CONTAINER MANUFACTURING METHOD AND CONTAINER MANUFACTURING APPARATUS

Abstract

A method of manufacturing a container includes: a container preparing step of placing a filling space of the pouch inside a receiving space of an outer container; and a pouch expanding step of supplying air to the filling space of the pouch and expanding the pouch toward the receiving space.

Description

TECHNICAL FIELD

The present disclosure relates to a manufacturing method and a manufacturing apparatus of a container which receives liquid, and more particularly, to a container that stores and discharges liquid and allows full consumption of the content without any remaining liquid.

BACKGROUND ART

FIG. 1A is a view illustrating a device for storing liquid content with high viscosity according to the related art.

Liquid such as shampoo and lotion are characterized by relatively high viscosity. When contained in a container 10, the content 20 with high viscosity tends to stick to internal walls of the container due to high viscosity of the content. Nevertheless, these products are generally sold in rigid containers 10 having openings smaller in diameter than the storage space, as illustrated in FIG. 1A, for esthetic reasons, convenience of usage, etc. That is, most of them are sold as they are contained in rigid containers having a shape illustrated in FIG. 1A because of consumer sensitivity, convenience of use, etc. As such, a method of discharging the content generally involves attaching a pump to a discharging portion 30. Sucking and discharging the content through a discharging tube 31 are done by a pumping operation using air pressure for convenience of use. When a sufficient amount of content 20 is in a storage space of the container 10, the content can be discharged through the discharging tube 31 with no trouble. However, when the content remaining in the container 10 is a small amount, the residual content sticks to the internal walls of the container, and does not easily fall off therefrom. Thus, it is difficult to discharge the residual content, and this is a great obstacle to completely consume the content such as shampoo and lotion.

FIG. 1B is a view illustrating a typical container, which is designed to consume the stored liquid content with high viscosity, having a small amount of content inside.

As illustrated in FIG. 1B, when the amount of the residual content 21 is small, the residual content 21 tends to adhere to the internal walls of the container 10 and is not easily separated from the container 10. In addition, the region where the discharging tube 31 attached to the pump can suck is limited. Thus, it becomes hard to effectively discharge the residual content 21 out of the container. When a large amount of the content is stuck to the internal walls of the container, it is not properly discharged, which causes the following serious problems.

Firstly, the unconsumed content which is out of reach still remains in the rigid container, and the content cannot be consumed completely and discarded, thereby causing unnecessary waste of resources.

Secondly, a discarded container may still contain lotion, shampoo, or detergent, which may cause environmental pollution.

Thirdly, when a discharger such as a pump is disassembled from the container to open a discharging port in order to completely consume the residual content in the container, the content can be contaminated due to foreign substances, etc. introduced from outside.

Fourthly, it is difficult to precisely discharge a wanted amount of content when a user disassembles the discharger from the container and attempts to discharge the content by turning over and shaking the container.

Meanwhile, in order to solve the above problems, an airless container has been suggested. In such configuration, the bottom of the container is designed to elevate upward and reduce the volume of the container according to consumption of the content. The elevation operation of pulling up the bottom of the container is performed by reduction of the pressure applied by the content onto the bottom. Thus, such structure is not applicable to a large-capacity container. Moreover, such structure is applicable only to a cylinder-shaped container. Thus, a freedom of design for the container is limited, and the production cost of the container increases.

Therefore, there is a need for a rigid container which appeals to customers' esthetic sense and are convenient to use. Also there is a need for a method capable of manufacturing it at an inexpensive cost, and effectively injecting and discharging content with high viscosity.

DISCLOSURE

Technical Problem

The inventor of the present disclosure has recognized that: when a small amount of liquid content remains in a container, the liquid content tends to stick to an internal walls of the container due to high viscosity and a surface tension of the liquid content; and thus it is difficult to discharge the residual content by using a pump, etc. The inventor also recognized that: a rigid container is more appealing to consumers; and a rigid container needs to have a pump, etc. attached to a discharging portion for a convenience of use, etc.

Therefore, the inventor of the present disclosure has devised a container and a device in which a pouch with elasticity (an elastic pouch) is inserted to a rigid container. The rigid container stores the liquid content in the elastic pouch. The new and innovative method allows the content stored therein to be conveniently and completely consumed even when a rigid container is used.

In order to easily discharge a residual amount of content in the elastic pouch in a rigid container thus described, filling the content into the elastic pouch should be conducted during a manufacturing process of the product.

FIGS. 2A and 2B are views illustrating a procedure of filling liquid, such as shampoo, lotion, etc., into a rigid container in a typical manufacturing process.

As illustrated in FIG. 2A, in a procedure of filling liquid such as shampoo or lotion in the rigid container, the rigid containers are arranged in a line on a conveying apparatus 50 and conveyed to content filling equipment 51. The content filling equipment can have one or more nozzles 60 depending on its design.

As illustrated in FIG. 2B, when rigid containers are disposed below one or multiple nozzles, the nozzle moves downwardly above an opening of a rigid container to fill the content 61 therein through the nozzle. Here, the time necessary for moving the nozzle downward and the time necessary for filling liquid in the container are directly related to production efficiency. Therefore, generally, the nozzle vertically moves only by a minimum distance in a given design. In another embodiment, the nozzle does not move and sprays the content at a fixed position. The nozzle and the opening of the rigid container are spaced apart from each other during a filling operation to improve the production efficiency, etc.

Meanwhile, the inventor of the present disclosure has also recognized a problem that: when the content is filled into the elastic pouch through the method described herein, an injection pressure of the content applied through the opening of the rigid container is not strong enough to overcome elasticity of the elastic pouch; and unless the injection of the content is performed by contacting the nozzle with the rigid container, it is not possible to inflate the elastic pouch up to the volume of the rigid container.

Therefore, in a cost efficiency aspect, there is a need to develop a method of manufacturing a container, which can inject the content into the elastic pouch using a typical content filling equipment without modification.

