MANUFACTURING A PACKAGING CONTAINER FROM FIBER-CONTAINING MATERIAL

Abstract

In a method for manufacturing a packaging container, a web of material including a fiber-containing material is conveyed through a preforming station and through a forming station. In the preforming station, a forming region of the web of material is preformed by cooperation of a preforming die upper part with a preforming die lower part, the forming region being deformed between the preforming die upper part and the preforming die lower part during the preforming. In the forming station, a packaging depression is formed in the preformed forming region by cooperation of a forming die upper part with a forming die lower part, wherein the preformed forming region is deformed between the forming die upper part and the forming die lower part during forming.

Claims

1. A method for manufacturing a packaging container, comprising: conveying a web of material including a fiber-containing material through a preforming station and through a forming station; in the preforming station, preforming a forming region of the web of material by cooperation of a preforming die upper part with a preforming die lower part, the forming region being deformed during the preforming between the preforming die upper part and the preforming die lower part; and in the forming station, forming a packaging depression in the preformed forming region by cooperation of a forming die upper part with a forming die lower part, the preformed forming region being deformed between the forming die upper part and the forming die lower part during the forming.

2. The method according to claim 1, wherein the fiber-containing material is a material comprising natural fiber.

3. The method according to claim 1, wherein the fiber-containing material comprises a paper material.

4. The method according to claim 1, wherein a fiber content of the web of material is at least 70 percent by mass.

5. The method according to claim 1, wherein a fiber content of the web of material is at least 75 percent by mass.

6. The method according to claim 1, wherein a fiber content of the web of material is at least 80 percent by mass.

7. The method according to claim 1, wherein a fiber content of the web of material is at least 85 percent by mass.

8. The method according to claim 1, wherein a fiber content of the web of material is at least 90 percent by mass.

9. The method according to claim 1, wherein a fiber content of the web of material is at least 95 percent by mass.

10. The method according to claim 1, wherein a plurality of bulges of the web of material is produced in the forming region during the preforming.

11. The method according to claim 1, wherein the web of material is bulged in the forming region towards both two-dimensional sides of the web of material during the preforming.

12. The method according to claim 1, wherein an undulating pattern is formed in the forming region of the web of material during the preforming.

13. The method according to claim 1, wherein, during the preforming, a degree of deformation of the web of material is greatest in portions which, after the forming, form a transition region between one or more side walls of the packaging depression and a bottom of the packaging depression.

14. The method according to claim 1, wherein, during the preforming, a portion of lower deformation is formed in the forming region of the web of material, the portion of lower deformation being framed by a portion of higher deformation.

15. The method according to claim 1, wherein the forming region of the web of material is moistened and/or heated before at least one of the preforming and the forming.

16. An apparatus for manufacturing a packaging container, comprising: a preforming station having a preforming die upper part and a preforming die lower part; a forming station arranged downstream of the preforming station and having a forming die upper part and a forming die lower part; and a transport device configured to convey a web of material through the preforming station and through the forming station; wherein the preforming die upper part and the preforming die lower part are configured to be moved relative to each other for deforming a forming region of the web of material between each other to preform the forming region; wherein the forming die upper part and the forming die lower part are configured to be moved relative to each other for deforming the preformed forming region of the web of material between each other to form a packaging depression; and wherein the preforming die upper part and the preforming die lower part are configured to create a plurality of bulges in the forming region of the web of material during the preforming.

17. The apparatus according to claim 16, further comprising a heating device for heating the web of material, wherein the heating device is arranged upstream of the preforming station or is arranged between the preforming station and the forming station.

18. The apparatus according to claim 16, further comprising a moistening station for moistening the web of material, wherein the moistening station is arranged upstream of the preforming station or is arranged between the preforming station and the forming station.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0033] In the following, the disclosure is further explained with reference to an exemplary embodiment. In the Figures:

[0034] FIG. 1 is a schematic side view of an apparatus for manufacturing a packaging container according to an embodiment;

[0035] FIG. 2 is a schematic sectional view through the preforming station of the apparatus;

[0036] FIG. 3 is a schematic sectional view through the forming station of the apparatus; and

[0037] FIG. 4 is a schematic top view of the web of material after passing through the preforming station and before passing through the forming station.

DETAILED DESCRIPTION

[0038] FIG. 1 shows a schematic representation of an apparatus 1 for manufacturing a packaging container according to an embodiment. The apparatus 1 includes a machine frame 3, on which a preforming station 7 and a forming station 9 are arranged one behind the other along a production direction 5.

[0039] Upstream of the preforming station 7 with respect to the production direction 5, a web of material 11 is unwound from a supply roll 13. The web of material 11 is conveyed by means of a transport device 15 along the production direction 5 successively through the preforming station 7 and the forming station 9. The web of material 11 includes a fiber-containing material, such as a paper material. The transport device 15 may include clamp chains that grip the web of material 11 from both lateral sides (right and left) with respect to the production direction 5, thereby conveying the web of material 11 along the production direction 5.

