Patent Description:
Patent Literature <NUM> describes a hot parison type blow molding apparatus and a resin container manufacturing method using the blow molding apparatus. Patent Literature <NUM> describes a large container obtained by blow molding a bottomed tubular preform, which is obtained by injection molding a polyester resin, after temperature adjustment.

<CIT> describes a device including an injection forming unit that produces a resin preform having a bottom; a blow forming unit; a support part that supports the preform; and a conveying unit that conveys the support part to the blow forming unit, wherein the blow forming unit further has a first mold unit for performing a first step in which the preform that was produced with the injection molding unit is subjected to heat-set blowing at a first temperature, a second mold unit for performing a second step in which an intermediate molded article that was blow molded through heat-set blowing is blow molded at a second temperature to produce a container, said second temperature being lower than the first temperature, and a movement unit that can move the first mold unit and the second mold unit relative to the support part in order to perform the first step and the second step continuously.

<CIT> describes a blow molding machine including an injection molding unit and a blow molding unit, wherein the injection molding unit includes a preform mold and an injection device configured to supply resin to the preform mold, wherein the injection device is fixed to a support plate, and wherein the support plate includes a position adjustment mechanism capable of adjusting a position of the injection device in an upper and lower direction with respect to the preform mold.

<CIT> describes a mold including a link member including a protruding grip forming part configured to form a grip part to a portion of a container by pressurizing a portion of a preform that is expanded during blow molding; and a piston member configured to move forward toward a cavity to thus press and rotate the link member.

<CIT> describes a method of making blown plastic containers having internal ribs.

As the hot parison type blow molding apparatus, if a method of injection molding a plurality of preforms along a predetermined arrangement direction and conveying the preforms in a direction intersecting the arrangement direction to blow mold containers is adopted, a number ratio of preforms can be changed between the injection molding part and the blow molding part, and thus, there are advantages such as downsizing of a blow molding mold and local cooling of the preforms during conveying. However, in this method, when the injection molded preforms are divided into blow molding units (divided into the number of blow cavities) and intermittently conveyed to the blow molding part, a length of waiting time until reaching the blow molding part changes for each unit, which tends to cause a temperature difference between the preforms.

An object of the present invention is to provide a resin container manufacturing method and a resin container manufacturing apparatus that can stably manufacture high-quality containers by reducing a temperature condition difference between preforms even when a conveying method that tends to cause the temperature difference between preforms is adopted.

Another object of the present invention is to provide a resin container manufacturing method and a resin container manufacturing apparatus that ensure a uniform temperature between preforms and can stably manufacture high-quality containers even when a conveying method that tends to cause a temperature difference between preforms is adopted.

A resin container manufacturing method according to one aspect of the present invention, which can solve the above problem, includes:.

A resin container manufacturing apparatus according to one aspect of the present invention, which can solve the above problem, includes:.

The present invention can provide a resin container manufacturing method and a resin container manufacturing apparatus that can stably manufacture high-quality containers by reducing a temperature condition difference between preforms even when a conveying method that tends to cause the temperature difference between preforms is adopted.

The present invention can also provide a resin container manufacturing method and a resin container manufacturing apparatus that ensure a uniform temperature between preforms and can stably manufacture high-quality containers even when a conveying method that tends to cause a temperature difference between preforms is adopted.

Note that, for convenience of description, the dimensions of the respective members illustrated in the drawings may be different from the actual dimensions of the respective members.

<FIG> is a schematic diagram in a plan view illustrating a resin container manufacturing apparatus <NUM> according to the present embodiment. <FIG> is a schematic diagram in a side view illustrating the resin container manufacturing apparatus <NUM> according to the present embodiment. The manufacturing apparatus <NUM> is a so-called <NUM>-station type molding apparatus, including: an injection molding part <NUM> that injection molds a plurality of preforms <NUM> along a predetermined arrangement direction C; a temperature adjustment part <NUM> that adjusts a temperature of the preform <NUM>; a blow molding part <NUM> that molds a resin container <NUM> from the preform <NUM>; and a take-out part <NUM> that takes out the molded container <NUM>. The container <NUM> manufactured by the manufacturing apparatus <NUM> can be a large bottle such as a <NUM> litres (<NUM>-gallon) bottle. The manufacturing apparatus is a one-step type that uses a divided blow method.

In this example, in the manufacturing apparatus <NUM>, the injection molding part <NUM>, the temperature adjustment part <NUM>, the blow molding part <NUM>, and the take-out part <NUM> are arranged linearly. The manufacturing apparatus <NUM> includes conveying mechanisms <NUM> and <NUM> (not shown in <FIG>) that convey the preform <NUM> and the container <NUM> along a conveying direction A intersecting the arrangement direction C over the temperature adjustment part <NUM> and the blow molding part <NUM>. The manufacturing apparatus <NUM> is provided with a conversion part <NUM> between the injection molding part <NUM> and the temperature adjustment part <NUM>. The conversion part <NUM> includes a conversion mechanism <NUM> that changes an alignment direction of the plurality of preforms <NUM> from the arrangement direction C to a direction along the conveying direction A.

The injection molding part <NUM> injection molds the plurality of preforms <NUM> so that the plurality of preforms <NUM> are aligned along the arrangement direction C. The injection molding part <NUM> includes at least one first injection mold <NUM> and at least two second injection molds <NUM>. The first injection mold <NUM> includes an injection cavity mold <NUM> provided with a plurality of (for example, four) recesses <NUM> that define outer shapes of a body portion and a bottom portion of the preform <NUM>. The first injection mold <NUM> is connected to an injection device <NUM> that injects a resin material, which is a raw material of the preform <NUM> (for example, polyester such as polyethylene terephthalate (PET), polycarbonate (PC), and the like), and the plurality of (for example, four) recesses <NUM> are linearly aligned in the arrangement direction C orthogonal to an injection direction B of the injection device <NUM>. The arrangement direction C also intersects (is orthogonal to) the conveying direction A. The injection device <NUM> is connected to a central portion of the first injection mold <NUM> in the arrangement direction C. A refrigerant is caused to flow through the first injection mold <NUM> and the second injection molds <NUM> of the injection molding part <NUM>. A temperature of the refrigerant is set to, for example, <NUM> to <NUM>.