Therefore, an object of the present disclosure is to provide a device, a container, and a method of manufacturing the same, which allows full usage of the content without remainder even when the liquid with high viscosity is stored in the rigid container through the container device which is capable of storing and discharging the liquid according to the present disclosure.

Another object of the present disclosure is to provide a device, a container, and a method of manufacturing the same, in which: an elastic pouch is inserted into the rigid container; a residual content can be discharged using the pressure applied by the elastic pouch onto the content toward the opening; the pressure is caused by (i) a reduction effect of the surface area upon contraction of the elastic pouch, (ii) the elasticity (the restoring force) of the elastic pouch, and (iii) a discharging pressure of a discharging device; the elastic pouch can be deformed into various shapes in accordance with a rigid container shape when the elastic pouch is inflated by the elasticity of the elastic pouch; and thereby the rigid container can be designed in various shapes.

Still another object of the present disclosure is to provide a device, a container, and a method of manufacturing the same, in which the content can be injected using a typical content filling method of the elastic pouch. In a typical method, the content cannot be injected to fill up the volume of the rigid container due to elasticity of the elastic pouch since the elastic pouch is not fully expanded when the content is injected by the filling nozzle through an opening of the rigid container. According to the present disclosure, an elastic pouch can be fully filled even using a typical content method.

The objects of the present disclosure are not limited to the above-mentioned objects, and other objects, which are not described here, can be clearly understood by those skilled in the art from the following description.

Technical Solution

According to an aspect of an embodiment, a method of manufacturing a container is provided. The container comprises: an outer container and a pouch, wherein the pouch is made of an elastic material, coupled to the outer container, and having a filling space therein. The method comprises: a container preparing step of placing the filling space of the pouch inside a receiving space of the outer container; and a pouch expanding step of supplying air to the filling space of the pouch and expanding the pouch toward the receiving space of the outer container.

The pouch expanding step may comprise: a pouch stretching step of elastically deforming the pouch towards an end portion of the outer container while the pouch is placed in the receiving space of the outer container, wherein the end portion of the outer container is located opposite to an opening of the outer container; and a pouch pressurizing step of injecting air into the pouch, which is elastically deformed in the pouch stretching step, and expanding the filling space of the pouch.

The pouch stretching step may comprise: inserting an air pressurizing/depressurizing unit into the filling space of the pouch; and moving the air pressurizing/depressurizing unit from the opening of the container to the end portion of the container to elastically deform the pouch.

The pouch expanding step may further comprise: a pouch depressurizing step of depressurizing the filling space of the elastically deformed pouch to a first reference depressurizing pressure using the air pressurizing/depressurizing unit, wherein the first reference depressurizing pressure is equal to or less than the atmospheric pressure; and an outer container depressurizing step of depressurizing the receiving space of the container to a second reference depressurizing pressure through a through-hole formed on the container, wherein the second reference depressurizing pressure is equal to or less than the atmospheric pressure.

The pouch pressurizing step may comprise: when a pressure of the receiving space of the outer container is equal to or less than the second reference depressurizing pressure, supplying air to the filling space of the pouch at a pressure equal to or greater than the atmospheric pressure and expanding the filling space of the pouch.

In the outer container depressurizing step, the receiving space of the outer container may communicate with the outside of the receiving space only through the through-hole.

In the pouch pressurizing step, a portion closer to the opening and a portion farther from the opening may be expanded simultaneously.

In the pouch expanding step, air may be supplied to the filling space of the pouch and the filling space may expand into the receiving space, air in the receiving space may be discharged to the outside of the outer container through a through-hole. The through-hole may be formed on the outer container. The container manufacturing method may further comprise: a pouch-expanded-state-maintaining step of blocking the through-hole of the outer container keeping the filling space in an expanded state. In the pouch-expanded-state-maintaining step, an internal pressure of the filling space of the pouch may be smaller than a restoring force of the pouch, and a force applied onto an inner surface of the pouch by the internal pressure of the filling space of the pouch and a force applied onto an outer surface of the pouch by a pressure of the receiving space between the pouch and the outer container may be in equilibrium with the restoring force of the pouch.

The aforementioned method may further comprise: a liquid filling step of filling liquid-state content into the filling space of the pouch in an expanded state. The liquid-state content may be filled into the filling space of the pouch in the atmospheric pressure state without applying an additional pressure to the liquid-state content.

The container preparing step may comprise: a first-external-container-gripping step of gripping an end portion of the outer container opposite to an opening of the outer container; and a second-external-container-gripping step of gripping the opening of the outer container.

The pouch expanding step may comprise: a pouch stretching step of elastically deforming the pouch towards an end portion of the outer container opposite to an opening of the outer container while the pouch is place inside the receiving space of the outer container; and a pouch pressurizing step of injecting a liquid content into the pouch, which is elastically deformed in the pouch stretching step, and expanding the filling space of the pouch.

According to another aspect of an embodiment, a manufacturing apparatus of a container, wherein the container comprises an outer container and a pouch, wherein the pouch is made of an elastic material, is coupled to the outer container, and having a filling space formed therein, is provided. The apparatus comprises: an air pressurizing/depressurizing unit movable into and out of the filling space of the pouch; and air holes formed at an outer surface of the air pressurizing/depressurizing unit and injecting or exhausting air into or from the filling space. The air pressurizing/depressurizing unit is movable from an opening of the pouch toward an end portion of the pouch in a sliding manner.

The air pressurizing/depressurizing unit may comprise: a unit body which is slidingly movable; and a head portion provided on the unit body. The air holes may be formed in the head portion, and an end portion of the head portion may be rounded.

The air holes may be formed on a side surface of the head portion or the end portion of the head portion.

The outer container may be provided with an opening. A locking portion of the pouch may be coupled with the opening of the outer container. The opening of the outer container may communicate with a receiving space of the outer container. The container manufacturing apparatus may further comprise a first gripping unit which pressurizes the end of the outer container to allow the outer container gripped.

