being divided and joined.
[0058] (15) A manufacturing apparatus for a packaging container,
characterized by comprising means for arranging and conveying a
plurality of container main bodies, each of which has a bottom face
part, sidewall parts, and a flange formed at an upper end part
periphery of the sidewall parts, and serially heat-sealing a lid
material to the flanges of the container main bodies, wherein
[0059] in each of the container main bodies, a pair of opposing
sidewall parts has an identical shape, and upper end parts of the
pair of sidewall parts are at least partly positioned higher than
another pair of opposing sidewall parts;
[0060] the container main bodies are arranged and conveyed in such
a manner that the pair of opposing sidewall parts of each of the
container main bodies is positioned perpendicular to a conveyance
direction of the container main bodies;
[0061] the lid material formed of a flat film or sheet is reeled
out from a reel roll and forwarded through a dancer roll; and
[0062] a plate having substantially the same shape as an upper end
contour shape of the pair of the opposing sidewall parts is brought
into abutment with the lid material and the lid material is
heat-sealed to the flange of each of the container main bodies by
using a heat-seal block.
[0063] (16) The manufacturing apparatus for a packaging container
according to the foregoing aspect (15), wherein:
[0064] the flange of each of the container main bodies and the lid
material are heat-sealed to each other in a vacuum chamber, the
vacuum chamber having a chamber main body and a chamber lid
abutting therewith, and the upper end contour shape of the pair of
opposing sidewall parts of each of the container main bodies being
similar to an upper end contour shape of sidewall parts of the
chamber main body corresponding to the pair of opposing sidewall
parts;
[0065] a support base for the container main bodies is provided at
the chamber main body side;
[0066] the lid material has a width greater than the width of the
container main bodies and narrower than the width of the vacuum
chamber;
[0067] the container main bodies are mounted on the support
base;
[0068] the vacuum chamber is tightly sealed by sandwiching the lid
material between the chamber lid and the chamber main body, the lid
material being brought into contact with the plate and deformed
into the upper end contour shape of the pair of opposing sidewall
parts;
[0069] after deaerating the vacuum chamber, the vacuum chamber is
filled with filler gas, and the pressure in the vacuum chamber is
adjusted;
[0070] the flange of each of the container main bodies and the lid
material are heat-sealed to each other by means of a heat-seal
block provided at the chamber lid side; and
[0071] the lid material on the outside of the flange of each of the
packaging containers is removed.
[0072] (17) A manufacturing apparatus for a packaging container,
characterized by comprising means for arranging and conveying a
plurality of container main bodies, each of which has a bottom face
part, sidewall parts, and a flange formed at an upper end part
periphery of the sidewall parts, and serially heat-sealing a lid
material to the flanges of the container main bodies, wherein
[0073] in each of the container main bodies, a pair of opposing
sidewall parts has an identical shape, and upper end parts of the
pair of sidewall parts are at least partly positioned higher than
another pair of opposing sidewall parts,
[0074] the container main bodies are arranged and conveyed in such
a manner that the pair of opposing sidewall parts of each of the
container main bodies is positioned parallel to a conveyance
direction of the container main bodies;
[0075] the lid material formed of a flat film or sheet is reeled
out from a reel roll and forwarded through a dancer roll; and
[0076] the lid material is heat-sealed to the flange of each of the
container main bodies by using a heat-seal block while correcting
and adjusting a sag of the lid material that occurs between reeling
out the lid material and heat-sealing the lid material to the
flange of each of the container main bodies by using the dancer
roll or another dancer roll different from that dancer roll, so
that the lid material follows the contour shape of the upper end
parts of the pair of opposing sidewall parts.
[0077] (18) The manufacturing apparatus for a packaging container
according to the foregoing aspect (17), wherein:
[0078] the flange of each of the container main bodies and the lid
material are heat-sealed to each other in a vacuum chamber, the
vacuum chamber having a chamber main body and a chamber lid
abutting therewith, and an abutment face between the chamber lid
and the chamber main body being a horizontal plane;
[0079] a support base for the container main bodies is provided at
the chamber main body side;
[0080] the lid material has a width greater than the width of the
container main bodies and narrower than the width of the vacuum
chamber;
[0081] the container main bodies are mounted on the support
base;
[0082] the vacuum chamber is tightly sealed by sandwiching the lid
material between the chamber lid and the chamber main body;
[0083] after deaerating the vacuum chamber, the vacuum chamber is
filled with filler gas, and the pressure in the vacuum chamber is
adjusted;
[0084] the flange of each of the container main bodies and the lid
material are heat-sealed to each other by means of a heat-seal
block provided at the chamber lid side; and
[0085] the lid material on the outside of the flanges of each of
the packaging containers is removed.
[0086] (19) The manufacturing apparatus for a packaging container
according to any one of the foregoing aspects (15) to (18), wherein
the heat-seal block is capable of being divided and joined.
Advantageous Effects of Invention
[0087] The present invention can provide a packaging container that
can be industrially mass-produced and allows contents thereof to be
displayed in a three-dimensional manner while ensuring sealing
performance, a packaged product that is contained in the packaging
container, and a manufacturing method and manufacturing apparatus
for manufacturing the packaging container.
