APPARATUS AND METHODS FOR PACKAGING PRODUCTS IN BLOW-THERMOFORMED PLASTIC CONTAINERS

Abstract: An apparatus comprises heating means (8) for heating a thermoformable sheet material (2), fluid bed supporting means (18) in said heating means (8) for supporting said sheet material (2), sealing means (10) of regions of said sheet material (2) and forming means (12) for forming containers (16) from said sheet material (2); the forming means (10) comprises longitudinally and transversely injectors (50) movable along, and transversely of, an advancing direction (F) of the sheet material (2); a method comprises heating a thermoformable sheet material (2) supported on a fluid bed, forming container from said sheet material (2) after heating said sheet material (2); the method further comprises inserting injectors means (50) between portions of the sheet material (2) before said sealing and moving said injectors means (50) to forming means (12).

Description: Apparatus and methods for packaging products in blow-thermoformed plastic containers The invention relates to a thermoforming system for packaging fluid state products into plastic containers after the containers have been blow-thermoformed from portions of sheet material . EP-A-0692364 discloses a thermoforming machine wherein a pair of sheet material portions is caused to pass through a preheating station to raise the temperature of the sheet material, making it approach the softening temperature, a sealing station, wherein the portions are sealed through a sealing mould in regions substantially defining the outlines of containers to be formed so as to obtain pockets from said portions, a forming station, wherein a pressurized forming fluid is injected into the pockets to make the pockets expand into a forming mould so as to obtain formed containers from the pockets, the containers being still joined along the outlines by parts of non-formed sheet material. The sheet material is indexed through the above-mentioned stations leaving lateral edges accessible for allowing the pressurized forming fluid to enter therethrough. In such machines it is sometimes a problem to move the sheet material, because the material, when it is heated to temperatures near to the softening temperature, tends to become sticky and less resistant. Furthermore, there may be a disadvantage consisting in that the containers can be contaminated by extraneous material through the openings used for introducing the forming fluid, mainly because the openings are generally turned upwards. In EP-A-0692364 the forming fluid is injected through an injector body, on which the portions of the sheet material are presses by portions of the forming mould and scrape the outer surfaces of the injectors when the sheet material is indexed at the end of each forming cycle. This fact causes possible damages of the sheet material. EP-A-0479152 describes a blow-forming machine for sheet material, wherein the injectors of the forming fluid are arranged in the forming station and are movable perpendicularly to the advancing direction of the sheet material, between an outer non-operating position and an inner operating position in which they are introduced between edge regions of the sheet material and penetrate into the forming mould to form filling ducts for the product into the formed containers. The movable injectors of EP-A-0479152 are difficult to be positioned between the portions of the sheet material and so divaricating means is provided in order to divaricate the edges of the sheet material and to facilitate the insertion of the injectors. It is an object of the invention to improve the known blow- thermoforming systems. Another object is to improve the conveying conditions of the sheet material in blow-thermoforming machines. A further object is to improve the hygienic conditions of the formed containers. A still further object is to improve the introduction of the forming fluid between the portions of the sheet material to be formed. In a first aspect of the invention, there is provided an apparatus comprising heating means for heating a thermoformable sheet material, forming means for forming containers from said sheet material, characterized in that, said heating means comprises fluid bed supporting means for supporting said sheet material . In a second aspect of the invention, there is provided a method, comprising heating a thermoformable sheet material, forming containers from said sheet material after heating said sheet material, characterized in that, during said heating there is provided supporting said sheet material on a fluid bed. Owning to the invention, it is possible to improve the conveying of sheet material in a blow-thermoforming machine, since the sheet material substantially does not come in contact with machine parts which can brake or damage it, or to which the sheet material can adhere. Furthermore, the containers can be formed with their closed bottom turned upwards and the neck opening turned downward, which prevents polluting means from entering into the container. In a third aspect of the invention, there is provided an apparatus, comprising a sealing station comprising sealing means suitable for sealing portions of sheet material along outlines of containers to be formed leaving in each outline an opening constituted by a non-sealed region, a forming station comprising injector means for a forming fluid so arranged as to be capable of being placed in each said opening to