Patent ID: 12220856

In the accompanying figures, an apparatus for making a container according to this invention has been labelled1in its entirety.

It should be emphasised that this invention relates to an apparatus1for making a container2which has a bottom wall3, a plurality of lateral walls4and a perimetric flange5. Moreover, as already indicated, the container2comprises an outer skeleton6and a layer of thermoplastic material7which adheres to the inside of the outer skeleton6. In turn, the outer skeleton6made with the apparatus1according to this invention includes at least one first sheet8and one second sheet9. Both the outer skeleton6, and the layer of thermoplastic material7can be made of any material suitable for the purpose.

In some embodiments, the first sheet8and the second sheet9extend one at least at the bottom wall3and the other at least at the perimetric flange5. At least one of the two, but preferably both, also extends at the lateral walls4. The first sheet8and the second sheet9may or may not be partly superposed (for example, at the lateral walls4of the container2). Both of the sheets may in any case extend at the bottom3, at the lateral walls4and/or at the perimetric flange5.

More generally, this invention is advantageously applied for making a wide variety of different containers2. In particular, it is advantageously applied both for making containers2in which the outer skeleton6is constituted of only two sheets, and for making containers2in which the outer skeleton6is constituted of more than two sheets.

In the preferred embodiment, there are only two sheets, a first sheet8, which comprises a central portion50intended to constitute the bottom of the outer skeleton6and a plurality of first flaps51which extend outwards from the edges of the central portion50and which are intended to constitute part of the lateral walls4of the outer skeleton6, and a second sheet9which comprises an annular perimetric portion52intended to constitute the flange of the outer skeleton6and a plurality of second flaps53which extend inwards from the annular perimetric portion52and which are intended to constitute part of the lateral walls4of the outer skeleton6. The first flaps51and the second flaps53are advantageously configured to be superposed (which are on top and which are underneath depends on which, of the first sheet8or the second sheet9, is placed over the other).

However, in other embodiments there may be many other solutions. For example, it may be the case that:the first sheet8is intended to constitute only the bottom of the outer skeleton6and that the lateral walls4are intended to be constituted only of the second sheet9;the second sheet9is intended to constitute only flange of the outer skeleton6and that the lateral walls4are intended to be constituted only of the first sheet8;the outer skeleton6is constituted of more than two sheets extending concentrically, which may or may not be superposed;the outer skeleton6is constituted of more than two sheets side by side transversally to one of the main directions of extension of the outer skeleton6(length or width), which may or may not be superposed;the outer skeleton6defines protruding portions inside the container2;the outer skeleton6comprises at least one sheet which has an annular portion intended to constitute the flange of the outer skeleton6, and a plurality of third flaps which extend outwards starting from the outer edge of the annular portion and which are intended to be folded on the annular portion towards the inside of it and then be three-dimensionally formed to form the lateral walls4;the first sheet8has a plurality of fourth flaps which extend outwards starting from the outer edge of the first flaps51and which are configured to couple with the annular perimetric portion52so that with it they define the flange6. The shape and dimensions of the fourth flaps may be such that they reflect the shape of the annular perimetric portion52or such that the fourth flaps project relative to the annular perimetric portion52, or such that the annular perimetric portion52projects below the fourth flaps;the outer skeleton6comprises a second sheet9which has a plurality of fifth flaps which extend outwards starting from the outer edge of the annular perimetric portion52and which are intended to be folded on the annular portion to increase the thickness of the perimetric flange5;the outer skeleton6comprises a first sheet8which has both the fourth flaps, and a plurality of sixth flaps which extend outwards starting from an outer edge of the fourth flaps and which are intended to be folded on the fourth flaps to increase the thickness of the perimetric flange5.

Irrespective of the structure of the sheets and of the outer skeleton6, the apparatus1according to this invention in some embodiments allows the container2to be made by fixing the sheets to each other exclusively using the layer of thermoplastic material7which adheres to both.

The layer of thermoplastic material7is made by thermoforming the thermoplastic material10, advantageously on the previously three-dimensionally formed sheets, and allows the sheets to be fixed to each other to obtain the container2in this way (an example of which is shown in the detail inFIG.9). This is advantageous since it allows containers2to be made without glue starting directly with the sheets in the spread out configuration, without the need to feed to the apparatus1the already three-dimensionally formed outer skeleton6. In contrast, in some embodiments, the apparatus1is configured to fix two or more sheets to each other even using glue.

In the example embodiments shown in the accompanying figures, the outer skeleton6is of the type in which the first sheet8extends at the bottom wall3and the lateral walls4, whilst the second sheet9extends at the perimetric flange5and the lateral walls4and is partly placed over the first sheet8. Therefore, in the description below, reference will mainly be made to this preferred embodiment, but that shall not be considered limiting.

Below is first a description of the apparatus1with reference to its single-lane embodiments, such as that illustrated inFIGS.1and39. In contrast, that is followed by a description of multi-lane embodiments of the apparatus1, such as those illustrated inFIGS.40to45. In the context of this description, the definition single-lane apparatus1means an apparatus1equipped with a single line for making containers2, whilst the definition multi-lane apparatus1means an apparatus1equipped with a plurality of lines for making containers2which operate in parallel, side by side.

First, the apparatus1comprises a supporting structure11, which is preferably configured to support the other components of the apparatus1which will be described below.

Second, the apparatus1comprises at least one conveying element15which defines a housing22, in which during operation the container2is made in the ways described below, which is associated with the supporting structure11and which is movable relative to the supporting structure11along a movement path16.

The movement path16extends from an infeed station17to an outfeed station18, and along it the apparatus1has at least one first feeding station19, one second feeding station20and one thermoforming station21placed downstream of the second feeding station20. Whilst the presence of two feeding stations allows containers2to be made in which the outer skeleton6is constituted of two sheets, if the outer skeleton6is constituted of a larger number of sheets, along the movement path16the apparatus1will also be able to have further feeding stations, advantageously one for each sheet to be used. It is also possible that two or more sheets may be fed in a single feeding station, in particular if the two or more sheets are not superposed in the finished outer skeleton6.

Returning to the embodiment in which the first feeding station19and the second feeding station20are present, depending on requirements it is possible either that the first feeding station19is upstream of the second feeding station20relative to the movement path16, or that, conversely, the second feeding station20is upstream relative to the first feeding station19.

The choice of one solution or the other will depend on the need to position the first sheet8, respectively, on the outside or on the inside of the second sheet9in the finished outer skeleton6.

In the embodiments illustrated in the figures the second feeding device24is placed downstream of the first feeding device23.

In the preferred embodiments, the apparatus1comprises a movement device14which is mounted on the supporting structure11and with which the conveying element15is associated. Therefore it is the movement device14which defines the movement path16and moves the conveying element15.

In the preferred embodiments, the movement path16is straight, as shown inFIG.8, but that shall not be understood to be limiting for this invention, since the movement path16may extend in a different way, for example, with a curved trajectory.

Therefore, essentially, by following the movement path16, starting from the infeed station17we encounter, in order, the first feeding station19, the second feeding station20, the thermoforming station21and the outfeed station18. If further feeding stations are present, they too are placed upstream of the thermoforming station21.

As regards the conveying element15, in the preferred embodiments it is movable since it is associated with the movement device14which makes it move relative to the supporting structure11along the movement path16described above. In particular, the conveying element15may be movable together with the movement device14and may be fixed to the movement device14. In the embodiment illustrated, for example, the movement device14comprises two identical chains, placed parallel to and spaced apart from each other, which move in a synchronised way along a looped path. One stretch of the looped path (the upper part in the accompanying figures) defines the movement path16from the infeed station17to the outfeed station18, whilst the remaining stretch constitutes a return path from the outfeed station18to the infeed station17. In these embodiments the conveying element15is mounted across the two chains or belts.

