CA2056395A1 - Method and apparatus for the fabrication of 3-dimensional blanks - Google Patents

Abstract

ABSTRACT

The invention relates to a method and apparatus for fabrication of 3-dimensional blanks for encasing articles, particular chocolate novelties. The apparatus uses a first pressing station for subdividing a sheet into multiple moulds and a second station for forming final moulds coinciding with the multiple moulds. The stations have clamping members for ensuring accurate registration of the moulds.

Description

WO 90/14g93 P(~/AU90/00227 The present invention relates to a method and apparatus for the fab~ication of 3 dimensional blan*~ for ~he pac:kaging of ar~cles and is par'dcularly, although not ~xclusively, directed to a method and apparatus for fabnca~on of 3 dimensional blanl~ for ~he mould;ng of foil enca~ed ar~des.
In the prior art hollow chocolate eggs, rabbits and o~her novellies are n~de us~g 3 dimensional foil blanks. These bl~s are cut into sheets when fo~med and contain a plurali~r of moulds. l~ese moulds are usually located transverse to the lon~tudinal direc~on of the conveying direction and m~y contain two rows of moulds. The shaped blanks form one h~lf of a mould for producing the hollow novel~des.
Each mould i~ formed by a pressing opera'don where a condnuous leng~
of foil passes through male and female dies. The shape of the dies is impressed into the foil to achieve each. ~dimension~l mould shape.
Once pressed the dies are opened and the foil advanced to shape the next mould. The foil is then cut to size e.g~ 5 moulds per sheet. Each sheet is placed in a spinning frame mated with a corresponding sheet ant chocolate inserted. When spun the chocolate inside the c~opera~ng moulds will form a hollow ar~cle encased in foil~
The problems ~nth the prior art are numerous. As a single press operation is used only one ~ype of shaped mould can be fabricated in a production run. If the foil tears the production line is halted with significant down time and wastage of the foil. As 'che foil is prep~ted t~ c;an be an expensive e3cerc~se. The stamping procedure is very slow and prone to pinholing of the ~ormed bl~
Alignment of the prep~ted foil with the shape fo~g moulds is not ex~ct with this proce~s and can result in slight drif~ng of the patterns.
It is an object of th~ present i:nYention to alleviate the abovementioned problems to produce a more cons~stent blank.
A fur~er object of l~e present invention is to provide an increase in the speed of produc~on of the blanlcs over the prior art.

, wo go/149~3 pc~r/Aul3o/no ~ 2 - ~5~;3~5 A still h~rth~ objeet of the invention is to provide a method and machine for forming mul~ple blanks at a pre~sing station.
With these objects in new the present invention ~ one aspect provides a method for producing 3 dimensional bl~cs containing a 5 plurality of moulds 1mpressed Ul a sheet material, ~d methad in~uding the steps of:-(i) clamping said ~heet;
(ii) fo~r~ing a first plurali~y of mould impressions ill said ~lamped 3heet at a ~ t 5tation to subdivide said sheet;
(iii3 moYirlg ~aid subdivided sheet to a second station;
~iv) clamping said stlbdivided sheet at said second sta~on;
(v) fo~g at least one set of final mould impressions coinci&g with said first plurality of mould impre~sions.
I~ a ~er a~pe~ of the invention ~ere ;8 provided an apparatus for producing 3 dimensional blarlks cont~g a plurality of moulds impres~ed in a sheet material, said apparatus ~c~luding a plurali~r of sequentialI~r arran~ed sta~on~ for form:ing said moulds; a first s~ation includin~ ~heet clarnping means and means for subdividin~ said sheet into a plurality of f~st :mould impressions, a second stativn including sheet ~lamping mean~ and a pair of c~operating complementary dies for forming final mould impressions coinciding with said plurality of first mould impressiorls.
- 25 - The above and other objects, features and advantages of the present inven~on will become apparent ~om the eIlSDg detailed description of preferTed em~odiments the~eof, which is to be considered in conjunction wi~ the accomparlying drawings, in which:-Fig. 1 is a side view of a first embodiment of ma~hine for the fabrica'don of 3 dimension~l blanks made in accordance with the inven~on;
Fig. 2 i~ a plan ~riew of the ~chine ~hown in Fig. 1 w~th the stations removed f~om the ma~hine;

