Packaging system and method for producing a packaging

Abstract

A packaging system having a packaging machine and a feeding device for the packaging machine. Packaging elements for receiving products in a predetermined format can be supplied to the packaging machine for a packaging process running thereon. The packaging machine may comprise a machine frame, at least one work station attached to the machine frame; a transport device that comprises a grouping unit for receiving packaging elements supplied by the feeding device to the packaging machine; and/or a transfer unit for transporting packaging elements received thereon to the work station. The grouping unit and the transfer unit can be brought together by way of a relative motion so that the packaging elements positioned on the grouping unit can be received by way of the transfer unit. The transfer unit may be capable of gripping the packaging elements. A method for producing a packaging as described above is also provided.

Claims

1. A packaging system comprising: a packaging machine and a feeding device for the packaging machine, wherein the feeding device is capable of supplying packaging elements for receiving products in a predetermined format to the packaging machine; wherein the packaging machine comprises a machine frame, at least one work station, a transport device, and a transfer unit capable of transporting packaging elements received thereon to the at least one work station, wherein the transport device comprises a grouping unit capable of receiving the packaging elements supplied by the feeding device to the packaging machine; wherein the grouping unit and the transfer unit are disposed for relative movement and capable of being brought together by way of a relative motion such that the packaging elements positioned on the grouping unit can be received using the transfer unit; wherein the transfer unit is capable of gripping the packaging elements; and wherein the grouping unit comprises a lifting mechanism and a conveyor belt that is mounted to be adjustable in height using the lifting mechanism.

2. The packaging system according to claim 1, wherein the transfer unit comprises a suction plate.

3. The packaging system according to claim 2, wherein the packaging elements are a plurality of trays and the suction plate comprises at least one reception mold that is adapted to engage with an upper opening region of a tray in a positive-fit manner and to firmly suction the tray on an inner contour of the upper opening region of the tray using a vacuum applied to the suction plate such that the suction plate is capable of transporting the plurality of trays to the at least one work station.

4. The packaging system according to claim 2, wherein the transfer unit further comprises a linear drive with a guide attached to the machine frame of the packaging machine and a carriage that is mounted on the guide and is adjustable in or opposite to a working direction of the packaging machine, and wherein the suction plate is attached to the carriage so that the suction plate is mounted adjustable along the guide between a receiving position, in which packaging elements can be transferred to the suction plate, and a transfer position, in which packaging elements transported by way of the suction plate can be transferred to the at least one work station.

5. The packaging system according to claim 1, wherein the grouping unit is attached as a module integrated into the machine frame of the packaging machine.

6. The packaging system according to claim 1, wherein the transfer unit is attached as a module integrated into the machine frame of the packaging machine.

7. The packaging system according to claim 1, wherein the grouping unit and the transfer unit are positioned within the machine frame beneath a film transport unit of the packaging machine extending in a working direction.

8. The packaging system according to claim 1, wherein the packaging machine is a thermoforming packaging machine, and wherein the at least one work station comprises a forming station of the thermoforming packaging machine that can be supplied with packaging elements using the transfer unit in a machine cycle for combining the packaging elements with a film.

9. The packaging system according to claim 1, wherein the feeding device comprises one of a destacker for separating packaging elements stacked therein, or a folding device for producing individual cardboard trays.

10. The packaging system according to claim 1, wherein the feeding device comprises a transport section that is capable of transferring at least a portion of the packaging elements provided for the predetermined format to the grouping unit.

11. The packaging system according to claim 1, wherein the conveyor belt of the grouping unit is spaced apart from the feeding device.

12. The packaging machine according to claim 1, wherein the feeding device comprises a transport section that can be operated together with the conveyor belt of the grouping unit to transport packaging elements in a direction of transport, and the conveyor belt can be decoupled from the transport section.

13. The packaging system according to claim 1, wherein the conveyor belt of the grouping unit is adjustable in height relative to the feeding device.

14. The packaging system according to claim 1, wherein the grouping unit is mounted within the machine frame, and the feeding device is positioned outside of the machine frame.

