Apparatus and method for making a container

This invention relates to an apparatus and a method for making a container. In particular, the invention can be applied in the field of making containers for products, in particular for food, cosmetic, pharmaceutical or other types of products.

There are currently various machines for making these containers, configured for forming a film fed from a reel by multi-impression moulding.

Generally speaking, these machines comprise a plurality of operating stations positioned in sequence, such as, for example, a heating station, a forming station and a cutting station.

The forming station generally comprises the use of a punch which is able to form the film, in such a way as to obtain the desired container, by means of forming techniques of known type which comprise specific mould dies and the blowing of air, for example by the punch itself.

Generally speaking, the use is known of a film made of a plastic material, or of a multi-layer poly-coupled material, for generating the above-mentioned containers.

Disadvantageously, the machines designed for forming containers made of plastic material are particularly complex, therefore having high installation and/or maintenance costs.

Moreover, the complexity of these machines makes them particularly bulky, thus reducing the number of machines which can be installed on the production lines and therefore a reduced number of products which can be produced daily.

The processing of the film made of plastic material comprises sealing together two sheets made of plastic material, then subsequently forming the container by blowing air between the two sheets. In other words, an edge of the future container is sealed and held still, however leaving free a portion of the edge to be able to then introduce air in the “space” formed between the two sheets which, when inflated, will define the containment space of the container.

In recent times, with the transition to a more sustainable industry aimed at reducing the use of plastic materials, it has been decided to use a film made of a cellulose-based material. For example, the film may be of a material such as thermoformable paper, or it may be a multilayer poly-coupled material with a prevalence of cellulose-based material.

Disadvantageously, the prior art production machines have proved ineffective in effectively and uniformly forming the cellulose-based material. In other words, during the blowing to inflate and form the material in this way, it has been found that the deformation of the two sheets is non-uniform, as well as there being a non-uniform distribution of the fibres which make up the material, resulting in products of lower quality or which cannot be used for the purposes of containing the products.

Moreover, the blowing of air inside the space formed between the two sheets may result in accidental separation or an unwanted breakage of the sheets, therefore resulting in a product which is damaged and unusable.

Even more disadvantageously, the blowing after the moulding could result in a container which is not well sealed, with the risk that it opens in undesired situations, thereby releasing the product and/or not adequately storing it.

The above-mentioned problems have been found, although to a lesser extent, for the forming of the plastic materials.

Document US 3946929 A describes a machine for making containers which comprises forming a plurality of identical equidistant recesses made of strips of aluminium, which are then heat sealed to each other to form compartments for receiving suppositories or the like.

The technical purpose of the invention is therefore to provide an apparatus and a method for making a container which are able to overcome the drawbacks of the prior art. The aim of the invention is therefore to provide an apparatus and a method for making a container, wherein the apparatus has a reduced size and an increase in the production volumes of the above-mentioned containers.

The aim of the invention is therefore to provide an apparatus and a method for making a container which allow containers of the desired quality to be obtained.

A further aim of the invention is to provide an apparatus and a method for making a container which allow a safe production of the container, without unwanted breakages of the container, during the making or during a subsequent use by a consumer.

The technical purpose indicated and the aims specified are substantially achieved by an apparatus and a method for making a container comprising the technical features described in one or more of the appended claims. The dependent claims correspond to possible embodiments of the invention.

In particular, the technical purpose indicated and the aims specified are substantially achieved by an apparatus for making a container defining a containment space for a product, for example a food, cosmetic, or pharmaceutical product. The apparatus defines at least two processing paths and comprises a feeding station and a forming station.

The feeding station is configured for introducing respective films, for example made of a plastic material or a cellulose-based material.

Preferably, the processing paths are parallel to each other.

The forming station, located downstream of the feeding station, comprises at least one forming device.

The forming device comprises a punch, comprising a first male mould element and a second male mould element positioned in respective ends of the punch, and two mould dies opposite, respectively, the first male mould element and the second male mould element. The mould dies are movable towards the punch in such a way as to intercept the films along the respective processing paths in such a way as to form them at respective processing surfaces in such a way as to form half-containers designed to make the container.

Preferably, the mould dies are specular to each other.

Preferably, the male mould elements and the mould dies define two halfcontainers identical to each other.

