CN103313837B - 热成形冲泡包的方法和设备 - Google Patents

热成形冲泡包的方法和设备 Download PDF

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CN103313837B
CN103313837B CN201180065011.2A CN201180065011A CN103313837B CN 103313837 B CN103313837 B CN 103313837B CN 201180065011 A CN201180065011 A CN 201180065011A CN 103313837 B CN103313837 B CN 103313837B
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A·M·伍德沃德
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Ekatra Research And Development Uk Ltd
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    • B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
    • B65B47/00—Apparatus or devices for forming pockets or receptacles in or from sheets, blanks, or webs, comprising essentially a die into which the material is pressed or a folding die through which the material is moved
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
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    • B29L2031/7122—Tea bags
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    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
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Abstract

本发明提供热成形气体和液体可透过的热塑性材料层(10)的方法，该热塑性材料层的平均厚度小于1.0毫米，所述方法包括以下步骤：使处于低于热成形所需温度的温度下的所述热塑性材料层与处于高于热塑性材料的热成形温度的温度下的模具(16)相接触，按压所述模具至与所述热塑性材料层相接触，模具和热塑性材料之间的所述接触使得热量从所述模具传递给所述热塑性材料且使所述热塑性材料的温度升高到可热成形的温度；这样的按压由此将所述热塑性材料热形成为与所述模具的形状一致。

Description

热成形冲泡包的方法和设备
发明的技术领域
本发明涉及包，特别是冲泡包，例如具有预先确定的三维形状的茶袋的制造。
发明背景
许多年以来，冲泡包，例如茶袋主要是以方形或圆形的两片多孔过滤材料薄片供应，其通常由纸制作，冲泡材料(如茶)夹在片材之间。这样的包将包内的难溶材料的流动限制在基本上两个维度上。因此这种包的冲泡性能有限。
因此，在过去的几十年中，冲泡包大批量生产的技术在发展，其具有更立体的形状，允许所述难溶物质有更多的空间移动。特别成功的是四面体形状的包，例如描述在以WO95/01907(Unilever)和WO2004/033303(IMASPA)公开的国际专利申请中的那些。
在四面体包的制造中，四面体形状通常通过在过滤材料管中制成相互垂直的横向密封而形成，而设计用于这种制造的装置不适合于制造其他的三维形状。
因此，期望开发一种能够制造各种三维形状的方法。
定义
应当指出，在具体说明任何数值范围时，任何特定的上限值可以与任何特定的下限值联用。
为了避免歧义，词语“包含(comprising)”旨在意指“包括(including)”，但不一定是“由......组成(consistingof)”或“由......构成(composedof)”。换句话说，所列出的步骤或项目不必是穷举的。
本文所见的本发明的公开内容被认为涵盖彼此之间多项从属的权利要求中所见的有实施方式，无论权利要求书实际有没有多项从属关系或从属是不是多余。
发明简述
本发明人已认识到，已知的热成形工艺，尽管能够生成各种三维形状，但是不适合用于冲泡包材料。
首先，冲泡包最常见的是用纸做的，其不是可热成形的。其次，即使它们由可热成形的材料做成，由于它们的孔隙率和材料的薄度，它们将不适于热成形。
已知的热成形方法包括加热材料的第一步骤和随后热成形所述材料的第二步骤。冲泡包材料的非常小的热容意味着任何热量将很快损失掉，因此该方法行不通。
即使可以找到解决热量问题的方法，所述材料的多孔性也阻止了使用空气压以成形该材料。已知的热成形技术通常使用空气压以成形材料。然而，冲泡包材料的多孔性使得这种方法是不切实际的，因为横跨材料的任何空气压力差异都将快速均衡。
如果不使用空气压力并将模具压入材料中，由于任意的多孔和薄冲泡包材料的脆性，则只可以形成有限数量的三维形状。
因此，似乎热成形不是一个产生各种各样的三维形状的冲泡包材料的实用方法。
然而，令人惊讶的是，本发明人已克服了这些障碍并开发了可以由冲泡包材料产生三维形状的热成形方法。
因此，本发明涉及热成形气体和液体可透过的热塑性材料层的方法，所述热塑性材料层的平均厚度小于1.0毫米，所述方法包括以下步骤：使处于低于热成形所需温度的温度下的所述热塑性材料层与处于高于所述热塑性材料的热成形温度的温度下的模具相接触，按压模具至与所述热塑性材料层相接触，模具和热塑性材料之间的所述接触使得热量从所述模具传递给所述热塑性材料且使所述热塑性材料的温度升高到可热成形的温度；这样的按压由此使得所述热塑性材料热成形为与所述模具的形状一致。
因此，在热成形开始之前不对热塑性材料进行加热。由于所述热塑性材料具有非常低的储热容量，这意味一旦与加热的模具相接触，它就将迅速升温。因此，本发明采用了其具有非常低的热容量的缺点并且利用这个特性开发出用于这样的材料的非常有效的热成形方法。
由于所述热塑性材料的温度仅是由来自所述模具的加热进行间接控制，所以在热成形过程中将存在温度变化。因此，优选所述热塑性材料在宽的温度范围内，优选在至少20℃的温度范围、更优选在至少40℃的温度范围内表现出塑性变形行为。
所述热塑性材料可以由各种各样的材料制成，然而，聚对苯二甲酸乙二醇酯(PET)和聚乳酸(PLA)是优选的。由于聚乳酸(PLA)在宽的温度范围内表现出塑性变形，其是特别优选的。
为使所述方法是有效的，优选所述模具显著比所述热塑性材料更热。因此模具和在与模具接触之前的热塑性材料的温差大于40℃，优选大于60℃，更优选为80℃至200℃。
在优选的实施方式中，所述热塑性材料在与加热的模具接触之前处于室温。因此，所述热塑性材料在与模具接触之前处于15℃至35℃的温度。
由于所述成形的材料的主要应用是作为冲泡包，因此材料通常是非常薄的。因此，优选所述热塑性材料的平均厚度小于0.5毫米、更优选小于0.20毫米、最优选为0.01到0.10毫米。
所述热塑性材料可以由各种不同的设计制成，但优选由热塑性材料的纤维制成，更特别地由织造的热塑性纤维制成。这样的纤维的直径可以小于0.5毫米、优选小于0.25毫米、更优选小于0.10毫米、最优选为0.001至0.05毫米。
热成形温度足以使热塑性材料在热成形应力作用下发生变形。因此，模具的温度优选为至少100℃、更优选为120℃至210℃、以使所得到的材料可以耐受直至这个水平的温度而不会缩回到其原来的片材形式。
所形成的材料的主要应用是作为冲泡包，因此，热成形的热塑性材料优选是气体和液体可透过的。特别地，优选热成形的热塑性材料对水性液体可透过的。
根据本发明的方法能够产生三维形状，其然后能够用作冲泡包材料。例如，可能是如四面体，半球状等的形状。
因此，该方法之后一般进行将颗粒产品装入到热成形的热塑性材料的步骤，所述颗粒产品通常包含难溶物质，如茶叶。然后该步骤之后通常进行密封所述热成形材料，以制成密封的多孔冲泡包。
本发明现在将通过举例的方式并参考以下附图来进行说明，其中：
图1是适于进行根据本发明的方法的热成形设备的示意图。
图2是图1中所示的相同设备在进行根据本发明的方法的过程中的示意图。
附图中，图1显示了由上夹具12和下夹具14在适当位置夹住的织造的50毫米厚度的聚乳酸10的片材。织造的片材10处于20℃的温度。
置于织造的片材上方的是阳模16，其处于120℃的温度下。
在使用中，阳模16向下移动以接触到织造的片材10。当其接触时，由于片材的热容非常低，织造的片材10中与阳模16相接触的部分加热直至120℃。
阳模继续向下移动，同时加热和热成形织造的片材，直到阳模处于图2所示的位置。
一旦织造的片材10完全热成形，阳模缩回，织造的片材迅速冷却且定形，这也是由于其极低的热容。