The two second injection molds <NUM> each include four injection core molds <NUM> and injection neck molds (neck molds) <NUM>, which are arranged along the arrangement direction C, respectively. The injection core molds <NUM> define inner shapes of a neck portion, the body portion, and the bottom portion of the preform <NUM>, and the injection neck molds <NUM> define an outer shape of the neck portion. The two second injection molds <NUM> are connected to a first rotating member <NUM>, which is a rotation plate, and are located on a circumference centered on a first central axis X1, and the two second injection molds <NUM> are configured to be intermittently rotatable with respect to the first central axis X1. Specifically, the two second injection molds <NUM> are arranged at positions rotated by <NUM>° from each other with respect to the first central axis X1. The first rotating member <NUM> is configured to intermittently rotate by <NUM>° per cycle of the injection molding to swap the positions of the two second injection molds <NUM> with each other.

One of the second injection molds <NUM> is arranged at a position where the first injection mold <NUM> is arranged (injection position P1), and the other one of the second injection molds <NUM> is arranged at a position rotated by <NUM>° on an opposite side of the injection position P1 with respect to the first central axis X1 (post-cooling position P2). The post-cooling position P2 is a position where the preform <NUM> injection molded at the injection position P1 is held and cooled by the injection core molds <NUM> and the injection neck molds <NUM>. The post-cooling position P2 is provided with a cooling pod <NUM> that can accommodate the preform <NUM> and can be raised and lowered. The cooling pod <NUM> is provided with a cavity <NUM> that accommodates the preform <NUM> and a flow path for a refrigerant such as water is provided around the cavity <NUM>, and the cooling pod <NUM> is a member capable of cooling the preform <NUM> from outside. The cooling pod <NUM> is set to a temperature of, for example, <NUM> to <NUM>, and preferably <NUM> to <NUM>.

In other words, the injection molding part <NUM> includes an injection part that is a part located at the injection position P1 and a post-cooling part that is a part located at the post-cooling position P2. The injection part injects molten resin into a cavity to mold the preform <NUM>. The post-cooling part cools the preform <NUM> molded at the injection part and released from the cavity.

Next, the conversion mechanism <NUM> of the conversion part <NUM> will be described with reference to <FIG> is a perspective view illustrating an outline of the conversion mechanism <NUM>. The conversion mechanism <NUM> includes holding members 510a and 510b (for example, a hand member or a chuck member) configured to hold the preform <NUM>, a second rotating member <NUM> which is a moving mechanism configured to move the holding members 510a and 510b, and two holding member conversion mechanisms <NUM> (for example, an electric motor) configured so that the holding members 510a and 510b can be changed in direction while the holding members 510a and 510b are moved. A second cooling pod 140b constituted by a pair of split molds capable of accommodating the preform <NUM> may be provided at a sending position P4, which will be described later, of the conversion mechanism <NUM>. The second cooling pod 140b is set to, for example, <NUM> to <NUM>, and is preferably set to a temperature higher than that of the first cooling pod <NUM>.

The holding members 510a and 510b include a holding part <NUM> (for example, a claw or a hand) that grips and holds a neck portion <NUM> of the preform <NUM>. The holding members 510a and 510b are configured so that the preform can be moved up and down, that is, can be raised and lowered. The holding part <NUM> is configured to be slidable in a horizontal direction with respect to the holding member 510a (510b). The holding member 510a (510b) is configured to be able to move up and down with respect to the second rotating member <NUM>.

The second rotating member <NUM> is configured to be rotated by a rotating mechanism <NUM> (for example, an electric motor) around a second central axis X2. In other words, the second rotating member <NUM> is configured to move the holding members 510a and 510b from a receiving position P3 for receiving the plurality of injection-molded preforms <NUM> in the injection molding part <NUM> to a sending position P4 for sending the preforms <NUM> to the temperature adjustment part <NUM>. The holding members 510a and 510b are supported by the second rotating member <NUM> at positions rotated by <NUM>° from each other with respect to the second central axis X2 on the second rotating member <NUM>. The two holding member conversion mechanisms <NUM> are provided on the second rotating member <NUM> so as to correspond to the holding members 510a and 510b, respectively. The post-cooling position P2 and the receiving position P3 are arranged so as to overlap each other in the vertical direction (up-down direction) of the manufacturing apparatus <NUM>. When the second cooling pod is provided, a second post-cooling position and the sending position P4, which will be described later, may be arranged so as to overlap each other in the vertical direction (up-down direction) of the manufacturing apparatus <NUM>.

The holding member conversion mechanisms <NUM> are configured to change the alignment direction of the plurality of preforms <NUM> from the arrangement direction C to a direction along the conveying direction A by rotating the holding members 510a and 510b on their own axes while moving the holding members 510a and <NUM>10b. That is, the holding members 510a and 510b are configured to be capable of intermittently rotating (rotating on their own axes) by <NUM>° around a third central axis X3 by the holding member conversion mechanisms <NUM>.

Here, operations of the conversion mechanism <NUM> will be described in detail with reference to <FIG> is a diagram illustrating the operations of the conversion mechanism <NUM>. Although the conversion mechanisms <NUM> in <FIG> and <FIG> do not always match with each other, they are common in the configurations described above, and the operation will be described with reference to <FIG> for convenience. In <FIG>, (a) shows an initial state of the conversion mechanism <NUM>, (b) shows a primary state of the conversion mechanism <NUM>, (c) shows a secondary state of the conversion mechanism <NUM>, and (d) shows a tertiary state of the conversion mechanism <NUM>.

In the initial state shown in (a) of <FIG>, the holding member 510a is arranged at the receiving position P3, and a plurality of holding parts <NUM> are arranged so as to be aligned in a direction along the arrangement direction C in the injection molding part <NUM>. In the initial state, the holding member 510b is arranged at the sending position P4, and a plurality of holding parts <NUM> are arranged so as to be aligned in a direction along the conveying direction A.