However, in other embodiments, the movement of the conveying elements15may also be achieved in other ways, for example by means of linear motor or planar motor systems. In particular, it may even be the case that the movement device14is a magnetic levitation conveyor and that the conveying element15is configured like a magnetic levitation carriage.

Advantageously, the movement of the conveying elements15will preferably always be carried out along a looped path constituted of the movement path16and of a return path.

Moreover, in the preferred embodiments, the apparatus1comprises a plurality of conveying elements15which are advantageously positioned one after another along the movement path16(or, more in general, along the looped path). That is clearly visible in the schematic illustration inFIG.7, which uses rectangles to schematically show conveying elements15which are spaced apart from each other. However, it is possible that the conveying elements15are not spaced apart from each other along the movement path16, instead being near each other.

The housing22is advantageously shaped. In fact, in the preferred embodiments, the shape of the housing22substantially corresponds to the shape of the outer surface of the container2to be made (which is defined by the outer skeleton6of the container2since the layer of thermoplastic material7adheres on the inside). In some embodiments the housing22may even have one or more protuberances54at its bottom, to cause the formation of one or more protuberances in the bottom of the container2. Advantageously, the conveying element15comprises a shaped mould which defines the housing22and which, at the thermoforming station21, becomes part of a thermoforming device31of the apparatus1.

Moreover, the apparatus1comprises at least one first feeding device23and one second feeding device24. In general the apparatus1may comprise a plurality of feeding devices placed at respective feeding stations.

The first feeding device23is positioned at the first feeding station19, and is configured to feed, in use, the first sheet8to the conveying element15. The first feeding device23is in fact configured to insert, in use, the first sheet8into the housing22defined by the conveying element15, when the conveying element15is placed at the first feeding station19.

In contrast, the second feeding device24is positioned at the second feeding station20and is configured to feed, in use, the second sheet9to the conveying element15. The second feeding device24is in fact configured to insert, in use, the second sheet9into the housing22defined by the conveying element15, when the conveying element15is placed at the second feeding station20

In the embodiments illustrated, the second feeding device24is positioned at the second feeding station20, which is placed downstream of the first feeding station19in which the first feeding device23is positioned. Consequently, during operation, first the first sheet8is inserted into the housing22, by means of the first feeding device23, and then the second sheet9is inserted over the first sheet8, by means of the second feeding device24, and the second sheet9may or may not be at least partly superposed on the first sheet8. In contrast, in other embodiments it may be the case that the first sheet8is inserted into the housing22after the second sheet9, over it, in that case the first feeding device23will be placed downstream of the second feeding device24.

In the preferred embodiments, the apparatus1also comprises a first magazine25, which is configured to store a plurality of first sheets8, and a second magazine26, which is configured to store a plurality of second sheets9.

The first feeding device23is operatively associated with the first magazine25. In particular, the first feeding device23is configured to pick up, in use, one of the first sheets8from the first magazine25and to feed it to the conveying element15. In the preferred embodiment, the first feeding device23is at least partly a destacking device which picks up the first sheet8to be used from the first magazine25.

The second feeding device24is operatively associated with the second magazine26. In particular, the second feeding device24is configured to pick up, in use, one of the second sheets9from the second magazine26and to feed it to the conveying element15. In the preferred embodiment, the second feeding device24is also at least partly a destacking device which picks up the second sheet9to be used from the second magazine26.

In the embodiments shown in the figures, the first magazine25and the second magazine26are placed above the movement path16and are configured to house respectively the first sheets8and the second sheets9stacked on top of each other along respective stacking directions.

The first magazine25has a first releasing mouth55, made at the front and transversally to the respective stacking direction, and a first loading mouth56, made at the side and parallel to the stacking direction. The second magazine26has a second releasing mouth57, made at the front and transversally to the respective stacking direction, and a second loading mouth58, made at the side and parallel to the stacking direction.

In the preferred embodiments, the first feeding device23comprises a first transferring element27and the second feeding device24comprises a second transferring element28.

The first transferring element27is movable between a first pick-up position and a first unloading position. When the first transferring element27is in the first pick-up position, the first transferring element27is associated with the first releasing mouth55of the first magazine25for picking up, in use, one of the first sheets8from the first magazine25, and when the first transferring element27is in the first unloading position, the first transferring element27is associated with the conveying element15placed at the first feeding station19for feeding, in use, the first sheet8to the conveying element15.

The second transferring element28is movable between a second pick-up position and a second unloading position. When the second transferring element28is in the second pick-up position, the second transferring element28is associated with the second releasing mouth57of the second magazine26for picking up, in use, one of the second sheets9from the second magazine26, and when the second transferring element28is in the second unloading position, the second transferring element28is associated with the conveying element15placed at the second feeding station20for feeding, in use, the second sheet9to the conveying element15.

Moreover, both the first transferring element27and the second transferring element28are advantageously configured to retain respectively the first sheet8and the second sheet9during the movement from the respective pick-up positions to the respective unloading positions. In particular, the first transferring element27and the second transferring element28are equipped with suction means, not shown in the figures, for retaining, respectively, the first sheet8and the second sheet9.

Advantageously the suction means are placed at a first face of the first retaining element, which is configured to make contact, in use, with the first sheet8, and at a second face of the second retaining element, which is configured to make contact, in use, with the second sheet9. In more detail, the suction means may comprise one or more suction cups and may be activated when the transferring elements are in the pick-up position and deactivated when the transferring elements have inserted the respective sheets into the housing22of the conveying element15. It is possible that the suction means comprise a plurality of suction holes.

In the embodiment illustrated, the first transferring element27and the second transferring element28are movable, respectively, between the first pick-up position and the first unloading position, and between the second pick-up position and the second unloading position, according to a rotary movement around, respectively, a first axis of rotation29and a second axis of rotation30. Preferably, the rotary movement (indicated by the arrow99in the schematicFIG.7) is an oscillating movement and preferably covers the smallest angle necessary to pass from the respective pick-up positions to the respective unloading positions.

Advantageously, the first magazine25and the second magazine26are positioned in such a way that the respective stacking directions are angled, respectively, relative to the first axis of rotation29and to the second axis of rotation30, as well as relative to the sliding plane of the conveying elements15along the movement path16(horizontal in the accompanying figures). Moreover, preferably, the stacking directions are not perpendicular to that sliding plane. The first loading mouth56and the second loading mouth58are at least partly directed upwards. That is particularly advantageous both since it makes loading of the first sheets8and of the second sheets9respectively inside the first magazine25and the second magazine26easy (loading which, for example, may be performed manually by a user), and since it reduces the times necessary for feeding both the first sheet8to the conveying element15and the second sheet9to the conveying element15. However embodiments are possible in which the first magazine25and the second magazine26are positioned differently, for example in which the first magazine25and the second magazine26are positioned with the respective stacking directions perpendicular to the sliding plane.

It should be emphasised thatFIG.7is an example figure and shows the first transferring element27which is simultaneously both in the first pick-up position in which it retains the first sheet8, and in the first unloading position still retaining the first sheet8, and the second transferring element28which is simultaneously both in the second pick-up position, in which it retains the second sheet9, and in the second unloading position still retaining the second sheet9.

Moreover, advantageously, both the first transferring element27and the second transferring element28are not movable only according to the rotary movement around the respective axis of rotation. In fact, they are also movable transversally, and preferably perpendicularly, to the respective axis of rotation. The first transferring element27is movable between a first retracted position and a first extended position and a further first extended position. The second transferring element28is movable between a second retracted position and a second extended position and a further second extended position.