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wo go/14993 Pcr/Au9o/oo227 3 2~5~i39~;;
- Fig. 3 is a cross-sectional view along and in the direction of arrows ~3 of Fig. 1 of a first station for subdividing a sheet with a first set of mould impressions;
Fig. 4 is a simil~r view to that of Fig. 3 ~howing the station in its closed position;
Fig. 5 is a cross-3ectional view along and irl the direction of arrows 5-5 of Fig. 4;
Fig. 6 is a perspective view of the blank as formed at the first station;
Fig. 7 is a cros~sec~onal view along and in the directisn of arrows 7-7 of Fig. 1 of a second staffon for further subdividing a sheet with a second set o mould impressions;
Fig. 8 is a cross-sec~onal view along and in the direction of arrows ~8 of Fig. 7 of the second station;
Fig. 9 is a ~oss~ectional ~2W along and in ~e direction of arTows 9-9 Fig. 8 of ~e second station;
Fig. 10 is a perspective vi~ of the blanlc as formed at the second station;
Fig. 11 s a cross-sectional view along and in the di~ection of . .
arrows 11-11 of Fig. 2 s)f a third sta'don;
Fig. 12 is a similar ~iew to that of Pig. 11 showing ~e third sta'don ~ its ~losed position;
Fig. 13 i~ a cros~sec~onal view along and in the direction of arrows 13^13 of Fig. 12 of the third sh'don;
Fig. 14 ~s a cro~e~onal view along and in the direction of arrows 1~14 of Fig. 2 of a fo~ station;
Fig. 15 is a cross-sec'don~l view along and in ~e direction of arrows 1~15 of Fig. 2 of a fifth station;
Fig. 16 is a view similar to Fig. 3 showing an alternative embo&ent for the opera'don of ~e various stations shown in Figs. 1 to 15;
Pig, 17 is a simil~ view to ~at of Fig. 6 showing a variation of the mould shape; and WO 90/14993 P~l'/AU90/00227 4 Z~5~3~35 Fig. 18 is the final bl~c fabricated by the machine shown ln Figs 1 to 16 using the blank in Fig. 17.
Turning to E~igs. 1 to 15 there is shown a machine 20 for form~ng ~dimer sional b1anlcs from a sheet material. ~e machine 5 ~ncludes two of~set endless chain conveyors :22,. 24 which are driven by sprockets 26 through motors (not shown~. The conveyors are controlled by a controller (not showrl~ to move the chains in an intermittent manner through the various statio~s to be des~ibed. A pl~Lrality of trays 28 are pivotally att~ched at diagonal corners 30, 32 to conveyors 22, 10 24 to provide horizontal movement of trays 28. I~e offset nature of conveyors 22, 24 will always maintain trays 28 in the horizontal disposi~don. In the embodiment il~ustrated each tray 28 is subdivided into two smaller ~ays 34, 36 to pronde a dual in-~ine fabrica'don machine. I~ ear that a s~n~le tray or multiple tr~y ~y5~em can be 15 used depending on req~ements. Each tray 3~, 36 is basically formed as a peripheral reetangular ~ame of L~haped Cro5~YeCtion. A lower ledge 38 (Fig. 3) supports a template 40 to ~o~m the base of trays 34, 36.
The machine 20 requires sheets 42 of material for placing in trays 34, 36. These sheets ~re usually formed ~om a preprinted.
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20 aluminium foil. Such foils ca~ include other material or be incorporated in a l~minate. Pref~ed m~terial~ to be used incllude alwninium foil wit~ a food ~rade v~sh and a three lay~ l~minate comprising an outer layer of polypropylene, a nuddle l~yer of aluminium foil and an inner layer of polyethylene. T~e sheets 42 can be provided ~ a stack 25 (not shown) or can be cut by the machine. ~ the embodiment illustrated a roll 4~ of sheet material is run over rollers 46 to stra~ghten the material and ~ then cut to length by a cutter 48. The cut sheets 42 are placed in trays 34, 36 for mould impressing.
The sheets are ~en transported sequen~lly through the 30 machine ~rough SL'C s~ations 50, 52, 54, 56 58 and ~0.
5ta~on 50 prondes an iniffal subdivision o~ sheet ~ into preliminary moulds a~ shown in Fig. 6. Fig. 6 shows that sheet 42 has been formed into three langitudin21 moulds 6~ r sta'don 50. It is to be WO 90/14993 ~'Cr/~U~O/~)0227 - 5 - 2~ ;3~
noted that the n~nber of moulcls ean vary depending on requirements.
Station 50 includes an outer support frame 64 f~om which depends a stationary box frame 66 having a divid~ 68 intermediate its length.
Secured to divider 68 is a ~iasing means 70, preferably pneumatically 5 controlled or spring tensioned, with a piston rod 72 passing ~rough an aperture in divider 68. In an especially preferred embodiment biasing means 70 is an air spring. Piston rod 72 is attached to a plate member 74 ha~g two long~tudin~l parallel depending dividers 76; 78. Each divider 76, 78 t~tes in a roller ~0. Dividers 76, 78 form a telescopic 10 rela~onship ~vith box ~ame 66. C:en~ally locatecl along plate member 74 is a pair of parallel flarlges 82 which cons~ain a longitudinal cl~mphg member 84. Clamping member is spring loaded by spr~ngs 86 and terminates with a bumper 88.
The movable part of statisn 50 comprises a base member 90 15 on which are mountecl male moulds 92. T~e moulcls 92 are separated by gaps 94 which gap~ are aligned with di~iders 76, 78. Base member 90 is attached to a r~proca~ng piston 96. Mould~ 92 can, ~n use, protrude through ap~tures 98 of te~plate 40.
~ operahon, ~e ini~ position is sh~wn in Fig, 3~ Moulds 20 92 are moved upwardly by piston g6 throu~h template ~0 to contact sheet 42. Fur~er upward m~vement of pi~ton 96 raise3 sheet 42 as moulds ~2 protrude through the te~pL~te un~l template 40 rests on base member 90. Sheet 42 will contact bumper 88 tc7 clamp sheet ~ to the central mould. As ~lamping member 84 is spnng loaded a con~nuous 25 clamping pressure will be maintained preventing any slippage of sheet 42. Further movement results in di~iders 76, 78 ent~g gaps 94 to draw sheet 42 i~wardly between the gaps and form the central mould.
Rollers 80 will assist in preven~ng any nipping or tearing of sheet 42.
Sheet 42 will be simultaneously drawn over the outennost moulds 92.
30 Rollers 80 wDl abut template ~0 and form a flattened area which subdivides the moulds ormed in t~e sheet. Fur~er upward msvement of piston 96 forces the free ends of box ~ame 66 to contact te~plate 40 to finali~e the moulding of sheet 42. I~is posi~on is shown in Fig. 4.