15. A packaging system comprising: a packaging machine and a feeding device for the packaging machine, wherein the feeding device is configured to supply packaging elements for receiving products in a predetermined format to the packaging machine; wherein the packaging machine comprises a work station, a transport device, and a transfer unit configured to transport packaging elements received thereon to the work station, wherein the transport device comprises a grouping unit configured to receive the packaging elements supplied by the feeding device to the packaging machine; wherein the grouping unit comprises a conveyor belt that is adjustable in height relative to the feeding device and the transfer unit, so that the packaging elements positioned on the grouping unit can be received using the transfer unit; and wherein the transfer unit is configured to grip the packaging elements.

16. The packaging system according to claim 15, wherein the packaging machine comprises a machine frame, the grouping unit and the transfer unit are mounted within the machine frame, the feeding device comprises a transport section that is movable in a direction of transport toward the grouping unit, and the transfer unit is movable within the machine frame in a direction transverse to the direction of transport to transport the packaging elements received thereon to the work station.

Description

DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

(1) In the following, an advantageous embodiment of the present invention will be explained in more detail making reference to a drawing, in which the individual figures show:

(2) FIG. 1A is a schematic top view of one embodiment of a packaging system in accordance with the teachings of the present disclosure;

(3) FIG. 1B is a schematic side view of one embodiment of a packaging machine in accordance with the present disclosure wherein the packaging machine is a thermoforming packaging machine;

(4) FIG. 2 is a perspective view of one embodiment of a detail of a packaging system in accordance with the present disclosure showing a grouping unit and a suction plate;

(5) FIG. 3 is a perspective view of one embodiment of a suction plate according the teachings of the present disclosure;

(6) FIG. 4 is a perspective view of the suction plate of FIG. 3 with a plurality of trays positioned thereon;

(7) FIG. 5 is a perspective view of another embodiment of a suction plate in accordance with the teachings of the present disclosure;

(8) FIG. 6 is a perspective view of the suction plate from FIG. 5 showing trays positioned thereon in a transparent manner;

(9) FIG. 7 is a sectional view of another embodiment of a suction plate in accordance with the teachings of the present disclosure having an unbent edge region and showing a folding device and a plurality of trays positioned thereon;

(10) FIG. 8 is a sectional view of the suction plate from FIG. 7 having the edge bent showing a plurality of trays positioned thereon;

(11) FIG. 9 is a schematic end view of one embodiment of a transport device in accordance with the teachings of the present disclosure wherein the transport device includes a height-adjustable grouping unit at a first setting; and

(12) FIG. 10 is a schematic end view of the transport device of FIG. 9 at a second setting.

DETAILED DESCRIPTION OF THE INVENTION

(13) The invention will now be described with reference to the drawing figures, in which like reference numerals refer to like parts throughout. For purposes of clarity in illustrating the characteristics of the present invention, proportional relationships of the elements have not necessarily been maintained in the drawing figures.

(14) The following detailed description of the invention references specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the present invention. The present invention is defined by the appended claims and the description is, therefore, not to be taken in a limiting sense and shall not limit the scope of equivalents to which such claims are entitled.

(15) FIG. 1A shows a packaging system 100 in a schematic top view. Packaging system 100 comprises a feeding device 15 and a packaging machine 1 which is supplied with packaging elements VE by feeding device 15.

(16) Feeding device 15 comprises a destacker or a folding device 80 as well as a transport section 90 which is adapted to transport packaging elements VE to packaging machine 1. Transport section 90 comprises a guide plate 91 along which packaging elements VE can be guided to one end 93 of transport section 90 in a predetermined position.

(17) Packaging machine 1 comprises a machine frame 6. Mounted within machine frame 6 is a transport device 12 for receiving and further transporting packaging elements VE transported by way of feeding device 15. Transport device 12 comprises a grouping unit 60 as well as a transfer unit 14.

