Technical Field
[0001] The present invention relates to a cork stopper coated with a resin layer for blocking
up the mouth portion of a container for beverages like whisky or wine.
Background Art
[0002] A cork stopper coated with a resin (rubber) layer integrated at one end with a flange
portion doubling as a handle is widely used as a cork stopper for blocking up the
mouth portion of a container for beverage like whisky or wine, referring to Patent
Literatures 1 to 4.
[0003] A cork stopper body of the cork stopper coated with a resin layer is formed in a
columnar shape by the compression molding process of a cork granule and a binder resin
or formed in a columnar shape by boring natural cork bark. A coating layer of resin
is formed for preventing a corky smell from diffusing into beverage in the container,
preventing cork dust from falling in the container, preventing a color change on the
cork surface caused by invasion of beverage into a cork layer, and the like.
[0004] Stable open-ability of the cork stopper regardless of a storage condition and a usage
condition of the container is demanded when the cork stopper is coated with a layer
made of resin. In the Patent Literatures, the friction coefficient of the surface
of the coated layer is appropriately determined by executing a silicone treatment
or a roughening treatment on the coated layer surface.
[0005] In a production method of a cork stopper in Patent Literature 5 proposed by the applicant
of the present application, a cork granule is pressed in a direction orthogonal to
the longitudinal direction, i.e. the axial direction, of the columnar body, namely
in the centripetal direction when the columnar cork stopper is molded under compression
with a binder resin.
[0006] The cork stopper obtained by such a compression molding, having a coating layer of
resin, has excellent flexibility in the diametrical direction and the sealing ability
is improved by followability to the container mouth. Thereby, good features such as
easy open-ability and prevention of damages at the time of opening are obtained.
List of Citations
Patent Literature
Summary of the Invention
Technical Problem
[0008] In case of the above-mentioned cork stopper coated with a resin layer, the friction
coefficient is optimized for improving the open-ability of the cork stopper by a silicone
treatment or a roughening treatment on the surface of the coating layer. However,
such treatment for optimizing the friction coefficient increases the production procedures
and the production cost.
[0009] When the stress of cork changes, the open-ability of the cork stopper is not stably
kept even if the friction coefficient is controlled. It is difficult to simultaneously
achieve improvement of the open-ability and prevention of popping of the cork stopper.
In addition, when the cork stopper coated with a resin layer is used for a container
for a beverage such as whisky or wine, the moisture content ratio of the core portion
varies from two weight percent to six weight percent depending on change of seasons.
[0010] When the moisture content ratio is low, the compression stress of the cork stopper
pressed into the mouth of the beverage container becomes large, thereby deteriorating
open-ability. Therefore, it is desired to maintain good open-ability in which variation
of the compression stress is less regardless of change of seasons.
[0011] As a result of verification by the inventors of the present application, the cork
stopper disclosed in Patent Literature 5 is superior in the stability of the stress
at the time of closing the container mouth to the cork stopper molded under pressure
along the axial direction.
[0012] The present invention is proposed in view of the above-mentioned problems and has
an object to provide a new cork stopper coated with a resin layer having a stable
open-ability while keeping the unique sealing ability of the cork stopper. In addition,
as a result of examinations in which the present invention is applied to a cork stopper
coated with a resin layer, the cork stopper coated with a resin layer which has stable
open-ability and is hardly popping out is easily obtained. Thus, the object of the
present invention is to provide such a new cork stopper in view of the verification
results.
Solution to the Problem
[0013] In one embodiment of the present invention, the cork stopper coated with a resin
layer comprises a columnar cork stopper body formed by a compression molding of a
cork granule with a binder resin and a resin coating layer covering an outer circumferential
surface of the cork stopper from an end side to another end of the cork stopper body
along an axial direction.
[0014] The cork stopper body and the resin coating layer constitute a core portion, and
the core portion, when being pressed in a hollow tubular portion with a tightening
allowance of 1.5 mm, experiences a compression stress of 100 N to 300 N in case of
a moisture content ratio of the core portion being 6 weight percent, and experiences
a compression stress smaller by 100 N to 150 N than that in case of a moisture content
ratio of the core portion being 2 weight percent.