When the first transferring element27is in the first pick-up position, in fact, in use it is moved first towards the first magazine25(from the first retracted position to the first extended position), for picking up one of the first sheets8, and then away from the first magazine25(from the first extended position to the first retracted position), after having picked up the first sheet8. In particular, this movement is caused by a first main actuator59, advantageously linear, which is part of the first feeding device23and which is switchable between a first retracted configuration and a first extended configuration. The first main actuator59rotates with the first transferring element27between the first pick-up position and the first releasing position. In more detail, when the first transferring element27is in the first pick-up position, the movement of the first transferring element27towards the first magazine25is caused by the switching of the first main actuator59from the first retracted configuration to the first extended configuration, whilst the movement of the first transferring element27away from the first magazine25is caused by the opposite switching of the first main actuator59, from the first extended configuration to the first retracted configuration.

Second, when the first transferring element27is in the first unloading position, it is movable first towards the conveying element15(from the first retracted position to the further first extended position) for inserting the first sheet8into the housing22of that conveying element15, and then away from the conveying element15(from the further first extended position to the first retracted position), after having released the first sheet8into the housing22. This movement is again caused by the first main actuator59which is switchable between the first retracted configuration and a further first extended configuration similarly to what was described for the first pick-up position (the further first extended configuration may or may not correspond to the first extended configuration adopted in the first pick-up position).

In some embodiments, the first main actuator59has a same stroke both when the first main actuator59switches between the retracted configuration and the first extended configuration, and when the first main actuator59switches between the retracted configuration and the further first extended configuration. However, that shall not be understood as limiting for this invention, since it is possible that the first magazine25and the conveying element15are positioned differently, in such a way that the two strokes are different.

In the embodiments in which the first sheet8must be folded from a flat configuration to a three-dimensional configuration, the first transferring element27is at least partly shaped to match the housing22defined by the conveying element15in such a way as to be insertable inside the housing22retaining the first sheet8. In fact the first transferring element27is configured to be inserted into the housing22so as to insert the first sheet8into it, at the same time causing its three-dimensional forming. In fact, since the first transferring element27is at least partly shaped to match the housing22, in use they act together, respectively as a punch and a die, for deforming the first sheet8in such a way that it adopts the shape dictated by the surface of the housing22defined by the conveying element15(externally) and by the surface of the first transferring element27(internally). Therefore, advantageously, the first transferring element27is at least partly shaped to match the housing22, at least in the zones in which, in use, the first sheet8must adopt a three-dimensional configuration. In particular, the zones in which that may be required may be the zones which correspond to the bottom wall3, and/or to the lateral walls4and/or to the perimetric flange5based on which of these zones are covered by the first sheet8.

Advantageously, the first transferring element27comprises a first gripping portion60and a first shaping portion61, which are movable relative to each other, advantageously according to a translating movement. Preferably, the first gripping portion60and the first shaping portion61are movable along the direction of action of the first main actuator59(both between the first retracted configuration and the first extended configuration, and between the first retracted configuration and the further first extended configuration). In particular, the first gripping portion60is configured to pick up, in use, one of the first sheets8from the first magazine25when the first transferring element27is in the first pick-up position and to retain, in use, this first sheet8during the movement of the first transferring element27from the first pick-up position to the first unloading position, until inside the housing22. For this reason, the suction means previously mentioned are advantageously associated with the first gripping portion60of the first transferring element27. In turn, the first shaping portion61is configured to three-dimensionally form the first sheet8inside the housing22.

In the preferred embodiments, both during the movement of the first transferring element27between the first pick-up position and the first unloading position, and during the movement of the first transferring element27between the retracted position and the extended positions, the first gripping portion60and the first shaping portion61move together with each other and together they substantially define the outer surface of the first transferring element27(which is facing the first magazine25, when the first transferring element27is in the first pick-up position, and facing the conveying element15, when the first transferring element27is in the first unloading position).

Advantageously, in the embodiment illustrated, when the first transferring element27is in the first pick-up position and the first main actuator59is in the first extended configuration, the first gripping portion60is movable, relative to the first shaping portion61, further towards the first magazine25, in such a way that the first gripping portion60makes contact with one of the first sheets8contained in the first magazine, the one placed at the first releasing mouth55. Advantageously, in use, the suction means are then activated for picking up the first sheet8in this way. After having picked up the first sheet8, the first gripping portion60is moved away from the first magazine25, retaining the first sheet8, until it has returned to the starting configuration in which the first gripping portion60and the first shaping portion61together define the surface described above. However, in other embodiments it may be the case that during the sheet pick-up step, the first gripping portion60and the first shaping portion61always move together with each other.

Then, retaining the first sheet8(and therefore keeping the suction means active), the first transferring element27is moved from the first pick-up position to the first unloading position. When the first transferring element27is in the first unloading position, the first main actuator59is switched from the first retracted configuration to the further first extended configuration. When the first transferring element27is in the first unloading position and in the further first extended position, the first transferring element27is inserted inside the housing22defined by the conveying element15. Therefore the first sheet8was deformed in such a way as to adopt the shape previously described.

Then, advantageously, first the first shaping portion61is moved away from the conveying element15, in contrast keeping the first gripping portion60in contact with the first sheet8. In fact in this way it is possible to avoid the risk of the friction between the first sheet8and the first shaping portion61being able to cause an unwanted extraction of the first sheet8from the housing22. Only then, after the suction means have been deactivated, the first gripping portion60is also moved away from the conveying element15until it is re-aligned with the first shaping portion61. A solution of this type is advantageous since it allows the first transferring element27to be extracted from the housing22while avoiding also pulling out the first sheet8.

In the embodiments illustrated, the first shaping portion61is ring-shaped and at the centre defines a zone in which the first gripping portion60is positioned. Advantageously, in the embodiment illustrated, in which the first sheet8is intended to form the bottom wall3and part of the lateral walls4of the outer skeleton6, the first shaping portion61is externally configured roughly in a frustopyramidal way. In particular, the first shaping portion61comprises angled lateral walls4, which are configured to make contact with the portions of the first sheet8which define the lateral walls4of the container2, and an annular front wall, which is configured to make contact with a part of the portion of the first sheet8which defines the bottom wall3of the container2. However, as already indicated, the shape of the first transferring element27is dictated by the shape of the container2to be formed; consequently, depending on the type of container2to be formed the shapes of the first shaping portion61and of the first gripping portion60will also change.

Otherwise, when the first transferring element27does not have to three-dimensionally form the first sheet8(for example since the first sheet8defines only a flat portion of the outer skeleton6, such as the bottom or the flange) the first transferring element27does not need to be shaped to match the housing22.

In the embodiments illustrated in the accompanying figures, the first feeding device23comprises a first shaft62rotatably fixed to the supporting structure11according to the first axis of rotation29, with which, by means of a first reduction unit63, a first motor64is associated which causes its oscillation between two limit positions which correspond to the pick-up position and to the releasing position of the first transferring element27.

Two first guiding bars65are slidably associated with the first shaft62along a direction perpendicular to the first axis of rotation29, and support a first base66of the first transferring element27.

Rigidly mounted on the first shaft62is the first main actuator59which in the embodiments illustrated comprises two first fluid cylinders67, whose first jackets68are fixed to the first shaft62, and whose first pistons69are fixed to the first base66. The direction of action of the first actuator is parallel to the direction defined by the first guiding bars65.