(18) Grouping unit 60 is functionally connected to feeding device 15 by way of a transfer gap S at end 93 of transport section 90. Transfer gap S is sized such that packaging elements VE can be easily transferred from transport section 90 to grouping unit 60. Grouping unit 60 comprises a conveyor belt 61 which is preferably configured to be reversible. Conveyor belt 61 can be operated together with transport section 90 or decoupled therefrom in direction of transport Q. In this case, respective packaging elements VE can be conveyed along direction of transport Q such that they are positioned at the latest on conveyor belt 61 in a predetermined format F, for example, the 2×2 format according to FIG. 1A. According to FIG. 1A, grouping unit 60 comprises a lifting mechanism 18 with a servomotor 62 which is designed to lift conveyor belt 61 along a lifting direction C directed out of the image plane.

(19) Shown in the working direction R of packaging machine 1 is transfer unit 14 formed as a suction plate 19 next to grouping unit 60. Further in working direction R, a work station A is positioned next to suction plate 19. Work station A can be a forming station 2. Suction plate 19 can be positioned above grouping unit 60, so that packaging elements VE positioned on conveyor belt 61 can be raised to suction plate 19 disposed thereabove in the lifting direction C and gripped by way of suction plate 19. Suction plate 19 can then be released in working direction R, packaging elements VE received thereon can be transported to work station A and delivered to the latter such that they can be combined with a further packaging material provided at work station A.

(20) FIG. 1B shows a schematic view of a packaging machine 1 in the form of a thermoforming packaging machine T. Packaging machine 1 comprises a work station 1 formed as a forming station 2, a sealing station 3, a transverse cutting device 4 as well as a longitudinal cutting device 5. They are arranged in this order along working direction R on machine frame 6.

(21) Attached to machine frame 6 of packaging machine 1 on the inlet side is a feed roller from which a base film U as lower packaging material 8 is withdrawn. Base film U is transported into forming station 2 by a film transport device FT, shown only in part in FIG. 1B. 2 packaging trays M are formed into base film U using forming station 2 by way of a thermoforming operation taking place there. Packaging trays M can be transported onward to a loading stretch 15 where they can be filled manually or automatically with a product 16. Downstream of loading stretch 15, packaging trays M filled with products 16 are transported onward to a sealing station 3. Packaging trays M can be sealed by sealing station 3 with a top film O which forms an upper packaging material 10, so that sealing top film O onto packaging trays M produces sealed packages V which are separated by way of transverse cutting device 4 and longitudinal cutting device 5 and can be transported away using a discharge device 13.

(22) Furthermore, packaging machine 1 shown in FIG. 1B comprises a controls terminal 9 at which process parameters can be set for the respective work stations provided at packaging machine 1. Controls terminal 9 comprises a control unit 11 which is shown only schematically. Control unit 11 is configured to perform computing operations, in particular in real time during the production process, in order to control packaging machine 1 based on processes, i.e. to possibly have respective process parameters of packaging machine 1 adjusted in relation to the process.

(23) Packaging machine 1 illustrated in FIG. 1B further comprises a transport device 12 according to FIG. 1A associated with work station A, but which is positioned in the working direction R downstream of forming station 2, i.e. provides packaging elements VE by way of suction plate 19 in a direction opposite to working direction R of forming station 2.

(24) FIGS. 1A and 1B illustrate, by way of example, that transport device 12 can transport packaging elements VE in or opposite to working direction R to forming station 2. Transport device 12 is configured to continuously supply packaging elements VE to forming station 2 during the manufacturing process which are combined with packaging trays M produced therein to create a (composite) packaging lower part VU.

(25) FIG. 2 shows a perspective view of transport device 12 integrated into machine frame 6 of packaging machine 1. According to FIG. 2, transport device 12 is transferred a plurality of trays 17 in a predetermined format F by feeding device 15, presently in a 2×2 format according to FIG. 1A, from outside machine frame 6 of packaging machine 1. Trays 17 in FIG. 2 are formed as cardboard trays K, but can also be made of a different material.