Next, the conversion mechanism <NUM> transitions to the primary state shown in (b) of <FIG> and then the secondary state shown in (c) of <FIG>. When transitioning from the initial state to the primary state and then to the secondary state, the second rotating member <NUM> rotates clockwise, and the holding member 510a and the holding member 510b are exchanged in position. When transitioning from the initial state to the primary state and then to the secondary state, the holding member 510a rotates counterclockwise on its own axis, and the holding member 510b rotates clockwise on its own axis. Then, when transitioning to the tertiary state shown in (d) of <FIG>, the second rotating member <NUM> rotates <NUM>° and stops. When transitioning to the tertiary state, the holding member 510a and the holding member 510b rotate <NUM>° in opposite directions and stop. In the tertiary state, the holding member 510a is arranged at the sending position P4, and the plurality of holding parts <NUM> are arranged so as to be aligned in a direction along the conveying direction A. In the tertiary state, the holding member 510b is arranged at the receiving position P3, and the plurality of holding parts <NUM> are arranged so as to be aligned in a direction along the arrangement direction C in the injection molding part <NUM>. When the second cooling pod is provided, the second cooling pod 140b accommodates and holds the preform <NUM> at the sending position P4.

Next, the positions of the holding member 510a and the holding member 510b are exchanged from the tertiary state to the secondary state and then the primary state, by operations which are opposite to the above-mentioned operations. That is, the second rotating member <NUM> rotates counterclockwise, the holding member 510a rotates clockwise on its own axis, and the holding member 510b rotates counterclockwise on its own axis. In this way, the conversion mechanism <NUM> returns to the initial state. By repeating the above operations, the holding member 510a and the holding member 510b are exchanged in position, and the preform <NUM> is transferred from the injection molding part <NUM> to the temperature adjustment part <NUM>. The second rotating member <NUM> has a rotation mode of switching between clockwise and counterclockwise every time it rotates by <NUM>°, but may also have a mode in which the direction of rotation is fixed clockwise or counterclockwise and the rotation is performed intermittently by <NUM>°.

Here, one preform located at one end of the plurality of preforms along the arrangement direction C in the injection molding part <NUM> is defined as a first preform and one preform located at another end is defined as an N1st preform (N1 is an integer of <NUM> or more). In the conversion mechanism <NUM>, when the holding members 510a and 510b are moved from the receiving position P3 to the sending position P4, they both rotate counterclockwise on their own axes to change an alignment direction of the holding parts <NUM> from the arrangement direction C to the conveying direction A. When the holding members 510a and 510b are moved from the receiving position P3 to the sending position P4, directions in which they rotate and move are different, but directions in which they rotate on their own axes are the same. That is, the conversion mechanism <NUM> is configured to be capable of changing the alignment direction of the plurality of preforms <NUM> from the arrangement direction C to a direction along the conveying direction A, so that the first preform (or the N1st preform) is always at the front.

Here, returning to <FIG> and <FIG>, the manufacturing apparatus <NUM> will be described. When the preform <NUM> is held by the conversion mechanism <NUM> between the injection molding part <NUM> and the temperature adjustment part <NUM>, the preform is naturally cooled in the atmosphere. In other words, the manufacturing apparatus <NUM> includes a natural cooling part <NUM> between the injection molding part <NUM> and the temperature adjustment part <NUM>. The above-mentioned conversion part <NUM> is provided in the natural cooling part <NUM>. Here, the term "natural cooling" used herein does not mean cooling to room temperature, but means natural cooling in the atmosphere.

The conveying mechanisms <NUM> and <NUM> are separately provided. The conveying mechanism <NUM> is configured to receive the preform <NUM> arranged at the sending position P4 of the conversion mechanism <NUM> and convey the preform <NUM> to the temperature adjustment part <NUM>. The conveying mechanism <NUM> is configured to receive the preform <NUM> conveyed to the temperature adjustment part <NUM> by the conveying mechanism <NUM>, and convey the preform <NUM> and the container <NUM> along the conveying direction A over the temperature adjustment part <NUM>, the blow molding part <NUM>, and the take-out part <NUM>. As the conveying mechanisms <NUM> and <NUM>, for example, a translational movement chuck (hand) may be adopted. Conveying of the preform between the conversion mechanism <NUM> and the conveying mechanism <NUM> and between the conveying mechanism <NUM> and the conveying mechanism <NUM> can be carried out by means known in the art to which the present invention belongs, so detailed explanation thereof is omitted. The conveying by the conveying mechanisms <NUM> and <NUM> is performed intermittently. An interval (pitch) between the preforms <NUM> and the containers <NUM> can be changed on halfway. For example, the conveying mechanism <NUM> is configured so that an interval (pitch) P1 of the injection molding part <NUM> can be converted to an interval P2 of the temperature adjustment part <NUM> (P1 < P2), and the transfer mechanism <NUM> is configured so that the interval P2 of the temperature adjustment part <NUM> can be converted to an interval P3 of the blow molding part <NUM> (P2 < P3). Further, the conveying mechanism <NUM> is configured to convert the number of the preforms <NUM> and the containers <NUM> to be conveyed by one intermittent conveying in the middle of a conveying path. Specifically, the conveying mechanism <NUM> is configured to intermittently convey two preforms to a heat retention temperature adjustment part <NUM> and a fine adjustment part <NUM>, which will be described later, and thereafter intermittently convey the preform and the container one by one.

The temperature adjustment part <NUM> includes a first temperature adjustment part <NUM> that adjusts the temperature of the preform, a second temperature adjustment part <NUM> that adjusts the temperature of the preform <NUM> under a condition different from that of the first temperature adjustment part <NUM>, the heat retention temperature adjustment part <NUM> that prevents a temperature drop of the temperature-adjusted preform <NUM>, and the fine adjustment part <NUM> that finely adjusts the temperature of the preform <NUM>.