The first shaping portion61is rigidly constrained to the first base66and moves together with it between the first retracted position and the first extended positions.

In contrast, the first gripping portion60is slidably associated with a plurality of first supporting pins70, fixed to the first base66, and which also extend parallel to the direction defined by the first guiding bars65. The first gripping portion60is therefore movable relative to the first base66and to the first shaping portion61between a first recessed position, in which it is aligned with the first shaping portion61, and a first projecting position in which it projects relative to the first shaping portion61away from the first base66. Also associated with the first supporting pins70are first springs71configured to keep or return the first gripping portion60in the first recessed position in the absence of stresses.

The shifting of the first gripping portion60from the first recessed position to the first projecting position is caused by a first secondary actuator72which is also fixed to the first shaft62. As can be seen inFIG.12, the rod73of the first secondary actuator72may interact with the first gripping portion60through a first hole74made in the first base66; however, advantageously, the rod73is not constrained to the first gripping portion60and can act on it exclusively by pushing towards the first projecting position; in contrast, the return towards the first recessed position is guaranteed by the first springs71when the action of the first secondary actuator72ceases.

Moreover, in the embodiments illustrated, the first gripping portion60comprises both a first resting plate75, and a plurality of first suction cups76connected to the suction means and fixed to the first resting plate75in such a way as to project slightly from it.

In some embodiments, the first gripping portion60may also be configured either to deform the first sheet8after having picked it up and before releasing it into the housing22, or to collect a first sheet8constituted of two or more detached parts (each of which would therefore in itself constitute a sheet) and to vary the position of those parts before releasing them into the housing22. In this case, the first gripping portion60may comprise two or more first parts77movable relative to each other in the plane perpendicular to the direction dictated by the first guiding bars65. Each first part77is equipped with retaining means for retaining the first sheet8or may be constituted of those retaining means (in this case the retaining means may be movable relative to the first resting plate75). Advantageously the retaining means may be part of the suction means and may for example be constituted of suction cups or of suction holes. One example of this type is shown inFIGS.38and39, in which the first gripping portion60comprises a fixed first resting plate75, and the retaining means comprise first suction cups76movable between a near position (FIG.39) and an apart position (FIG.38).

In the embodiments illustrated, in which the second sheet9is intended to constitute the perimetric flange5and part of the lateral walls4of the outer skeleton6, the second transferring element28has many similarities to the first transferring element27and what was described for the first transferring element27shall also be considered applicable to the second transferring element28, with the appropriate adjustments (for example substituting “first” with “second” in the naming of the various parts).

Therefore the second transferring element28can be moved by a second main actuator78, advantageously linear, which is switchable between a second retracted configuration and a second extended configuration, in the second pick-up position, and between the second retracted configuration and a further second extended configuration in the second unloading position.

Similarly to the stroke of the first main actuator59, the stroke of the second main actuator78too may or may not be the same when the second main actuator78switches between the second retracted configuration and, respectively, the second extended configuration and the further second extended configuration.

In the preferred embodiments, the second transferring element28too may advantageously be at least partly shaped to match the housing22defined by the conveying element15, at least in the zones in which, in use, the second sheet9must adopt a three-dimensional configuration as a result of the interaction between the second transferring element28and the housing22. The second transferring element28too advantageously comprises a second gripping portion79and a second shaping portion80which are movable relative to each other, similarly to the first gripping portion60and to the first shaping portion61, as well as suction means associated with the second gripping portion79. However, the second gripping portion79can be distinguished from the first gripping portion60as regards the shape which will be dictated by the need to position the suction means at a portion of the sheet to be moved.

In the preferred embodiments, both during the movement of the second transferring element28between the second pick-up position and the second unloading position, and during the movement of the second transferring element28between the second retracted position and the second extended position and the further second extended position, the second gripping portion79and the second shaping portion80move together with each other and together they substantially define the outer surface of the second transferring element28.

Advantageously, when the second transferring element28is in the second pick-up position and the second main actuator78is in the second extended configuration, the second gripping portion79is further movable, relative to the second shaping portion80, towards the second magazine26, in such a way that the second gripping portion79makes contact with one of the second sheets9contained in the second magazine26, the one placed at the second releasing mouth57. Advantageously, in use, the suction means are then activated for picking up the second sheet9in this way. After having picked up the second sheet9, the second gripping portion79is moved away from the second magazine26, retaining the second sheet9, until it has returned to the starting configuration in which the second gripping portion79and the second shaping portion together define the surface described above. However, in other embodiments it may be the case that during the sheet pick-up step, the second gripping portion79and the second shaping portion80always move together with each other.

Then, retaining the second sheet9(and therefore keeping the suction means active), the second transferring element28is moved from the second pick-up position to the second unloading position. When the second transferring element28is in the second unloading position, the second main actuator78is switched from the second retracted configuration to the further second extended configuration.

In the embodiments in which the second sheet9defines the flange of the outer skeleton6and must also be three-dimensionally formed to at least partly make the lateral walls4, the relative transferring device advantageously also comprises a clamping portion81, which is configured to couple with the conveying element15to clamp, in use, the portion of the second sheet9which defines the flange of the container2. In particular, the clamping portion81is activated to retain this portion of the second sheet9, before the second gripping portion79and the second shaping portion80are inserted inside the housing22.

In more detail, when the second transferring element28is in its releasing position, as a result of the movement of the second transferring element28from the second retracted position towards the further second extended position, the clamping portion81is movable between a home position, in which it is spaced apart from the conveying element15and, in use, does not interfere with the second sheet9retained by the second transferring element28, and an operating position in which it clamps the second sheet9against the conveying element15. In the preferred embodiment, the clamping portion81is slidably associated with the rest of the second transferring element28parallel to the second direction of switching of the second main actuator78, and there are auxiliary elastic return means82which push it towards the home position.

In general, in the embodiment illustrated in the accompanying figures, the structure of the second feeding device24reproduces that of the first feeding device23; without repeating what was described above, the second feeding device24comprises a second shaft83, a second reduction unit84, a second motor85, second guiding bars86, a second base87, the second main actuator78, a plurality of second supporting pins88, second springs89, a second secondary actuator90, a second hole91, a second resting plate92and a plurality of second suction cups93.

Moreover, in the case of the second retaining element the clamping portion81is present which in the embodiments illustrated has an annular shape, and which comprises a plurality of rods94slidably associated with sliding seats95made in the second base87. The auxiliary elastic return means82are mounted between the second base87and the clamping portion81, around the rods94, for pushing the clamping portion81outwards in the absence of stresses.

Finally, if the second sheet9has flaps which extend outwards from the portion intended to constitute the annular flange, the second feeding device24and/or the second magazine26may be equipped with a folding unit configured to fold the flaps on the flange after the second sheet9has been picked from the stack of second sheets9.

When the second transferring element28is in the second unloading position and the second main actuator78is in the further second extended configuration, the second transferring element28is inserted inside the housing22defined by the conveying element15. Therefore the second sheet9was deformed in such a way as to adopt the shape previously described, whilst its portion intended to constitute the flange remained clamped between the clamping portion81and the conveying element15.

In the embodiments illustrated, the second shaping portion80is ring-shaped like the first shaping portion61and at the centre defines a zone in which the second gripping portion79is positioned.

In some embodiments the first transferring element27and/or the second transferring element28may be configured in such a way as to cause, at the same time as insertion of the first sheet8and/or respectively of the second sheet9into the housing22, the non-simultaneous folding of different flaps of the first sheet8and/or respectively of the second sheet9, in such a way as to cause flaps even of the same sheet to be superposed.