wo 90/ 1 4g93 rcl /A U~0/00227 - 6 ~ i$3~5 Fig. 4 shows that ~le moulds 92 have impressed into sheet ~2 the mould shapes shown in Fig. 6. It will be noted that the height of the moulds 62 formed in sheet 42 can be vaned by chan~g the thickness of templ~te 40. The fo~ on of moulds 62 is from the ce:ntre and outwardly therefrom m opposing direc~ons. This results ~n less s~ess being applied to sheet 42 and a uni~o~m movement of the sheet over moulds 92. C)nce moulds 62 have been formed the procedure is reversed. Tray 28 is then moved to .~tation 520 Station 52 is very simil~r to ~ta'don 50 and s~ integers have been referenced with the same re~erence nu~nerals anc~ an "A"
suffix. The differences are tha~ male moulds 92 have been subdivided transversely to ~rm S~teen (15) male moulds 92A i.e. a grid of 5 x 3.
Again it must be emphasized ~at the grid can be increased or decreased depending on requirements. From Figs. 7 and 8 it is shown that dividers 76A, 78A are transverse to the dire ~ on of dividers 76, 78 of station 50. To provlde ~he Dncrease in subcUv~on, ~urther din ders 100, 102 depend fro m plate m e m ber 104. Plate m ernber 104 is supported by trvo biashng m ealls 106, 108 s~oL~ar to b ~ g m eauns 70 of sta~on S0.
Fig. 8 clearly sho ws ~he telescopic ruature of the dividers 76A, 78A, 100, 102 ~ th box fra m e 66A. As wi~h stabion 50 ~he ~ er di~iders 100, 102 terrnunate wl~h ro~ers 110. Wrng~ets 112 aIe atta~hed to the free ends of box fraIne 66A aund d~vider~ 76A, 78A, 1 W, 102 amd are a~ned ~nth the ng~budin~l gaps formed betwee~ mould~ 62 sho~m Dn Fig. 6. llhe winglets will assist in location and guida~ce o~ the dinders in further subdivision of sheet 42.
Operation of station 52 is idenl:ical- to that de~cribed in relation to station 50. Again, the ~elescopic na~ure of ~he dinders allows for a smooth sequen~al subdivision of moulds 62 into the moulds 114 as shown in Fig. 10. The moulds 114 are formed from the centre and outwardly ~ere~om in opposing directions.
The furthe~ subdivided ~heet ~ is passed through to station 54. Stativn 54 is very ~imilar to st~ion~ 50 and 52 arld similar reference numerals have been used ~or ~imilar inte~ with the sufflx "B/'. The WO 90/149~3 pc~-r/A U9~/00227 ~?5~i3~i differences between station 52 and station 54 are that male moulds 92B
are shaped with almost ~e final desired shape. Div~ders 76A, 78A, 100 and 102 have ~een replaced by the feD~le moulds 115 and clamping member 8BA has been replaced by a female mould 118. Additional 5 female moulds 120 are also secured to the inner waLls of box frame 66B.
As ean be seen in Fig. 11 the mQulds 116, 118 and 120 are solid and telescopic in nature and operated in a similar m~nner as ~e dividers in station 50, 52. Fig 14 shows the completion of the formation of the almost completed mould shapes. Sheet ~ then moves to sta~on 56.
Station 56 impre~se~ the final mould shapes into sheet ~.
Si~r reference mlmeTals have been used for similar integer3 with a SllffK of "C'~. As this is the final shaping process fem~le moulds 116, 118 and 120 are replaced by a heated female r~ould 122. Mo~d 122 is secured to dinder 68C by an insulation heat bar~ 124. With ~he applied pressure and heat a s'dff~g of the sheet will occlLr. If the sheet i8 the laminate of polypropylenelaluminium foiVpolye~hylene the hea'dng will soften the polyethylene to form a series of moulds in ~heet ~2.
Station 58 is optional and is a cufflng sta~don. Blades 126 are located in a bl~ 128 and co operate with a spling loaded pressure pad 130. Blades 126 can be in any desired formation for completel~ severing sheet 42 into indivi~ual moulds. l~e sheet 42 need no~ be severed as it can be used direc~y in a spinning ~ame.
Ihe finished sheet is finally ~ansported to statiora 60 (Fig. 1) where a suction l~ng mechar~m 132 removes the formed ~heet 42 ~om ~ays 28 and places ~hem on a nested stack 134.
The inven'don has many advantages ove~ the pnor art. As a plurality of mnulds can be pressed simultaneously the moulds can be different. l~e speed of operation is significan'dy increased and four-fdd increases in production can be ~xpected. The smoo~ movement of the sheet over the male moulds decreases the rejection rate of moulded sheets and reduces the down'dme during production runs. ~rom the foregoing it will be understood that the shaped-foil blanks formed by the method and apparatus of the u~ven'don are especially suitable for the wo go/14993 PCT/AU90/l)OZ~7