[0015] Generally, when the cork stopper coated with a resin layer is used for a container
for beverages such as whisky or wine, the moisture content ratio of the core portion
varies from two weight percent to six weight percent depending on change of seasons.
When the moisture content ratio is low, the compression stress of the cork stopper
pressed into the mouth of the beverage container becomes large, thereby deteriorating
open-ability.
[0016] In the case of a cork stopper coated with a resin layer of the embodiment of the
present invention, the compression stress is as small as 100 N to 300 N when the moisture
content ratio of the core portion is 6 weight percent, and the difference from the
case when the moisture content ratio of the core portion is 2 weight percent is as
small as 100 N to 150 N.
[0017] Therefore, open-ability is stably kept regardless of change of season. If the compression
stress at 6 weight percent of moisture content ratio in the core portion is smaller
than 100 N, the sealing ability becomes deteriorated. If the compression stress at
6 weight percent of moisture content ratio in the core portion is larger than 300
N, the compression stress becomes large when the moisture content ratio changes to
2 weight percent, thereby deteriorating the open-ability.
[0018] In the cork stopper coated with a resin layer as mentioned above, the cork stopper
body can be formed by a compression molding executed in a centrifugal direction.
[0019] In the cork stopper coated with a resin layer of the embodiment of the present invention,
the cork stopper body is molded under compression in the centripetal direction, thereby
having a superior flexibility in the diametrical direction.
[0020] When such a cork stopper coated with a resin layer is pressed to block up the container
mouth portion, the cork stopper elastically contacts the inside of the mouth portion
by flexibility and is elastically compressed with the resin coating layer interposed
between the cork stopper and the inside of the mouth portion, thereby obtaining a
stable sealing ability.
[0021] The strength in the longitudinal direction (in the axial direction) of the cork stopper
body, coupled with the binding force of binder resin, becomes large, thereby preventing
breakage of the cork stopper at the time of opening or closing.
[0022] In the cork stopper coated with a resin layer as mentioned above, the cork stopper
body can have an attachment hole configured to attach a flange portion, the attachment
hole extending from the one end side toward the other end side of the cork stopper
body along an axial direction.
[0023] In the cork stopper of the embodiment, the flange portion is attached to the attachment
hole and the cork stopper is easily closed or opened using the flange portion as a
handle.
[0024] In such a case, the cork stopper coated with a resin layer can comprise an expanding
portion with a diameter larger than an outer diameter of an other portion of the core
portion, the expanding portion extending from a region corresponding to a bottom of
the attachment hole to the other end of the cork stopper.
[0025] In such a configuration, the expanding portion prevents popping out of the stopper.
[0026] Further, the expanding portion can be formed by heating the core portion. When the
core portion is heated, the cork stopper body thermally expands. In the embodiment
of the present invention, the core portion from the region corresponding to the bottom
of the attachment hole to the other end is solid and the cork stopper body is molded
under compression in the centripetal direction, thereby the thermal expansion enlarges
the diameter of the core portion. Therefore, the expanding portion is easily formed
by heating.
[0027] In the cork stopper coated with a resin layer as mentioned above, the resin coating
layer can be made of a polyethylene terephthalate. When the cork stopper coated with
a resin layer is used for a beverage container, the resin coating layer contacts liquid.
The resin coating layer is made of a polyethylene terephthalate with high barrier
property, so that a corky smell is prevented from diffusing into a beverage in the
container. Polyethylene terephthalate is harmless and hygienic, thereby being suitable
for a resin layer of a cork stopper for beverages.
[0028] In the cork stopper coated with a resin layer as mentioned above, the resin of the
coating layer can include a lubricant.
[0029] In the above-mentioned embodiment, the resin of the coating layer includes a lubricant,
so that the friction coefficient of the coating layer surface is easily controlled
and a stable open-ability is obtained.
Advantageous Effects of the Invention
[0030] The present invention is able to provide a cork stopper coated with a resin layer
with stable open-ability while keeping the unique sealing ability of the cork stopper.