Preferably, the male mould elements and the mould dies define two halfcontainers having different shapes, but having the same sealing ring.

Advantageously, the forming device guarantees a reduced size of the forming station and therefore of the apparatus itself.

Advantageously, the forming of the two half-containers before any sealing operation guarantees the correct forming of the container avoiding undesired breakages and in compliance with the desired quality standards. Moreover, the forming of the two half-containers before any sealing operation avoids unwanted separations of them.

Moreover, the technical purpose indicated and the aims specified are substantially achieved by a method for making a container defining a containment space for a product, preferably a food product.

The method comprises the following steps:

- feeding at least one film in at least two processing paths;

- forming the container forming each film at respective processing surfaces. The forming step is performed by reciprocally moving two mould dies towards a punch provided with a first male mould element and a second male mould element in such a way as to intercept each film and form it defining respective half-containers.

The step of forming the container further comprises joining the halfcontainers defining the container.

Further features and advantages of the present invention will become more apparent from the following indicative, and hence non-limiting, description of an embodiment of an apparatus and a method for making a container.

The description is set out below with reference to the accompanying drawings which are provided solely for purposes of illustration without restricting the scope of the invention and in which: - Figure 1 is a schematic view of the apparatus according to the invention comprising a forming station;

- Figure 2 is a schematic cross-section view, with some parts cut away for clarity, of the forming station of Figure 1 , in an open die configuration;

- Figure 3 is a schematic cross-section view of the forming station of Figure 2, in a contact configuration, wherein the die is open but a pressing device is configured to make contact with a respective mould die;

- Figure 4 is a schematic cross-section view of the forming station of Figure 2, in a closed die configuration.

With reference to the accompanying drawings, the numeral 1 denotes in its entirety an apparatus for making a container “C” which, for simplicity of description, will hereafter be referred to as the apparatus 1 .

The container “C” defines a containment space for a product, preferably for a food product.

The apparatus 1 defines at least two processing paths “L” and comprises a feeding station 2 configured for introducing at least one film “F”, for example made of a plastic material, or a cellulose-based material, or an aluminium- based material, for each processing path “L”.

Preferably, the two processing paths “L” are parallel to each other.

At least with regard to the operations performed by the apparatus 1 , the following description in this text is totally equivalent for a film “F” made of plastic material, of cellulose-based material, or of aluminium-based material, unless explicitly described.

It should also be noted that the term film “F” made of a cellulose-based material means in this text the fact that the film “F” may be entirely thermoformable cellulose-based, for example it may be made of thermoformable paper and/or paperboard, or it may be a poly-coupled material, for example multi-layer material, with a prevalence of cellulose- based material.

In the latter case, the film “F” made of poly-coupled material (not illustrated) may comprise a first layer of paper and/or paperboard, a second layer of thermoplastic polymer and a third layer of paper and/or paperboard. Still more preferably, the poly-coupled material may comprise a fourth layer, optionally peelable, made of thermoplastic polymer configured to come into contact with the product. The accompanying drawings show only the first layer of paper, which may be seen as the material which defines the outside of the container “C”.

Preferably, the first layer of paper and/or paperboard is made from 50-300 gr/m2 paper coupled by the second layer (for example polyethylene) to the third layer of 50-300 gr/m2 paper. The fourth layer, which is optionally peelable, may be made of polyethylene (abbreviated PE) or polypropylene (abbreviated PP) or polyactic acid (abbreviated PLA) or other plastic materials.

The term "grammage" is used to mean a value of paper and/or paperboard density, which is expressed as a value in grams per square metre.

Even though the paper and/or the paperboard has a thickness which is usually dependent on the grammage used, the thickness of the paper and/or the paperboard may vary depending on various factors, such as, for example, the type of processing performed during the production of the paper and/or the paperboard or the quantity of wood fibre present in it. In fact, for the same grammage, there may be a high density paper and/or paperboard which has a predetermined thickness and a low density paper and/or paperboard which is thicker than the predetermined thickness.

The film “F” may be introduced using the feeding station 2 unrolling a reel for each processing path “L”.

The film “F” may also be introduced using the feeding station 2 feeding single sheets.