2~5~3~5 production of foil-encased hollow arti~les suc~ as hollow c~ocolate eggs or hollow chocolate rabbits or oth~ such hollow chocolate novelffes.
However, it i~ also to be understood ~at said shaped-foil b~s are suitable for the packa~ing of a wide range of other products such as 5 confec~onery for hum~n consump'don; ice cream; food industty goods;
cosmetics and toiletries; pet products, such a~ confectionery not for hlLman consumption; garderL product~; sporting goods; hobbies;
automotive products; ~ashion gift products; hardware products; toys;
ag~icultural products; convenience pa~; promotional produ~ such as 10 for pop concert~, ~por~ng events, and the like; souvenirs; and trzvel goods.
~ the first em~odiment, sta'dons 50, 52, 54, 56 have movable pistons 96, 96A, 96B, 96C for con~olling the mould fo~g operations.
Fig. 16 illustrates a second embodimen~ wh~e box frame 130 reciprocates 15 vertically throug~ a pi3ton~ylinder arrange~ent 132. Fig. 16 shows the equivalent of station 50 of the first embodiment. The opera~on of the embodiment shown in Pig. 16 is fairl~ similar to ~at previously described and will not be furth~ described.
Reference to Figs. 17 and 18 show variation~ of moulds that 20 can be produced by the present ~nvention. The blan~ 134 shown in Fig.
17 can be obtained by omitting station 50 and replacing male moulds 92A
of station 52 wi~ male moulds similar to tho~e at ~ ion 50 but ha~nng longitudinal direction~ transverse to ~ose shown at station 50. At stations 54, 56 the m~le rnoulds 92B, 92C will have the shapes shown in 25 blank 136 of Fig. 18. Station 56 may also be omitted if ~e desired stiffen~ng of the final moulded sheet is not required.
It is W~ved that the invention and many of its attendant advantages will be understood from the fore~oing de~cription and it will be apparent ~at various changes may be made in the foxm, construction 30 and arrangement of the parts and that change~ may be made in the form, construc~ons and arrangement of the method and apparatus described without depar~ng from the sp~rit and scope o~ the invention or sscrificing all of its material ~tv~ntsges, ffle hrms hereinbefore

3 P~/AU90/00227 g X~,'5f~3~S
described beLng merely prefe~ed embodimer~ eof.

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Claims (25)

THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:-

1. A method for producing 3-dimensional blanks containing a plurality of moulds impressed in a sheet material, said method including the steps of:-(i) clamping said sheet;
(ii) forming a first plurality of mould impressions in said clamped sheet at a first station to subdivided said sheet;
(iii) moving said subdivided sheet to a second station;
(iv) clamping said subdivided sheet at said second station;
(v) forming at least one set of final mould impressions coinciding with said first plurality of mould impressions.