A condition for adjusting the temperature of the preform <NUM> in the first temperature adjustment part <NUM> has a higher ability to lower the temperature of the preform <NUM> than a condition for adjusting the temperature of the preform <NUM> in the second temperature adjustment part <NUM>. Here, the "higher ability to lower the temperature" means that the preform <NUM> can be cooled more rapidly than a comparison target. More specifically, it means that a temperature range of the preform to be lowered per unit time is large. For example, when the preform <NUM> is molded from polyethylene terephthalate, in the first temperature adjustment part <NUM>, the temperature of the preform <NUM> may be adjusted from a state where an average temperature of the preforms <NUM> is <NUM> to <NUM> to a state where the average temperature is <NUM> to <NUM>, and in the second temperature adjustment part <NUM>, the temperature of the preform <NUM> may be adjusted from a state where the average temperature of the preforms <NUM> is <NUM> to <NUM> to a state where the average temperature is <NUM> to <NUM>.

As the first temperature adjustment part <NUM> and the second temperature adjustment part <NUM>, various temperature adjustment means, such as a method of sandwiching the preform between a temperature adjustment cavity mold and a temperature adjustment core mold (temperature adjustment rod mold), a method of blowing air onto the preform, various infrared heaters, a RED method, and an electromagnetic wave heating method, can be adopted. As a preferred embodiment, the first temperature adjustment part <NUM> includes a temperature adjustment core mold and a temperature adjustment cavity mold configured to adjust the temperature of the preform <NUM> by sandwiching the preform <NUM> therebetween, and the second temperature adjustment part <NUM> includes a temperature adjustment blow core mold that adjusts the temperature of the preform <NUM> by blowing a gas onto the preform <NUM> and optionally includes a temperature adjustment cavity mold that accommodates the preform <NUM>. In the preferred embodiment, a preliminary blow may be performed in the second temperature adjustment part <NUM> to slightly inflate the preform <NUM> before conveying the preform <NUM> to the blow molding part <NUM>.

As another preferred embodiment, the first temperature adjustment part <NUM> may adopt a method for adjusting the temperature of the preform <NUM> from inside by convection by supplying and blowing gas to an inside of the preform <NUM> accommodated in the temperature adjustment cavity side by the temperature adjustment blow core mold, and continuously discharging the blown gas to an outside of the preform. As another preferred embodiment, the second temperature adjustment part <NUM> may adopt a method for preliminary blowing the preform <NUM> by supplying and blowing gas to the inside of the preform <NUM> accommodated in the temperature adjustment cavity side by the temperature adjustment blow core mold without discharging the gas to the outside of the preform <NUM> during blowing.

In the above-mentioned first temperature adjustment part <NUM> and second temperature adjustment part <NUM>, the outside of the preform <NUM> may be brought into contact with the temperature adjustment cavity mold, and the temperature of the preform <NUM> may be adjusted from outside by heat conduction. A space (cavity) of the temperature adjustment cavity accommodating the preform <NUM> may be set larger in the second temperature adjustment part <NUM> than in the first temperature adjustment part <NUM>. The first temperature adjustment part <NUM> and the second temperature adjustment part <NUM> are configured so that the temperature adjustment of two preforms can be performed respectively. A temperature adjustment medium (cooling medium) is flowed through the temperature adjustment cavity mold and the temperature adjustment core mold of the first temperature adjustment part <NUM> and the second temperature adjustment part <NUM>. In this case, a temperature of the cooling medium is set to, for example, <NUM> to <NUM>, preferably <NUM> to <NUM>.

The heat retention temperature adjustment part <NUM> is set to a temperature close to a blow optimum temperature at a uniform temperature as a whole so as to prevent the temperature of the preform <NUM> which has been temperature-adjusted to a temperature close to a temperature suitable for blow molding from dropping. As the heat retention temperature adjustment part <NUM>, various temperature adjustment methods, such as various infrared heaters, a RED method, and an electromagnetic wave heating method can be adopted. The heat retention temperature adjustment part <NUM> is configured to be capable of adjusting the temperature of one preform (specifically, preventing a temperature drop of the preform).

The fine adjustment part <NUM> finely adjusts the temperature of the preform <NUM> to a temperature suitable for blow molding. Here, "finely adjust" means finely adjusting the temperature of the whole preform <NUM> to a temperature suitable for blow molding. Specifically, "finely adjust" means, for example, that the temperature of the preform is intentionally made different for each part according to a shape of the container, or that the temperature unevenness for each part of the preform <NUM> is finely adjusted. The fine adjustment part <NUM> may be a local temperature adjustment part that locally adjusts the temperature of the preform <NUM>. The fine adjustment part <NUM> may adopt a temperature adjustment method such as an infrared heater method, a RED method, an electromagnetic wave heating method, and an air cooling method. The fine adjustment part <NUM> is arranged immediately before the blow molding part <NUM>. The fine adjustment part <NUM> is configured to be able to perform heating or cooling so that the temperature of one preform can be adjusted. The fine adjustment part <NUM> may also be configured to carry out a heating treatment and a cooling treatment at the same time so that a lower part of the body portion from a central part of the body portion can be cooled while an upper part of the body portion (immediately below the neck portion) of the preform <NUM> is locally heated.

Next, the blow molding part <NUM> will be described. In this example, the blow molding part <NUM> includes a primary blow part <NUM> and a final blow part <NUM>, and is configured to blow mold the container <NUM> in two stages. The primary blow part <NUM> includes a primary blow mold constituted by, for example, a stretch rod, a blow core mold, and a blow cavity mold. The primary blow part <NUM> is configured so that an intermediate molded product <NUM> can be molded by introducing air while stretching the preform <NUM> with, for example, the stretch rod. The final blow part <NUM> includes a final blow mold constituted by, for example, a blow core mold and a blow cavity mold, and if necessary, a stretch rod. The final blow part <NUM> is configured so that the container <NUM> can be molded by, for example, stretching the intermediate molded product <NUM> by air. The blow cavity mold of the primary blow part <NUM> may be set to a temperature (for example, <NUM> to <NUM>) higher than a temperature (for example, <NUM> to <NUM>) of the blow cavity mold of the final blow part <NUM> in order to perform heat treatment on the intermediate molded product <NUM>.