In other words, the film “F” may be a continuous web or a series of sheets with finished dimensions that, once introduced in the apparatus 1 , are processed until obtaining the container “C”. The apparatus 1 further comprises a forming station 3 positioned downstream of the feeding station 2. The forming station 3 comprises at least one forming device 4.

The forming device 4 comprises a punch 5 and two mould dies 6. Preferably, the forming device 4 is configured for making a mould vertically or horizontally. In other words, the apparatus 1 is set up and configured to make a mould vertically or horizontally meaning that a moulding direction may be, respectively, horizontal (if the mould is vertical) or vertical (if the mould is horizontal).

As shown in more detail in Figures 2 to 4, the punch 5 comprises a first male mould element 5a and a second male mould element 5b positioned in respective ends of the punch 5. Preferably, each male mould element 5a and 5b has a substantially rounded shape and follows the final geometry of the container “C” to be made. In other words, the ends of the punch 5 may be free of sharp edges to prevent damaging the film “F” during forming. However, this is not necessary and depends on the above-mentioned final geometry of the container “C”.

The two mould dies 6 are opposite the first male mould element 5a and the second male mould element 5b, respectively. More specifically, the two mould dies 6 face towards the first male mould element 5a and the second male mould element 5b (that is to say, towards the ends of the punch 5).

The two mould dies 6 are movable towards the punch 5 in such a way as to intercept the films “F” along the respective processing paths “L” in such a way as to deform them at the respective processing surfaces “A” in such a way as to form half-containers designed to make the container “C”.

It should be noted, therefore, that a moulding direction is identified as a direction of movement of the mould dies 6 and, in the case of a vertical mould, the moulding direction is horizontal, whilst in the case of a horizontal mould, the moulding direction is vertical.

More in detail, the first male mould element 5a and the second male mould element 5b are positioned at the respective ends of the punch 5, on opposite sides along the moulding direction.

Preferably, the two mould dies 6 can be moved by specific pneumatic devices 7 or other similar devices to obtain their movement (that is, their translation) towards the punch 5 between an open die configuration, shown in Figure 2, in which the mould dies 6 are spaced from the respective male mould elements 5a, 5b and from the film “F” and a closed die configuration, shown in Figure 4, in which the mould dies 6 are moved close to the respective male mould elements 5a, 5b and the film “F” is deformed and defines the half-containers.

In other words, the punch 5 is a fixed member whose ends face towards the processing paths “L” (that is to say, towards the film “F”) and towards the two mould dies 6. The two mould dies 6 also face towards the male mould elements 5a and 5b and towards the processing paths “L” (that is to say, towards the film “F”). For this reason, the films “F” are interposed between the mould dies 6 and the respective male mould elements 5a and 5b.

The mould dies 6 can be specular to each other. In other words, both of the mould dies 6 are shaped in such a way as to form the two half-containers with the same geometry. In other words, the two mould dies 6, in conjunction with the respective male mould elements 5a and 5b, are configured to obtain a same half-shell (that is to say, half-container).

Alternatively, the mould dies 6 may be formed in such a way as to form the two half-containers with a different geometry. In other words, the two mould dies 6, in conjunction with the respective male mould elements 5a and 5b, are configured to obtain two separate half-shells (that is to say, halfcontainers) which can be used to obtain a specific container “C”. In other words, the two half-containers will have a same connecting section suitable for joining them to form a container ‘C’ which is not symmetrical relative to a plane for joining the two half-containers.

Preferably, the two mould dies 6 are shaped to match the respective male mould elements 5a and 5b.

Preferably, each mould die 6 has a shape which is shaped to match the respective half-container to be formed.

Even more preferably, each mould die 6 and the male mould elements 5a and 5b are shaped to match the respective half-containers to be formed.

Preferably, the punch 5 comprises a heating element, not illustrated, for heating the first male mould element 5a and the second male mould element 5b. In other words, the punch 5 is provided with a heating element configured to heat the ends of the punch 5 in such a way as to improve the forming action performed by the punch 5 on the film “F” in conjunction with the mould dies 6. For this reason, when the mould dies 6 intercept the film “F” and press it against the respective male mould element 5a and 5b, as shown in Figure 2 to Figure 4 in which the film F is not illustrated, each heated male mould element 5a and 5b in turn heats the film “F”, thus improving its deformation properties and obtaining a complete, more homogeneous forming.