Brief Description of Drawings
[0031]
- FIG. 1
- is a diagrammatical longitudinal section showing one embodiment of the cork stopper
coated with a resin layer of the embodiment of the present invention.
- FIG. 2
- is a flow chart diagrammatically showing a production process of the above-mentioned
cork stopper.
- FIG. 3
- is a table showing the measurement results of the compression stress depending on
the moisture content ratio when the stopper coated with a resin layer of the embodiment
of the present invention is pressed in a hollow tubular part with a tightening allowance
of 1.5 mm, compared with that of the conventional stopper coated with a resin layer.
Description of Embodiments
[0032] The embodiment of the present invention is explained referring to the attached drawings.
FIG. 1 is a diagrammatical longitudinal section showing one embodiment of the cork
stopper coated with a resin layer of the embodiment of the present invention.
[0033] A cork stopper 1 coated with a resin layer comprises a columnar cork stopper body
2 obtained by a compression molding of a cork granule and a binder resin, a resin
coating layer 3 coated on the outer circumferential surface of the cork stopper body
2 from an end 2a side (in the vicinity of the end 2a) to the other end 2b in the direction
of the axis L, and a flange portion 5 integrally formed with the end 2a of the cork
stopper body 2.
[0034] The cork stopper body 2 and the resin coating layer 3 constitute a core portion 4.
The cork stopper body 2 is formed by molding under pressure in the centripetal direction
and has an attachment hole 20 for attaching the flange portion 5 formed from the end
2a side to the other end 2b side along the direction of the axis L.
[0035] An expanding portion 41 having an outer diameter larger than that of other portions
is formed from the region corresponding to a bottom portion 20a of the attachment
hole 20 to the other end 2b of the core portion 4. The bottom portion 20a of the attachment
hole 20 is concavely curved.
[0036] The reference numeral 20b in the figure shows the start point of the concave bottom
portion 20a. The expanding portion 41 is formed from the region corresponding to the
start point 20b to the other end 2b of the core portion 4.
[0037] The flange portion 5 is made of glass and comprises a disk-like flange body 50 and
a columnar projecting portion 51 projecting downward from the center of the flange
body 50. The projecting portion 51 is pressed into the attachment hole 20 of the cork
stopper body 2 in such a manner that the lower surface of the flange body 50 abuts
against the upper surface of the cork stopper body 2.
[0038] The abutting surface and the pressed surface are coated with an adhesive agent, thus
the cork stopper body 2 and the flange portion 5 are integrally fixed. A washer 6
made of polyethylene is fitted around the outer circumference of the cork stopper
body 2 so as to contact the lower surface of the flange portion 50. A part of the
cork stopper body 2 to which the washer 6 is provided is not coated with the resin
coating layer 3.
[0039] The washer 6 is provided between an upper open edge portion 70a of a mouth portion
70 and the lower surface of the flange portion 50. The washer 6 prevents a direct
contact of the open edge portion 70a and the lower surface of the flange body 50 when
the stopper coated with a resin layer of this embodiment is pressed into the mouth
portion 70 (hollow tubular portion) of a container 7 for whisky (two-dotted line)
for closing. In this specification the term "close" means to block up the mouth portion
70 of the container 7 with the cork stopper coated with a resin layer 1.
[0040] The container 70 made of glass does not contact the flange portion 5 made of glass
and a consumer is able to block up the mouth portion without having an unpleasant
feeling.
[0041] In the explanation referring to FIG. 1, the end 2a side is an upper end and the other
end 2b side is the lower end. The flange portion 5 is made of glass in the above-mentioned
embodiment; however, the flange portion 5 can also be made of another hard resin or
metal. In FIG. 1 the shapes of the expanding portion 41 and the mouth portion 70 of
the container 7 are enlarged for easy explanation.
[0042] The production method of a cork stopper 1 coated with a resin layer is explained
further referring to FIG. 2. In a step S1, a mixture of a cork granule and binder
is produced. The cork granule is made by crushing natural cork bark and granulating
the crushed cork.
