Apparatus and method for forming opening devices on a sheet packaging material for packaging pourable food products
10493671 ยท 2019-12-03
Assignee
Inventors
Cpc classification
B29C2043/3483
PERFORMING OPERATIONS; TRANSPORTING
B29C43/18
PERFORMING OPERATIONS; TRANSPORTING
B29C2043/3444
PERFORMING OPERATIONS; TRANSPORTING
B29C43/34
PERFORMING OPERATIONS; TRANSPORTING
B29C31/048
PERFORMING OPERATIONS; TRANSPORTING
B29C43/36
PERFORMING OPERATIONS; TRANSPORTING
B29L2031/7166
PERFORMING OPERATIONS; TRANSPORTING
International classification
B29C43/18
PERFORMING OPERATIONS; TRANSPORTING
B29C31/04
PERFORMING OPERATIONS; TRANSPORTING
B29C43/36
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An apparatus for forming an opening device on a receiving portion of a sheet packaging material for packaging pourable food products comprises a molding unit having a first and a second mold selectively set in an open configuration, in which they are spaced from one another to allow feed of the packaging material therebetween, and in a closed configuration, in which they cooperate with faces of the packaging material and delimit a closed mold cavity housing the receiving portion of the packaging material and adapted to be filled with molten plastic material to define, when the plastic material sets, the opening device. The apparatus further comprises feeding device to feed molten plastic material to the molding zone in the open configuration of the first and second mold, and pressing device exerting pressure on the dose to force it to fill the mold cavity and to form the opening device.
Claims
1. A method for forming a plurality of opening devices on each one of a plurality of receiving portions provided on sheet packaging material for packaging pourable food products, each of the receiving portions receiving a respective opening device of the opening devices, the receiving portions being equally spaced apart from one another in a longitudinal direction of the sheet packaging material itself; said method being carried out by an apparatus comprising a molding unit operating at a molding zone of the apparatus; said method comprising: arranging a first mold and a second mold of said molding unit in an open configuration, in which the first and second molds are spaced apart from one another to allow feed of said sheet packaging material linearly between the first and second molds in the longitudinal direction; setting said first and second molds in a closed configuration, in which the first and second molds cooperate with opposite faces of said sheet packaging material and delimit a closed mold cavity housing one of said receiving portions of said sheet packaging material; feeding a dose of molten plastic material onto one of said receiving portions of said sheet packaging material, said first and second molds being in said open configuration during said feeding of said dose of molten plastic material; linearly conveying said sheet packaging material with said dose of molten plastic on said receiving portion of said sheet packaging material in said longitudinal direction until said dose of molten plastic becomes positioned between said first and second molds, said first and second molds remaining in said open configuration during the linear conveying of said sheet packaging material; pressing said dose to force the dose to fill said mold cavity by moving said first and second molds relative to one another to the closed configuration; and compression-molding the respective opening device of the opening devices on said receiving portion of said sheet packaging material while conveying said first and second molds linearly in said longitudinal direction.
2. The method as claimed in claim 1, wherein said pressing is performed by respective surfaces of said first and second molds delimiting said mold cavity.
3. A method comprising: conveying sheet packaging material linearly in a conveying direction, the sheet packaging material comprising multiple layers, at least one of the multiple layers comprising a through-hole, and at least one of the multiple layers being a lamination layer that extends over the through-hole; positioning a first mold and a second mold in spaced apart relation to one another to allow the sheet packaging material to be linearly conveyed between the first and second molds in the conveying direction, the first and second molds being at the same position in the conveying direction and being spaced apart from one another in a direction transverse to the conveying direction; feeding a dose of molten plastic material onto the lamination layer of the sheet packaging material extending over the through-hole of the sheet packaging material; conveying the sheet packaging material with the dose of molten plastic material on the sheet packaging material in the conveying direction, the sheet packaging material being linearly conveyed between the first and second molds while the first and second molds are in spaced apart relation to one another; closing the first and second molds by moving the first and second molds relative to one another in the transverse direction when the dose of molten plastic material on the sheet packaging material is at the same position as the first and second molds in the conveying direction so that the first and second molds cooperate with opposite surfaces of the sheet packaging material to delimit a closed mold cavity around the through-hole of the at least one multiple layer of the sheet packaging material with the molten dose of plastic material being on the lamination layer within the closed mold cavity; and forming an opening device on the through-hole of the at least one multiple layer of the sheet packaging material while the sheet packaging material and the first and second molds all continue to be linearly conveyed.