If the film “F” is cellulose-based, the heating of the punch 5 allows a plastic deformation of all the layers of paper to be obtained and dehydrating it so as to reduce the elastic return to the primitive shape.

Optionally, each mould die 6 may also comprise respective heating elements.

Preferably, the punch 5 comprises blowing elements, not illustrated, suitable for releasing a fluid from the first male mould element 5a and from the second male mould element 5b when each male mould element 5a and 5b intercepts the film “F” and is at least partly inserted in the respective mould die 6. In other words, when the mould dies 6 intercept the film “F” and press it against each male mould element (5a and 5b), as shown in Figure 2 to Figure 4 (in which the film “F” is not illustrated), each male mould element (5a and 5b) releases a jet (that is, a flow) of air fluid in order to better distribute the material against the respective mould die 6 to obtain a complete and more defined forming.

The fluid may be air, with a low moisture content, or water vapour if the film “F” is cellulose-based, as described in more detail below. For example, the punch 5 may comprise both the heating element and the blowing elements in such a way that, in common with the action of pressing the mould dies 6 against the respective ends of the punch 5, defining the first male mould element 5a and the second male mould element 5b, it is able to form as best as possible the respective half-containers.

Preferably, each mould die 6 is provided with a semi-tubular portion designed to define a portion of the semi-container suitable, once the container “C” has been formed, for inserting the product in the container “C” (that is to say, in the containment space). For this reason, the male mould elements 5a and 5b are also provided with a respective tubular portion shaped to match that of the respective mould die 6. In this way, during the pressing action of each mould die 6 on the punch 5 it is possible to obtain a half-conduit of the half-container which, once the container “C” has been formed, defines a conduit suitable for introducing the product in the containment space.

The forming station 3 may be provided with two or more forming devices 4 for simultaneously forming two or more half-containers from the processing surface “A”. For example, the forming station 3 of Figure 1 may comprise two different forming devices 4 for making a multi-impression forming.

Each male mould element 5a and 5b may be provided with a perimeter protective element (not illustrated) designed to protect a portion of each respective processing surface “A” of the film “F” in such a way as to form, during a forming of the half-containers by means of the forming device 4, a ring for sealing the half-container. In other words, the punch 5 may be provided at the relative ends with a ring or similar element surrounding the punch 5 itself which, during the action of pressing the mould dies 6 against the ends of the punch 5, allows a part of the film “F” to be immobilised and protected, which will therefore define the above-mentioned sealing ring.

By immobilising the film “F” the latter is blocked and the subsequent forming by the male mould elements 5a and 5b and the respective mould dies 6 is then made possible. Alternatively, the forming station 3 may comprise respective pressing devices 8 respectively interposed between each male mould element 5a and 5b and the respective processing path “L”.

In other words, the forming station 3 may comprise a pressing device 8, interposed between each mould die 6 and the respective male mould element 5a and 5b and even more particularly between each male mould element 5a and 5b and the respective film “F” to be formed.

Each pressing 8 may be defined in the form of a further plate, designed to press the film “F” against the respective mould die 6, the plate being configured to immobilise and protect a perimeter portion of the respective processing surface “A” of the film “F”.

In particular, each pressing device 8 is configured to protect a portion of each processing surface “A” of the film “F” in such a way as to form, during a forming of the half-containers by means of the forming device 4, a respective sealing ring of the half-container.

As may be seen in Figure 3, each pressing device 8 is configured to make contact with the respective mould die 6, thus immobilising the film “F”, in a contact configuration, when each male mould element 5a, 5b is still far from the respective mould die 6.

This contact configuration precedes the forming by the male mould elements 5a and 5b and by the respective mould dies 6, that is to say, it precedes the closed die configuration. In effect, as it moves in the mould dies 6 towards the respective male mould elements 5a and 5b, the movement passes from the open die configuration to the closed die configuration through the contact configuration.

According to a version not illustrated, the forming station 3 may comprise respective pressing devices, each interposed between each male mould element 5a and 5b and the respective processing path “L”, which differs from that described above in that it is configured to make contact with the respective mould die 6 without immobilising the film “F” in the contact configuration, to allow the film “F” to slide through the pressing device in an initial forming step.