BRIEF DESCRIPTION OF DRAWINGS
[0088] FIG. 1 is a diagram showing an example of a container main
body of a packaging container according to the present
invention;
[0089] FIG. 2 is a diagram showing an example of the container main
body of the packaging container according to the present
invention;
[0090] FIG. 3 is a diagram showing an example of the container main
body of the packaging container according to the present
invention;
[0091] FIG. 4 is a diagram showing an example of the container main
body of the packaging container according to the present
invention;
[0092] FIG. 5 is a diagram showing an example of the container main
body of the packaging container according to the present
invention;
[0093] FIG. 6 is a diagram showing an example of the container main
body of the packaging container according to the present
invention;
[0094] FIG. 7 is a diagram showing an example of the container main
body of the packaging container according to the present
invention;
[0095] FIG. 8 is a diagram showing schematically an example of a
manufacturing apparatus for manufacturing the packaging container
according to the present invention;
[0096] FIG. 9 is a diagram showing an example of a configuration of
a part of the manufacturing apparatus for manufacturing the
packaging container according to the present invention;
[0097] FIG. 10 is a diagram showing schematically an example of the
manufacturing apparatus for manufacturing the packaging container
according to the present invention;
[0098] FIG. 11 is a diagram showing an example of a configuration
of a part of the manufacturing apparatus for manufacturing the
packaging container according to the present invention;
[0099] FIG. 12 is a diagram showing an example of a packaging
container of a reference example of the present invention;
[0100] FIG. 13 is a diagram showing an example of a packaging
container of a reference example of the present invention;
[0101] FIG. 14 is a diagram showing an example of a packaging
container of a reference example of the present invention; and
[0102] FIG. 15 is a diagram showing schematically a conventional
manufacturing apparatus for manufacturing a packaging
container.
MODE FOR CARRYING OUT THE INVENTION
[0103] A packaging container according to the present invention is
characterized by comprising a container main body that has a bottom
face part, sidewall parts, and a flange formed at an upper end part
periphery of the sidewall parts, and a lid material heat-sealed to
the flange. The lid material is made of a film or a sheet. The
container main body has a pair of opposing sidewall parts formed
into an identical shape, and the upper end parts of the pair of
sidewall parts are at least partly positioned higher than upper end
parts of another pair of opposing sidewall parts.
[0104] As described above, the conventional packaging container has
a flat structure in which the flange at the periphery of the
opening part of the container main body is provided to be in the
same plane. According to the structure of the packaging container
of the present invention, on the other hand, a pair of opposing
sidewall parts has an identical shape, and upper end parts of the
pair of sidewall parts are at least partly positioned higher than
the upper end parts of another pair of opposing sidewall parts.
Therefore, the flange is not in the same plane and provides a
three-dimensional effect while keeping sealing performance of the
packaging container.
[0105] Note that, regarding the upper end parts of the pair of
sidewall parts having the higher part than the upper end parts of
the other pair of opposing sidewall parts, the height of the higher
part from a mount surface on which the packaging container of the
present invention is placed is preferably 1.2 to 2 times higher
than the height of the upper end parts of the other pair of
sidewall parts from the same mount surface.
[0106] Because the shape of the packaging container of the present
invention is bilaterally symmetric, a sealed container having a
three-dimensional effect can be realized while keeping the
familiarity of the conventional, rectangular parallelepiped
packaging containers. Moreover, as will be described hereinafter,
the packaging container of the present invention can be
industrially mass-produced without forming wrinkles in the lid
material, with an added improvement in the conventional
manufacturing apparatus for manufacturing a packaging
container.
[0107] FIG. 1 shows an example of the shape of the container main
body of the packaging container according to the present invention.
The container main body shown in FIG. 1 has a quadrangular bottom
face part (11), a pair of opposing sidewall parts (12) forming a
triangular roof, and a remaining other pair of rectangular sidewall
parts (13). The container main body of FIG. 1 shows that upper end
parts of the pair of sidewall parts are at least partly positioned
higher than upper end parts of the other pair of sidewall parts and
the upper end contour shape of the higher sidewall parts forms an
upward triangle. However, the shape of the upper end parts of the
higher sidewall parts may be formed into an upward arc, an upward
trapezoid or the like.
[0108] The packaging container and contents thereof can bring about
a three-dimensional effect by forming the pair of opposing sidewall
parts into an identical shape and positioning at least a part of
the upper end parts of the pair of sidewall parts to be higher than
the upper end parts of the other pair of opposing sidewall parts so
that the upper end parts of the former pair of sidewall parts have
the apex of the triangular roof, instead of making the levels of
the sidewall parts of the container main body the same.
[0109] The material of the above-mentioned container main body is
not particularly limited; thus, any material can be employed so
long as a heat-sealable flange can be formed. The plastic resins
used in the conventional packaging containers can favorably be
used. Similarly, a heat-sealable film or sheet may be used as a
material for the lid.
[0110] A flange (14) of the container main body may be inclined
outward. Typically it is preferred that the flange be formed in
such a manner that, after the flange and the lid material are
heat-sealed together, the flange is substantially flat and the
flange width is substantially constant as viewed from above.