If the apparatus1is configured to fix two sheets to each other using glue, in accordance with some embodiments advantageously it also comprises a glue application unit which may be positioned at a gluing station, between the feeding stations of the two sheets involved, and which may be configured to apply the glue on the sheet already positioned inside the housing22before insertion of the other sheet.

In contrast, in other embodiments, the apparatus1may comprise a glue application unit associated with the feeding device placed downstream for applying the glue directly on the sheet moved by that feeding device before it is inserted into the housing22.

The apparatus1also comprises a thermoforming device31, which is positioned at the thermoforming station21. The thermoforming device31is configured to thermoform, in use, the thermoplastic material10on the sheets inserted into and if necessary formed in the housing22, when the conveying element15is placed at the thermoforming station21, and in this way to make the layer of thermoplastic material7which is part of the container2. The aspects strictly linked to the thermoforming device31, like all of its possible variants, are in themselves known to an expert in the sector and therefore will not be described in detail below. For this reason, the accompanying figures do not show in detail all of the elements which are part of the thermoforming device31.

In the preferred embodiments, when it is in the thermoforming station21, the conveying element15is an integral part of the thermoforming device31, constituting its mould. Coupling with it is a closing element which is also part of the thermoforming device31. At least one of the conveying element15or the closing element is movable perpendicularly to the movement path16, between a non-operating position in which the two are spaced apart, and an operating position in which they are clamped against each other in a gas-tight way.

The apparatus1also comprises positioning means for the thermoplastic material10, which are configured to feed the thermoplastic material10to thermoforming device31, above the housing22of the conveying element15, between the conveying element15itself and the closing element.

In some embodiments the thermoplastic material10is supplied to the apparatus1in the form of a web32wound in a reel34, and the positioning means comprise reel34unwinding means33, which feed the web32to the thermoforming device31.

Moreover, the apparatus1advantageously comprises cutting units36which are configured to cut the web32. In some of these embodiments the cutting units36are configured to cut the web32before (or at the same time as) thermoforming of the thermoplastic material10on the first sheet8and on the second sheet9, by the thermoforming device31. In contrast, in other embodiments, the cutting units36are configured to cut the web32after thermoforming of the thermoplastic material10on the first sheet8and on the second sheet9, by the thermoforming device31.

Moreover, in some embodiments, the cutting units36cut the web32without interrupting the continuity of the web32itself. In this case, advantageously, the positioning means comprise a first supporting roller35for the reel34of web32being unwound, and a second motor-driven roller38on which the residual web39is wound in a new reel34after cutting. The second motor-driven roller38is also used for pulling the web32and unwinding the reel34in such a way as to gradually position the new web32necessary above the conveying element15(in contrast the first supporting roller35will advantageously be braked).

However other embodiments are possible in which, in contrast, the positioning means for the thermoplastic material10are configured to feed the thermoplastic material10to thermoforming device31, already cut into sheets. For example, similarly to what was described for the first feeding device23and for the second feeding device24and the respective magazines, the sheets of thermoplastic material10may be picked up by the positioning means from a suitable magazine. Alternatively it is possible for the sheets to be obtained in turn by cutting into pieces, without or without scrap, a web32of thermoplastic material10and for them to be fed directly to the thermoforming device31, therefore without being loaded inside a magazine.

In the embodiment shown in the figures, with the first supporting roller35and the second motor-driven roller38, the web32is made to slide relative to the thermoforming device31along a direction perpendicular to the movement path16. However, alternative embodiments are possible, in which the web32is made to slide differently relative to the thermoforming device31, for example along a direction parallel to the movement path16.

It should be emphasised that inFIG.5, the web32is shown simultaneously in the position in which it is located before the thermoforming, that is to say, with the closing element in a non-operating position and spaced apart from the conveying element15(which is the configuration effectively adopted by the apparatus1inFIG.5), and in the position in which it is located during the thermoforming, that is to say, with the closing element in an operating position and coupled with the conveying element15; when the closing element is in the non-operating position, the web32is spaced apart from the conveying element15.

In the preferred embodiments, the apparatus1also comprises an unloading device40, which is placed at the outfeed station18. The unloading device40is configured to pick up the container2made from the conveying element15at the outfeed station18. For example, the unloading device40picks up the container2from the conveying element15by means of suction: for that purpose the unloading device40may comprise further suction means, not shown in the figures, for retaining the container2. Advantageously, the unloading device40comprises a movable element41which is movable between a gripping position, in which it is associated with the conveying element15placed in the outfeed station18for picking up in use the container2from the conveying element15, and a releasing position, in which it is associated with an unloading surface43for releasing, in use, the container2onto the unloading surface43. In the embodiment illustrated, the unloading device40is capable of translating, relative to the supporting structure11, both in a vertical direction, and in a horizontal direction. In particular, in the embodiment illustrated, the movable element41is capable of translating along a first vertical guide13, which is in turn capable of translating along a second horizontal guide12. In the accompanying figures the movable element41is constituted of the rod of an actuator, whose jacket constitutes the first guide13.

The unloading surface43may be movable relative to the supporting structure11or is fixed relative to the supporting structure11. In the embodiment illustrated, the unloading surface43is constituted of a conveyor belt32which allows the containers2previously positioned on it to be moved away from the outfeed station18.

As can be seen inFIG.7, it is also possible for the unloading device40to be configured to release a container2onto the unloading surface43when other containers2are already present on it, by varying its stroke, in this case, in particular, the unloading device40may stack a plurality of containers2inside each other.

However, an expert in the sector will be capable of selecting the unloading device40best suited to the features both of the other components of the apparatus1and of the containers2made.

Finally, a printing unit for printing on the container2may be associated with the unloading device40or with the unloading surface43.

In some embodiments, the apparatus1also comprises a folding device101which is configured to fold, in use, the perimetric flange5of the container2, relative to the lateral walls4, at connecting zones between the perimetric flange5and the lateral walls4. In particular, the folding device101is configured to fold the perimetric flange5in such a way as to fold it below a top plane in which the connecting zones lie.

Such embodiments are advantageously applied in the case of a container2in which at the outfeed of the thermoforming station21(without folding devices), the perimetric flange5tends to adopt an initial configuration (shown, for example, inFIGS.46and52) in which it is angled upwards relative to the top plane, whilst in order to guarantee a better use of the container2during the sealing step it is preferable that the perimetric flange5lies substantially in the top plane. In general, the perimetric flange5tends to adopt that initial configuration when the material of which the outer skeleton6is constituted has sufficient elasticity at the connecting zones.

Therefore, thanks to the folding device101, it is possible to make the perimetric flange5adopt a final configuration (shown, for example, in FIGS.48and56) in which the perimetric flange5is positioned substantially in the top plane or nearer to it. In order to achieve that result, during folding the perimetric flange5is forced to adopt an intermediate configuration, in which it is folded below the top plane, as previously described: that is advantageous since, on one hand it eliminates part of the elasticity of the material at the connecting zones, whilst, on the other hand, the remaining elasticity tends to then make the perimetric flange5elastically return towards the final configuration.

In some embodiments, such as that shown inFIG.46to48, the folding device101is configured to fold the perimetric flange5when the container2is in the housing22defined by the conveying element15. In these embodiments, the folding device101comprises a folding element102which is movable, relative to the conveying element15, between an inactive position and an active position. When the folding element102is in the inactive position, it is uncoupled from the conveying element15. In contrast, when the folding element102is in the active position, it is coupled with the conveying element15for folding in use the perimetric flange5bringing it into the intermediate position. For that purpose, the folding element102is advantageously shaped in such a way as to fold the perimetric flange5at zones which are spaced apart from the angular zones of the perimetric flange5(advantageously that also applies for the other embodiments described below).

