Patent Description:
<CIT> discloses an example of such an apparatus, i.e. corresponding to the preamble of claim <NUM>.

Typically, methods for the production and filling of foods provide for the following steps:.

The step of providing the weakening portions is also performed by using blades or cutters which normally operate to provide an incision at the connecting edge.

This type of method, as well as the apparatuses used, have two types of drawbacks: the use of cutting blades or cutters to perform splitting into groups is not particularly flexible and it is rather complex, at the apparatus level, to vary the dimensions of the groups or the extension of the weakening portions. Other problems add to these, especially if one wishes to replace PS with PET or with PP in order to provide the containment receptacles.

In this case, in fact, a significant reduction of the lifespan of the blades or cutters is observed, with a considerable increase in the costs to be borne.

Furthermore, if one uses PET or PP as material, be they transparent or colored, since they are characterized by greater tenacity it is practically impossible to provide weakening portions capable of allowing mutual separation of the various receptacles by mutual bending without using scissors or cutters.

In particular, PET in sheet form (i.e., in plates having a thickness of more than <NUM> microns) having an initial degree of crystallinity up to <NUM>%, is a resilient and tough material and accordingly, in order to generate by means of an incision with cutters the weakening portion at a connecting edge between at least two different accommodation receptacles it is necessary to go in the direction of systems in which the cutters are mutually closer and must produce an incision of substantially all of the thickness of the material; despite this, achievement of the intended aim is still not ensured.

Moreover, this aspect causes a shorter lifespan of the cutters for application on PET and consequently a higher cost to be borne.

Finally, the process becomes difficult to replicate.

The aim of the present invention is to provide an apparatus and a method for the production and filling of containers designed to contain food that is capable of improving the background art in one or more of the aspects indicated above.

Within this aim, an object of the invention is to provide an apparatus and a method for the production and filling of containers designed to contain food that allows a reduction of maintenance costs.

Another object of the invention is to devise an apparatus and a method for the production and filling of containers designed to contain food that is extremely flexible and makes it possible to vary easily the shape of the groups of mutually connected containers and of the weakening portions.

Not the least object of the invention is to provide an apparatus and a method for the production and filling of containers designed to contain food that is highly reliable, relatively easy to provide and has competitive costs, and maintains high industrial productivity, which currently is specific to the provision of containers made of PS.

This aim, as well as these and other objects which will become more apparent hereinafter, are achieved by an apparatus and a method for the production and filling of containers designed to contain food according to the independent claims, optionally provided with one or more of the characteristics of the dependent claims.

Further characteristics and advantages of the invention will become more apparent from the description of a preferred but not exclusive embodiment of the apparatus and method for the production and filling of containers designed to contain food according to the invention, illustrated by way of non-limiting example in the accompanying drawings, wherein:.

With reference to the figures, the apparatus for the production and filling of containers designed to contain food, generally designated by the reference numeral <NUM>, comprises at least one device <NUM> for forming a sheet <NUM> made of polymeric material in order to provide a plurality of accommodation receptacles <NUM> which have at least one access opening <NUM>, at least one filling unit <NUM> adapted to fill, through the respective access opening <NUM>, the accommodation receptacles <NUM> with at least one type of food, and at least one sealing unit <NUM>, which is adapted to seal the access opening <NUM> by means of a closure film <NUM>.

According to the present invention, the apparatus <NUM> comprises at least one device <NUM> for removing a plurality of portions to be removed, and at least one laser emitter <NUM> for providing a weakening portion <NUM> at a connecting edge <NUM> between at least two adjacent accommodation receptacles <NUM>.

Conveniently, the portions to be removed comprise angular connecting portions <NUM> formed between the respective contiguous accommodation receptacles <NUM>.

The portions to be removed may also comprise lateral portions which are extended in a longitudinal direction.

In particular, the polymeric material is constituted by a material with high tenacity.

The polymeric material used is chosen in the group comprising:.

The apparatus <NUM> comprises a first section <NUM>, which accommodates the at least one filling unit <NUM>, the at least one sealing unit <NUM> and the at least one device <NUM> for removing a plurality of portions to be removed, and in particular for removing the angular connecting portions <NUM>, and a second section <NUM>, which accommodates the at least one laser emitter <NUM>.

The separation between the first section <NUM> and the second section <NUM> is ensured by a separation wall or partition which allows the crossing of the accommodation receptacles <NUM> but is capable of isolating the atmospheres in which the devices that are present respectively in the first section <NUM> and in the second section <NUM> operate.

This makes it possible to provide a region, constituted by the section <NUM>, in which there is no humidity caused by the filling and optional cleaning operations, and in which the laser emitter <NUM> can operate under optimum conditions.

The second section <NUM> is arranged downstream of the first section <NUM> with respect to the movement flow of the accommodation receptacles <NUM>.

The apparatus <NUM> is provided with a movement device <NUM> known per se for the transfer of the accommodation receptacles <NUM> along a movement direction <NUM> from the first section <NUM> to the second section <NUM>.