[0043] The binder is a resin adhesive agent. In a step S2, the cork stopper body 2 is manufactured
in such a manner that the mixture obtained in the step S1 is molded under compression
in the centripetal direction (in the direction perpendicular to the axis L of the
cork stopper body 2) based on the method disclosed in Patent Literature 5.
[0044] The obtained cork stopper body 2 is compressed in the centripetal direction, so that
an excellent flexibility in the diametrical direction is obtained as mentioned above
and a large strength along the axis L, coupled with the binding force of binder resin,
is obtained. In a step S3, the attachment hole 20 is formed in the cork stopper body
2. The attachment hole 20 is formed by making a boring in the cork stopper body 2
from the end 2a side (the upper side in FIG. 1) to the other end 2b side along the
axis L.
[0045] In a step S4, the resin coating layer 3 is formed on the outer circumferential surface
(referred to as the circumferential surface hereinafter) of the cork stopper body
2 from the end 2a side to the other end 2b. For providing the resin coating layer
3, a urethane adhesive agent is applied on the circumferential surface of the cork
stopper body 2.
[0046] Then, the circumferential surface of the cork stopper body 2 is covered with a heated
polyethylene terephthalate film and then is pressed into a mold. The polyethylene
terephthalate film in an extended condition is thermally attached on the circumferential
surface of the cork stopper body 2.
[0047] Thus, the resin coating layer 3 is formed by a polyethylene terephthalate bonded
on the entire circumferential surface of the cork stopper body 2 and the core portion
4 is formed with the cork stopper body 2 and the resin coated layer 3.
[0048] Polyethylene terephthalate is preferably used for the resin of the resin coating
layer for a beverage container because polyethylene terephthalate is harmless, hygienic
and excellent in preventing diffusion of a corky smell into a beverage in the container.
However, the resin is not limited to polyethylene terephthalate.
[0049] Polyethylene, nylon, polybutylene terephthalate, ethylene-vinyl acetate copolymer,
or the like can be selectively used depending on usage. The resin of the resin coating
layer 3 desirably includes a lubricant. The lubricant can be a resin lubricant such
as a spherical silicone resin and a spherical polyethylene resin, or an inorganic
lubricant such as silica, clay and talc.
[0050] In a step S5, silicone is applied and heated on the circumferential surface (zone
1 in FIG. 1) of the core portion 4 on the side of the other end 2b, from the start
point 20b of the bottom 20a of the attachment hole 20 to the other end 2b. A coating
layer of silicone is formed on the zone Z1 of the core portion 4 by heating. A region
of the cork stopper body 2 corresponding to the zone Z1 axially expands by such heating.
[0051] The region is solid and the cork stopper body 2 is formed by a compression molding
in the centripetal direction, so that the region expands in the diametrical direction
by the thermal expansion and the expanding portion 41 is formed at the region of the
core portion 4 corresponding to the zone Z1 as shown in FIG. 1. In a step S6, the
washer 6 is fitted at a predetermined position and the flange portion 5 is attached
after forming the expanding portion 41 along with the silicone film.
[0052] The end (the upper end) 2a of the cork stopper body 2 and the circumferential surface
of the projecting portion 51 of the flange portion 5 are applied with an adhesive
agent, then the projecting portion 51 is pressed into the attachment hole 20 as mentioned
above, and the adhesive agent is hardened, thereby attaching the flange portion 5.
Thus, the production procedure of the resin cork stopper 1 is finished.
[0053] In the step S5, heating is executed after silicone has been applied; however, heating
can also be executed without applying silicone.
[0054] In manufacturing of the resin cork stopper 1, the tightening allowance is generally
required for the cork stopper of a container for beverages such as whisky, so that
an outer diameter D1 of a columnar portion 40 of the core portion 4 other than the
expanding portion 41 is set larger by 1.5 mm than the smallest inner diameter of an
inner diametrical face 70b of the mouth portion 70 of the container 7.
[0055] Namely, when the cork stopper 1 coated with a resin layer is pressed into the mouth
portion 70 of the container 7 shown in FIG. 1 for blocking up the mouth portion 70,
the columnar portion 40 is elastically deformed by compression along the shape of
the inner diametrical face 70b of the mouth portion 70 shown with two-dotted lines.