4. The method according to claim 3, wherein the through-hole is in a base layer of the sheet packaging material.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Three preferred, non-limiting embodiments of the present invention will be described by way of example with reference to the accompanying drawings, in which:
(2)
(3)
(4)
(5)
(6)
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
(7) Number 1 in
(8) In the example shown, package 1 is parallelepiped-shaped and of the type known by the trade name Tetra Brik Aseptic (registered trademark). Forming apparatus according to the present invention, however, also applies to advantage to packaging materials for other types of packages, such as the gable-top packages known by the trade name Tetra Rex (registered trademark).
(9) With particular reference to
(10) In the case of an aseptic package 1 for long-storage products, such as UHT milk, packaging material 2 also comprises a layer 6 of gas-barrier material, e.g. aluminium foil or ethyl vinyl alcohol (EVOH) film, which is superimposed on a layer 5 of heat-seal plastic material, and is in turn covered with another layer 5 of heat-seal plastic material forming the inner face of package 1 eventually contacting the food product.
(11) In other words, layers 5 and 6 define respective lamination layers applied to base layer 4 when producing packaging material 2 in the form of a continuous strip.
(12) Packaging material 2 also comprises a number of receiving portions 8 (only one shown in the drawings) equally spaced in a lengthwise direction A of the packaging material, and to which opening devices 3 are subsequently molded by using forming apparatus 10.
(13) In the example shown, each receiving portion 8 is defined by a so-called pre-laminated hole, i.e. a hole 9 formed through base layer 4 of packaging material 2 and covered by lamination layers 5, 6, so that hole 9 is sealed by a respective sheet cover portion 11.
(14) In a possible alternative embodiment not shown, cover portion 11 may even be defined by only one or some of layers 5, 6. For example, cover portion 11 may be made solely of gas-barrier material.
(15) In another possible alternative embodiment not shown, cover portion 11 may be defined by a patch fixed to the rest of packaging material 2 to seal a hole formed, in this case, through the full thickness of such packaging material 2.
(16) In a further alternative embodiment not shown, each receiving portion 8 may be simply defined by a hole formed through the full thickness of the packaging material 2 and which is destined to be sealed by the relative opening device 3.
(17) In the following description, reference is made to one receiving portion 8 and one opening device 3 for the sake of simplicity.
(18) As shown in particular in
(19) A cap 14 (
(20) More specifically, confetti portion 12 and pouring element 13 are molded in one piece and define opening device 3, whilst cap 14 is formed separately from the opening device 3 and then applied thereto.
(21) Confetti portion 12 and cover portion 11 of hole 9 together define a sealing portion 15 sealing opening 16 of pouring element 13.
(22) As shown particularly in
(23) As shown in
(24) On the side destined in use to face cap 14, confetti portion 12 may have an integral projecting pull ring 21, which is used by the user to detach sealing portion 15 from pouring element 13 along annular membrane connection portion 19 and so free opening 16 to pour out the product.
(25) More specifically, pull ring 21 extends inside, and at a predetermined distance from, neck portion 18, and is joined to confetti portion 12 by a tab 22.
(26) As shown in
(27) With reference to
(28) Forming apparatus 10 advantageously further comprises feeding means 35 to feed a dose 36 of molten plastic material to molding zone 31 in the open configuration of first and second mold 32, 33, and pressing means 37 carried by molding unit 30 and exerting pressure on dose 36 to force it to fill mold cavity 34 and to form opening device 3.
(29) In particular, feeding means 35 receive the dose 36 from a molten plastic material distributing unit, for example an extruder not shown, and delivers the dose 36 to the molding zone 31.
(30) It is pointed out that the term dose is used in the present description and in the claims to indicate a pre-defined/measured amount of plastic material in a paste state, i.e. in a molten or semi-molten state, which is removed from the molten plastic material delivering unit.
(31) It is also pointed out that molding zone 31 includes not only first and second mold 32 and 33 but the entire region where such first and second mold 32, 33 operate, including the space interposed between the first and second mold 32, 33 in the open configuration thereof.
(32) In the preferred embodiment shown in
(33) In greater details, in the specific solution disclosed in
(34) First mold 32 comprises an outer annular element 40 and a core element 41, coupled to one another in a sliding manner along axis B; in particular, core element 41 engages a through opening 42 of annular element 40.
(35) First mold 32 can be set in a first configuration (
(36) In practice, seat 43 of first mold 32 defines part of mold cavity 34 in the closed configuration of first and second mold 32, 33.
(37) Second mold 33 comprises an outer annular element 50, a core element 51 engaging a through opening 52 of outer annular element 50, and an intermediate annular element 53 also engaging opening 52 and radially interposed between outer annular element 50 and core element 51. Core element 51 and intermediate annular element 52 cooperate with one another in a sliding manner along axis B. Outer annular element 50 is made up of a plurality of components 54 which can be radially opened to allow disengagement of the opening device 3 from second mold 33.