The container manufacturing apparatus may further comprise a stage unit. The locking portion of the pouch, which is coupled to the opening of the outer container, may be seated on the stage unit. The air pressurizing/depressurizing unit may be installed on the stage unit. The stage unit may move downward by a predetermined distance when the first gripping unit pressurizes the end of the outer container.

The container manufacturing apparatus may further comprise a second gripping unit. The second gripping unit may grip an end of the outer container in a direction perpendicular to a direction in which the first gripping unit grips the outer container.

A through-hole may be formed on the end of the outer container and communicates with the receiving space. The first gripping unit may comprise: a first gripping unit body; a suction passage formed on the first gripping unit body and communicating with the through-hole; and an elastic gripping portion contacting the end of the outer container while the through-hole of the outer container is in contact with the suction passage.

According to another aspect of an embodiment, a container manufactured by the aforementioned container manufacturing method is provided. The container comprises a coupling unit. The coupling unit is fitted into an opening of the pouch when the outer container and the pouch are coupled to each other. The coupling unit includes a through space. The through space connects the filling space of the pouch to an outside. The coupling unit pressurizes a part of the pouch to internal walls of an opening of the outer container.

Advantageous Effects

The present disclosure is intended to solve the above problems, and the container device according to the present disclosure provides a device, a container, and a method of manufacturing the same, in which liquid content with high viscosity is contained, and thereby all content can be consumed without leaving residue.

In the device, the container, and the method of manufacturing the same according to an embodiment of the present disclosure, an elastic pouch can be inserted into the rigid container and can effectively discharge the last drop of residual content by using (i) the pressure applied when the elastic pouch pushes the content toward an opening, (ii) the reduction effect of the surface area according to the contraction of the elastic pouch, (iii) elasticity (the restoring force) of the elastic pouch, and (iv) the discharging pressure of the discharging device. The elastic pouch can be inflated by the elasticity of the elastic pouch and deformed into various shapes in accordance with the rigid container. Thus, the rigid container can be designed in various shapes.

In the container, and the method of manufacturing the same according to an embodiment of the present disclosure, the content can be injected into the container also by using a typical content filling method employing an elastic pouch. In the typical method, the content cannot be injected in the container to fill up the volume of a given rigid container due to elasticity of the elastic pouch unless the elastic pouch is expanded before a filling nozzle is positioned above an opening of the rigid container to spray or flow the content into the container. In contrast, in the present invention, the content can fill up the volume of a given rigid container even using the typical method.

DESCRIPTION OF DRAWINGS

FIG. 1A is a view illustrating a device for storing liquid content with high viscosity according to a typical art.

FIG. 1B is a view illustrating a typical container, which is designed to consume the stored liquid content with high viscosity, having a small amount of content inside.

FIG. 2A is a view illustrating a process of filling liquid, such as shampoo, lotion, etc., into a rigid container in a typical manufacturing process.

FIG. 2B is another view illustrating a process of filling liquid, shampoo, lotion, etc., into a rigid container in the typical manufacturing process.

FIG. 3 is a view illustrating a container manufacturing apparatus according to an embodiment of the present disclosure.

FIGS. 4 to 7 are views illustrating a method of filling liquid into a container by using the container manufacturing apparatus of FIG. 3.

FIG. 8 is a view illustrating a container filled using the container manufacturing method of FIGS. 4 to 7.

FIG. 9 is a flowchart illustrating the container manufacturing method of FIGS. 4 to 7.

FIG. 10 is a flowchart illustrating expanding a pouch in a container manufacturing method of FIG. 9.

BEST MODE

The advantages and features of the present disclosure and the method for achieving them will become apparent with reference to the embodiments, which will be described in detail below together with the accompanying drawings. However, the present disclosure is not limited to the embodiments disclosed below, but can be implemented in many different forms, and the embodiments are merely provided to fully convey the scope of the disclosure to those skilled in the art to which the present disclosure pertains, and the present disclosure is only defined by the scope of the claims.

Although the terms such as first, second, etc. are used to describe various components, these components are not limited by these terms. These terms are used only to distinguish one component from another. Therefore, the first component described below can also be the second component within the technical spirit of the present disclosure.

Throughout the specification, same reference numerals refer to same or similar components.

The respective features of various embodiments of the present disclosure can be coupled or combined with each other partially or entirely. Respective embodiments can be implemented either independently or together with each other.

Meanwhile, the potential effects that can be expected by the technical features of the present disclosure. The technical features, which are not specifically described in the specification of the present disclosure, are regarded as described in the present specification. The present embodiment is provided to help those skilled in the art understand the present disclosure. The contents illustrated in the drawings can be exaggerated compared to the actual dimension for the purpose of explanation. Description on some configurations is omitted for better brevity and clarity.

In the present specification, the ‘liquid’ refers to a wide range of liquid state rather than a solid or gaseous state. That is, it means all states that have a short intermolecular distance and low kinetic energy but are not bonded with each other as strong as solid-phase molecules, and is used as the meaning that includes all liquids ranging from the liquid having a low viscosity such as water to the liquid with a high viscosity such as gels.

In the present specification, a pouch is a flexible pouch and can have either a fixed shape or a non-fixed shape. The pouch has elasticity which creates a restoring force for returning to its original shape when its shape is stretched or inflated by an external force. A pouch, as a simple flexible pouch, changes in shape by an external force because it is not fixed in shape.

In the present specification, a container means all kinds of containers made of rigid materials such as plastic, glass, and metal, and also is referred to as ‘rigid container’.

In the present specification, a coupling unit means a structure which is coupled with an opening of the pouch and also coupled with a container coupling portion of the container (the injection port of the container), thereby coupling the pouch and the container so that the pouch can be fixed in the container. The coupling unit can further include a fixing portion or an air blocking portion so that a space between the container and the pouch can be completely sealed from the outside. The coupling unit can be integrally manufactured with the pouch through insert injection, etc. in the process of manufacturing the pouch.

Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings so that those skilled in the art to which the present disclosure pertains can easily practice. The present disclosure can be implemented in many different forms, but is not limited to the embodiments described herein. In order to clearly describe the present disclosure, in the drawings, parts not related to the description are omitted, and the same or similar components are denoted by the same reference numerals throughout the specification. In addition, since the size and the thickness of the respective components illustrated in the drawings have been arbitrarily illustrated for convenience of explanation, the present disclosure is not necessarily limited to those illustrated in the drawings.

FIG. 3 is a view illustrating a container manufacturing apparatus according to an embodiment of the present disclosure. FIGS. 4 to 7 are views illustrating a method of filling liquid into a container by using the container manufacturing apparatus of FIG. 3. Also, FIG. 8 is a view illustrating the container which is filled by the container manufacturing method of FIGS. 4 to 7.

Referring to FIGS. 3 and 4, a container manufacturing apparatus 1 according to an embodiment of the present disclosure is an apparatus for manufacturing a container 2. The container 2 includes a pouch 220 made of an elastic material and is capable of suppressing the filled-in content to be left over in the course of consuming it.

The container 2 manufactured by the container manufacturing apparatus 1 according to the present embodiment can include, for example, an outer container 210, a pouch 220, and a coupling unit 230. The outer container 210 is made of a rigid material such as glass or plastic. The pouch 220 is made of an elastic material coupled to the outer container 210 and has a filling space 226 formed therein. The coupling unit 230 is capable of firmly coupling the pouch 220 to the outer container 210 and securing a passage to the filling space 226 of the pouch 220.

In a typical art, a conventional filling equipment simply flows liquid content, such as cosmetics or detergents, into the container 1 without applying such a great additional pressure to the liquid content. In such case, the pouch 220 is not sufficiently expanded out to a receiving space 216 of the outer container 210 under the condition that the pouch 220 is coupled to the outer container 210 of the container 2.

That is, when the typical filling equipment is used, the weight of the liquid content filled in the filling space 226 of the pouch 220, which is initially laid in a contracted state, is smaller than the elastic force of the pouch 220. Accordingly, the pouch 220 remains in the contracted state. As a result, a desired amount of liquid content is not filled in the pouch 220.

Therefore, in a container manufacturing apparatus 1 according to an embodiment of the present disclosure, the pouch 220 expands up to a predetermined size under the condition that the outer container 210 is coupled to the pouch 220. A sufficient filling space 226 is secured, and the pouch 220 is maintained in the expanded state. Thus, the conventional problem caused using the typical filling equipment can be solved.

The container manufacturing apparatus 1 according to an embodiment of the present disclosure may include a table T, a stage unit 110, an air pressurizing/depressurizing unit 120, a first gripping unit 130, a second gripping unit 140, and a third gripping unit 150.

More specifically, the table T is supported by a bottom surface (not illustrated). The stage unit 110, the air pressurizing/depressurizing unit 120, the first gripping unit 130, the second gripping unit 140, and the third gripping unit 150 can be installed on the table T.

The stage unit 110 is installed on the table T and is vertically movable by a predetermined distance. A stage unit body 111 is vertically and slidably connected to the table T. A container installation portion 112 is provided on the stage unit body 111. A part of the container 1 is fitted in the container installation portion 112.

For example, the container installation portion 112 can be formed in a cylindrical shape. A coupling unit 230 of the container 200, a locking portion 224 of the pouch 220, and a neck portion 214 of the outer container 210 can be seated in an installation hole (not illustrated) formed at the center of the container installation portion 112. When the container 2 is seated on the container installation portion 112, an opening 215 formed at the neck portion 214 of the outer container 210 is closed by the pouch 220. The coupling unit 230 pressurizes on a part of the pouch 220 toward an inner surface side of the opening 215 so that the opening 215 of the outer container 210 can be firmly sealed.

The air pressurizing/depressurizing unit 120 is positioned in the installation hole of the container installation portion 112, and slides vertically with respect to the container installation portion 112. The air pressurizing/depressurizing unit 120 is inserted into the filling space 226 of the pouch 220, and has air holes 124 formed at the outer surface thereof. The internal air of the filling space 226 flows in and out through the air holes 124.

More specifically, the air pressurizing/depressurizing unit 120 includes a unit body 121 which is slidable with respect to the stage unit 110, and a head portion 122 formed at one side of the unit body 121 and having the air holes 124 formed therein. The end portion 123 of the head portion 122 is rounded so that damages to the pouch 220 can be suppressed and the pouch 220 can be uniformly expanded when the head portion 122 pressurizes the end portion 222 of the pouch 220 and the pouch 220 is expanded and deformed.

Although it has been described in the present embodiment that multiple air holes 124 are formed in the head portion 122, it is also possible to form a single air hole 124.

When multiple air holes 124 of the head portion 122 are provided, the air holes 124 can be linearly positioned at the side surface of the head portion 122. However, this is merely illustrative, and in another embodiment, the air holes 124 can be positioned in a spiral shape or positioned in an irregular pattern at the side surface of the head portion 122. In yet another embodiment, the air holes 124 are positioned at the end portion 123 side of the head portion 122. In further another embodiment, the air holes 124 are positioned both at the end portion of the head portion 122 and at the side surface thereof.

The air holes 124 of the air pressurizing/depressurizing unit 120 are connected to a pump unit (not illustrated) of the container manufacturing apparatus 1. Air can be discharged through the air holes 124 or provided through the air holes 124 using the pump unit.

In addition, a unit body 121 of the air pressurizing/depressurizing unit 120 can move vertically upon receiving a driving force from a driving unit (not illustrated). The driving unit can be a rack and pinion or a linear motor for converting RPM into a linear direction, but the driving unit is not limited thereto.