Preferably, the conveying element15has a first central axis104, coming out of the housing22. Advantageously, the conveying element15also has a first annular frame105which delimits the top of the housing22. In the preferred embodiments, the first annular frame105defines a first operating surface106which is at least partly angled outwards relative to the first central axis104. In particular, in those embodiments the first operating surface106preferably has a first angled portion107which forms a first angle119relative to the first central axis104. This first angle119is between 100° and 170°, preferably between 115° and 155°, and even more preferably between 125° and 145°. In the embodiment illustrated, the first angle119is equal to 135°. It should be noticed that in the context of this invention, the first angle119is measured as the smallest angle of rotation necessary in order to position the first angled portion107parallel to the first central axis104, by moving the first angle portion107according to a direction coming out of the same first angled portion107. In the figures, the first angle119therefore lies in the plane of the drawing and is measured above the first angled portion107. In particular,FIG.47shows the first central axis104at the first annular frame105to illustrate the first angle119.

Advantageously, the first operating surface106has, in addition to the first angled portion107, a first horizontal portion108.

Moreover, preferably the folding element102defines a second angled portion122and a second horizontal portion123.

In some embodiments, such as that illustrated inFIGS.46to48, the folding device101described above is constituted of the thermoforming device31. In this case, the presence of the first horizontal portion108and of the second horizontal portion123is advantageous since the coupling between these two horizontal portions108,123allows the obtainment of an optimum coupling between the folding element102and the first annular frame105facilitating thermoforming of the thermoformable material10on the outer skeleton6.

In these embodiments in which the folding element102is associated with the conveying element15, the apparatus1has, along the movement path16, a folding station100at which the folding device101is advantageously positioned. In particular, the folding station100may correspond to the thermoforming station21.

In other embodiments, such as that shown inFIGS.49to60and that shown inFIGS.61to65, the folding device101is configured to fold the perimetric flange5when the container2is in a seat110defined by an intermediate element109, after it has been extracted from the conveying element15. In these embodiments the folding device101comprises that intermediate element109, which defines the seat110for receiving in use the container2. The seat110is advantageously delimited by a second annular frame111. Moreover, the intermediate element109has a second central axis113, coming out of the seat110. In these embodiments, the second annular frame111defines a second operating surface121which is at least partly angled outwards relative to the second central axis113. Advantageously, the second operating surface121, relative to the second central axis113, forms a second angle120which is between 110° and 180°, preferably between 135° and 180°, and even more preferably between 150° and 180°. For example, in the embodiments illustrated, the second angle120is equal to 175°. It should be noticed that in the context of this invention, the second angle120is measured as the smallest angle of rotation necessary in order to position the second operating surface121parallel to the second central axis113, by moving the second operating surface121according to a direction coming out of the same second operating surface121. In the figures, the second angle120therefore lies in the plane of the drawing and is measured above the second operating surface121. In particular,FIG.52shows the second central axis113at the second annular frame111to illustrate the second angle120.

Preferably, in these embodiments the unloading device40comprises a first gripping element114. Advantageously, that first gripping element114is movable between a first extracting position (FIG.50) and an inserting position (FIGS.51and52). When the first gripping element114is in the first extracting position, it is associated with the conveying element15at the outfeed station18for picking up, in use, the container2from the housing22. In contrast, when the first gripping element114is in the inserting position, it is associated with the intermediate element109for inserting, in use, the container2into the seat110(depending on the embodiments the first gripping element114may or may not release the container into the seat110). Moreover, the folding element102is preferably associated with the unloading device40and is movable relative to the intermediate element109between an inactive position (FIGS.51and52) and an active position (FIGS.53and54). When the folding element102is in the inactive position, it is uncoupled from the intermediate element109. In contrast, when the folding element102is in the active position, it is coupled with the intermediate element109for folding in use the perimetric flange5.

In the embodiments illustrated, the folding element102is associated with the first gripping element114and is advantageously movable relative to the first gripping element114, according to a direction of movement103parallel to the second central axis113, from the inactive position to the active position when the first gripping element114is in the inserting position (as can be seen in Figures from51,53and55).

Moreover, the first gripping element114comprises a first member124and a second member125which are movable relative to each other. In these embodiments, the folding element102is advantageously coupled together with the first member124, whilst the second member125comprises gripping members126. Advantageously, the gripping members126are suction cups connected to a pneumatic circuit for retaining the container2by suction (the pneumatic circuit is not shown in the accompanying figures). However the aspects linked to the gripping members126shall not be understood as limiting for this invention and, in any case, they are known to an expert in the sector.

Advantageously, the first gripping element114also comprises at least one elastic element127and at least one rigid element128which are at least partly interposed between the first member124and the second member125and which are configured to connect those two members124,125to each other.

In particular, the rigid element128advantageously comprises a main body129and a locking portion130(FIG.60). The main body129extends between a first end131, which is fixed to the first member124in such a way that the rigid element128is movable together with the same first member124, and a second end132, which has the locking portion130. In more detail, made in the second member125there is a through hole into which the rigid element128is slidably inserted with the locking portion130projecting outside the through hole in such a way as to prevent the rigid element128from slipping out of the second member125during the movement of the first member124and the second member125relative to each other. Advantageously, the first gripping element114comprises a plurality of rigid elements128and made in the second member125there is a plurality of through holes, with each of the rigid elements128being inserted into a respective through hole. Each rigid element128is advantageously a pin.

The elastic element127advantageously extends between a third end133, which abuts against a surface of the first member124which is directed towards the second member125, and a fourth end134, which abuts against a surface of the second member125which is directed towards the first member124. In the embodiments illustrated, the elastic element127is positioned around the rigid element128. The elastic element127is configured to vary its configuration, between an extended configuration and a compressed configuration, during the movement of the first member124relative to the second member125, as described in detail below.

Preferably, the first gripping element114comprises a plurality of elastic elements127, advantageously one for each rigid element128. Each elastic element127is advantageously a spring (for example, a compression spring). When the first gripping element114reaches the inserting position, the elastic element127is initially in the extended configuration and the second member125abuts against the locking portion130of the rigid element128(in the figures it abuts against an annular element135interposed between the locking portion130and the second member125), as shown inFIGS.51and52. Then, with the first gripping element114remaining in the inserting position, the first member124is moved towards the intermediate element109: this movement of the first member124causes both the movement of the closing element102from the inactive position to the active position (since the closing element102is coupled together with the first member124), and the variation of the configuration of the elastic element127from the extended configuration to the compressed configuration (FIGS.53and54). After the folding, the first member124is moved away from the intermediate element110: this movement of the first member124causes both the movement of the closing element102from the active position to the inactive position and the variation of the configuration of the elastic element127from the compressed configuration to the extended configuration (FIGS.55and56).

The presence of the elastic element127(of the elastic elements127) and of the rigid element128(of the rigid elements128) therefore allows the movement of the first member124(and of the folding element102) relative to the second member125, as a whole keeping the first gripping element114in the inserting position with the gripping members126associated with the intermediate element109.

In some embodiments, such as that shown inFIGS.49to60, the first gripping element114is also movable between the inserting position (FIG.55) and a first uncoupling position (FIG.58). When the first gripping element114is in the inserting position, it is associated with the intermediate element109for picking up, in use, the container2from the seat110(it is also possible that it never released the container there). In contrast, when the first gripping element114is in the first uncoupling position, it is associated with a placing surface116for releasing, in use, the container2onto the same placing surface116.