introduce a forming fluid through said openings, said injector means being coupled to moving means arranged transversally with respect to the advancing direction of said sheet material and suitable for moving said injector means between an outer non-operating position and an operating position at the inside of saidportions, and vice-versa, characterized in that, said injector means is further coupled to longitudinally moving means arranged along said advancing direction and suitable for moving said injector means between said sealing station and said forming station, and vice-versa. In a fourth aspect of the invention, there is provided a method, comprising sealing at a sealing station portions of sheet material along outlines of containers to be formed leaving in each edge an opening constituted by a non-sealed region, injecting at a forming station a forming fluid through injector means into each said opening to introduce through said opening a forming fluid, moving said injector means transversally with respect to an advancing direction of said sheet material between an outer non-operating position and an operating position at the inside of said portions, and vice- versa, characterized in that, it further comprises longitudinally moving said injector means along said advancing direction between said sealing station and said forming station, and vice-versa. Owing to these aspects of the invention, it is considerably easier to insert the injector means between the portions of the sheet material, since the injector means can be inserted between the portions in the sealing station before sealing the strips . The invention could be better understood and carried out with reference to the attached drawing, which shows a non-limitative example thereof, wherein: Figure 1 is a schematic plan view of a machine for forming containers from sheet material comprising a sheet material preheating station, a sheet material sealing station, a container forming station; Figure 2 is a schematic plan view of the pre-heating station; Figure 3 is a broken and enlarged section taken along the plane III-III of Figure 2; Figure 4 is a section taken along the plane IV-IV of Figure 2; Figure 5 is a broken and enlarged section taken along the plane V-V of Figure 3; Figure 6 is a schematic plan view of the sheet material sealing stations and container forming station; Figure 7 is a deviated section taken along the plane VII-VII of Figure 6; Figure 8 is a deviated section taken along the plane VIII-VIII of Figure 6; As shown in Figure 1, sheet material 2 is unwound from a reel 4 supported on a shaft 6 around a horizontal axis Z and, after being folded by folding means 14 to form a pair of opposed facing portions, the sheet material 2 is indexed along a direction F through a pre-heating station 8, a sealing station 10 and e forming station 12. In the pre-heating station 8 the sheet material 2 is heated to a temperature near to the softening temperature, in the sealing station 10 the portions of the sheet material 2 are sealed in regions defining the outlines of the containers to be formed so as to obtain pockets open downwards, and in the forming station 12 the pockets are expanded to obtain containers 16 joined together by substantially undeformed regions of the sheet material 2. Therefore, at the exit of the forming station 12, the formed containers 16 are connected to each other by undeformed regions of the portions of the sheet material 2 and are arranged with the respective openings turned downwards. Consequently it is rather unlikely that polluting material could be able to enter into the containers 16. As shown in Figures 2, 3, 4 and 5, the pre-heating station 8 comprises a supporting element 18 having inclined lateral walls 20 diverging downwards, said supporting element being fixed at the bottom to positioning means 22. On a side of each wall 20 a pre-heating plate 24 is provided, said pre-heating plate being supported by a fixing plate 28 by means of adjusting screws 26. Each fixing plate 28 is connected to a respective pair of positioning rods 30 connected to a side wall 32 through bushings 34. The side walls 32 project upwards from a bottom wall 33. The positioning rods 30 can be axially adjusted at the inside of the bushings 34 so as to allow the pre-heating plates 24 to be approached to or moved away from the supporting element 18 to vary the amount of heat transmitted to the sheet material 2. The end of the supporting element 18 turned towards the reel 4 is provided with a wedge-shaped element 38 having first sides 36 converging towards the reel 4 and second sides 40 diverging downwards like the walls 20. The end of the supporting element 18 facing away from the reel 4 is provided with further sides 42 diverging towards the reel 4. The supporting element 18 is divided into two consecutive parts 18a, 18b each of which is internally provided with a conduit 44 into which a supporting fluid for the sheet material is introduced, for example pressurized air, through a respective tube 46. The end of each conduit 44 opposite to the tube 46 opens into a cavity 48, open upwards at the upper edge region of the supporting element 18. When the sheet material 2 is placed astride the support element 18, the cavity 48 defines a closed space, in which the supporting fluid accumulates, said supporting fluid creating an air-cushion which supports the sheet material 2 preventing it from contacting the walls 20 and from scraping. Therefore the