(26) According to FIG. 2, trays 17 are transferred in the predetermined format F to grouping unit 60 arranged within machine frame 6, in particular to conveyor belt 61 provided there which is mounted vertically adjustable along lifting direction C by way of lifting mechanism 18. Lifting mechanism 18 is adapted to lift trays 17 positioned on conveyor belt 61 according to predetermined format F in lifting direction C for transferring trays 17 to transfer unit 14 positioned thereabove in a receiving position P1. Conveyor belt 61 can subsequently again be lowered back to its original position in which it can be transferred packaging elements VE by feeding device 15.

(27) Transfer unit 14 shown in FIG. 2 is mounted adjustable in or opposite to working direction R of packaging machine 1 between receiving position P1, in which trays 17 can be transferred thereto, and a transfer position P2 along a transport plane E, in which trays 17 transported by transfer unit 14 can be transferred to forming station 2.

(28) According to FIG. 2, transfer unit 14 is configured as a suction plate 19. Suction plate 19 is mounted adjustable between receiving position P1 and transfer position P2 by a linear drive 20 in or opposite to working direction R of packaging machine 1. Linear drive 20 is equipped with a guide 21 oriented in working direction R of packaging machine 1 on machine frame 6 and a carriage 22 that is displaceably mounted thereon and to which suction plate 19 is attached. Furthermore, an electric motor 64, e.g. a servo motor, adapted to control an adjustment motion of suction plate 19 is preferably attached to machine frame 6. The operation of electric motor 64 can be coordinated by control unit 11 of packaging machine 1.

(29) The configuration shown in FIG. 2 shows that suction plate 19 as such is moved to and fro only horizontally in transport plane E for continuously supplying trays 17 received thereon to forming station 2 for further processing with packaging recesses M formed thereon.

(30) FIG. 3 shows suction plate 19 according to one variant in an isolated view. Suction plate 19 shown in FIG. 3 comprises a plate-shaped upper part 23 with which suction plate 19 can be attached to carriage 22 (see FIG. 2). Furthermore, suction plate 19 comprises a plate-shaped center member 24 which is connected to upper part 23. Several reception molds 25 extend from center member 24 on a side facing away from upper part 23. Reception molds 25 are shaped in such a way that, with regard to trays 17 that are provided to them for transport, they can at least in part receive them as a negative mold in a positive-fit manner in their upper opening region 26.

(31) Reception molds 25 can each be available separately or coupled to center member 24 as an exchange or retrofit attachment W for suction plate 19 in order to convert suction plate 19 for flexible use with respect to different tray geometries. Reception molds 25 shown in FIG. 3 are each configured in particular as hollow bodies H for reducing the weight of suction plate 19.

(32) Reception molds 25 are configured according to FIG. 3, in particular, as centering members Z, in order to possibly compensate for a slight offset of supplied trays 17 when they are received at suction plate 19. Reception molds 25 designed in particular as centering members Z aim to ensure that trays 17 placed thereonto can be received in a precise position on suction plate 19, so that further work steps, apart from the actual transport purpose, for example, a folding operation K described in the context of FIG. 7 and FIG. 8, are promoted.

(33) Furthermore, FIG. 3 shows that bores 30 are formed along respective side walls 28 of reception molds 25. During transport of trays 17 which are attached in a positive-fit manner on reception molds 25, respective bores 30 abut in sections against the former's inner wall surface 31 (see FIG. 4) of upper opening region 26, so that a vacuum VK applied to suction plate 19 via bores 30 of respective reception mold 25 suctions tray 17 attached thereto by way of a predetermined holding force P in order to align trays 17 in a predetermined position X (see FIG. 4) on suction plate 19, i.e. to transport them in the predetermined format F and transfer them to forming station 2.

(34) FIG. 4 shows suction plate 19 from FIG. 3 with trays 17 received thereon in predetermined position X. According to FIG. 4, trays 17 received each have a bowl-shaped trough shape MF with an upper opening region 26 into which respective reception molds 25 immerse in a positive-fit manner.

(35) Upper opening regions 26 formed on respective trays 17 have an inner contour 27 which corresponds at least substantially to the formation of respective side walls 28 of reception molds 25. According to FIG. 4, respective side walls 28 of reception molds 25, which are oriented towards the side of machine frame 6, are slanted so that they have a slanted suction surface 29 (see FIG. 3).