Meanwhile, a first gripping unit 130 and a third gripping unit 150 are movably installed on a vertical frame 180. The vertical frame 180 vertically extends from the table T. A pair of second gripping units 140 is installed on the table T and moves in a direction perpendicular to the direction in which the vertical frame 180 extends. That is, the pair of second gripping units 140 moves along a direction parallel to a surface of the table T.

When a locking portion 224 of the pouch 220 and a coupling unit 230 are installed at one side of the outer container 210, that is, the neck portion 214, and the opening 215 of the outer container 210 is installed toward the stage unit 110, the first gripping unit 130 contacts a second side 212 of the outer container 210 and pressurizes the outer container 210 toward the stage unit 110 so that the outer container 210 is gripped.

When the first gripping unit 130 is lifted upward from the vertical frame 180 and then moves down to the outer container 210 to press/grip the outer container 210, the first gripping unit 130 comes in contact with the second side 212 of the outer container 210 and a pressure is applied to the outer container 210. The first side 213 of the outer container 210 moves downward by a predetermined distance onto the stage unit 110. Thus, the container 2 is prevented from being damaged due to a pressure suddenly applied.

Meanwhile, a through-hole 217 is formed on the second side of the outer container 210 and communicates with the receiving space 216 of the outer container 210. The first gripping unit 130 includes a first gripping unit body 131, a suction passage 133, and an elastic gripping portion 134. The first gripping unit body 131 is connected vertically with the vertical frame 180 in a sliding manner. The suction passage 133 is formed at the first gripping unit body 131 and communicates with the through-hole 217 of the outer container 210. The elastic gripping portion 134 contacts the second side 212 of the outer container 210 when the through-hole 217 of the outer container 210 contacts the suction passage 133.

At this time, the suction passage 133 is connected to a pumping unit (not illustrated) of the container manufacturing apparatus 1. When the through-hole 217 communicates with the suction passage 133, a negative pressure is provided from the pumping unit, thereby discharging the air of the receiving space 216 to the outside through the through-hole 217.

Then, when the elastic gripping portion 134 made of an elastic material such as rubber or silicone contacts the second side 212 of the outer container 210, the outer container 210 is prevented from being damaged by the contact momentarily occurred between the outer container 210 and the first gripping unit 130.

A pair of second gripping units 140 is provided. The two second gripping units 140 are spaced apart from each other with the stage unit 110 therebetween. Each second gripping unit 140 includes a gripping unit body 141, a gripping portion 142, and a moving portion 143. The gripping portion 142 is positioned at a first end of the gripping unit body 141 and surrounding the neck portion 214 of the outer container 210. The moving portion 143 is connected to a second end of the gripping unit body 141 and capable of moving the gripping unit body 141 in a horizontal direction, that is, the direction that approaches the stage unit 110 or is away therefrom.

The pair of the second gripping units 140 grips the neck portion 214 of the outer container 210 when the container 2 is installed on the stage unit 110. Thus, the container 2 is suppressed from being shaken horizontally. In another embodiment of the present disclosure, the pair of the second gripping units 140 can be designed so that one unit is fixed and only the other unit is driven.

The third gripping unit 150 is positioned on the vertical frame 180, and is interposed between the first gripping unit 130 and the table T. The third gripping unit 150 can surround an outer circumference of the outer container 210, thereby suppressing the container 2 from being shaken when the container 2 is installed on the stage unit 110.

In the present embodiment, the opening 215 of the outer container 210 and an opening 225 of the pouch 220 are directed downward. However, in another embodiment, the opening 215 of the outer container 210 and the opening 225 of the pouch 220 may be directed upward. In this case, the stage unit 110 can include a suction passage that contacts the through-hole 217 of the outer container 210, and the air pressurizing/depressurizing unit 120 can be installed at the first gripping unit 130.

Meanwhile, in the present embodiment, the outer container 210, the pouch 220, and the coupling unit 230 are manually positioned in the container manufacturing apparatus 1. However, in another embodiment, the second gripping unit 140 and/or the third gripping unit 150 may be omitted if the outer container 210, the pouch 220, and the coupling unit 230 are automatically positioned in the container manufacturing apparatus 1 by a conveyor belt, a robot, etc.

Hereinafter, a container 2 manufacturing method according to an embodiment of the present disclosure will be described in detail.

First, the container 2 is seated on the stage unit 110 of the manufacturing apparatus 1. The container 2 includes the outer container 210, the pouch 220, and the coupling unit 230. The pouch 220 is coupled to the outer container 210 so that the filling space 226 is positioned in the receiving space 216 of the outer container 210. The coupling unit 230 is fitted into the opening 225 of the pouch 220 when the outer container 210 is coupled to the pouch 220. A through space 235 for communicating the filling space 226 of the pouch 220 with the outside is formed in the coupling unit 230.

The neck portion 214 is positioned at one side 213 of the outer container 210. The opening 215 of the outer container side that communicates with the receiving space 216 is formed in the neck portion 214. In an embodiment, the neck portion 214 is formed smaller in diameter than an outer container body 211.

The pouch 220 is made of an elastic material and has the filling space 226. The pouch 220 includes the pouch body 221 and the locking portion 224. The opening 225 is formed at a first side 223 of the pouch body 221. The locking portion 224 is in a plate shape, formed at the first side of the pouch body 221, and formed lager than an outer diameter of the pouch body 221.

The coupling unit 230 includes a coupling unit body 231 fitted into the opening 225 of the pouch 220, and a coupling unit side locking portion 232 formed at one side of the coupling unit body 231. The coupling unit body 231 is formed larger in an outer diameter than the coupling unit body 231. The through space 235 for communicating with the filling space 226 of the pouch 220 is formed in the center of the coupling unit body 231.