sheet material 2 floats with a very low friction on air-cushion interposed between the sheet material 2 and the walls 20. With reference now to Figures 6, 7 and 8, the sealing station 10 and the forming station 12 are shown, said stations comprising a first group 48a and a second group 48b of injector nozzles for injecting a forming fluid, for example pressurized air. The nozzle groups 48a, 48b comprise nozzles 50 arranged in a longitudinal plane passing through the middle plane of the support element 18 and aligned thereto. The groups 48a, 48b of nozzles 50 are coupled to vertical positioning means 52, for example pneumatic cylinders, which lift and lower them to move each group from an outer position, in which each group does not interfere with the portions of the sheet material 2, to a position between said portions. Each of the pneumatic cylinders 52 is placed between a first end crossbar 54 of a respective movable frame 56 and a middle cross-bar 58 of the same movable frame 56. The middle cross-bar 58 of each movable frame 56 is connected to driving rods 62 engaged in vertical driving means comprising bushings 60 inserted in the first end cross-bar 54 and in a second end cross-bar 64 of the movable frame 56 connected to the first cross-bar 54 by posts 66. Therefore the middle cross-bars 58 may slide vertically driven by the vertical actuating means 52. The driving rods 60 of each movable frame 56 are internally provided with holes 68 which communicate with further holes 70 of the nozzles 50 through collectors 72 of a body 74 of each group 48a, 48b of nozzles 50. Each second cross-bar 58 is provided with coupling means 73, comprising wheels 75 slidably engaged on tracks 76 defining longitudinal driving means arranged parallel to the direction F and integral with the bottom wall 33. The second cross-bars 58 are further connected, by means of respective appendices 78, to opposing lengths of a belt 80 wound on pulleys 82, one of which is coupled to rotating driving means 84, supported by respective vertical shafts 88. Therefore, by actuating the pulley 80, the first group of nozzles 48a may be moved from the sealing station 10 to the forming station 12 while the second group of nozzles 48b is moved from the forming station 12 to the sealing station 10, and vice-versa. A forming cycle is carried out in the following way: dragging means, not shown, indexes the sheet material 2 from the preheating station 8 to the sealing station 10, in which the first nozzles group 48a is in a lifted position; then, the sealing mould 90 is closed and air is injected into the pockets to be formed through the nozzles 50 of the first group of nozzles 48a, so as to prevent wall regions of the pockets from sticking to each other; then the sealing mould 90 is opened and the dragging means further indexes the sheet material with the formed pockets up to the forming station 12, the nozzles 50 of the second nozzles group 48b, which were in the forming station 12, are brought to the sealing station 10, said nozzles 50 of the second group of nozzles 48b being in their lowered position, the nozzles 50 of the first nozzles group 48a still inserted into the respective pockets follow the sheet material 2 up to the forming station 12; in the forming station 12 a forming mould 92 is closed and air is injected into the formed pockets to expand the pockets so as to form the containers 16. Such step takes place while the nozzles 50 of the second group 48b of nozzles have been lifted and positioned between the preheated portions of sheet material 2. The nozzles 50 of the first group of nozzles 48a are then lowered, in order to be able to return again into the sealing station 10 and start a new cycle, while the formed containers 16 are sent to the subsequent working step.

Claims: CLAIMS 1. Apparatus, comprising heating means (8) for heating a thermoformable sheet material (2), forming means (12) for forming containers (16) from said sheet material (2), characterized in that, said heating means (8) comprises wedge- shaped supporting means (18) for supporting said sheet material (2) . 2. Apparatus according to claim 1, wherein said wedge-shaped supporting means (18) comprises lateral walls (20) diverging downwards . 3. Apparatus according to claim 1, or 2, wherein said wedge- shaped supporting means (18) is provided with conduit means (44) so arranged as to direct a supporting fluid towards said sheet material (2). 4. Apparatus according to claim 3, wherein said conduit means (44) open into a cavity (48) open towards said sheet material (2). 5. Apparatus according to any one of the preceding claims, wherein said wedge-shaped supporting means (18) is provided, at at least one of its ends, with end walls (36, 42) converging outwardly. 6. Apparatus according to any one of the preceding claims, wherein said wedge-shaped supporting means (18) is disposed along an advancing direction (F) of the sheet material (2) . 7. Apparatus according to any one of the preceding claims, wherein said wedge-shaped supporting means (18) is provided at a heating station (8) of said sheet material (2). 8. Apparatus according to claim 7, wherein said heating station (8) comprises a pair of heating plates (24) facing said wedge-shaped supporting means (18) . 