Next, a manufacturing method for manufacturing the container <NUM> by the manufacturing apparatus <NUM> will be described. <FIG> is a flowchart of a manufacturing process of the container <NUM>. As shown in <FIG>, the container <NUM> is manufactured by an injection molding process S1 of injection molding the plurality of preforms <NUM> along the arrangement direction C, a conversion process S1. <NUM> of changing the alignment direction of the plurality of preforms <NUM> from the arrangement direction C to a direction along the conveying direction A, a temperature adjustment process S2 of adjusting the temperature of the preform <NUM>, and a blow molding process S3 of molding the container <NUM> from the preform <NUM>, and the container <NUM> is taken out from the manufacturing apparatus <NUM> in a take-out process S4. Hereinafter, the manufacturing method for manufacturing the container <NUM> will be described with reference to <FIG>.

The injection molding process S1 includes an injection process S1-<NUM> and a post-cooling process S1-<NUM>. In the injection process S1-<NUM>, molten resin is injected into an injection cavity formed by mold clamping the injection cavity mold <NUM>, the injection core mold <NUM>, and the injection neck mold <NUM>, by the injection device <NUM> to form the preform <NUM>. After a predetermined time has elapsed since the injection, the preform <NUM> is demolded (released) from the injection cavity mold <NUM>, and the first rotating member <NUM> is rotated by <NUM>° to move the preform <NUM> held by the injection core mold <NUM> and the injection neck mold <NUM> from the injection position P1 to the post-cooling position P2.

Subsequently, in the post-cooling process S1-<NUM>, the preform <NUM> held by the injection core mold <NUM> and the injection neck mold <NUM> which are moved to the post-cooling position P2 is cooled for a predetermined time. The cooling of the preform <NUM> is performed from the inside by the injection core mold <NUM> and the injection neck mold <NUM>, in which a refrigerant such as water flows. After the preform <NUM> is moved to the post-cooling position P2, the cooling pod <NUM> is raised to accommodate the preform in the cooling pod <NUM>. The cooling pod <NUM> also cools the preform <NUM> from the outside. In this case, in order to improve a cooling efficiency of the post-cooling process S1-<NUM>, the body portion of the preform <NUM> may be sandwiched between the injection core mold <NUM> and the cooling pod <NUM> to be strongly adhered (pressed and deformed). Here, even when the preform <NUM> is moved from the injection position P1 to the post-cooling position P2, the preform <NUM> is cooled from the inside via the injection core mold 122a (122b), so that this movement time can also be regarded as a part of the initial post-cooling process S1-<NUM>.

During the post-cooling process S1-<NUM> of cooling the preform <NUM> held by the injection core mold <NUM> and the injection neck mold <NUM> at the post-cooling position P2, the next injection process S1-<NUM> is performed by another injection core mold <NUM> and another injection neck mold <NUM> arranged at the injection position P1. That is, the next injection process S1-<NUM> and the post-cooling process S1-<NUM> are performed in parallel. After a predetermined time, the preform <NUM> is demolded from the injection core mold <NUM> and the injection neck mold <NUM> and is accommodated in the cooling pod <NUM>. Subsequently, the cooling pod <NUM> is lowered to a height at which the conversion mechanism <NUM> can receive the preform <NUM>. After that, the first rotating member <NUM> is rotated again to perform the next injection process S1-<NUM> and the post-cooling process S1-<NUM>. By repeating these processes, the injection molding process S1 is continuously performed.

Next, in the conversion process S1. <NUM>, the preform <NUM> accommodated in the cooling pod <NUM> and aligned in the arrangement direction C are held by the holding member 510a (510b) of the conversion mechanism <NUM> arranged at the receiving position P3. After that, the cooling pod <NUM> is further lowered to make the preform <NUM> rotatable by the second rotating member <NUM>. Then, by rotating the second rotating member <NUM>, the preform <NUM> is moved from the receiving position P3 to the sending position P4. During this time, the holding member 510a (510b) is rotated on its own axis so that the preforms <NUM> are aligned in an extending direction of the conveying direction A. Then, the holding member 510a (510b) is raised, the preform <NUM> is held by the conveying mechanism <NUM>, and the preform <NUM> is released from the holding member 510a (510b). Next, the conveying mechanism <NUM> intermittently sends out two preforms <NUM> to the temperature adjustment part <NUM>, and the temperature adjustment part <NUM> delivers the preform <NUM> from the conveying mechanism <NUM> to the conveying mechanism <NUM>. During the conversion process S1. <NUM>, the preform <NUM> is naturally cooled in the atmosphere. As a result, the temperature of the preform <NUM> is made uniform before it is conveyed to the temperature adjustment part <NUM> (natural cooling process). If necessary, a second post-cooling process of the preform <NUM> is performed at the sending position P4. As a result, whitening (crystallization) due to slow cooling of the preform <NUM> formed by a crystalline resin material (PET), which tends to occur during natural cooling, can be prevented.

While the preform <NUM> is being sent out by the conveying mechanism <NUM>, the preform <NUM> to be molded by the next injection molding process S1 is held by the holding member 510b (510a). After the sending of the preform <NUM> in the conveying direction A at the sending position P4 is completed, by rotating the second rotating member <NUM>, the preform <NUM> molded by the next injection molding process S1 is moved from the receiving position P3 to the sending position P4. By repeating this process, the conversion process S1. <NUM> is continuously performed.

After the preform <NUM> is conveyed to the temperature adjustment part <NUM>, the preform <NUM> is conveyed in the temperature adjustment part <NUM> by the conveying mechanism <NUM>, and then the temperature adjustment process S2 is performed. In the temperature adjustment process S2, the preform <NUM> is sequentially conveyed to the first temperature adjustment part <NUM>, the second temperature adjustment part <NUM>, the heat retention temperature adjustment part <NUM>, and the fine adjustment part <NUM>, and the temperature of the preform <NUM> is adjusted to a temperature suitable for the next blow molding process S3. That is, the temperature adjustment process S2 includes a first temperature adjustment process S2-<NUM>, a second temperature adjustment process S2-<NUM>, a heat retention temperature adjustment process S2-3b, and a fine adjustment process S2-3a. The heat retention temperature adjustment process S2-3b and the fine adjustment process S2-3a are provided as necessary and may be omitted. However, by providing the heat retention temperature adjustment process S2-3b, the temperature can be made uniform with high accuracy, and by providing the fine adjustment process S2-3a, the shape of the container can be easily controlled.