[0111] As described above, in the packaging container of the
present invention, the flange is provided at the upper end part
periphery of the sidewall parts of the container main body, and the
lid material made of a film or sheet is heat-sealed to the flange,
thereby bringing about various effects.
[0112] One of the effects is the fact that the packaging container
can be sealed completely. Therefore, when a content of the
packaging container is, for example, a food product, a space with
the environment of the kitchen can be sealed up by completely and
tightly sealing the packaging container immediately after the food
product is placed therein, preventing the future contamination.
Controlling a space of the packaging container, i.e., MAP (Modified
Atmosphere Packaging) can be realized, enabling controlling to a
nitrogen atmosphere, nitrogen/carbon-dioxide atmosphere,
nitrogen/carbon-dioxide/oxygen atmosphere, and the like. In
addition, even when the food product contains sauce or other types
of liquid, the configuration of the packaging container of the
present invention can prevent liquid leakage.
[0113] Another effect is the fact that the lid material can be made
highly glossy and highly transparent. Because the packaging
container of the present invention employs a film or sheet for a
lid material, the top face of the packaging container can be made
highly glossy and highly transparent. Such a configuration can
display contents clearly and gives the sense of freshness. Also,
applying or introducing an antifogging agent to the lid material
can provide antifogging properties into the packaging
container.
[0114] Note that, although the lid material may be made of a single
layer or a stack of multiple layers, it is preferred that the lid
material be as thin as possible in order to create a highly glossy,
highly transparent lid material. For instance, in a case where the
lid material is made of a film, the thickness thereof can be
approximately 30 .mu.m or more but less than 150 .mu.m. In a case
where the lid material is formed of a sheet, the thickness thereof
can be approximately 150 .mu.m or more but equal to or less than
250 .mu.m.
[0115] The above-mentioned lid material of the container of the
present invention is in the form of a flat film or sheet when
reeled out from a raw material roll or fed as a piece of raw sheet,
is deformed so as to follow the shape of the upper end edge the
container main body prior to or during heat-sealing and then
heat-sealed.
[0116] In the conventional packaging containers, normally a
convex-type or concave-type lid obtained by molding a sheet is
externally or internally fitted to the container main body.
According to the packaging container of the present invention, on
the other hand, the lid material formed of a flat film or sheet is
deformed into the shape of the upper end edge of the container main
body and heat-sealed thereto as described above, eliminating the
need to mold the lid material into a lid in a separate processing
line. In addition, the amount of waste can be reduced because there
is no need to use unnecessary members such as a shrink film or
adhesive tape, making the packaging container light and
environmentally responsive.
[0117] Furthermore, adjusting the heat seal strength between the
container main body and the lid material and providing a protruding
tab to a part of the end part of the lid material can bring about
easy openability.
[0118] Furthermore, in the packaging container of the present
invention, it is preferred that the top edge parts of the pair of
sidewall parts having the above-mentioned high position and a
bottom edge part at the bottom face side be in substantially an
identical shape. This makes the shape of the bottom face part of
the container main body three-dimensional, bringing about a
three-dimensional effect of the inside of the packaging container
and a contained product thereof. Because the shape of the bottom
face part of the container main body is substantially the same as
the shape of the lid material on the top face of the packaging
container, a plurality of the packaging containers can be stacked
vertically. By raising the bottom face part of the packaging
container, contents contained in the container are also raised.
Therefore, unevenness heating in a food product can be prevented
when heating the food product in a microwave oven. The uneven
heating is because when heating a food product in a microwave oven,
the upper part of the food product heats up more easily than the
bottom of the same.
[0119] A container main body shown in FIG. 2 is an example obtained
by making the shape of the bottom face part of the container main
body shown in FIG. 1 substantially the same as the shape of the top
face of the packaging container. More specifically, in the
container main body shown in FIG. 2, a pair of opposing sidewall
parts (22) has its top edge part and its bottom edge part at the
bottom face side shaped into an upward convex triangle, and the
remaining other pair of opposing sidewall parts (23) is shaped into
a rectangle. A container main body shown in FIG. 3 is a
modification of the container main body shown in FIG. 2, in which a
pair of opposing sidewall parts (32) has its top edge part and its
bottom edge part at the bottom face side in the shape of reversed
"V" and the remaining other pair of opposing sidewall parts (33) is
shaped into a rectangle.
[0120] In a container main body shown in FIG. 4, a pair of opposing
sidewall parts (42) has its top edge part and its bottom edge part
at the bottom face side shaped into an upward arc, and the
remaining other pair of sidewall parts (43) is shaped into a
rectangle. In a container main body shown in FIG. 5, a pair of
opposing sidewall parts (52) has its top edge part and its bottom
edge part at the bottom face side shaped into a trapezoid, and the
remaining other pair of sidewall parts (53) is shaped into a
rectangle. In case of each of the container main bodies shown in
FIGS. 2 to 5, a hand can easily be placed in the space formed below
the bottom face part, allowing the packaging container to be
carried easily and allowing one to eat the food contents thereof
easily.
[0121] Also, the foregoing container main bodies of the present
invention may have a configuration provided with a partition, as
shown in FIGS. 6(a) to 6(e). In this case, two container main
bodies are connected to each other. The top face part of a sidewall
part functioning as the partition may or may not be heat-sealed to
the lid material.