In other words, each pressing device is configured to make contact with the mould die 6 and a perimeter portion of the respective processing surface “A”, without, however, immobilising it in the contact configuration, when each male mould element 5a, 5b is still far from the respective mould die 6. At the end of the forming, in the closed die configuration, the pressing device is configured to come into contact with the respective film “F” and define the sealing ring.

The forming station 3 may also comprise respective further pressing devices, wherein each further pressing device is interposed between each male mould element 5a and 5b and the respective processing path “L”, externally surrounds the pressing device and is configured to come into contact with the respective mould die 6 and a further perimeter portion of the film “F”, surrounding externally the perimeter portion, immobilising it in the contact configuration, when each male mould element 5a, 5b is still far from the respective mould die 6.

In this way, during the forming of the half-containers by means of the forming device 4, the film “F” can slide through the pressing device when the film “F” is blocked by the further pressing device.

In fact, during the action of pressing the mould dies 6 against the male mould elements 5a and 5b, the forming device 4 is configured to form each processing surface “A” using a sliding movement through the pressing device of the film “F”, when the film “F” is blocked by the further pressing device.

The material present between each perimeter portion, and each further perimeter portion, surrounding each processing surface “A” intended to be formed, may thus be involved in and act in conjunction in the forming of the container “C” since each pressing device allows the sliding of the respective film “F” during the forming, whilst each further pressing device blocks the film “F” during the forming.

In other words, each area of material, located outside the perimeter portion, may operate in conjunction with the respective processing surface “A” for making a respective reserve of material which each forming punch can intercept and pull between it and the respective mould die 6.

The sealing ring formed at the end of the forming, in the closed die configuration, may be used for sealing together the two half-containers.

Preferably, between the two sealing rings it is possible to insert a film suitable for separating two different products inside the same container "C". As shown in the accompanying drawings, the apparatus 1 also comprises a conveyor 9 configured for conveying the two processing paths “L” (that is to say, the respective films “F”) in such a way that the respective halfcontainers face each other.

During such conveying of the half-containers the respective sealing rings also face each other. Moreover, the respective half-conduits (if present) also face each other.

Preferably, the apparatus 1 also comprises a sealing station 10 comprising at least one sealing device 10a for sealing together the half-containers to form the container “C”.

The sealing device 10a is configured for sealing together the respective sealing rings (if present) facing each other of the two half-containers, thus obtaining the desired container “C”. For this reason, the sealing device 10a is configured for sealing together two half-containers by means of the respective sealing rings.

During this sealing step, the half-conduits, if present, also seal with to each other using respective sealing portions.

Optionally, if the films “F” are made of respective cellulose-based materials, the apparatus 1 may also comprise a deforming station 1 1 , positioned downstream of the feeding station 2 and upstream of the forming station 3, which comprises at least one deforming device 11 a having respective engagement surfaces 1 1 b provided with a corrugated geometry and configured to engage the respective film “F” in such a way as to impart the corrugated geometry, on respective deforming surfaces of the film “F”. The forming device 4 is configured for forming each film “F” deformed by the deforming device 11 a.

The undulating geometry advantageously makes it possible to obtain a more uniform distribution of the cellulose fibres of each respective film “F” which, during the forming of the half-containers, allows a more homogeneous forming to be obtained and a reduction in the possibility of damaging the half-container during the making of the container “C”.

Advantageously, each deforming device 1 1 a is able to impart the undulating geometry on the respective film “F” in such a way as to better redistribute the material making up the film “F” so as to be able to take full advantage of the deformability.

In fact, the film “F” is deformed, obtaining a deformation surface which, after the individual deformations made by the undulating geometry of the engaging surface 1 1 b, will have a greater extension than the original processing surface “A” of the film “F”. In other words, the deforming obtained using the respective deforming device 1 1 a allows a film “F” to be obtained with an extension greater than the initial one.

Since the undulating geometry has already been deformed with the deforming station 1 1 , at least partly, a deeper and more homogeneous forming of the cellulose-based film “F” in the forming device 4 is guaranteed. The deforming station 1 1 is particularly suitable for cellulose-based film but is possible in the case of film made of plastic material.

If the film “F” is cellulose-based, it is also particularly advantageous that the blowing elements of each male mould element 5a, 5b are able to release steam, or pressurised air, at different times.