[0056] The inner diametrical face 70b of the mouth portion 70 and the columnar portion 40
elastically contact with each other to be sealed by the restoration elasticity of
the elastic deformation, thereby preventing leakage of liquid in the container 7.
The resin coating layer 3 covers the circumferential surface of the cork stopper body
2, so that a corky smell is prevented from diffusing into the beverage in the container
7.
[0057] The elastic contact portion of the inner diametrical face 70b of the mouth portion
70 and the columnar portion 40 includes the resin coating layer 3 therebetween, thereby
achieving sealing performance completely. When the resin coating layer 3 includes
the above-mentioned lubricant so as to control the friction resistance with the inner
diametrical face 70b of the mouth portion 70, the compression stress at the time of
closing the mouth portion is easily controlled and a stable open-ability is obtained.
[0058] The cork stopper coated with a resin layer produced as mentioned above and the conventional
cork stopper coated with a resin layer disclosed in Patent Literatures 1, 2 and 4
include moisture of 2.0 weight percent (moisture content ratio) at the time of production
and the moisture content ratio changes from 2.0 weight percent to 6.0 weight percent
depending on the conditions thereafter. When the moisture content ratio changes, the
compression stress when the cork stopper blocks off the mouth portion of the container
by being pressed therein also changes.
[0059] FIG. 3 shows the measurement results of the compression stress depending on the moisture
content ratio when the stopper coated with a resin layer of the embodiment of the
present invention is pressed into the hollow tubular part with the tightening allowance
of 1.5 mm, in comparison with that of the conventional cork stopper coated with a
resin layer.
[0060] In FIG. 3, the product compressed in the axial direction (the vertical direction)
is a conventional cork stopper coated with a resin layer produced in such a manner
that a columnar body is formed by a compression molding of a cork granule and binder
in the axial direction and the circumferential surface is coated with resin layer.
[0061] The product compressed in the radial direction (the centripetal direction) is a cork
stopper coated with a resin layer of the embodiment of the present invention in which
a columnar body produced by the method disclosed in Patent Literature 5 is coated
with a resin layer. The former is called a conventional product and the latter, a
cork stopper coated with a resin layer of the embodiment of the present invention,
is referred to as "Inventive Product".
[0062] As shown in FIG. 3, the values of the compression stress of the Inventive Product
when the moisture content ratio is 2.0 weight percent and 6.0 weight percent are lower
than those of the conventional cork stopper, thereby the open-ability of Inventive
Product is superior to that of the conventional cork stopper. The Inventive Product
is smaller than the conventional cork stopper in the change amount of the compression
stress between the moisture content ratio of 2.0 weight percent and 6.0 weight percent.
[0063] Therefore, any change caused by circumstances and seasons in the open-ability of
Inventive Product is smaller than that of the conventional cork stopper, such that
the Inventive Product is superior to the conventional cork stoppers in the suitability
as the cork stopper.
[0064] Several examinations were executed in the range of a moisture content ratio from
2.0 weight percent to 6.0 weight percent. It was found that in view of sealing ability,
the open-ability and popping of the cork stopper, in case of pressing the core portion
in the hollow tubular portion with the tightening allowance of 1.5 mm, the compression
stress should be 100 N to 300 N when the moisture content ratio of the core portion
4 is 6 weight percent and should be smaller by 100 N to 150 N than that when the moisture
content ratio of the core portion is 2 weight percent.
[0065] It was also found that the excellent features of the cork stopper coated with a resin
layer of the embodiment of the present invention are based on the fact that the cork
stopper body was formed by a compression molding in the centripetal direction, and
the friction coefficient of the surface of the core portion was easily controlled,
different from those of the conventional cork stopper coated with a resin layer.
[0066] When the cork stopper 1 coated with a resin layer blocks up the container 7, a part
of the expanding portion 41, as shown in FIG. 1 abuts or elastically contacts the
inside of a shoulder portion 71 of which the diameter gradually enlarges from the
mouth portion 70 of the container 7 to a container main body (not shown in the figure).