2. The method of claim 1, wherein said clamping of said sheet takes place at the same position.

3. The method of claim 1 or claim 2, wherein said clamping is intermediate said sheet and in the subdivision direction.

4. The method of any one of the preceding claims, wherein said mould impressions are sequentially formed commencing from the middle of said sheet and moving in opposing outward directions.

5. The method of any one of the preceding claims, wherein said first plurality of mould impressions are formed in a two stage process, a first stage where the sheet is subdivided in one direction and a second stage where said subdivided sheet is further dubdivided in a direction transverse to said one direction.

6. The method of any one of the preceding claims, wherein said at least one final mould impressions are preformed in two stages, a first stage where almost final impressions are made and a second stage where the final impressions are made under heat and imcreased pressure.

7. The method of any one of the preceding claims, wherein said first plurality of mould impressions are formed by the relative movement of a plurality of dividers between a plurality of dies corresponding to the desired shape of the mould impressions to be formed.

8. The method of any one of the preceding claims, wherein said final mould impressions are formed by the relative movement of a plurality of complementary opposing dies.

9. An apparatus for producing 3-dimensional blanks containing a plurality of moulds impressed in a sheet material, said apparatus including a plurality of sequentially arranged stations for forming said moulds; a first station including sheet clamping means and means for subdividing said sheet into a plurality of first mould impressions; a second station including sheet clamping means and a pair of co-operating complementary dies for forming final mould impressions coinciding with said plurality of first mould impressions.

10. The apparatus of claim 9, wherein said sheet clamping means of said first station includes an elongated member located intermediate said sheet and parallel to the subdivision direction.

11. The apparatus of claim 9 or claim 10, wherein said means for subdividing said sheet moulds pairs of parallel dividers which draw said sheet over corresponding moulds to subdivide said sheet.

12. The apparatus of claim 11, wherein said pairs of parallel dividers are contained one within the other and move sequentially from the innermost to the outermost to form said subdivisions.

13. The apparatus of claim 12, wherein the inner pairs of parallel dividers terminate with rollers.

14. The apparatus of claim 11, wherein said corresponding moulds are located on a planar base member, said sheet is adapted to be located with a tray having a removable template forming the floor of said tray and said template having a plurality of apertures through which said corresponding moulds can protrude.

15. The apparatus of claim 14, wherein said tray forms part of a conveyor system.

16. The apparatus of any one of claims 9 to 15, wherein said sheet clamping means of said second station includes a pair of co-operating complementary dies.

17. The apparatus of claim 16, wherein said pair of co-operating complementary dies comprises a set of male moulds mounted on a base member and a plurality of telescopic female moulds which includes said sheet damping means.

18. The apparatus of claim 17, wherein an additional station is located between said first and second stations, said additional station being of similar construction to said first station but subdividing said sheet in parallel directions transverse to said subdivision direction.

19. The apparatus of claim 18, wherein said additional station includes pairs of parallel dividers which draw said sheet over corresponding moulds to further subdivide said sheet.

20. The apparatus of claim 19, wherein said pairs of parallel dividers of said additional station are contained one within the other and move sequentially from the innermost to the outermost to form said further subdivisions.

21. The apparatus of claim 20, wherein the inner pairs of parallel dividers of said additional station terminate with rollers.

22. The apparatus of any one of claims 19 to 21, wherein the free ends of said parallel dividers have winglets attached thereto in a section perpendicular to said dividers, said winglets being aligned with the impressions formed by said dividers of said first station to provide alignment of said sheet.

23. The apparatus of any one of claims 9 to 22, wherein a final pressing station is located after said second station, said final pressing station including complementary male and female dies, said final pressing station applying heat and pressure to finalize the mould shapes impressed in said sheet.

24. An apparatus for producing 3-dimensional blanks substantially as hereinbefore described with reference to the accompanying drawings.

25. A method for producing 3-dimensional blanks substantially as hereinbefore described with reference to the accompanying drawings.