Claims (23)

1.热成形气体和液体可透过的热塑性材料层的方法，所述热塑性材料层的平均厚度小于1.0毫米，所述方法包括以下步骤：使处于低于热成形所需温度的温度下的所述热塑性材料层与处于高于所述热塑性材料的热成形温度的温度下的模具相接触，按压模具至与所述热塑性材料层相接触，模具和热塑性材料之间所述接触使得热量从所述模具传递给所述热塑性材料且使所述热塑性材料的温度升高到可热成形的温度；这样的按压由此使得所述热塑性材料热成形为与所述模具的形状一致，随后进行将颗粒产品装入到所述热成形的热塑性材料的步骤。
2.根据权利要求1的方法，其中所述热塑性材料在至少20℃的温度范围表现出塑性变形行为。
3.根据权利要求1的方法，其中所述热塑性材料在至少40℃的温度范围表现出塑性变形行为。
4.根据权利要求1至3中任一项的方法，其中所述热塑性材料含有聚对苯二甲酸乙二醇酯或聚乳酸。
5.根据权利要求1至3中任一项的方法，其中所述模具和在与所述模具接触之前的所述热塑性材料的温差大于40℃。
6.根据权利要求1至3中任一项的方法，其中所述模具和在与所述模具接触之前的所述热塑性材料的温差大于60℃。
7.根据权利要求1至3中任一项的方法，其中所述模具和在与所述模具接触之前的所述热塑性材料的温差大于80℃。
8.根据权利要求1至3中任一项的方法，其中所述热塑性材料在与所述模具接触之前的温度为15℃至35℃。
9.根据权利要求1至3中任一项的方法，其中所述热塑性材料的平均厚度小于0.5毫米。
10.根据权利要求1至3中任一项的方法，其中所述热塑性材料的平均厚度小于0.2毫米。
11.根据权利要求1至3中任一项的方法，其中所述热塑性材料的平均厚度小于0.1毫米。
12.根据权利要求1至3中任一项的方法，其中所述热塑性材料由热塑性材料的纤维制成。
13.根据权利要求12的方法，其中所述纤维是织造的热塑性纤维。
14.根据权利要求13的方法，其中所述纤维的直径小于0.5毫米。
15.根据权利要求13的方法，其中所述纤维的直径小于0.25毫米。
16.根据权利要求13的方法，其中所述纤维的直径小于0.10毫米。
17.根据权利要求13的方法，其中所述纤维的直径小于0.05毫米。
18.根据权利要求1至3中任一项的方法，其中所述模具的温度为至少100℃。
19.根据权利要求1至3中任一项的方法，其中所述模具的温度为至少120℃。
20.根据权利要求1至3中任一项的方法，其中使所述热塑性材料成形为四面体或半球形的形状。
21.根据权利要求1至3中任一项的方法，其中所述颗粒产品包含难溶物质。
22.根据权利要求21的方法，其中所述难溶物质为茶叶。
23.根据权利要求21的方法，所述方法之后进行密封所述热成形材料，以制作密封的多孔冲泡包。
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