[0122] It is preferred that the bottom face part of the packaging
container of the present invention be substantially flat and have
projections projecting downward at positions enabling stacking of
the packaging container on another packaging container. Making the
bottom face part substantially flat (horizontal) in this manner
enables easy packing of contents and prevents the contents from
shifting to one side of the packaging container. In addition, in a
case of simply making the bottom face part substantially flat, a
plurality of the packaging containers cannot be stacked vertically
on top of each other. However, with the projections provided at
predetermined positions on each bottom face part, a plurality of
the packaging containers can be stacked on top of each other. In
other words, the foregoing projections can be provided at, for
example, each of the four corners of the bottom face part in such a
manner as to project downward from the bottom face part by a
distance approximately equivalent to the height difference between
the highest position of the upper end part of each sidewall part
and the lowest position of the same. Such a configuration allows
the packaging container of the present invention to be stacked on
another packaging container. Note that the position for placing the
foregoing projection and the size of the projection are not limited
to those described above; thus, the projection may be provided in
such a manner as to allow the packaging containers of the present
invention to be stacked on another packaging container.
[0123] FIGS. 7(a) to 7(c) each show an example of a packaging
container having a flat bottom face part and projections. As shown
in FIG. 7, it is preferred that the bottom edge parts of the
above-mentioned projections (65) have substantially the same shape
as the top edge parts of sidewall parts (62) (63) corresponding to
the bottom edge parts. The top edge parts of the sidewall parts
(62) (63) corresponding to the bottom edge parts are the top edge
parts located in the upper portions of the sidewall parts (62) (63)
provided with the projections (65).
[0124] In the example shown in FIG. 7, the projections (65) at the
lower portions of the sidewall parts (62) with a trapezoidal top
edge part are inclined so as to be parallel with the inclined
portions of the top edge parts (FIG. 7(b)). The projections (65) at
the lower portions of the sidewall parts (63) with a horizontal top
edge part are horizontal so as to be parallel to the top edge parts
(FIG. 7(c)).
[0125] In such a configuration where the bottom face part (61) is
substantial flat (horizontal) and the projections (65) projecting
downward are provided at the positions enabling stacking of the
packaging container on another packaging container, a space is
formed below the bottom face part (61). This space not only allows
stacking of the packaging containers on top of each other, but also
allows the packaging container to be picked up easily. As described
above, such a configuration can prevent unevenness in temperature
of the food product when heating the food product in a microwave
oven.
[0126] It is also preferred that the packaging container of the
present invention have a function of automatically opening a steam
hole or holes of the foregoing lid material by pressure of steam
generated when heating the contents of the foregoing packaging
container in a microwave oven. This configuration is excellent in
terms of convenience since the contents of the packaging container
can be heated in a microwave without peeling in advance a part of
the film or sheet functioning as the lid material of the packaging
container.
[0127] For example, the film used in Seiro Pack (Microsteamer).RTM.
can be used as the lid material (see Japanese Patent No.
4817583).
[0128] To provide the ability of automatically opening an hole or
holes to the packaging container, it is preferred that at least a
part of the flange of the foregoing container main body and a part
of the lid material, which are heat-sealed to each other, have a
weaker sealing strength than the other parts and have a function of
being peeled and opened by pressure of steam generated when the
contents of the packaging container are heated in a microwave oven.
In order to realize this function, a part of the flange provided at
the periphery of the sidewall parts of the container main body may
be made narrower than the other parts.
[0129] The packaged product having a food product contained in the
foregoing packaging container of the present invention, such as a
packaged lunch (or bento), enables easy visibility of the food
contents and is excellent in exhibiting a three-dimensional
appearance. In addition, because the packaging container is sealed,
the packaging container is excellent in terms of hygiene and can
extend the expiration date of the food product contained
therein.
[0130] The manufacturing method for a packaging container according
to the present invention is a manufacturing method for a packaging
container, comprising steps of arranging and conveying a plurality
of container main bodies and serially heat-sealing a lid material
to flanges of the container main bodies.
[0131] According to an aspect of the manufacturing method for a
packaging container according to the present invention, the
container main bodies are each arranged and conveyed in such a
manner that a pair of opposing sidewall parts of each of the
container main bodies is positioned perpendicular to a conveyance
direction of the container main bodies.
[0132] The lid material formed of a flat film or sheet is reeled
out from a reel roll and fed above or on the container main bodies
through a dancer roll. In order to heat-seal the lid material to
the flanges of the container main bodies without generating
wrinkles in the lid material, it is preferred that the lid material
be deformed into substantially the same shape as the upper end
contour shape of the pair of opposing sidewall parts of each
container main bodies. In so doing, a plate having substantially
the same shape as the upper end contour shape of the pair of
opposing sidewall parts may be brought into abutment with the lid
material.
[0133] Then, the flange of each of the container main bodies and
the lid material are heat-sealed to each other using a heat-seal
block. In this manner, the packaging containers according to the
present invention can be manufactured serially.
[0134] The manufacturing apparatus for a packaging container that
implements the foregoing manufacturing method for a packaging
container is now described hereinafter.
