Resin container and a manufacturing method thereof

Abstract

In a state where a gas barrier sheet ( 10 ) having a gas barrier layer is held between a heat plate ( 12 ) and a pressing plate, the gas barrier sheet is disposed between two molds together with a sub tank ( 44 ) and a separator ( 46 ) constituting attachment parts, the molds are then closed and a resin is injection-molded forming a resin layer ( 36 ). A method for manufacturing a resin container by melt-adhering an intermediate molded product ( 38 ) and another intermediate molded product ( 38 ) constituting a pair therewith by heating with a heat plate ( 12 ) thereafter, and a resin container manufactured by this manufacturing method.

What is claimed:  
     
         1 . A resin container formed by superposing peripheral edge portions of at least two intermediate molded products, each of the intermediate molded products comprising at least two layers including a sheet member and a resin layer, in which the sheet members of the at least two intermediate molded products are melted and adhered to each other and the resin layers of the intermediate molded products are melted and adhered to each other.  
     
     
         2 . A method for manufacturing a resin container comprising an intermediate molded product forming step of forming concave intermediate molded products, each of the intermediate molded products comprising at least two layers including a sheet member and a resin layer, a sheet material melt-adhering step of superposing the peripheral edge portions of the intermediate formed products to melt and adhere the sheet members to each other, and a resin layer melt-adhering step of melt-adhering the resin layers of the intermediate molded products to each other.  
     
     
         3 . A method for manufacturing a resin container according to    claim 2   , wherein the resin layers are respectively provided outside of said sheet members in said intermediate molded product forming step, and the pressure inside the sheet members which have been bag-shaped in said resin layer member melt-adhering step is reduced so as to be lower than outside the bag-shaped sheet members so as to melt-adhere said resin layers of said intermediate molded products to each other.  
     
     
         4 . A method for manufacturing a resin container according to    claim 3   , wherein a communicating portion for communicating between the inside of said resin layers and the outside thereof is provided in the joining portion of said resin layers to each other, and said method further comprising a gas exhaust step for exhausting gas between said sheet members and said resin layers.  
     
     
         5 . A method for manufacturing a resin container according to    claim 4   , wherein said sheet member is melt-adhered to said resin layer at the temperature at which said resin layers of said intermediate molded products are melt-adhered to each other.  
     
     
         6 . A resin container according to    claim 1   , wherein a non-melt-adhered portion of said sheet member and said resin layer is provided on the peripheral portion of said resin layer.  
     
     
         7 . A resin container according to    claim 6   , wherein a member which is not melt-adhered to said resin layer is provided in said non-melt-adhered portion.  
     
     
         8 . A method for manufacturing a resin container according to    claim 2   , wherein a non-melt-adhered portion of said sheet member and said resin layer is provided in the peripheral portion of said resin layer.  
     
     
         9 . A method for manufacturing a resin container according to    claim 8   , wherein a cooling portion is provided in a portion of a mold corresponding to the peripheral portion of said resin layer and used for said intermediate molded product forming step.  
     
     
         10 . A resin container according to    claim 1   , wherein engaging portions which are engaged with each other are provided in the portions of said sheet members where said sheet members are to be melt-adhered to each other.  
     
     
         11 . A method for manufacturing a resin container according to    claim 2   , wherein engaging portions which are engaged with each other are provided in the portions of said sheet members where said sheet members are bonded to each other and after said sheet members are engaged with each other, said sheet members are melt-adhered to each other.  
     
     
         12 . A method for manufacturing a resin container according to    claim 2   , wherein a reinforcing layer which is not melted by injected resin is provided at least on an area of said sheet member opposite a resin injecting hole.  
     
     
         13 . A resin container according to    claim 1   , wherein an engaging portion between said resin layer and said sheet member is contained in the bonding end portion between said resin layer and said sheet member.  
     
     
         14 . A method for manufacturing a resin container according to    claim 6   , wherein the bonding end portions between said resin layers and said sheet members are engaged with each other in said melt-adhering step.  
     
     
         15 . A resin container according to    claim 1   , wherein the distance of the bonding portion between the respective sheet members and the resin layers is different from the distance of the bonding portion between said sheet members.  
     
     
         16 . A method for manufacturing a resin container according to    claim 3   , wherein welding is performed so that the distance of the bonding portion between the respective sheet members and the resin layers is different from the distance of the bonding portion between said sheet members in said sheet member welding step.  
     
     
         17 . A resin container according to    claim 1   , wherein said intermediate molded products are divided into an upper intermediate molded product and a lower intermediate molded product, and the sheet member of the upper intermediate molded product has better moldability and less permeability than the sheet member of the lower intermediate molded product.  
     
     
         18 . A method for manufacturing a resin container according to    claim 2   , wherein an extension portion extending from the point where said resin layer bonds with the other intermediate molded product to the point where said sheet member bonds with the other intermediate molded product is provided in said intermediate molded product molding step.  
     
     
         19 . A method for manufacturing a resin container according to    claim 2   , wherein in said intermediate formed product forming step, a gap inside a cavity near said resin injecting hole is made wider than a gap in the other portion within the cavity.  
     
     
         20 . A resin container according to    claim 1   , wherein in an engaging portion between an attached part and said sheet member, said part is formed as a concave shape.  
     
     
         21 . A method for manufacturing a resin container according to    claim 2   , wherein in the engaging portion between the attached part and said sheet member said attached part is made concave and the resin layer is formed in said intermediate molded product molding process.