When the pouch 220 is coupled to the outer container 210, the coupling unit 230 is installed at the opening 225 of the pouch 220 and pressurizes on a part of the pouch 220 toward the outer container side opening 215 of the outer container 210 so that the outer container 210 and the pouch 220 are firmly coupled, thereby suppressing the air from flowing into or out the space between the outer container side opening 215 of the outer container 210 and the pouch 220. In addition, the coupling unit 230 is made of a material harder than the pouch 220, for example, a plastic material such as PP, PE, ABS, or nylon or a metal material such as SUS. Therefore, when the filling of the liquid content into the container 2 has been completed, and a pumping means (not illustrated) for discharging the liquid content to the outside is installed at the opening 225 of the pouch 220, the coupling unit 230 is not deformed in shape by an external force and firmly keeps the shape of the opening 225 of the pouch 220, thereby suppressing the opening 225 of the pouch 220 from rolling-in by insertion of the pumping means.

In the present embodiment, the coupling unit 230 is coupled to the opening 225 of the pouch 220. However, in another embodiment, the coupling unit 230 may be omitted. In such structure, a support member, which is made of a material harder than a material of the pouch 220, is positioned in the locking portion 224 of the pouch 220.

The container 2 is seated on the stage unit 110 of the manufacturing apparatus 1 as follows. First, the outer container 210, the pouch 220, and the coupling unit 230 of the container 2 are coupled to each other. The air pressurizing/depressurizing unit 120 passes through the through space 235 of the coupling unit 230. The container 2 is seated on the stage unit 110 so that the head portion 122 of the air pressurizing/depressurizing unit 120 is positioned in the filling space 226 of the pouch 220.

In the above-mentioned embodiment, the container 2 includes the coupling unit 230 coupled to the pouch 220. However, in another embodiment, the coupling unit 230 may be omitted. In such case, a part (the locking portion 224) of the pouch 220 can be made of a rigid material, or a rigid support member can be provided in the locking portion 224 of the pouch 220.

While the container 2 is seated on the stage unit 110, the second gripping unit 140 can surround the outer circumferential surface of the outer container 210 so that the outer container 210 is gripped.

Next, referring to FIG. 5, when the container 2 is seated on the stage unit 110, the first gripping unit 130 moves to the stage unit 110 to contact the other side 212 of the outer container 210. At this time, the through-hole 217 formed in the other side 212 of the outer container 210 communicates with the suction passage 133 of the first gripping unit 130.

Then, the second gripping units 140 move in a horizontal direction to grip the neck portion 214 of the outer container 210.

Then, referring to FIG. 6, when the container 2 is gripped by the gripping units 130, 140, 150, the air pressurizing/depressurizing unit 120 slidingly moves toward the first gripping unit 130, that is, in the opposite direction of the opening 215 of the outer container 210 heads. Thus, the pouch 220 is elastically deformed.

Then, the filling space 226 of the pouch 220 is stretched upward by a predetermined size. The air pressurizing/depressurizing unit 120 depressurizes the filling space 226 of the elastically deformed pouch 220 to a first reference depressurizing pressure P_NR1, which is equal to or smaller than atmospheric pressure. When the filling space 226 is depressurized down to the first reference depressurizing pressure P_NR1, a part of an inner surface of the pouch 220 is attached and fixed to the air pressurizing/depressurizing unit 120.

Next, referring to FIG. 7, when the filling space 226 is depressurized to the first reference depressurizing pressure P_NR1, the receiving space 216 of the outer container 210 is depressurized to the atmospheric pressure or less through the air passage 133 of the first gripping unit 130. At this time, a part of the inner surface of the pouch 220 can be attached and fixed to the air pressurizing/depressurizing unit 120. Thus, the pouch 220 is prevented from being elastically deformed to an unintended shape when the receiving space 216 is depressurized. That is, a part of the pouch 220 is prevented from being sucked into the through-hole 217 of the outer container 210 and deformed.

In the present embodiment, the filling space 226 is depressurized first, and then the receiving space 216 is depressurized. However, in another embodiment, the two depressurization processes can be performed simultaneously.

This time, the first reference depressurizing pressure P_NR1 can be equal to or smaller than a second reference depressurizing pressure P_NR2. The receiving space 216 of the outer container 210 can communicate with the outside of the receiving space 216 only through the through-hole 217.

Then, when the internal pressure of the receiving space 216 is reduced to the second reference depressurizing pressure P_NR2 or less, the air pressurizing/depressurizing unit 120 provides a reference pressurizing pressure P_PR, which is equal to the atmospheric pressure or is greater than the atmospheric pressure, to the filling space 226. When the pressure of the receiving space 216 is at the second reference depressurizing pressure P_NR2, which is smaller than the atmospheric pressure, and the reference pressurizing pressure P_PR, which is greater than the atmospheric pressure, is applied to the filling space 226, the pouch body 221 of the pouch 220 instantly expands in the receiving space 216 of the outer container 210.

At this time, the filling space 226 of the pouch 220 expands uniformly. Put it another way, the pouch 220 expands to a portion of the filling space 226 which is distant from the opening 215 of the outer container 210 (that is, a portion adjacent to the other side 212 of the outer container 210) and to a portion of the filling space 226, which is close to the opening 215 (that is, a portion adjacent to one side 213 of the outer container 210) simultaneously.

The air holes 124 of the air pressurizing/depressurizing unit 120 are provided on the end portion 222 in an eccentric manner. Thus, if the air pressurizing/depressurizing unit 120 provides the reference pressurizing pressure P_PR to the filling space 226 without the depressurization procedure for the receiving space 216 of the outer container 210, the end portion 222 of the pouch 220, in which the air holes 124 are disposed, would be first inflated. This would make the pouch 220 unevenly inflated. If the pouch 220 is unevenly inflated, the portion of the pouch body 221 inflated earlier may contact the internal wall of the outer container 210, and thus block the passage through which the air in the receiving space 216 of the outer container 210 is discharged via the through-hole 217. This may lead to an incomplete inflation of the pouch 220 which is undesirable.