Such movement device <NUM>, for example constituted by belts <NUM>, is configured to transfer the containment receptacles from the forming device <NUM> to the filling unit <NUM>, to the sealing unit <NUM>, and to the device <NUM> for removing the plurality of portions to be removed, and in particular for removing the angular connecting portions <NUM>.

Advantageously, the device <NUM> for removing a plurality of angular connecting portions <NUM> comprises a die-cutting unit 5a or a punching unit 5b.

Specifically, the device <NUM> is provided with tools, constituted for example by a die-cutter or a punch, which can move on command along a working direction which is substantially perpendicular to the plane of arrangement of the angular connecting portions <NUM> to be removed, such tools being designed to penetrate within the material in order to protrude below the plane of arrangement of the angular connecting portions <NUM> to be removed, cutting and discharging downward the portions to be removed, and in particular the removed angular connecting portions <NUM> (as shown in the sectional view of <FIG>).

Advantageously, the laser emitter <NUM> emits at a wavelength that is at least partly absorbed by the polymeric material.

By way of example, it is possible to use a CO<NUM> laser with a wavelength equal to <NUM> microns, <NUM> microns or <NUM> microns. The laser emitter <NUM> is configured to provide a localized reduction of the transverse cross-section of the connecting edge <NUM> along a weakening portion <NUM>.

Localized reduction of transverse cross-section one is understood to mean a reduction of the cross-section of the connecting edge <NUM> that is substantially constant along the longitudinal extension of the weakening portion <NUM>, but also the provision of a plurality of openings which pass through the connecting edge and are mutually spaced so as to provide the weakening portion <NUM>.

Furthermore, the reduction of the cross-section along the connecting edge <NUM> may also have through openings interleaved by a constant reduction of the thickness or by reduction sequences of different thicknesses.

By way of example, the localized reduction of the transverse cross-section is at least equal to <NUM>%, preferably at least equal to <NUM>%, and even more preferably at least equal to <NUM>% with respect to the initial cross-section.

Of course, nothing forbids providing different percentages of reduction of the transverse cross-section in order to obtain a different breaking strength.

The apparatus <NUM> comprises an apparatus for separating the accommodation receptacles <NUM> into groups <NUM>.

Advantageously, respective weakening portions <NUM> are formed between the adjacent accommodation receptacles <NUM> of the same group <NUM>.

Conveniently, the thickness of the connecting edge <NUM> on which the step of providing the weakening portion <NUM> is to be performed is comprised between <NUM> microns and <NUM> microns and more preferably between <NUM> microns and <NUM> microns.

According to a preferred practical embodiment, the separation apparatus comprises a laser emitter <NUM>.

In this case, the laser emitter <NUM> or the laser emitters <NUM>, accommodated in the second section <NUM>, is or are configured to provide both the weakening portions <NUM> and the cuts <NUM> at connecting edges between the containment receptacles <NUM> in order to provide the groups <NUM>.

The apparatus <NUM> may comprise, upstream of the device <NUM> for removing a plurality of portions to be removed, a first magazine for the storage of the sealed accommodation receptacles <NUM>.

In addition, or as an alternative, the apparatus <NUM> can have, upstream of the at least one laser emitter <NUM>, a second storage magazine.

The apparatus <NUM> may furthermore have, between the first section <NUM> of the apparatus <NUM> and the second section <NUM> of the apparatus <NUM>, an intermediate storage magazine.

The storage magazines, to be understood as first storage magazine, second storage magazine and intermediate storage magazine, can be constituted by regions provided within the same environment in which the other devices of the apparatus <NUM> are arranged. Nothing forbids, in any case, locating the storage magazines within different regions which are separate from the regions in which the various devices of the apparatus <NUM> are arranged.

Furthermore, the various devices that compose the apparatus <NUM> can be located in different environments, locations or industrial buildings.

For example, the first section <NUM> and the second section <NUM> might be arranged in different industrial buildings or in regions of the same industrial building which are mutually distant.

The device for the separation of the accommodation receptacles <NUM> into groups <NUM> can be arranged in various positions along the extension of the apparatus <NUM>.

For example, the separation device can be arranged upstream of the device <NUM> for removing a plurality of portions to be removed.

In this manner it is possible to provide the groups <NUM> directly and then perform on them, by virtue of the device <NUM>, the removal of the plurality of portions to be removed and to provide the weakening portions by means of the laser emitter.

Furthermore, the device for separating the accommodation receptacles <NUM> into groups <NUM> may also be arranged between the device <NUM> and the laser emitter <NUM> in order to provide at least one weakening portion <NUM>.

Finally, as already explained, the device for separating into groups <NUM> can be arranged downstream of the laser emitter <NUM> and of the device <NUM> in order to provide the weakening portions <NUM>.

According to a further aspect, the present invention relates to a method of using the apparatus for the production and filling of containers designed to contain food, comprising:.

The portions to be removed during the removal step comprise at least respective angular connecting portions <NUM> formed between respective contiguous accommodation receptacles <NUM>.