[0135] The manufacturing apparatus for a packaging container has
means for arranging and conveying a plurality of container main
bodies, means for reeling out a lid material from a reel roll and
supplying the lid material above/or on the container main bodies,
and means for heat-sealing the lid material to the flanges of the
container main bodies.
[0136] The means for conveying the container main bodies arranges
and conveys the container main bodies in such a manner that a pair
of opposing sidewall parts of each container main body is
positioned perpendicular to a conveyance direction of the container
main bodies. The lid material is supplied above or on of the
container main bodies through a dancer roll. In addition, a plate
is provided in order to deform the lid material into substantially
the same shape as the upper end contour shape of the pair of
opposing sidewall parts of each of the container main bodies.
[0137] The means for heat-sealing the lid material is provided with
a heat-seal block for heat-sealing the lid material to the flange
of each of the container main bodies.
[0138] It is preferred that, in the manufacturing method for a
packaging apparatus according to the present invention,
heat-sealing the flange of each container main body and the lid
material to each other be performed in a vacuum chamber. According
to this configuration, the inside of the packaging container can be
controlled to a nitrogen atmosphere, nitrogen/carbon-dioxide
atmosphere, nitrogen/carbon-dioxide/oxygen atmosphere, or the
like.
[0139] A vacuum chamber that has a chamber main body and a chamber
lid abutting therewith, in which the upper end contour shape of the
pair of opposing sidewall parts of each of the container main
bodies is similar to the upper end contour shape of the
corresponding sidewall parts of the chamber main body, can be used
as the foregoing vacuum chamber. It is preferred that a support
base for the container main bodies be provided at the chamber main
body side. When using the vacuum chamber, it is preferred that the
width of the lid material be greater than the width of the
container main body and narrower than the width of the vacuum
chamber.
[0140] When using the vacuum chamber in the foregoing manufacturing
method for a packaging container according to the present
invention, first, each of the conveyed container main bodies is
mounted on the support base, and the lid material supplied above or
on the container main bodies is sandwiched between the chamber lid
and the chamber main body. Then, after tightly sealing the vacuum
chamber, the vacuum chamber is deaerated, and the vacuum chamber
becomes filled with filler gas, adjusting the pressure of the
vacuum chamber. Thereafter, the flange of the container main body
and the lid material are heat-sealed together by means of the
heat-seal block provided at the chamber lid side. Finally, the lid
material on the outside of the flange of the packaging container is
removed by a means such as a cutter.
[0141] The manufacturing method for a packaging container that uses
the foregoing vacuum chamber as described above can be implemented
by the manufacturing apparatus for a packaging container that has
the foregoing vacuum chamber.
[0142] The other aspect of the manufacturing method for a packaging
container according to the present invention is described
hereinafter.
[0143] First, as with the foregoing manufacturing method, a
plurality of container main bodies are arranged and conveyed. In so
doing, the container main bodies are each arranged and conveyed in
such a manner that the pair of opposing sidewall parts is parallel
to the conveyance direction of the container main bodies.
[0144] The lid material is reeled out from a reel roll and fed
above or on the container main bodies through a dancer roll. At
this moment, a sag of the lid material that occurs between reeling
out the lid material and heat-sealing the lid material to the
flange of each of the container main bodies is corrected and
adjusted by using the dancer roll or another dancer roll different
from that dancer roll. In this manner, the lid material can be
formed into a shape that follows the contour shape of the upper end
parts of the pair of opposing sidewall parts.
[0145] By heat-sealing the lid material to the flange of the
container main body using the heat-seal block, the packaging
containers according to the present invention can be manufactured
serially.
[0146] The other aspect of the manufacturing apparatus for a
packaging container according to the present invention that is
capable of implementing the foregoing manufacturing method is
described hereinafter.
[0147] The manufacturing apparatus according to this aspect of the
present invention comprises, as a means for arranging and conveying
a plurality of container main bodies, means for arranging and
conveying the container main bodies in such a manner that the pair
of opposing sidewall parts is parallel to the conveyance direction
of the container main bodies.
[0148] The manufacturing apparatus also has means for reeling out a
lid material from a reel roll and feeding the lid material above/on
the container main bodies through a dancer roll, and means for
correcting and adjusting a sag of the lid material that occurs
between reeling out the lid material and heat-sealing the lid
material to the flange of each of the container main bodies by
using the dancer roll or another dancer roll different from that
dancer roll. In this manner, the lid material can be formed into a
shape that follows the contour shape of the upper end parts of the
pair of opposing sidewall parts.
[0149] The manufacturing apparatus also has means for heat-sealing
the lid material to the flanges of the container main bodies using
a heat-seal block.
[0150] According to the manufacturing method for a packaging
container of the foregoing aspect as well, the flange of each
container main body and the lid material can be heat-sealed to each
other within a vacuum chamber, realizing MAP (Modified Atmosphere
Packaging).
[0151] A vacuum chamber that has a chamber main body and a chamber
lid abutting therewith, in which the abutment face between the
chamber lid and the chamber main body is a horizontal plane, can be
used as the foregoing vacuum chamber. In the case of using this
vacuum chamber as well, it is preferred that, as with the vacuum
chamber described above, a support base for the container main
bodies be provided at the chamber main body side, and that the
width of the lid material be greater than the width of each
container main body and narrower than the vacuum chamber.