In the present embodiment, the pouch 220 is uniformly inflated in the receiving space 216 so that the pouch 220 can be smoothly inflated.

In the above-mentioned present embodiment, each of the air holes 124 of the air pressurizing/depressurizing unit 120 sucks and discharges the air. However, in another embodiment, some air holes 124 of the plurality of air holes 124 may be configured to suck the air whereas the other air holes 124 to discharge the liquid content.

When the filling space 226 is depressurized to the first reference depressurizing pressure P_NR1, the receiving space 216 is depressurized to the second reference depressurizing pressure P_NR2, and the liquid content are supplied from the other air holes 124, the pouch 220 can be expanded by supplying the liquid content at the atmospheric pressure or the pressure close to the atmospheric pressure. In another embodiment, the liquid content can be supplied at a pressure of the atmospheric pressure or more to have the pouch 220 expanded in a wanted size.

Next, referring to FIG. 8, a blocking means 240 is installed in the through-hole 217 of the outer container 210 to keep the filling space 226 in the expanded state once the filling space 226 of the pouch 220 is expanded in a desired size.

The blocking means 240 employed for the container manufacturing method according to the present embodiment can be an adhesive member such as a sticker and suppresses the air from flowing into the through-hole 217. In another embodiment, the blocking means 240 can be a valve means such as a check valve and selectively blocks the movement of air. When the blocking means 240 is the check valve, the blocking means 240 can be installed to the outer container 210 in preparing the container 2.

In the above-mentioned present embodiment, the air pressurizing/depressurizing unit 120 fills the air in the filling space 226 of the pouch 220. In another embodiment, the air pressurizing/depressurizing unit 120 directly fills the liquid content into the filling space 226 of the pouch 220.

Hereinafter, a container manufacturing method according to an embodiment of the present disclosure will be described.

FIG. 9 is a flowchart illustrating the container manufacturing method shown in FIGS. 4 to 7. FIG. 10 is a flowchart illustrating an expanding process of the pouch shown in the container manufacturing method in FIG. 9.

Referring to FIGS. 9 and 10, a step S110 of preparing the container is performed. The container 2 includes the outer container 210 and the pouch 220 coupled to the outer container 210. The filling space 226 is positioned in the receiving space 216 of the outer container 210.

The step S110 of preparing the container includes gripping a first outer container and gripping a second outer container. In the step of gripping the first outer container, the first gripping unit 130 grips the opposite side end portion 212 of the opening 215 side of the outer container 210. In the step of gripping the second outer container, the opening 215 of the outer container 210, that is, the neck portion 214 is gripped.

Then, the container manufacturing method includes a step S220 of expanding the pouch is performed. Air is supplied to the filling space 226 of the pouch 220 and the filling space 226 of the pouch 220 is expanded in the receiving space 216.

In the step S220 of expanding the pouch, when the pouch 220 is inserted into the receiving space 216 of the outer container 210, a step S121 of stretching the pouch is performed. The pouch 220 is elastically deformed toward the opposite direction of the opening 215 of the outer container 210.

Then, a step S122 of depressurizing the pouch is performed. The filling space 226 of the elastically deformed pouch 220 is depressurized to the first reference depressurizing pressure P_NR1, which is equal to or smaller than the atmospheric pressure, by the air pressurizing/depressurizing unit 120.

Then, a step S123 of depressurizing the outer container is performed. The receiving space 216 of the outer container 210 is depressurized to the atmospheric pressure or less through the through-hole 217. The through-hole 217 is formed on the outer container 210.

Then, a step S124 of pressurizing the pouch 220 is performed. Air is injected into the pouch 220, which is elastically deformed in the step S121 of stretching the pouch, to expand the filling space 226 of the pouch 220.

In the step S120 of expanding the pouch, air is supplied to the filling space 226 of the pouch 220 and the volume of the filling space 226 increases in the receiving space 216. Air in the receiving space 216 is discharged to the outside of the outer container 210 through the through-hole 217. The through-hole 217 is formed on the outer container 210.

Then, a step S130 of keeping the pouch in an expanded state is performed. When the filling space 226 of the pouch 220 is expanded, the blocking means 240 is installed in the through-hole 217 of the outer container 210 in order to keep the filling space 226 in the expanded state.

In the step S130 of keeping the pouch in the expanded state, the internal pressure of the filling space 226 of the pouch 220 is smaller than the restoring force of the pouch. A force applied onto an inner surface of the pouch 220 by the internal pressure of the filling space 226 of the pouch 220 and a force applied onto the outer surface of the pouch 220 by an internal pressure of the receiving space 216 between the pouch 220 and the outer container 210 is in equilibrium with the restoring force of the pouch 220.

Then, a step S140 of filling liquid is performed. Liquid-state content is filled into the filling space 226 of the expanded pouch 220. The content is filled into the filling space 226 of the pouch 220 at the atmospheric pressure and no additional pressure is applied.

According to the proposed embodiment, it is possible to fill liquid content into an elastic pouch in an outer container using the typical filling equipment.

The present disclosure is not limited to the above-mentioned embodiments. Various modifications can be made within the scope of the claims in reference with the detailed description of the disclosure, and the accompanying drawings.

INDUSTRIAL APPLICABILITY

The present disclosure relates to a container manufacturing method and a container manufacturing apparatus. It is possible to fill up liquid in the container and discharge content to the last drop without leaving remainder.

Claims

1. A method of manufacturing a container,

wherein the container comprises: an outer container and a pouch, wherein the pouch is made of an elastic material, coupled to the outer container, and having a filling space therein,

wherein the method comprises: a container preparing step of placing the filling space of the pouch inside a receiving space of the outer container; and a pouch expanding step of supplying air to the filling space of the pouch and expanding the pouch toward the receiving space.