(36) FIG. 4 also shows that respective trays 17 are received by suction plate 19 both in a positive-fit as well as in a force-fit manner. In this case, the positive-fit engagement is achieved by way of reception molds 25 produced as negative vacuum molds. The force-fit engagement for transporting trays 17 is supplied by vacuum VK applied to the respective inner wall surface 31 of trays 17.

(37) FIG. 5 shows suction plate 19 according to another variant for transporting a format F of trays 17′ that is different than is shown by way of suction plate 19 described in the context of the previous figures. According to FIG. 5, a total of nine wedge-shaped trays 17′, which can be used, for example, for packing triangular slices, can be received at suction plate 19. Trays 17′ are there transported by way of suction plate 19 in a 3×3 format.

(38) The technical principle, according to which trays 17′ can be secured to suction plate 19 both by positive-fit engagement at their upper opening region 26 and by force-fit engagement based on vacuum VK applied in this region, is also given in FIG. 5.

(39) Formed in suction plate 19 of FIG. 5 is a plurality of bores 30 in a plate member 32 as well as in respective reception molds 25 to distribute vacuum VK applied to suction plate 19 for evenly securing trays 17′.

(40) FIG. 6 shows several connection channels 33 formed in plate part 32 of suction plate 19 and respective connections 61 which deliver vacuum VK generated at suction plate 19 all the way to bores 30 formed on side walls 28 of reception molds 25. Vacuum VK applied via the respective connection channels 33 and/or connections 61 can be selectively directed and blocked at individual reception molds 25 by way of suitable valve control.

(41) FIG. 7 shows suction plate 19 with folding device 34 formed integrally thereon. Folding device 34 comprises an adjustably mounted lifting mechanism 70 integrated into suction plate 19. Lifting mechanism 70 comprises a lifting element 42, for example, in the form of a plate which is arranged movable inside upper part 23 formed to be hollow in part and shown in FIG. 7, and a pressure element 34 arranged therebelow which is present in particular in the form of an inflatable membrane 46.

(42) Lifting element 42 is connected by way of connection pins 47 to reception molds 25. Connection pins 47 pass through a forming plate 37 of folding device 34 embodied for a folding process K (see FIG. 8). Lifting element 42, which is positioned above forming plate 37, and reception molds 25, which are attached to lifting element 42 by way of connection pins 47 and positioned on a side of forming plate 37 facing away, form a functionally coherent module of folding device 34.

(43) In the pressure-loaded state, membrane 46 raises lifting element 42 upwardly away from forming plate 37. As a result, reception molds 25 coupled thereto for folding process K are raised at the same time for producing a sealing flange 36 (see FIG. 8) on trays 17 placed thereon. In the unpressurized state, lifting element 42 rests on an upper side 50 of forming plate 37. Reception molds 25 are accordingly in an extended position 38 shown in FIG. 7. In this position 38, reception molds 25 are positioned spring-loaded by way of respective spring elements 49. The jointly acting spring rate of respective spring elements 49 can be matched to the pressure-loaded operation of membrane 46 in such a way that a predetermined folding stroke KH indicated in FIG. 8 is obtained.

(44) According to FIG. 7 and FIG. 8, the sealing flange 36 is formed for respective trays 17, which are arranged on reception molds 25, along an edge 35 of respective upper opening region 26 formed thereon.

(45) For the production of respective sealing flanges 36, reception molds 25 can be at least in part retracted at forming plate 37 disposed thereabove into receptacles 48 formed thereon in order to draw trays 17 arranged thereon toward forming plate 37.

(46) FIG. 8 shows that trays 17 arranged on reception molds 25 are deformed along their edge 35 by folding stroke KH, as a result of which sealing flange 36 is formed on respective trays 17.