[0152] A case in which the vacuum chamber having the horizontal
abutment face between the chamber lid and the chamber main body is
described hereinafter with respect to the above-mentioned other
aspect of the manufacturing method for a packaging container
according to the present invention.
[0153] First, container main bodies are arranged and conveyed in
such a manner that a pair of opposing sidewall parts of each
container main body is parallel to the conveyance direction of the
container main bodies, and then each container main body, conveyed
to a predetermined position, is mounted on the support base.
Furthermore, a sag on the lid material is adjusted by the dancer
roll, and the resultant lid material is supplied and held between
the chamber lid and the chamber main body. The rest of the steps
such as deaerating the vacuum chamber and filling the vacuum
chamber with filler gas to adjust the pressure of the vacuum
chamber, are the same as those of the foregoing method. As a
result, the flange of the container main body and the lid material
are heat-sealed together.
[0154] Such a manufacturing method for a packaging container can be
implemented by a manufacturing apparatus for a packaging container
that employs the vacuum chamber having the horizontal abutment face
between the chamber lid and the chamber main body in the foregoing
manufacturing apparatus according to the other aspect of the
present invention.
[0155] Since a heater is generally embedded in the heat-seal block,
it is difficult to process the heat-seal block into a complicated
shape. When processing the heat-seal block so as to conform it to
the flange of the packaging container in which the upper end
contour shape of the pair of opposing sidewall parts is in the
shape of a triangular roof, trapezoid, reversed "V" shape (as shown
in FIG. 3) or the like, it is sometimes difficult to adjust the
angle corresponding to the vertex of each contour.
[0156] Therefore, it is preferred that the foregoing heat-seal
block be capable of being divided or joined. For instance, when
manufacturing a packaging container that is in the shape of a
triangular roof or reversed "V" shape, a heat-seal block capable of
being divided into right and left at the apex portion may be used.
The angle of the joined portion can be adjusted easily by using
such a heat-seal block, and a heat-seal block whose shape can
easily be matched with the shape of the packaging container can be
obtained. Similarly, when manufacturing a trapezoidal packaging
container, a heat-seal block capable of being divided into three
portions, i.e., the flat portion having inclined portions at both
sides thereof, may be used and joined by adjusting the angles of
the respective vertex portions.
[0157] The method and apparatus for reeling out a lid material from
a reel roll to serially manufacture packaging containers have
described above. When using pieces of raw sheet, a manufacturing
method and a manufacturing apparatus for covering and heat-sealing
the individual pieces of raw sheet onto the respective container
main bodies can be employed.
Embodiment 1
[0158] FIG. 8 shows an example of the configuration of the
manufacturing apparatus for the packaging container according to
the present invention. The apparatus shown in FIG. 8 is an example
of an apparatus for heat-sealing a lid material to a container main
body that has a quadrangular bottom face part, a pair of opposing
sidewall parts in the shape of a triangular roof, and another pair
of rectangular sidewall parts. The container main body is placed
and conveyed in such a manner that the pair of opposing sidewall
parts in the shape of a triangular roof is perpendicular to the
conveyance direction of the container main body. This apparatus
heat-seals the lid material to a flange of the container main body
by using a heat-seal block.
[0159] In the manufacturing apparatus shown in FIG. 8, as mentioned
above, a plurality of container main bodies (701) are arranged on a
conveyor (703) and conveyed in such a manner that a pair of
opposing sidewall parts in the shape of a triangular roof is
perpendicular to the conveyance direction of the container main
bodies. From above, a lid material (702) formed of a film or sheet
is reeled out from a reel roll (704) and fed through a dancer roll
(705). A plate (not shown) that is substantially in the same shape
as the shape of the triangular roof of the pair of opposing
sidewall parts of each container main body is brought into abutment
with the lid material to correct the shape of the lid material.
Moreover, as shown in FIG. 8, it is preferred that the angle of the
lid material be adjusted with a jig (706) prior to heat-sealing the
lid material to a flange of each container main body, the jig being
capable of adjusting the angle of the lid material. Shaping the lid
material so as to conform to the shape of the top face of the
container main body in this manner can prevent the occurrence of
wrinkles in the lid material when heat-sealing the lid material to
the flange of the container main body.
[0160] Subsequently, the flange of each of the container main
bodies and the lid material are heat-sealed to each other. In so
doing, the flange of each container main body and the lid material
are held between a support base (707) provided under the container
main body and a heat-seal block (708) provided above the support
base, to thermally weld the flange and lid material to each other.
The shape of the support base and the shape of the heat-seal block
may be changed in accordance with the shape of the packaging
containers to be manufactured.
[0161] Finally, the lid material is cut on the slightly outside of
the flange of each container main body, completing the packaging
container of the present invention. In so doing, the lid material
may be cut by a cutter (709) that is arranged in accordance with
the shape of the top face part of the packaging container. The
shape of the cutter may be changed in accordance with the shape of
the packaging container. Furthermore, there is another favorable
example in which a portion that can be separated along the shape of
the flange of each container main body is formed in the lid
material in advance. In such a case, perforations or the like, for
example, may be formed in the lid material.