In other embodiments, like that shown inFIGS.61to65, the unloading device40also comprises a second gripping element118which is movable between a second extracting position (FIG.63) and a second uncoupling position (FIG.64). When the second gripping element118is in the second extracting position, it is associated with the intermediate element109for picking up, in use, the container2from the seat110. In contrast, when the second gripping element118is in the second uncoupling position, it is coupled with a placing surface116to release the container2onto the placing surface116.

Preferably, the two gripping elements114,118are movable in a coordinated way and advantageously rigidly connected to each other, in such a way that when the first gripping element114is in the first extracting position, the second gripping element118is in the second extracting position, and when the first gripping element114is in the inserting position the second gripping element118is in the second uncoupling position, as well as in such a way that the shifts between those positions occur simultaneously as illustrated in the accompanying figures.

In these embodiments which comprise the two gripping elements114,118, the folding element102is associated with the first gripping element114(as previously described for the other embodiments and as shown in the accompanying figures) or with the second gripping element118(embodiment not shown in the figures).

If the folding element102is associated with the first gripping element114, the folding element102is advantageously movable relative to the first gripping element114, according to a direction of movement103parallel to the second central axis113, from the inactive position to the active position, for folding the perimetric flange5, when the first gripping element114is in the inserting position.

In contrast, if the folding element102is associated with the second gripping element118, the folding element102is advantageously movable relative to the second gripping element118, according to the direction of movement103parallel to the second central axis113, from the inactive position to the active position for folding the perimetric flange5, when the second gripping element118is in the second extracting position. In this case it is possible that what was described for the first gripping element114may be applied for the second gripping element118(and not for the first gripping element114). That means that the second gripping element118comprises the first member124, the second member125, the elastic elements127and the rigid elements128. In other words, the structure of the gripping elements114,118may be inverted compared with what is illustrated in the accompanying figures.

In these embodiments it is possible that the folding of the perimetric flange5occurs, when the container2is in the seat110of the intermediate element109, either by means of the folding element102associated with the first gripping element114or by means of the folding element102associated with the second gripping element118, with the folding element102preferably being movable along the direction of movement103parallel to the second central axis113.

This embodiment, in which the folding element102is associated with one of either the first gripping element114or the second gripping element118, allows an increase in the productivity of the apparatus1by separating the respective movements of the container2from the conveying element15to the intermediate element110and from the intermediate element110to the placing surface116.

In fact, as can be clearly seen inFIGS.64and65, during the movement of the container2from the conveying element15to the intermediate element110, performed by the first gripping element114, the second gripping element118moves the container from the intermediate element110to the unloading surface116.

If required in order to make the finished container, it is also the case that one or more of the second transferring element28, the thermoforming device31and the folding element102(if present) is equipped with one or more heating elements configured to heat localised zones of the various sheets which constitute the outer skeleton6.

In some embodiments, downstream of the thermoforming device31, the apparatus may also comprise a padding station at which a pad is applied to the bottom wall3(for example an absorbent pad if the container2is intended to contain meat). Since padding stations are in themselves known to experts in the sector it will not be described any further herein.

Below is a description of the apparatus1with reference to multi-lane embodiments, several examples of which are shown inFIGS.40to43. It should be emphasised that what was previously described for the various components of the single-lane apparatus1, and which may be applied to the multi-lane embodiments of the apparatus1, will not be described again below. First, the multi-lane apparatus1comprises a group44of conveying elements15, each of which defines a housing22.

The conveying elements15of the group44are movable in a way coordinated with each other relative to the supporting structure11, each along a respective movement path16which extends between a respective infeed station17and a respective outfeed station18, and along which there are present, at least one respective first feeding station19, one respective second feeding station20and one respective thermoforming station21(or multiple feeding stations if multiple sheets are used as previously described). In this case too, the movement of the conveying elements15may occur thanks to one or more movement devices14of the type described above. In the preferred embodiments, the movement paths16of all of the conveying elements15of the group44are parallel to each other, and the conveying elements15are side by side along a direction perpendicular to the movement paths16. Moreover, advantageously, the movement paths16are straight, but that shall not be understood to be limiting for this invention, since the movement paths16may extend in a different way, for example, with a curved trajectory.

In the embodiments shown inFIGS.40to42, the conveying elements15are part of a single body, are side by side and are movable together with each other. The respective housings22are made in the single body defined above. If the conveying elements15are part of a single body, their movement is advantageously caused by a single movement device14.

Moreover, preferably, similarly to what was described for the single-lane version in which the apparatus1advantageously comprises a plurality of conveying elements15, the multi-lane apparatus1advantageously comprises a plurality of groups44of conveying elements15. The conveying elements15of each group44are side by side perpendicularly to the movement paths16, whilst the different groups44are distributed along the movement paths16or, more generally, along the looped paths. In other words, whilst in the single-lane apparatus1a succession of conveying elements15moves along the movement path16, in the multi-lane apparatus1a succession of groups44of conveying elements15moves along the movement paths16. In the embodiments illustrated, the groups44of conveying elements15are advantageously movable simultaneously with each other.

In the embodiments illustrated, each group44of conveying elements15comprises conveying elements15which are part of a single body. That means that the conveying elements15of a same group44are movable in a way coordinated with each other and, in particular, are movable together with each other. The embodiment ofFIG.43shows ten groups44of conveying elements15: a first half of these groups44is located in the upper part of the respective looped paths (that is to say, in the movement path16) and is moved in the direction indicated by the arrow98(towards the right in the figure), whilst the other half of these groups44is located on a lower part of the respective looped paths (that is to say, in the return path) and is moved in the direction indicated by the respective arrow97(towards the left in the figure).

The apparatus1also comprises a plurality of first feeding devices23and a plurality of second feeding devices24.

Each of the first feeding devices23is positioned at a different first feeding station19and is configured to feed, in use, the first sheet8to a different conveying element15and to insert, in use, the first sheet8into the respective housing22when the conveying element15is placed at the respective first feeding station19.

Similarly, each of the second feeding devices24is positioned at a different second feeding station20and is configured to feed, in use, the second sheet9to a different conveying element15and to insert, in use, the second sheet9over the first sheet8, into the respective housing22, when the conveying element15is placed at the respective second feeding station20.

Both the first feeding devices23, and the second feeding devices24are associated one with each movement path16, in such a way that, along each movement path16, only one first feeding device23and only one second feeding device24acts on each conveying element15.

Therefore, as a whole, present along the movement paths16there is a plurality of first feeding stations19, at each of which only one first feeding device23is positioned, and a plurality of second feeding stations20, at each of which only one second feeding device24is positioned.

In some embodiments, the first feeding stations19are distributed, in terms of positioning, into a plurality of first feeding zones45which are separate from each other. The first feeding devices23of the first feeding stations19placed in a same first feeding zone45are side by side along a direction perpendicular to the movement paths16and are advantageously configured to operate in a synchronised way.

In particular, the first feeding stations19, at each of which a different first feeding device23is positioned, are distributed into the first feeding zones45in such a way that two first feeding stations19which are present along two adjacent movement paths16, are positioned, respectively, in two separate first feeding zones45. As will become clear from the following description, the distribution of the first feeding stations19into separate feeding zones is particularly advantageous when the first sheet8has a width greater than the outer skeleton6, as in the cases illustrated in the accompanying figures. In this case too, insertion of the first sheet8may occur either upstream, or downstream, of insertion of the second sheet9into the housing22.