[0067] An anchoring effect is achieved between the expanding portion 41 and the shoulder
portion 71 by abutting or elastic contact of the expanding portion 41 and the inside
of the shoulder portion 71, thereby preventing popping of the cork stopper and stably
keeping a blocked up condition of the cork stopper 1 coated with a resin layer.
[0068] When the cork stopper 1 coated with a resin layer is closed or opened, the expanding
portion 41 passes through the smallest diameter portion D2 of the inner diametrical
face 70b of the mouth portion 70 so that the expanding portion 41 is largely compressed
under elasticity in the centripetal direction. By the reaction force of the elastic
compression, a large force is required for closing or opening of the cork stopper.
[0069] Considering operation ability of closing or opening the cork stopper and prevention
of popping of the cork stopper, the expanding width of the expanding portion 41, namely
the result of the calculation formula, largest outer diameter D3 of the expanding
portion 41 minus the outer diameter D1 of the columnar portion 40 and multiplies 0.5
thereafter, is preferably 0.1 mm to 0.3 mm.
[0070] The expanding width of the expanding portion 41 is less than 0.1 mm, thereby reducing
prevention function of popping of the cork stopper. When the expanding width of the
expanding portion 41 exceeds 0.3 mm, the burden applied to the fingers of an operator
at the time of closing or opening becomes large. The coating layer of silicone is
formed on the surface (the zone Z1) of the expanding portion 41, thereby smoothly
opening or closing and preventing sound at the time of closing or opening.
[0071] The expanding portion 41 extends from the region corresponding to the start point
of 20b of the attachment hole 20 to the other end 2b of the core portion 4, namely
the entire area of the zone Z1. Thus, the largest outer diameter D3 of the expanding
portion 41 becomes larger than the outer diameter D1 of the columnar portion 40. In
addition, the relation of the diameters with the outer diameter D4 corresponding to
the deepest portion of the bottom 20a of the attachment hole 20 of the expanding portion
41 is as follows: D3 is larger than D4 which is larger than D1, as shown in FIG. 1.
[0072] However, the expanding portion 41 can be formed in a zone Z2 expanding from the deepest
portion of the bottom 20a of the mounting hole 20 to the other end 2b. When the expanding
portion 41 is formed in the zone Z2, in the step S5, the zone Z2 is applied with silicone
and heated, or the zone Z2 is heated without applying silicone, thereby forming the
expanding portion 41 in the zone Z2 by thermal expansion.
[0073] In the above-mentioned embodiments, a cork stopper coated with a resin layer is used
for a container for whisky. The container is also used for beverages such as brandy,
wine, champagne, Japanese sake or juice. The shape of the cork stopper 1 coated with
a resin layer in FIG. 1 is an example and the embodiment of the present invention
is not limited to such a shape. In the figure, the core portion 4 has an expanding
portion 41.
[0074] However, the core portion 4 can be constituted with a straight body without the expanding
portion 41 as long as the moisture content ratio and the compression stress of the
core portion 4 are in the above-mentioned relation. In the above-mentioned embodiment,
the excellent features of the above-mentioned relation of the moisture content ratio
and the compression stress of the core portion are based on the compression molding
of the cork stopper body in the centripetal direction.
[0075] However, the present invention also includes the case wherein the above-mentioned
features of the relation of the moisture content ratio and the compression stress
of the core portion are obtained by other compression molding.
List of Reference Signs
[0076]
- 1
- cork stopper coated with a resin layer
- 2
- cork stopper body
- 2a
- end
- 2b
- other end
- 3
- resin coating layer
- 4
- core portion
- 5
- flange portion
- 6
- washer
- 7
- container
- 20
- attachment hole
- 20a
- bottom
- 20b
- start point of the concave bottom portion 20a
- 41
- expanding portion
- 50
- flange body
- 51
- projecting portion
- 70
- mouth portion of beverage container (hollow tubular portion)
- 70a
- upper open edge portion
- 70b
- inner diametrical face
- D1 - D4
- diameters
- L
- axis
- Z1
- zone
- Z2
- zone