9. Apparatus according to claim 8, wherein said heating plates (24) are movable by driving means (30, 34) by which said heating plates (24) are positioned at a predetermined distance from said wedge-shaped supporting means (18) 10. Apparatus according to claim 7, or 8, or 9, and further comprising, a sealing station (10) downstream of said heating station (8), said sealing station (10) comprising sealing means (90) for sealing portions of said sheet material (2) along outlines of containers to be formed, leaving in each outline an opening formed by a non-sealed region of said sheet material (2). 11. Apparatus according to any one of claims 7 to 10, and further comprising a forming station (12) downstream of said sealing station (10). 12. Apparatus according to claims 10 and 11, wherein first nozzle means (48a, 50) and second nozzle means (48b, 50) are provided at said sealing station (10) and said forming station (12) , said nozzle means (48a, 50; 48b, 50) being movable from said sealing station (10) to said forming station (12), and vice-versa. 13. Apparatus according to claim 12, wherein said nozzle means (50) is provided with injection means (68, 72, 72) for injecting a forming fluid between said portions of sheet material (2) . 14. Apparatus according to claim 12, or 13, wherein said first nozzle means (48a, 50) and said second nozzle means (48b, 50) are associated with longitudinally moving means (56, 80) extending along said advancing direction (F) . 15. Apparatus according to claim 14, wherein said longitudinal moving means (56, 80) comprises opposing lengths of belt means (80) . 16. Apparatus according to any one of claims 12 to 15, wherein said first nozzle means (48a, 50) and said second nozzle means (48b, 50) are associated with transversal moving means (52) extending transversely of said advancing direction (F) . 17. Apparatus according to claim 16, as appended to claim 14, or 15, wherein said transversal moving means (52) is placed on movable frames (56) which are part of said longitudinal moving means (56, 80) . 18. Method, comprising heating a thermoformable sheet material (2), forming containers from said sheet material after heating said sheet material, characterized in that during said heating, there is provided supporting said sheet material (2) on wedge- shaped supporting means (18). 19. Method according to claim 18, wherein said supporting comprises arranging portions of said sheet material (2) along walls (20) of said wedge shaped supporting means (18) . 20. Method according to claim 19, wherein said supporting comprises injecting supporting fluid means through conduit means (44) opening towards said sheet material (2). 21. Method according to claim 19 or 20, wherein, during said supporting, there is provided advancing said sheet material (2) along an advancing direction (F) to a forming station (12) for forming containers (16) from said sheet material (2) by injecting said forming fluid means between said portions (2). 22. Method according to any one of claims 18 to 21, wherein said supporting occurs at a heating station (8) of said sheet material (2) . 23. Method according to claim 22, wherein at said heating station (8) heating plates (24) are positioned at a predetermined distance from said wedge-shaped supporting means . 24. Method according to claim 21, or 22, or 23 wherein said advancing comprises advancing said portions (2) through a sealing station (10) before advancing said portions (2) to said forming station (12). 25. Method according to claim 24, wherein at said sealing station (10) there is provided sealing said portions (2) along outlines of containers to be formed, leaving in each outline an opening formed by a non-sealed region of said portions (2). 26. Method according to any one of claims 21 to 25, wherein during said sealing and during said forming there is provided keeping nozzle means (50) between said portions (2). 27. Method according to claim 26, wherein said keeping is maintained during said advancing. 28. Method according to any one of claims 21 to 27, wherein during said advancing there is provided moving said nozzle means (50) together with said portions (2) from said sealing station (10) to said forming station (12), and vice-versa. 29. Method according to any one of claims 21 to 28, and further comprising inserting said nozzle means (50) between said portions of sheet material (2) before said advancing. 30. Method according to any one of claims 21 to 29, and further comprising extracting said nozzle means (50) from said formed containers (16) . 31. Apparatus, comprising a sealing station (10) comprising sealing means (90) for sealing portions of sheet material (2) along outlines of containers to be formed, leaving in each outline an opening through a non-sealed region of the corresponding portion (2), a forming station (12) comprising injecting means (50) for injecting a forming fluid, said injecting means being positionable into each of said openings to introduce a forming fluid therethrough, said injecting means (50) being coupled to transverse moving means (52) arranged transversely of an advancing direction (F) of said sheet material (2), said moving means (52) being suitable for moving said injecting means (50) from an outer non-operative position and an operative position inside of said portions, and vice- versa, characterized in that, said injecting means (50) is further coupled to longitudinal moving means (56, 80) arranged along said advancing direction (F) and suitable for advancing said injector means (50) between said sealing station (10) and said forming station (12) and vice-versa. 