[0162] The completed packaging container (710) is collected from a
conveyor (711), and the resultant cut lid material (712) is
forwarded directly through a roll, rolled up, and collected.
Embodiment 2
[0163] An example of a manufacturing apparatus that is configured
to heat-seal a flange of a container main body and a lid material
to each other in a vacuum chamber is described hereinafter with
respect to the manufacturing apparatus for a packaging container
described in Embodiment 1.
[0164] FIG. 9 is a diagram showing an example of a configuration of
the vacuum chamber. As shown in FIG. 9, the vacuum chamber has a
chamber main body (751) and a chamber lid (752) that can come into
abutment with the chamber main body. The vacuum chamber is formed
into a sealed vacuum chamber by bringing these chamber main body
and chamber lid into abutment with each other. The chamber main
body (751) is provided with a container support base (753) on which
each container main body is mounted.
[0165] The flanges of the container main bodies and the lid
material are heat-sealed to each other in the vacuum chamber,
wherein, as in Embodiment 1, the lid material is abut with the
plate and thereby deformed into the upper end contour shape of the
pair of opposing sidewall parts of the container main body and
conveyed. Therefore, it is preferred that the upper end contour
shape of the pair of opposing sidewall parts be similar to the
upper end contour shape of the corresponding sidewall parts of the
chamber main body (751). Use of such a vacuum chamber having the
chamber main body (751) and the chamber lid (752) capable of coming
into abutment therewith can heat-seal the flange of the container
main body and the lid material to each other in the vacuum chamber
without generating wrinkles in the lid material.
[0166] The width of the lid material is greater than the width of
the container main body in the short direction thereof and narrower
than the width of the vacuum chamber in the short direction. Due to
this width of the lid material, both end parts of the lid material
in the width direction in the vacuum chamber do not come into
contact with the vacuum chamber when the lid material is held
between the chamber main body (751) and the chamber lid (752), and
thereby a space is formed. As a result, the internal space in the
chamber main body (751) becomes continuous with the internal space
in the chamber lid (752), enabling deaeration and gas
replacement.
[0167] As described above, the container main bodies are each
mounted on the container support base (753) of the chamber main
body (751), and the lid material, brought into contact with the
plate and deformed into the upper end contour shape of the pair of
opposing sidewall parts, is supplied between the chamber main body
(751) and the chamber lid (752). The vacuum chamber is then tightly
closed by sandwiching the lid material between the chamber main
body (751) and the chamber lid (752). After the vacuum chamber is
deaerated and evacuated in this state, filler gas is introduced to
the vacuum chamber to adjust the pressure therein. The filler gas
may be selected appropriately from among nitrogen gas, a mixed gas
of nitrogen and carbon dioxide, a mixed gas of nitrogen, carbon
dioxide and oxygen, and the like.
[0168] A heat-seal block (754) that is provided at the chamber lid
(752) side is dropped to heat-seal the flange of the container main
body and the lid material to each other. Subsequently, the vacuum
chamber is opened, and the lid material outside the flange of the
packaging container is removed, completing the packaging container
according to the present invention.
[0169] Note that the steps subsequent to the step of opening the
vacuum chamber are the same as those of Embodiment 1, wherein the
lid material outside the flange can be cut using the cutter (709).
In addition, as with Embodiment 1, a portion that can be separated
along the shape of the flange of each container main body can be
formed in the lid material in advance.
Embodiment 3
[0170] Another example of the configuration of the manufacturing
apparatus for a packaging container according to the present
invention is shown in FIG. 10. The apparatus shown in FIG. 10 is an
example of an apparatus that arranges and conveys a container main
body in such a manner that a pair of opposing sidewall parts
thereof is parallel to the conveyance direction of the container
main body, the container main body having a quadrangular bottom
face part, the pair of opposing sidewall parts in the shape of a
triangular roof, and the remaining other pair of rectangular
sidewall parts.
[0171] In the manufacturing apparatus shown in FIG. 10, as
described above, a plurality of container main bodies (801) are
arranged on a conveyor (803) and conveyed in such a manner that a
pair of opposing sidewall parts in the shape of a triangular roof
of each container main body is parallel to the conveyance direction
of the container main bodies. From above, a lid material (802)
formed of a film or sheet is reeled out from a reel roll (804) and
fed through a dancer roll (805). In order to form the lid material
into the contour shape of the upper end parts of the sidewall parts
that is in the shape of a triangular roof, a sag of the lid
material that is generated between reeling out the lid material and
heat-sealing the lid material to a flange of each container main
body is corrected and adjusted using the dancer roll (806). By
adjusting the feed length of the lid material in this manner, the
lid material can be formed into the contour shape of the upper end
parts of the pair of opposing sidewall parts, and wrinkles that are
generated in the lid material when heat-sealing the lid material to
the flange of each container main body can be prevented.
[0172] Subsequently, the flange of each container main body and the
lid material are heat-sealed to each other. In so doing, the flange
of each container main body and the lid material are held between a
support base (807) provided under the container main body and a
heat-seal block (808) provided thereabove, and subjected to
heat-welding. The shape of the support base and the shape of the
heat-seal block may be changed in accordance with the shape of the
packaging containers to be manufactured.