In fact, the male mould elements 5a, 5b may be configured to release a jet of water vapour before the closed die configuration, for preparing each cellulose-based film “F” to be formed, but also after the forming, in order to stabilise the shape of the half-container just formed.

If the forming device 4 is heated, that is to say, each male mould element 5a, 5b, or the corresponding mould dies 6 are heated, this heating may advantageously act in conjunction with any water vapour emitted by each male mould element 5a, 5b for stabilising and/or defining the final shape of each half-container just formed.

Advantageously, if the apparatus 1 comprises the pressing devices 8, configured for immobilising the film “F”, each deforming device 1 1 a is configured for imparting the undulating geometry in the respective processing surface “A”, intended to be subsequently formed. In other words, the punch 5 is configured for forming the processing surface “A” previously deformed.

On the other hand, if the apparatus 1 comprises the pressing devices, configured to come into contact with the film “F” without immobilising it, each deforming device 1 1 a is configured to impart the undulating geometry in the area of material located on the outside of the perimeter portion, with which the processing surface “A” may operate in conjunction with for making the reserve of material which the respective male mould element 5a, or 5b can intercept and form.

Preferably, the apparatus 1 further comprises at least one heating station 12 interposed between the feeding station 2 and the forming station 3 and is configured for pre-heating the respective film “F”.

Preferably, if the deforming station 1 1 is present, the heating station 12 is interposed between the feeding station 2 and the forming station 3.

The pre-heating of the film “F” helps to obtain a more facilitated forming of the film “F” and, if the deforming station 1 1 is present, an improved distribution of the fibres of the cellulose-based material which further facilitates the forming of the half-containers.

Advantageously, the above-mentioned apparatus 1 (according to the various embodiments) makes it possible to obtain a container “C” of the desired quality.

Advantageously, the forming operation performed before the sealing prevents breakages or unwanted separations of the two half-containers, unlike the prior art methods. Advantageously, the apparatus 1 allows a safe production of the container “C”, without unwanted breakages of the container “C”, during the making or during a subsequent use by a consumer.

The invention also relates to a method for making a container “C” defining a containment space for a product, for example a food, cosmetic or pharmaceutical product.

The method is preferably implemented by means of the above-mentioned apparatus 1 and, therefore, the steps described below are to be understood as performed in the individual stations of the apparatus 1 .

The method comprises a first step of feeding at least one film “F” made of a plastic material, of a cellulose-based material, or of aluminium, in at least two processing paths “L”.

The feeding step is preferably performed by unrolling at least one reel or feeding single sheets of the film “F” in the respective processing paths “L”. For example, the feeding step may be performed by preparing a film “F” made of a multilayer poly-coupled material with a prevalence of cellulose- based material comprising a first layer of paper and/or paperboard, a second layer of thermoplastic polymer and a third layer of paper and/or paperboard and optionally a fourth layer, for example peelable, made of thermoplastic polymer configured to enter into contact with the product.

The method further comprises a step of forming the container “C”. This step is obtained by forming each film “F” at respective processing surfaces “A”. In particular, the forming step being performed by reciprocally moving two mould dies 6 towards a punch 5 provided with a first and a second male mould element 5b, 5b in such a way as to intercept each film “F” and form it to define respective half-containers and joining said half-containers defining said container “C”.

The movement step comprises keeping the punch 5 stationary and moving the mould dies 6 between an open die configuration and a closed die configuration, through a contact configuration.

The half-containers are joined preferably by sealing. Preferably, the method comprises a step of preheating the film “F”.

The preheating step is performed before the forming step, preheating a portion of the plastic material or the cellulose-based material, suitable for entering into contact with the product with the container “C” formed. The advantages discussed above for the apparatus 1 are also valid with regard to the method just described.

For this reason, the invention is able to overcome the drawbacks of the prior art.

Advantageously, the invention makes it possible to obtain containers “C” with a desired quality avoiding in particular undesired breakages or separations of the half-containers.

Moreover, the apparatus 1 is less structurally complex than the prior art machines, resulting in reduced installation and maintenance costs.

Moreover, the smaller overall size of the apparatus 1 allows the installation of several apparatuses in a working environment, thus resulting in an increase in the overall production volume.