(38) With particular reference to
(39) In particular, chamber 55 is delimited, on one side, by forming surface 45 of first mold 32 and, on the opposite side, by a forming surface 60 defined by head portion of second mold 33 facing packaging material 2; in greater details, forming surface 60 is defined by head portions of the various component elements of second mold 33, i.e. outer annular element 50, core element 51 and intermediate annular element 53.
(40) Chamber 56 is delimited, on one side, by radially outer surface 61 of intermediate annular element 53 and, on the opposite side, by radially inner surface 62 of outer annular element 50.
(41) Chamber 58 is instead entirely defined by an inner shaped surface 63 of core element 51.
(42) In this specific embodiment, surfaces 45, 60, 61, and 63, bounding mold cavity 34, define pressing means 37, which are therefore carried by both first and second mold 32, 33.
(43) With reference to
(44) In practice, feed device 65 can be moved between a first position, in which it is interposed between first and second mold 32, 33 and feeds dose 36 to one of the first and second mold 32, 33, in the present case first mold 32, and a second position, in which it is moved away from first and second mold 32, 33.
(45) In use, forming one opening device 3 on a relative receiving portion 8 of packaging material 2 is performed as follows, starting from an initial condition of forming apparatus 10, in which first and second mold 32, of molding unit 30 are in the open configuration (
(46) First, feed device 65 is displaced to the first position (
(47) The next step consists in arranging one receiving portion 8 of packaging material 2 in a position facing both first and second mold 32, 33; this step can be performed by moving either packaging material 2 with respect to molding unit 30 or the molding unit 30 with respect to the packaging material 2; it is also clear that packaging material 2 and molding unit 30 may be both advanced along direction A, even if with different speeds in order to arrange one receiving portion 8 of the packaging material 2 in a position facing both first and second mold 32, 33.
(48) At this point, first and second mold 32, 33 are displaced to the closed configuration (
(49) It is clear that the closed configuration of molding unit 30 can be achieved not only by moving both first and second mold 32, 33 along axis B towards packaging material 2, as shown in
(50) It should be noted that the part of packaging material 2 fed between first and second mold 32, 33 is transversal, preferably orthogonal, to axis B, along which one of, or both, first and second mold 32, 33 is/are moved.
(51) During the movement from the open to the closed configuration, first and second mold 32, 33 exert a compressing action on the dose 36, which is forced to fill the entire mold cavity 34 and to form opening device 3.
(52) In particular, a relative movement occurs between core element 41 and outer annular element 40 (illustrated by the arrow shown in
(53) The pressing action on the molten plastic material contained in confetti-shaped chamber 55 pushes cover portion 11 of packaging material 2 against mold second 33, so that side 11b of cover portion 11 contacts forming surface 60.
(54) At this stage, layer 5 of heat-seal plastic material of cover portion 11, facing first mold 32, melts with the plastic material into mold cavity 34.
(55) The molten plastic material spreads radially inside confetti-shaped chamber 55 until it eventually reaches the intersection of this chamber 55 with shaped chamber 58, where cover portion 11, having no solid support by second mold 33, is pierced neatly by the pressure of the molten plastic material; at this point, molten plastic material fills the whole of shaped chamber 58.
(56) In exactly the same way, when the molten plastic material reaches the annular portion at the intersection of confetti-shaped chamber 55 and tubular chamber 56, cover portion 11 is pierced by the pressure of the molten plastic material, which therefore flows into the whole of tubular chamber 56 to form neck portion 18 of pouring element 13 and thread 25.
(57) In other words, the molten plastic material of dose 36 pierces through cover portion 11 at the intersections between confetti-shaped chamber 55 and tubular and shaped chambers 56 and 58 of mold cavity 34 to form through openings, which are subsequently sealed off by the plastic material to fully restore the integrity of packaging material 2.
(58) Once the plastic material filling the whole of mold cavity 34 sets, components 54 of outer annular element 50 of second mold 33 radially open and first and second mold 32 and 33 are moved to the open configuration (shown in
(59) Number 10 in
(60) Forming apparatus 10 differs from forming apparatus 10 in that feed device 65 is configured to selectively feed a dose 36 of molten plastic material directly onto a relative receiving portion 8 of packaging material 2, in turn advanced along direction A through molding zone 31 and between first and second mold 32 and 33.
(61) In particular, in the example shown in
(62) The method for forming opening devices 3 on relative receiving portions 8 of packaging material 2 can be the same as the one described with reference to forming apparatus 10, except that doses 36 are directly fed onto packaging material 2 and not to one of the first and second mold 32, 33.
(63) Once feed device 65 has delivered one dose 36 to a relative receiving portion 8 of packaging material 2, such dose 36 sticks to the receiving portion 8 itself so keeping the same position in which it was fed; in other words, by being formed by a paste plastic material, i.e. a molten or semi-molten plastic material, doses 36 are sticky and therefore adheres to the respective receiving portions 8 of packaging material 2.