32. Apparatus according to claim 31, and further comprising heating means (8) arranged upstream of said sealing station (10) for heating said thermoformable sheet material (2), said heating means being provided fluid bed supporting means (18) for supporting said sheet material (2) . 33. Apparatus according to claim 32, wherein said fluid bed supporting means (18) comprises wedge-shaped supporting means having lateral walls (20) diverging downwards. 34. Apparatus according to claim 32 or 33, wherein said fluid bed supporting means is provided with conduit means (44) for directing a supporting fluid towards said sheet material (2). 35. Apparatus according to claim 34, wherein said conduit means (44) opens into a cavity (48) open towards said sheet material (2) . 36. Apparatus according to any one of claims 31 to 35, wherein said supporting means (18) is provided, at at least one of its ends, with end walls (36, 42) converging outwardly. 37. Apparatus according to any one of claims 32 to 36, wherein said fluid bed supporting means (18) is aligned with said advancing direction (F) . 38. Apparatus according to any one of claims 32 to 37, wherein said fluid bed supporting means (18) is provided at a heating station (8) of said sheet material (2). 39. Apparatus according to claim 38, wherein said heating station (8) comprises a pair of heating plates (24) facing said fluid bed supporting means (18) . 40. Apparatus according to claim 39, wherein said heating plates (24) are movable by driving means (30, 34) by which said heating plates (24) are positioned at a predetermined distance from said fluid bed supporting means (18) . 41. Apparatus according to any one of claims 31 to 40, wherein said injecting means (50) comprises first nozzle means (48a, 50) and second nozzle means (48b, 50) . 42. Apparatus according to claim 41, wherein said nozzle means (50) is provided with injecting means (68, 72, 72) for injecting a forming fluid between said portions (2). 43. Apparatus according to claim 41, or 42, wherein said first nozzle means (48a, 50) and said second nozzle means (48b, 50) are associated with opposing lengths of belt means (80) of said longitudinal moving means (56, 80) . 44. Apparatus according to any one of claims 41 to 43, wherein said transverse moving means (52) is arranged on movable frames (56) , said movable frames (56) being part of said longitudinal moving means (56, 80) . 45. Method, comprising sealing at a sealing station (10) portions of sheet material (2) along outlines of containers to be formed leaving in each outline an opening through a non- sealed region of a corresponding portion of said outline, injecting in a forming station (12) a forming fluid through injector means (50) into each of said openings to introduce a forming fluid through said opening, moving said injector means transversally with respect to an advancing direction of said sheet material (2) from an outer non-operative position to an inner operative position inside of said portions, and vice- versa, characterized in that, it further comprises moving said injecting means (50) longitudinally along said advancing direction (F) from said sealing station (10) to said forming station (12), and vice-versa. 46. Method according to claim 45 and further comprising heating a thermoformable sheet material (2) before said sealing, while supporting said sheet material (2) on a fluid bed. 47. Method according to claim 46, wherein said supporting comprises arranging said portions (2) along walls (20) of fluid bed supporting means (18). 48. Method according to claim 46, or 47, wherein said supporting comprises injecting a supporting fluid through conduit means (44) opening towards said sheet material (2). 49. Method according to any one of claims 46 to 48, wherein, during said supporting there is provided advancing said sheet material (2) along an advancing direction (F) to said forming station (12) . 50. Method according to any one of claims 46 to 49, wherein said supporting occurs at a heating station (8) of said sheet material (2) . 51. Method according to claim 50, wherein at said heating station (8) heating plates (24) are positioned at a predetermined distance from said fluid bed supporting means 52. Method according to claim 49, or 50, or 51 wherein said advancing comprises advancing said sheet material (2) through said sealing station (10) before advancing said sheet material (2) to said forming station (12) . 53. Method according to any one of claims 45 to 52, wherein during said sealing and during said forming there is provided keeping nozzle means (50) between said portions of sheet material (2 ) . 54. Method according to claim 53, wherein during said advancing said nozzle means (50) are kept between said portions (2) . 55. Method according to any one of claims 49 to 54, wherein during said advancing there is provided moving said nozzle means (50) from said sealing station (10) to said forming station (12) and vice-versa. 56. Method according to any one of claims 49 to 55, and further comprising inserting said nozzle means (50) between said portions (2) before said advancing. 57. Method according to any one of claims 45 to 56, and further comprising extracting said nozzle means (50) from said formed containers (16) .

Inventors: BIANCHINI ALESSANDRO, DI GRANDE SAL, BIANCHINI, ALESSANDRO, DI GRANDE, SAL
Applicants: BIANCHINI ALESSANDRO, ELOPAK SYSTEMS, GRANDE SAL DI, BIANCHINI, ALESSANDRO, DI GRANDE, SAL, ELOPAK SYSTEMS A/G
Application year: 2000
Main classification: B65B
IPC codes: B29B13, B29C35, B29C49