In the first temperature adjustment process S2-<NUM>, the preform <NUM> is sandwiched between the temperature adjustment core mold and the temperature adjustment cavity mold of the first temperature adjustment part <NUM> so that the temperature of the preform <NUM> is adjusted. In the second temperature adjustment process S2-<NUM>, the temperature of the preform <NUM> is adjusted by blowing gas on the preform <NUM> appropriately accommodated in the temperature adjustment cavity mold by the temperature adjustment blow core mold of the second temperature adjustment part <NUM>.

However, in another example, in the first temperature adjustment part <NUM> in the first temperature adjustment process S2-<NUM>, the temperature of the preform <NUM> may be adjusted from the inside by convection by supplying and blowing gas to the inside of the preform <NUM> accommodated in the temperature adjustment cavity side by the temperature adjustment blow core mold and continuously discharging the blown gas to the outside of the preform. Further, in another example, in the second temperature adjustment part <NUM> in the second temperature adjustment process S2-<NUM>, the preform <NUM> may be preliminary blown by supplying and blowing gas to the inside of the preform <NUM> accommodated in the temperature adjustment cavity side by the temperature adjustment blow core mold without discharging the gas to the outside of the preform <NUM> during blowing.

In the above-mentioned first temperature adjustment process S2-<NUM> and second temperature adjustment process S2-<NUM>, the outside of the preform <NUM> may be brought into contact with the temperature adjustment cavity mold, and the temperature of the preform <NUM> may be adjusted from the outside by heat conduction. The space (cavity) of the temperature adjustment cavity accommodating the preform <NUM> may be set larger in the second temperature adjustment process S2-<NUM> than in the first temperature adjustment process S2-<NUM>.

In the heat retention temperature adjustment process S2-3b, the heat retention temperature adjustment part <NUM> maintains the temperature of the preform <NUM> adjusted by the first temperature adjustment process S2-<NUM> and the second temperature adjustment process S2-<NUM>. In the fine adjustment process S2-3a, the fine adjustment part <NUM> finely adjusts the temperature of the preform <NUM> to a temperature suitable for blow molding. In the present embodiment, two preforms <NUM> are intermittently conveyed to the heat retention temperature adjustment part <NUM> and the fine adjustment part <NUM>, and thereafter the preform <NUM> and the container <NUM> are intermittently conveyed one by one. That is, one of the two preforms <NUM> conveyed to the heat retention temperature adjustment part <NUM> and the fine adjustment part <NUM> is conveyed to the fine adjustment process S2-3a without going through the heat retention temperature adjustment process S2-3b.

After the fine adjustment process S2-3a of the temperature adjustment process S2, the preform <NUM> is conveyed to the blow molding part <NUM> by the conveying mechanism <NUM>, and the blow molding process S3 is performed. In the blow molding process S3, the preform <NUM> is shaped into the intermediate molded product <NUM> by the primary blow part <NUM> (primary blow process), and the intermediate molded product <NUM> is shaped into the container <NUM> by the final blow part <NUM> (final blow process). After the blow molding process S3, the container <NUM> is conveyed to the take-out part <NUM> by the conveying mechanism <NUM>, and the container <NUM> is taken out. Through these processes, the container <NUM> can be obtained. Except for the fine adjustment process S2-3a, the average temperature of the preform <NUM> is adjusted to gradually decrease over the injection molding process S1, the conversion process S1. <NUM>, and the temperature adjustment process S2. That is, as shown in Patent Literature <NUM>, the blow molding process S3 is performed by using only residual heat in the preform <NUM> obtained by the injection molding process S1 without reheating the preform in the temperature adjustment process S2.

Hereinafter, a modification of the above embodiment will be described with reference to <FIG> and <FIG>. Since the modification is the same as the above-described embodiment except for differences in configurations of the temperature adjustment part <NUM>, the conveying mechanism <NUM>, and the blow molding part <NUM>, overlapping parts are designated by the same reference numerals and descriptions thereof will be omitted.

A manufacturing apparatus <NUM> according to the modification includes a conveying mechanism <NUM> configured to intermittently convey the preform <NUM> and the container <NUM> from a temperature adjustment part <NUM> to a blow molding part <NUM>, two by two. The manufacturing apparatus <NUM> includes a temperature adjustment part <NUM> provided with the first temperature adjustment part <NUM> and the second temperature adjustment part <NUM>, and provided with two fine adjustment parts <NUM> instead of the heat retention temperature adjustment part. The manufacturing apparatus <NUM> includes a blow molding part <NUM>, which is provided with two final blow parts <NUM> including a stretch rod, a blow core mold, and a blow cavity mold, instead of the primary blow part, and is configured to be able to blow mold two containers <NUM> at one time. Therefore, the manufacturing apparatus <NUM> can manufacture two containers <NUM> at the same time in the blow molding process S3. A temperature of the blow cavity mold provided in the final blow part <NUM> of the blow molding part <NUM> according to the modification may be set to room temperature (for example, <NUM> to <NUM>).