[0040] The preforming station 7 includes a preforming die upper part 17 and a preforming die lower part 19. The material web 11 is conveyed between the preforming die upper part 17 and the preforming die lower part 19. The preforming die upper part 17 and the preforming die lower part 19 are movable relative to each other with respect to a vertical direction toward each other into a closed position in order to deform the web of material 11 between each other. The preforming die upper part 17 may include a male forming part and the preforming die lower part 19 may include a corresponding female forming part.

[0041] FIG. 2 shows a schematic sectional view through the preforming die upper part 17 and the preforming die lower part 19 with the web of material 11 arranged therebetween. The preforming die upper part 17 has a forming profile on its lower side and the preforming die lower part 19 has a complementary forming profile on its upper side. When the preforming die upper part 17 and the preforming die lower part 19 are moved towards each other with respect to a vertical direction into a closed position, the web of material 11 between the preforming die upper part 17 and the preforming die lower part 19 is deformed according to the forming profiles.

[0042] In the illustrated embodiment, a plurality of bulges are defined by the forming profiles of the preforming die upper part 17 and the preforming die lower part 19, by means of which protrusions 25 are created in the web of material 11 during preforming of the web of material 11 in the preforming station 7. Both upward and downward bulges 25 are created in the web of material 11, thereby creating an undulating pattern, at least in a sectional view. In FIG. 2, a height and a depth of the bulges 25 are exaggerated for simplified illustration. In practice, a height and a depth of the bulges 25 may be significantly smaller relative to a length of the formed forming region of the web of material 11.

[0043] Preforming in the preforming station 7 prepares the web of material 11 for further forming in the forming station 9. By forming the bulges 25, the web of material 11 is pre-stretched to some extent in the processed forming area.

[0044] In the illustrated embodiment, bowl-shaped packaging depressions 27 are to be produced (see FIG. 3). When forming such packaging depressions 27, a deformation of the web of material 11 is highest in the portions that form the side walls 29 of the packaging depression 27 and in portions that form a transition region 31 between the side walls 29 of the packaging depression 27 and a bottom 33 of the packaging depression 27. In order to prevent the occurrence of high loads in these portions and thus possibly a tearing of the material web 11 during forming in the forming station 9, the web of material 11 is formed in corresponding portions during preforming in the preforming station 7 with an increased degree of deformation. This is shown in FIG. 2 by higher or deeper bulges 25 generated in the web of material 11 in the corresponding portions.

[0045] FIG. 4 shows the web of material 11 in plan view between the preforming station 7 and the forming station 9. A forming region formed in the preforming station 7 includes a portion 35 of higher deformation. This portion will later form the outer walls 29 and/or the transition region 31 between the outer walls 29 and the bottom region 33 of the packaging depression 27. The portion 35 of higher deformation encloses a portion 37 of lower deformation that will later form, for example, the bottom region 33 of the packaging depression 27.

[0046] The forming station 9 includes a forming die upper part 21 and a forming die lower part 23. The web of material 11 is conveyed between the forming die upper part 21 and the forming die lower part 23. The forming die upper part 21 and the forming die lower part 23 are movable relative to each other with respect to a vertical direction toward each other to a closed position, so as to deform the web of material 11 therebetween and to form the packaging depression 27 in the forming region preformed in the preforming station 7. The forming die upper part 21 may include a male forming part, and the forming die lower part 23 may include a corresponding female forming part. FIG. 3 shows a schematic sectional view of the forming die upper part 21 and the forming die lower part 23.

[0047] In the illustrated embodiment, a heating device 39 for heating the web of material 11 is provided upstream of the preforming station 7 with respect to the production direction 5 and between the preforming station 7 and the forming station 9, respectively. Heating the web of material 11 may facilitate forming the material web 11 in the preforming station 7 and in the forming station 9. Alternatively, only one of the illustrated heating devices 39 may be provided, or the heating devices 39 may both be omitted.

[0048] In the illustrated embodiment, a moistening station 41 is provided upstream of the preforming station 7 with respect to the direction of production 5 and between the preforming station 7 and the forming station 9, respectively. The moistening station stations 41 are configured to moisten the web of material 11, for example by spraying the web of material 11 with a liquid, in particular with water. Moistening the web of material 11 may facilitate forming of the web of material 11 in the preforming station 7 or in the forming station 9. Alternatively, only one of the two illustrated moistening stations 41 may be provided, or the moistening stations 41 may both be omitted.

[0049] The apparatus 1 including the preforming station 7 and the forming station 9 may be provided on its own. However, the apparatus 1 may also be provided, for example, as part of a packaging machine, in particular as part of a thermoforming packaging machine. For this purpose, for example, in the arrangement shown in FIG. 1 downstream of the forming station 9 with respect to the direction of production 5, an insertion section for inserting products to be packaged into the packaging depressions 27 may be provided. Downstream of the insertion section, a sealing station may be provided for sealing the packaging depressions 27. A cutting device may be provided so as to separate the packaging depressions 27 from the material web 11.