[0173] Finally, the lid material is cut on the slightly outside of
the flange of each container main body, completing the packaging
container of the present invention. In so doing, the lid material
may be cut by a cutter (809) that is positioned in accordance with
the shape of the top face part of the packaging container. The
shape of the cutter may be changed in accordance with the shape of
the packaging container. Furthermore, it is preferred that a
portion that can be separated along the shape of the flange of each
container main body be formed in the lid material in advance.
[0174] The completed packaging container (810) is collected from a
conveyor (811), and the resultant cut lid material (812) is
forwarded directly through a roll, rolled up, and collected.
Embodiment 4
[0175] An example of a manufacturing apparatus that is configured
to heat-seal a flange of a container main body and a lid material
to each other in a vacuum chamber is described with respect to the
manufacturing apparatus for a packaging container described in
Embodiment 3.
[0176] FIG. 11 is a diagram showing an example of a configuration
of the vacuum chamber. As shown in FIG. 11, the vacuum chamber has
a chamber main body (851) and a chamber lid (852) that can come
into abutment with the chamber main body. The vacuum chamber is
formed into a sealed vacuum chamber by bringing these chamber main
body and chamber lid into abutment with each other. As shown in
FIG. 11, the abutment face between the chamber main body (851) and
the chamber lid (852) form a horizontal plane.
[0177] A lid material is supplied between the chamber main body
(851) and the chamber lid (852), and the width of the lid material
is greater than the width of the container main body in the
longitudinal direction thereof and narrower than the width of the
vacuum chamber in the longitudinal direction thereof. Therefore,
both end parts of the lid material in the width direction in the
vacuum chamber do not come into contact with the vacuum chamber
when the lid material is held between the chamber main body (851)
and the chamber lid (852), and a space is formed. As a result, the
internal space in the chamber main body (851) becomes continuous
with the internal space in the chamber lid (852), enabling
deaeration and gas replacement.
[0178] The chamber main body (851) is provided with a container
support base (853) on which each container main body is mounted,
and a heat-seal block (854) is provided at the chamber lid (852)
side.
[0179] In the manufacturing apparatus for a packaging container
according to Embodiment 4, a container main body is mounted on the
container support base (853) provided in the chamber main body
(851), and a lid material is supplied between the chamber main body
(851) and the chamber lid (852). The chamber main body (851) and
the chamber lid (852) are closed having the lid material
therebetween, and the vacuum chamber is tightly sealed. After the
vacuum chamber is deaerated and evacuated in this state, filler gas
is introduced to the vacuum chamber to adjust the pressure therein.
The filler gas may be selected appropriately from among nitrogen
gas, a mixed gas of nitrogen and carbon dioxide, a mixed gas of
nitrogen, carbon dioxide and oxygen, and the like.
[0180] A heat-seal block (854) that is provided at the chamber lid
(852) side is dropped to heat-seal the flange of the container main
body and the lid material to each other. Subsequently, the vacuum
chamber is opened, and the lid material outside the flange of the
packaging container is removed, completing the packaging container
according to the present invention.
[0181] Note that the steps subsequent to the step of opening the
vacuum chamber are the same as those of Embodiment 3, wherein the
lid material outside the flange can be cut using the cutter (809)
or the like. It is preferred that a portion that can be separated
along the shape of the flange of the container main body be formed
in the lid material in advance.
[0182] Embodiments 1 to 4 each have described examples of an
apparatus for manufacturing a packaging container having a pair of
opposing sidewall parts in the shape of a triangular roof. However,
even when the upper end contour shape of the pair of opposing
sidewall parts is an upward arc shape, a trapezoid shape, a
reversed "V" shape as shown in FIG. 3, or the like, the packaging
container of the present invention can be manufactured by changing
the shape of the plate, support base, heat-seal block, and cutter
accordingly. Also, by configuring the heat-seal block so as to be
able to be divided and joined, the heat-seal block that conforms to
the shape of the packaging container can be created easily.
EXPLANATION OF REFERENCE NUMERALS
[0183] 11, 21, 31, 41, 51, 61: Bottom face part
[0184] 12, 22, 32, 42, 52, 62: A pair of opposing sidewall
parts
[0185] 13, 23, 33, 43, 53, 63: Another pair of opposing sidewall
parts
[0186] 14, 24, 34, 44, 54, 64: Flange
[0187] 65: Projection
[0188] 701, 801: Container main body
[0189] 702, 802: Lid material
[0190] 703, 803: Conveyor
[0191] 704, 804: Reel roll
[0192] 705, 805: Dancer roll
[0193] 706: Jig for adjusting the angle of the lid material
[0194] 806: Dancer roll
[0195] 707, 807: Support base
[0196] 708, 808: Heat-seal block
[0197] 709, 809: Cutter
[0198] 710, 810: Packaging container
[0199] 711, 811: Conveyor
[0200] 712, 812: Cut lid material
[0201] 751, 851: Chamber main body
[0202] 752, 852: Chamber lid
[0203] 753, 853: Container support base
[0204] 754, 854: Heat-seal block
[0205] 91, 101, 111: Bottom face part
[0206] 92, 102, 112: One sidewall
[0207] 94, 104, 11: Flange
[0208] 120: Conventional manufacturing apparatus
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