As in the above modification, in the present disclosure, the configuration can be changed according to the number of blow-molded products. In the manufacturing apparatus <NUM> and <NUM> of the present disclosure, the number of containers (N2) to be blow-molded at one time is smaller than the number of preforms (N1) to be injection-molded at one time. For example, the number of each molded product may be container: preform = <NUM>:<NUM> or <NUM>:<NUM> or <NUM>:<NUM> (a ratio of N2 to N1 may be changed according to specifications of the container to be manufactured). In the manufacturing apparatuses <NUM> and <NUM> of the present disclosure, the blow molding parts <NUM> and <NUM> include the final blow part <NUM> that blow-molds N2 (N2 is an integer of <NUM> or more) containers <NUM> each time, and in the blow molding parts <NUM> and <NUM>, the preform <NUM> and the container <NUM> are intermittently conveyed by N2 pieces. In a case where one preform located at one end of the plurality of preforms <NUM> along the arrangement direction C in the injection molding part <NUM> is defined as a first preform and one preform located at another end is defined as an N1st preform (N1 is an integer of <NUM> or more), N1 and N2 satisfy a relationship of N1 > N2. Since the number of containers to be taken when molding the container in the blow molding process is small, the number of blow molding molds is reduced, and space saving of the manufacturing apparatus can be achieved.

In order to achieve a high cycle, a technique is developed in which a cooling time of the preform in the injection molding process, which is a rate-determining stage, is shortened and the preform is demolded at a high temperature, and the preform is additionally cooled in a temperature adjustment process on a downstream side (<CIT>). The technique is applied to an intermittent rotary conveying type or intermittent linear conveying type hot parison type blow molding apparatus. Here, unlike the intermittent rotary conveying type, the intermittent linear conveying type can change the ratio of the injection molding part to the blow molding part, and has advantages such as downsizing of the blow molding mold and local cooling of the preform during intermittent conveying. However, since the injection molded preforms are usually divided into blow molding units (divided into the number of blow cavities) and intermittently conveyed to the blow molding part, there is also a disadvantage that a length of waiting time until reaching the blow molding part changes for each unit, which tends to cause a temperature difference between the preforms. Depending on a type of the container, a ratio of the number of injection moldings to the number of blow moldings may be appropriately changed to, for example, <NUM>:<NUM>, <NUM>:<NUM>, or <NUM>:<NUM>. At the ratio of <NUM>:<NUM>, a temperature difference between the preforms blown at the beginning and the end is even more notable.

The manufacturing method (manufacturing apparatus) of the present invention is a hot parison type blow molding method (manufacturing apparatus), and has a configuration in which the injection-molded N1 preforms are divided into units of the blow molding number N2 (number of the blow cavities) and intermittently conveyed to the blow molding process, and a temperature difference between the preforms is likely to occur for each unit. Hereinafter, effects and functions will be described based on the configuration of the manufacturing method, and the same effects and functions will be exhibited in the configuration of the manufacturing apparatus corresponding to the configuration of the manufacturing method. In the above resin container manufacturing method, the multi-stage temperature adjustment process S2 is performed, which includes at least the first temperature adjustment process S2-<NUM>, the second temperature adjustment process S2-<NUM>, and the fine adjustment process S2-3a, and further includes the heat retention temperature adjustment process S2-3b as necessary. By conveying the preform <NUM> through the multi-stage temperature adjustment process S2 to the blow molding process S3, the container <NUM> can be blow-molded by reducing a difference in temperature conditions between the preforms <NUM>, and a high-quality container can be stably manufactured.

Further, by conveying the preform <NUM> and the container <NUM> along the conveying direction A intersecting the arrangement direction C over the temperature adjustment process S2 and the blow molding process S3, the temperature of the preform <NUM> can be adjusted while simplifying the conveying mechanism and shortening a time required for conveying. Further, in the above-mentioned injection molding process S1, the preform <NUM> is injection-molded along the arrangement direction C intersecting the conveying direction A in the temperature adjustment process S2 and the blow molding process S3. Therefore, by arranging an injection port of the injection device <NUM> in a central portion in a longitudinal direction of the cavity mold used in the injection molding process S1, the injection device <NUM> itself can be arranged in a lateral direction (direction along the conveying direction) of the cavity mold, and occupied space required for manufacturing the resin container <NUM> can be reduced.

In addition to the temperature adjustment process S2 including the first temperature adjustment process S2-<NUM>, the second temperature adjustment process S2-<NUM>, and the fine adjustment process S2-3a, by providing a natural cooling process between the injection molding process S1 and the temperature adjustment process S2, the temperature of the preform <NUM> can be adjusted in more multi-stages, the container <NUM> can be blow-molded by further reducing the difference in the temperature conditions between the preforms <NUM>, and a high-quality container <NUM> can be more stably manufactured. By naturally cooling the preform <NUM> tin the atmosphere between the injection molding process S1 and the temperature adjustment process S2, a cooling time of the injection molding process S1 can be shortened, the injection molding process S1 can be repeated in a short time, and a production amount of the container <NUM> per unit time can be further increased.

At a stage shortly after the injection molding process S1, the temperature of the preform <NUM> is relatively high, which deviates from the optimum temperature for blow molding. As the blow molding process S3 approaches, it is required to adjust the temperature of the preform <NUM> to the optimum temperature for blow molding. By adopting a condition that has a higher ability to lower the temperature of the preform <NUM> in the first temperature adjustment process S2-<NUM> than that in the second temperature adjustment process S2-<NUM>, the temperature of the preform <NUM> can be lowered in a short time immediately after the injection molding process S1 is completed, and in the second temperature adjustment process S2-<NUM>, the temperature of the preform <NUM> can be adjusted to the optimum temperature for blow molding. Therefore, the high-quality container <NUM> can be manufactured more stably.

According to the preferred embodiment of the first temperature adjustment part <NUM> and the second temperature adjustment process <NUM>, in the first temperature adjustment process S2-<NUM>, the temperature of the preform <NUM> can be lowered in a short time by sandwiching the preform <NUM> between the temperature adjustment core mold and the temperature adjustment cavity mold, and in the second temperature adjustment process S2-<NUM>, the temperature of the preform <NUM> can be adjusted to the optimum temperature for blow molding by the method of blowing gas onto the preform <NUM>. Therefore, the high-quality container <NUM> can be manufactured more stably.