(64) Number 10 in
(65) Forming apparatus 10 differs from forming apparatus 10 in that molding unit 30 comprises a first mold 71 facing in use side 11a of cover portion 11 of the relative receiving portion 8, bounded towards packaging material 2 by a forming surface 45 identical to forming surface 45 of first mold 32 and defining, on its side opposite the one facing packaging material 2, an open seat 43 for receiving a dose 36 of molten plastic material from feed device 36; forming apparatus 10 also comprises a second mold 70, having the same structure as second mold 33 and facing in use side 11b of cover portion 11 of a relative receiving portion 8.
(66) It should be noted that packaging material 2 in
(67) Analogously to first and second mold 32, 33 of forming apparatus 10, first and second mold 71, 70 are selectively set in an open configuration (
(68) In this case, feed device 65 is configured to selectively feed a dose 36 of molten plastic material in seat 43 of first mold 71, when first and second mold 71, 70 are in the open configuration (
(69) Seat 43 is connected in use to mold cavity 34 through an axial channel 72 extending from a bottom wall of the seat 43 to forming surface 45.
(70) First mold 71 further comprises a plunger 73 slidably engaging seat 43 to press in use dose 36 placed in said seat 43 to force the molten plastic material to flow into mold cavity 34.
(71) In particular, plunger 73 is displaceable along axis B between an extracted position, in which it is detached from the open side of seat 43 in order to allow feeding of a dose 36 into the seat 43, and a final pressing position, in which it fully engages seat 43 and forces the molten plastic material forming dose 36 to flow through channel 72 into mold cavity 34.
(72) Displacement of plunger 73 from the extracted position to the final pressing position is activated as first and second mold 71, 70 are in their closed configuration.
(73) Plunger 73 has a through axial hole 74 having the same diameter as channel 72, coaxial with the latter and engaged, in a sliding manner, by a rod 75 to allow molten plastic material to fully flow out of first mold 71.
(74) In this case, plunger 73 and rod 75 define pressing means 37 together with the surfaces 45, 60, 61, 62 and 63 delimiting mold cavity 34.
(75) The method for forming opening devices 3 on relative receiving portions 8 of packaging material 2 by using forming apparatus 10 is similar to the one described with reference to forming apparatus 10, except that the dose 36 is pressed by plunger 73 and rod 75 to fill mold cavity 34, after setting first and second mold 71, 70 in the closed configuration; in other words, the molten plastic material of the dose 36 is not pressed by first and second mold 71, 70, while these molds are moving to the closed configuration, but the pressing action is performed by plunger 73 and rod 75 after the first and second mold 71, 70 have reached the closed configuration.
(76) The advantages of the forming apparatus 10, 10, 10 and the forming method according to the present invention will be clear from the foregoing description.
(77) In particular, the fact that the step of feeding the dose 36 of molten plastic material to form one opening device 3 is performed in the open configuration of first and second mold 32, 33, 71, 70 allows this step to be well separated from the step of compressing the molten plastic material into the mold cavity 34. In this way, it is possible to achieve a better control and quality of these two steps than in the case of injection molding, wherein feeding of the dose to form one opening device and molding of the opening device are made in the same process. In this latter case, it is difficult to determine whether a possible problem occurring during the operation of injection molding is caused by the feeding of the plastic material or by the proper molding step.
(78) In addition, performing the feeding of the plastic material separately from the molding step permits to position the relative devices (feed device 65 and molding unit 30) in a more flexible way along the path of the packaging material 2 than in known injection molding apparatus.
(79) This is particularly evident when the dose 36 is directly fed onto the packaging material 2; in this case, the feeding step can be performed in any position along the path of the packaging material 2, even in a position far from the molding unit 30.
(80) The separation of the feeding step from the molding step allows to move molding unit 30 along the path of the packaging material 2; in this case, the dose 36 may be received by the molding unit 30 in a position spaced from the one in which the molding operation is performed. In other words, it would be not necessary to move also the feed device 65, and in particular the molten plastic material delivering unit, i.e. the extruder, along the path of the packaging material 2 together with molding unit 30.
(81) Moreover, performing the molding operation by compressing the dose 36 of molten plastic material requires less force than injecting the same material through a hole in the molds and therefore less power and less costs.
(82) Clearly, changes may be made to forming apparatus 10, 10, 10 and the forming method as described herein without, however, departing from the scope as defined in the accompanying Claims.
(83) In particular, the molding operations described may be also applied on receiving portions 8 of any outer profile, i.e. even not circular, to produce opening devices having tubular pouring elements with non-circular cross-sections, e.g. oval, elliptical or simply defined by closed-loop profiles.