2. The method of claim 1,

wherein the pouch expanding step comprises:

a pouch stretching step of elastically deforming the pouch towards an end portion of the outer container while the pouch is placed in the receiving space of the outer container, wherein the end portion of the outer container is located opposite to an opening of the outer container; and

a pouch pressurizing step of injecting air into the pouch, which is elastically deformed in the pouch stretching step, and expanding the filling space of the pouch.

3. The method of claim 2, wherein the pouch stretching step comprises:

inserting an air pressurizing/depressurizing unit into the filling space of the pouch; and

moving the air pressurizing/depressurizing unit from the opening of the container to the end portion of the container to elastically deform the pouch.

4. The method of claim 3,

wherein the pouch expanding step further comprises: a pouch depressurizing step of depressurizing the filling space of the elastically deformed pouch to a first reference depressurizing pressure using the air pressurizing/depressurizing unit, wherein the first reference depressurizing pressure is equal to or less than the atmospheric pressure; and an outer container depressurizing step of depressurizing the receiving space of the container to a second reference depressurizing pressure through a through-hole formed on the container, wherein the second reference depressurizing pressure is equal to or less than the atmospheric pressure, wherein the pouch pressurizing step comprises: when a pressure of the receiving space of the outer container is equal to or less than the second reference depressurizing pressure, supplying air to the filling space of the pouch at a pressure equal to or greater than the atmospheric pressure and expanding the filling space of the pouch.

5. The method of claim 4,

wherein, in the outer container depressurizing step, the receiving space of the outer container communicates with the outside of the receiving space only through the through-hole.

6. The method of claim 2,

wherein, in the pouch pressurizing step,

a portion closer to the opening and a portion farther from the opening are expanded simultaneously.

7. The method of claim 1,

wherein, in the pouch expanding step, air is supplied to the filling space of the pouch and the filling space expands into the receiving space, air in the receiving space is discharged to the outside of the outer container through a through-hole, wherein the through-hole is formed on the outer container,

wherein the container manufacturing method further comprises: a pouch-expanded-state-maintaining step of blocking the through-hole of the outer container keeping the filling space in an expanded state,

wherein, in the pouch-expanded-state-maintaining step, an internal pressure of the filling space of the pouch is smaller than a restoring force of the pouch, and

wherein a force applied onto an inner surface of the pouch by the internal pressure of the filling space of the pouch and a force applied onto an outer surface of the pouch by a pressure of the receiving space between the pouch and the outer container are in equilibrium with the restoring force of the pouch.

8. The method of claim 1, further comprising:

a liquid filling step of filling a liquid-state content into the filling space of the pouch in an expanded state,

wherein the liquid-state content are filled into the filling space of the pouch in the atmospheric pressure state without applying an additional pressure to the liquid-state content.

9. The method of claim 1,

wherein the container preparing step comprises:

a first-external-container-gripping step of gripping an end portion of the outer container opposite to an opening of the outer container; and

a second-external-container-gripping step of gripping the opening of the outer container.

10. The method of claim 1,

wherein the pouch expanding step comprises:

a pouch stretching step of elastically deforming the pouch towards an end portion of the outer container opposite to an opening of the outer container while the pouch is place inside the receiving space of the outer container; and

a pouch pressurizing step of injecting a liquid content into the pouch, which is elastically deformed in the pouch stretching step, and expanding the filling space of the pouch.

11. A manufacturing apparatus of a container, wherein the container comprises an outer container and a pouch, wherein the pouch is made of an elastic material, is coupled to the outer container, and having a filling space formed therein, the apparatus comprising:

an air pressurizing/depressurizing unit movable into and out of the filling space of the pouch; and

air holes formed at an outer surface of the air pressurizing/depressurizing unit and injecting or exhausting air into or from the filling space,

wherein the air pressurizing/depressurizing unit is movable from an opening of the pouch toward an end portion of the pouch in a sliding manner.

12. The container manufacturing apparatus of claim 11, wherein the air pressurizing/depressurizing unit comprises:

a unit body which is slidingly movable; and

a head portion provided on the unit body,

wherein the air holes are formed in the head portion, and

wherein an end portion of the head portion is rounded.

13. The container manufacturing apparatus of claim 12,

wherein the air holes are formed on a side surface of the head portion or the end portion of the head portion.

14. The container manufacturing apparatus of claim 11,

wherein the outer container is provided with an opening,

wherein a locking portion of the pouch is coupled with the opening of the outer container,

wherein the opening of the outer container communicates with a receiving space of the outer container, and

wherein the container manufacturing apparatus further comprises a first gripping unit which pressurizes the end of the outer container to allow the outer container gripped.

15. The container manufacturing apparatus of claim 14, further comprising:

a stage unit,

wherein the locking portion of the pouch, which is coupled to the opening of the outer container, is seated on the stage unit,

wherein the air pressurizing/depressurizing unit is installed on the stage unit,

wherein the stage unit moves downward by a predetermined distance when the first gripping unit pressurizes the end of the outer container.

16. The container manufacturing apparatus of claim 14, further comprising a second gripping unit,

wherein the second gripping unit grips an end of the outer container in a direction perpendicular to a direction in which the first gripping unit grips the outer container.

17. The container manufacturing apparatus of claim 14,

wherein a through-hole is formed on the end of the outer container and communicates with the receiving space, and

wherein the first gripping unit comprises:

a first gripping unit body;

a suction passage formed on the first gripping unit body and communicating with the through-hole; and

an elastic gripping portion contacting the end of the outer container while the through-hole of the outer container is in contact with the suction passage.

18. A container manufactured by the container manufacturing method of claim 1, further comprising:

a coupling unit,

wherein the coupling unit is fitted into an opening of the pouch when the outer container and the pouch are coupled to each other,

wherein the coupling unit includes a through space,

wherein the through space connects the filling space of the pouch to an outside, and

wherein the coupling unit pressurizes a part of the pouch to an internal wall of an opening of the outer container.