In the embodiment in which the preform <NUM> is preliminarily blown in the temperature adjustment process S2, an intermediate molded body can be formed before the blow molding process S3, and the container <NUM> can be blow molded from the intermediate molded body in the blow molding process S3. Accordingly, particularly in a high-weight preform <NUM> used for blow molding of a large container <NUM>, the temperature of the preform <NUM> can be satisfactorily adjusted, and the high-quality container <NUM> can be stably manufactured.

When the fine adjustment process S2-3a is a local temperature adjustment process, it becomes easy to blow mold the container into a desired shape. Further, blow molding of specially shaped containers such as large containers with handles can be facilitated.

By providing the conversion process S1. <NUM> of changing the alignment direction of the preforms <NUM> from the arrangement direction C to a direction along the conveying direction A between the injection molding process S1 and the temperature adjustment process S2, the preform <NUM> can be smoothly conveyed to the temperature adjustment process S2 and the blow molding process S3. Therefore, it is possible to maintain or improve quality of the container <NUM> even under a short cycle time while further improving the production amount of the container <NUM> per unit time. Further, if the natural cooling step is performed in the conversion process S1. <NUM>, natural cooling can be performed during the direction change of the preform <NUM>, and the container can be manufactured more efficiently.

Since the injection molding process S <NUM> includes the injection process S <NUM>-<NUM> and the post-cooling process S <NUM>-<NUM>, the preform <NUM> can be released from the cavity in a state where the cooling is not completely completed in the injection process S1-<NUM>, and the cooling of the preform <NUM> can be continued in the post-cooling process S <NUM>-<NUM>. When the preform <NUM> is being cooled in the post-cooling process S1-<NUM>, the injection process S <NUM>-<NUM> of the next preform <NUM> can be performed, the injection molding process S <NUM> can be repeated in a short time, and the production amount of the container <NUM> per unit time can be further increased. That is, high cycle container manufacturing can be achieved. Further, since the temperature of the preform <NUM> can be adjusted in multiple stages even in a high cycle by providing the temperature adjustment process S2 with the first temperature adjustment process S2-<NUM>, the second temperature adjustment process S2-<NUM>, and the fine adjustment process S2-3a, the container <NUM> can be blow-molded by reducing the difference in the temperature conditions between the preforms <NUM>, and the high-quality container <NUM> can be stably manufactured.

In the above resin container manufacturing method, the temperature adjustment process S2 includes the heat retention temperature adjustment process S2-3b for preventing the temperature drop of the preform <NUM>. Therefore, it is possible to prevent the preform <NUM> whose temperature has been adjusted to the optimum temperature for blow molding from dropping due to a waiting time before the blow molding, the temperature of the preform <NUM> is reliably made uniform, and the high-quality container <NUM> can be stably manufactured.

Even in the high-cycle method in which the injection molding process S1 is repeated in a short time to increase the production amount of the container <NUM> per unit time, by providing the heat retention temperature adjustment process S2-3b, the temperature of the preform <NUM> can be reliably made uniform, and the high-quality container can be stably manufactured.

In the above resin container manufacturing method, the multi-stage temperature adjustment process S2 is performed, which includes the first temperature adjustment process S2-<NUM>, the second temperature adjustment process S2-<NUM>, the heat retention temperature adjustment process S2-3b, and the fine adjustment process S2-3a. By conveying the preform <NUM> through the multi-stage temperature adjustment process S2 to the blow molding process S3, the container <NUM> can be blow-molded by reducing a difference in temperature conditions between the preforms <NUM>, and the high-quality container <NUM> can be more stably manufactured.

By naturally cooling the preform <NUM> in the atmosphere between the injection molding process S1 and the temperature adjustment process S2, the cooling time of the injection molding process S <NUM> can be shortened, the injection molding process S <NUM> can be repeated in a short time, and the production amount of the resin container <NUM> per unit time can be further increased. When the temperature adjustment process S2 includes the first temperature adjustment process S2-<NUM>, the second temperature adjustment process S2-<NUM>, the heat retention temperature adjustment process S2-3b, and the fine adjustment process S2-3a, by providing the natural cooling process between the injection molding process S <NUM> and the temperature adjustment process S2, the temperature of the preform <NUM> can be adjusted in more multi-stages, the container <NUM> can be blow-molded by further reducing the difference in the temperature conditions between the preforms, and the high-quality container <NUM> can be more stably manufactured.

In the present disclosure, linear conveying does not mean only the case where the preforms can be connected by exactly one straight line, and even when the preforms are conveyed by a plurality of conveying paths tilted at slightly different angles, the effect of aligning by the conversion mechanism <NUM> can be obtained. In the present disclosure, the effects of the present disclosure can be obtained even by aligning the plurality of preforms arranged in an inclination of, for example, <NUM>° to <NUM>° with respect to the conveying path extending substantially linearly of the temperature adjustment part <NUM> and the blow molding part <NUM> by the conversion mechanism <NUM>. Further, orthogonal refers not only to an exact <NUM>° angle, but also includes angles of, for example, approximately <NUM>° ± <NUM>°.

Temperature conditions of the first temperature adjustment part <NUM>, the second temperature adjustment part <NUM>, the heat retention temperature adjustment part <NUM>, and the fine adjustment part <NUM> may be finely adjusted for each preform to be conveyed.

The present invention is not limited to the above embodiment and may be modified or improved as appropriate. Materials, shapes, dimensions, numerical values, forms, numbers, arrangement places, and the like of components in the above embodiment are optional and not limited as long as the present invention can be achieved.

Claim 1:
A resin container (<NUM>) manufacturing method comprising:
an injection molding process of injection molding a plurality of preforms (<NUM>) along a predetermined arrangement direction (C);
a temperature adjustment process of adjusting a temperature of the preform; and
a blow molding process of molding a resin container (<NUM>) from the preform,
characterised in that
after the injection molding process, the preform and the container are conveyed along a conveying direction (A) perpendicular to the arrangement direction over the temperature adjustment process and the blow molding process, and
the temperature adjustment process includes a first temperature adjustment process of adjusting the temperature of the preform, a second temperature adjustment process of adjusting the temperature of the preform under a condition different from that of the first temperature adjustment process, and a fine adjustment process of finely adjusting the temperature of the preform.