(47) Suction plate 19 shown in FIG. 7 holds reception molds 25 arranged thereon in a spring-loaded manner in extended position 38, in which trays 17 are transferred without sealing flange 36 formed thereon to the suction plate 19. FIG. 8 shows respective reception molds 25 in a retracted position 39, in which reception molds 25 are drawn into corresponding receptacles 48 of forming plate 37 disposed thereabove by way of the lifting mechanism 70 which is now pressure-loaded against the spring preload. By immersing respective reception molds 25 into receptacles 48 of forming plate 37 provided for this purpose, folded edge 35 shown in FIG. 7 is deformed in such a way that respective sealing flanges 36 shown in FIG. 8 are produced on trays 17.

(48) According to FIG. 7 and FIG. 8, bending grooves 45 are formed on forming plate 37 that are adjacent to respective receptacles 48 and support the folding process K of sealing flanges 36. A circumferentially formed abutment edge 44 formed at respective receptacles 48 also has a positive effect for the creation of a precise sealing flange 36.

(49) Furthermore, FIGS. 7 and 8 show that suction plate 19 shown therein also has a dynamic pressure test unit 41. Dynamic pressure test unit 41 is formed on forming plate 37 in such a way that it can be verified in particular whether a tray 17 is properly positioned on suction plate 19 for a transfer process to work station A. It can also be verified by way of the dynamic pressure test unit 41 whether sealing flange 36 has been folded within tolerance limits.

(50) FIG. 9 shows transport device 12 in a side view, where suction plate 19 is used as a tilting guide KF, in addition to its previous function explained in the context of the invention. Trays 17 raised by way of lifting mechanism 18 in lifting direction C are there tilted during the lifting process toward suction plate 19 by way of reception molds 25 formed thereon until trays 17′ assume the predetermined position X shown in FIG. 10 at suction plate 19. For this purpose, the lifting motion along lifting direction C can be adapted in accordance with the tray geometry. FIGS. 9 and 10 further show a servo motor 65 which is provided for the operation of conveyor belt 61 on lifting mechanism 18.

(51) Transport device 12 employed in the invention, including suction plate 19 employed according to the invention, can be used at different locations along packaging machine 1 for supplying respective trays 17 that are fed to packaging machine 1 from outside for a further processing process performed thereon, for example, for combining with packaging trays M thermoformed at forming station 2. In particular, transport device 12 can be positioned in working direction R of packaging machine 1 of FIG. 1 upstream or downstream of forming station 2 configured as work station A, for producing trays 17 corresponding to packaging trays M produced thereon for producing packaging lower parts VU combined from trays 17 and packaging trays M. (see FIG. 1B). Respective packaging lower parts VU produced in forming station 2 are then transported onward quasi as a tray composite to loading stretch 15.

(52) Transport device 12 used in the invention is not restricted to the use at a thermoforming packaging machine T according to FIG. 1, but can also be used in an advantageous manner at other types of machines, such as tray sealers.

(53) From the foregoing, it will be seen that this invention is one well adapted to attain all the ends and objects hereinabove set forth together with other advantages which are obvious and which are inherent to the structure. It will be understood that certain features and sub combinations are of utility and may be employed without reference to other features and sub combinations. This is contemplated by and is within the scope of the claims. Since many possible embodiments of the invention may be made without departing from the scope thereof, it is also to be understood that all matters herein set forth or shown in the accompanying drawings are to be interpreted as illustrative and not limiting.

(54) The constructions and methods described above and illustrated in the drawings are presented by way of example only and are not intended to limit the concepts and principles of the present invention. Thus, there has been shown and described several embodiments of a novel invention.

(55) As is evident from the foregoing description, certain aspects of the present invention are not limited by the particular details of the examples illustrated herein, and it is therefore contemplated that other modifications and applications, or equivalents thereof, will occur to those skilled in the art. The terms “having” and “including” and similar terms as used in the foregoing specification are used in the sense of “optional” or “may include” and not as “required”. Many changes, modifications, variations and other uses and applications of the present construction will, however, become apparent to those skilled in the art after considering the specification and the accompanying drawings. All such changes, modifications, variations and other uses and applications which do not depart from the spirit and scope of the invention are deemed to be covered by the invention which is limited only by the claims which follow.