More specifically, in the preferred embodiments, as shown for example inFIGS.40to42, there are preferably two separate first feeding zones45. In these embodiments the first feeding stations19are grouped relative to each other in such a way that two first feeding stations19positioned along adjacent movement paths16, are part, respectively, one of one of the two first feeding zones45and the other of the other of the two first feeding zones45. That means that the first feeding stations19are grouped in such a way as to be positioned in a staggered arrangement on two rows.

More generally, given a number N of first feeding zones45, it is advantageously the case that the first feeding stations19are distributed between them in a regular fashion, that is to say, in such a way that, when the group44of conveying elements15is located in one of the first feeding zones45, interposed between each pair of conveying elements15which at that moment are located in respective adjacent first feeding stations19there are N−1 conveying elements15whose first feeding stations19are placed in other feeding zones.

If the first feeding stations19are grouped in two separate first feeding zones45, in the ways indicated above, advantageously, as in the embodiments illustrated in the accompanying figures, two conveying elements15which are adjacent have a distance D1between the respective centres, measured perpendicularly to the movement paths16, such that double said distance D1is less than the total of the widths of the first sheets8which the respective first feeding devices23are configured to feed to those conveying elements15. When the respective first feeding devices23are configured to feed first sheets8which are identical to each other, that condition may be more simply expressed by saying that the distance D1between the respective centres is less than the width of a first sheet8.

In this way the conveying elements15of the group44may be transversally drawn near. Much more so than would be dictated by the dimensions of the first sheets8if simultaneously feeding all of the first sheets8to all of the conveying elements15of the group44.

However, it is also possible to set a lower limit for drawing near, given that preferably there must not be any superposing of the first sheets8which are inserted into the respective housings22at the same first feeding zone45. That limit may be expressed by saying that the distance D2between the centres of two conveying elements15which, in a same first feeding zone45are located at respective adjacent first feeding stations19, again measured perpendicularly to the movement paths16, must be greater than or equal to half of the total of the widths of the first sheets8which the respective first feeding devices23are configured to feed to those conveying elements15. In the context of this description, the definition “adjacent feeding stations” with reference to a feeding zone indicates two feeding stations which are both active in the feeding zone and between which no other feeding station is interposed.

This aspect is shown both in the left-hand configuration ofFIG.44, in which double the distance is equal to the width of the first sheet8(the two first sheets8are identical), and in the right-hand configuration ofFIG.44, in which double the distance between the first centre46and the second centre47is greater than the width of the first sheet8. In contrast, the central configuration ofFIG.44shows the case in which the condition indicated above is not satisfied and the two first sheets8are partly superposed (the superposed area is highlighted with angled hatching).

Transversally drawing near the conveying elements15is advantageous since it allows a smaller quantity of thermoplastic material10to be used. In fact, if the first feeding devices23were grouped in a single first feeding zone45, the adjacent conveying elements15would have to be spaced apart from each other in such a way as to make the distance between the centres of two adjacent conveying elements15greater than or equal to the width of the first sheet8. In more detail, conveying elements15close to each other, as well as allowing a reduction in the transversal dimensions of the apparatus1, allow a smaller quantity of thermoplastic material10to be used during thermoforming of the thermoplastic material10in the embodiments in which the thermoplastic material10is cut from a web32whose residual component is then recovered (it does not apply if the thermoplastic material10is fed to the apparatus1already in sheets pre-cut to size).

In any case, in other embodiments which are not illustrated in the figures, the first feeding stations19may be grouped relative to each other in a single first feeding zone45. In this case, in the first feeding zone45the first feeding devices23, each of which is positioned at a different first feeding station19, are side by side perpendicularly to the movement paths16.

Moreover, preferably, even the positioning of the second feeding stations20may occur in any of the ways described for the first feeding stations19.

In the preferred embodiments shown in the figures, in which the second sheet9has a width equal to that of the container2and of the housing22, the second feeding stations20are grouped relative to each other in a single second feeding zone48, and the second feeding devices24in the second feeding zone48are side by side perpendicularly to the movement paths16. That is advantageous since it allows a reduction in the space occupied by the second feeding devices24parallel to the movement paths16and makes the apparatus1more compact. This solution is applicable both if the first feeding stations19are grouped in a single first feeding zone45, and if the first feeding stations19are grouped in separate first feeding zones45. In particular, in the embodiments in which the first feeding stations19are grouped in more than one first feeding zone45, the single second feeding zone48may be positioned downstream or upstream of all of the first feeding zones45(downstream in the accompanying figures) depending which sheet must be inserted into the housing22first.

In contrast, in other embodiments, the second feeding stations20may also be distributed relative to each other into a plurality of separate second feeding zones48, similarly to what was described above for the first feeding zones45.

Similar assessments about the distribution into different feeding zones also apply for any other type of feeding station present in the apparatus1(third feeding stations, fourth feeding stations, etc.).

Moreover, the apparatus1comprises a plurality of thermoforming devices31, each positioned at a different thermoforming station21, that is to say, at a thermoforming station21placed along a different movement path16. Each of the thermoforming devices31is configured to thermoform, in use, the thermoplastic material10on the sheets which are inserted into the housing22of a respective different conveying element15placed at the respective thermoforming station21, and in this way to make the layer of thermoplastic material7of the container2. As shown inFIGS.40to42, similarly to what was described for the first feeding devices23and for the second feeding devices24, as a whole the movement paths16have a plurality of thermoforming stations21, and positioned at each of these thermoforming stations21there is a single thermoforming device31.

In the preferred embodiments, the thermoforming stations21are grouped relative to each other in a single thermoforming zone49. In this way, the different thermoforming stations21are side by side perpendicularly to the movement paths16. Moreover, advantageously, the thermoforming devices31are part of a single multi-chamber thermoforming unit, of which each thermoforming device31constitutes one chamber. The thermoforming devices31may share the system for creating the vacuum or for generating an overpressure.

However, in other embodiments, the thermoforming stations21may be distributed into a plurality of thermoforming zones49which are separate from each other.

In the preferred embodiments, the conveying elements15which are part of each of the groups44, the first feeding devices23, the second feeding devices24, any nth feeding devices and the thermoforming devices31are present in equal numbers to each other. In particular, the conveying elements15which are part of a same group44, the first feeding devices23, the second feeding devices24and the thermoforming devices31are four in number in the embodiment ofFIG.40, five in the embodiment ofFIG.41and ten in the embodiment ofFIG.42.

However, that shall not be understood as limiting for this invention, since it is possible that the number of conveying elements15which are part of a same conveying group44, the number of first feeding devices23, the number of second feeding devices24and the number of thermoforming devices31may differ from each other.

This invention brings important advantages.

In fact, thanks to this invention, it was possible to provide a new apparatus which allows a container to be made whose outer skeleton comprises at least two separate sheets, without the need to three-dimensionally form the sheets and constrain them to each other in advance.

Furthermore, thanks to this invention it is possible to make an apparatus which allows simplification of the operations for making a container whose outer skeleton comprises at least two separate sheets starting with the sheets which are in the spread out configuration and separate.

Not least, thanks to the different embodiments of this invention, it was possible to provide an apparatus which allows a container to be made whose outer skeleton comprises at least two sheets which are partly superposed. Additionally, thanks to the different embodiments of this invention, it was possible to provide an apparatus which allows a container to be made whose outer skeleton comprises at least two sheets which are fixed to each other either by means of glue or exclusively by the layer of thermoplastic material which adheres to both.

Finally, it should be noticed that this invention is relatively easy to produce and that even the cost linked to implementing the invention is not very high. The invention described above may be modified and adapted in several ways without thereby departing from the scope of the inventive concept.

All details may be substituted with other technically equivalent elements and the materials used, as well as the shapes and dimensions of the various components, may vary according to requirements.