Furthermore, the portions to be removed may also comprise lateral portions which are extended in a longitudinal direction.

The polymeric material is preferably a polymeric material with high tenacity.

Conveniently, the polymeric material is chosen from the group comprising:.

Conveniently, as regards PP, the polymeric material comprises PP in its copolymers.

Advantageously, the separation step is performed by means of a laser beam designed to perform respective cuts <NUM> at connecting edges between the containment receptacles <NUM>.

Conveniently, the thickness of the connecting edge <NUM> is comprised between <NUM> microns and <NUM> microns.

More preferably, the sheet made of polymeric material comprises a sheet made of PET which has an initial degree of crystallinity of less than or equal to <NUM>%.

Preferably, the sheet <NUM> made of PET comprises a sheet made of transparent PET.

Nothing forbids using a sheet made of transparent PP.

At the end of the method according to the invention, one obtains groups (known as multipacks) <NUM> of accommodation receptacles <NUM>; respective weakening portions <NUM> are formed between mutually adjacent accommodation receptacles <NUM> of the same group <NUM> and are adapted to allow the separation of each accommodation receptacle <NUM> from the other accommodation receptacles <NUM> of the same group <NUM>.

The use of a laser to provide the weakening portions <NUM> allows the method according to the invention to be enormously flexible, being easily programmable if the dimensions of the accommodation receptacles <NUM> or the shape of the groups <NUM> or the geometric characteristics of the weakening portions <NUM> change.

Furthermore, the method according to the invention provides for a sterilization step which is performed upstream or downstream of the thermoforming step.

The method further provides for performing, in the emission step, a step of extraction of the fumes and of the volatile substances.

This extraction step makes it possible to eliminate from the emission region the fumes, the volatile substances, but at the same time improves the efficiency of the action of the laser.

According to the present invention, it is possible to provide for the use of mass pigments and colors which remove or reduce the transparency of the finished sheet made of PET or PP and copolymers thereof.

Moreover, nothing forbids using polymeric materials, for example PET, which are recycled or partially recycled.

Nothing forbids providing for the use also of different polymeric materials with different tenacity, such as for example PS (polystyrene).

In practice it has been found that the invention achieves the intended aim and objects, providing an apparatus and a method which are extremely flexible and capable of allowing the provision of weakening portions even on containers made of particularly high-tenacity polymeric material, which allow a practical and simple mutual separation of the containers.

Furthermore, the solution found is easy to implement starting from known systems currently used to provide for example groups of containers for foods made of PS (polystyrene).

It is in fact possible to adapt the cutting assembly normally used, for example by lifting the cutters, to allow the removal of the portions to be removed, and to add downstream of the apparatus the second section <NUM> which accommodates the laser emitter <NUM> in order to obtain the apparatus <NUM> according to the invention.

The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the accompanying claims; all the details may furthermore be replaced with other technically equivalent elements.

In practice, the materials used, as long as they are compatible with the specific use, as well as the contingent shapes and dimensions, may be any according to the requirements and the state of the art.

In practice it has been found that the invention achieves the intended aim and objects, providing a method that is extremely flexible and capable of allowing the provision of weakening portions even on containers made of high-tenacity polymeric materials such as PET or PP, which allow a practical and simple mutual separation of the containers.

Claim 1:
An apparatus (<NUM>) for the production and filling of containers designed to contain food, comprising at least one device (<NUM>) for forming a sheet (<NUM>) made of polymeric material in order to provide a plurality of accommodation receptacles (<NUM>) which have at least one access opening (<NUM>), at least one filling unit (<NUM>) adapted to fill, through said access opening (<NUM>), said accommodation receptacles (<NUM>) with at least one type of food, at least one sealing unit (<NUM>) adapted to seal said access opening (<NUM>) by means of a closure film (<NUM>), at least one device (<NUM>) for removing a plurality of portions to be removed, and at least one laser emitter (<NUM>) for providing at least one weakening portion (<NUM>) at a respective connecting edge (<NUM>) between at least two adjacent accommodation receptacles (<NUM>), said polymeric material being chosen from the group comprising:
- PET (polyethylene terephthalate);
- PP (polypropylene) and copolymers thereof;
characterized in that said apparatus (<NUM>) comprises a first section (<NUM>) of the apparatus (<NUM>) which accommodates said at least one filling unit (<NUM>), said at least one sealing unit (<NUM>) and said at least one device (<NUM>) for removing a plurality of portions to be removed, and a second section (<NUM>) of the apparatus (<NUM>) which accommodates said at least one laser emitter (<NUM>), said at least one second section (<NUM>) being separate from said first section (<NUM>), wherein the separation between the first section (<NUM>) and the second section (<NUM>) is ensured by a separation wall or partition which allows the crossing of the accommodation receptacles (<NUM>) but is capable of isolating the atmospheres in which the devices that are present respectively in the first section (<NUM>) and in the second section (<NUM>) operate.