DE102022111821A1 - Method for producing a packaging element - Google Patents

Abstract

Method for producing a packaging element (1) from a manufactured material (2) and a carrier material (3), comprising the following steps: a) providing the manufactured material (2); b) connecting the manufactured material (2) to the carrier material (3 ), which is provided as continuous material; so that a first composite (4) is created from the manufactured material (2) and the carrier material (3);c) carrying out at least one transport of the manufactured material (2) with the carrier material (3); andd) carrying out at least one processing step in which the first composite (4) is processed, so that a second composite (5) forming the packaging element (1) is produced from the manufactured material (2) and the carrier material (3).

Description

The invention relates to a novel method for producing packaging elements and packaging.

In usual processes for producing packaging and/or packaging elements, packaging elements are regularly produced from blanks of a packaging element material. One example is the production of finished shells, which are made from cuts of flat raw materials. The processing of blanks in the production of packaging elements has the disadvantage that a transport system is required to transport the individual blanks. Such transport systems are often quite complex. In contrast, there are much simpler transport systems for materials that are delivered on a roll and can be processed as endless material. Here the endless material itself offers a very good opportunity to be conveyed from one station to the next station in a processing device by running the endless material through the various stations. However, certain materials cannot be provided as continuous material on a roll or this type of provision involves other disadvantages.

The object of the present invention is to at least partially solve the problems described with reference to the prior art. This object is achieved with the invention according to the features of the independent claims. Further advantageous refinements are specified in the dependently formulated claims as well as in the description and in particular in the description of the figures. It should be noted that the person skilled in the art combines the individual features with one another in a technologically sensible manner and thus arrives at further refinements of the invention.

1. a) Bereitstellen des konfektionierten flächigen Materials;
2. b) Verbinden des konfektionierten flächigen Materials mit dem Trägermaterial, welches als Endlosmaterial bereitgestellt wird; so dass ein erster Verbund von dem konfektionierten flächigen Material und dem Trägermaterial erzeugt wird;
3. c) Durchführen mindestens einer Beförderung des konfektionierten flächigen Materials mit dem Trägermaterial; und
4. d) Durchführen mindestens eines Verarbeitungsschrittes, in welchem der erste Verbund bearbeitet wird, so dass ein das Verpackungselement bildender zweiter Verbund von dem konfektionierten flächigen Material und dem Trägermaterial erzeugt wird.

Described here is a method for producing a packaging element from a manufactured material and a carrier material, comprising the following steps:

1. a) Providing the assembled flat material;
2. b) connecting the assembled flat material to the carrier material, which is provided as an endless material; so that a first composite is created from the assembled sheet material and the carrier material;
3. c) Carrying out at least one transport of the assembled sheet material with the carrier material; and
4. d) Carrying out at least one processing step in which the first composite is processed, so that a second composite forming the packaging element is produced from the assembled flat material and the carrier material.

The manufactured material is preferably a manufactured flat material. In particular, the manufactured material forms, for example, a surface section. Preferably, it is a material that would in principle also be suitable for processing as a continuous material - for example, it is a material that can be provided on a roll or a coil and which, however, is assembled or divided.

The prefabricated material can in particular also be a shaped body made from a prefabricated flat material - for example a half-shell, a preformed half-shell or a similar shaped body. Such a manufactured material can, for example, also be referred to as a “pre-form”. Then, upstream of the method described here, a shaping process for producing the manufactured material designed as a shaped body takes place.

The carrier material is preferably a deep-drawable material which can be processed in the processing steps according to step d) together with the manufactured material and does not hinder or even favor the intended processing steps. The carrier material is preferably a barrier material or preferably the carrier material can function as a barrier or barrier layer in the packaging element produced using the method. Further details will be provided below.

The manufactured material is in particular a fiber material, in particular paper or cardboard. The term “assembled” in this context means that the material is prepared, in particular cut, for the packaging element to be produced. If the packaging element to be produced is, for example, a bowl or a lid, then the manufactured material is preferably a blank that has (preferably exactly) the dimensions required to produce this bowl or lid. If necessary, individual prefabricated materials can also be connected to one another by a strand of the material of the prefabricated materials. By cutting, the assembled materials may not be completely separated from the starting material, but only sections are cut out or perforations or weakenings are made in the starting material rial of the manufactured material, which prevent further processing of the starting material of the manufactured material as a continuous material because the mechanical stability necessary for processing as a continuous material is missing.

The term “cardboard” refers to a flat material that essentially consists of fibers (particularly fibers of plant origin). In particular, it is a material made from cellulose fibers. Such a material is preferably formed by dewatering a fiber suspension. In particular, “cardboard” has increased mechanical strength compared to paper. The “cardboard” preferably has a minimum weight per square meter of cardboard area of 130 g/m ² [grams/square meter]. Materials with a lower weight per area are often referred to as paper. A cardboard box can also be a composite material made of several layers of paper with a weight per area of less than 130 g/m ² [grams/square meter]. If necessary, such a composite material can also contain air and, for example, be designed with a corrugated paper layer. Such a flat material can also be formed from a fiber composite or include a fiber composite that is not compact but encloses open or closed pores of air.

The manufactured material can also be a different material - for example a porous material, which was produced, for example, based on a foam. Preferably, the manufactured material is deformable in processing methods for producing the packaging element in order to produce a shaped packaging element.

The manufactured material preferably has a material thickness that is greater than a material thickness of the carrier material. Preferably, the assembled material is particularly suitable for forming a rigid structure of the packaging element.

The prepared material in step a) is provided, for example, with a manipulator arm that removes the material from a warehouse and provides it. Any method of providing the material may be used. The manufactured material is preferably placed on a carrier material, which is preferably provided as an endless material from a roll or in a similar manner.

In step b), the assembled material is connected to the carrier material. This can be done, for example, by gluing the manufactured material to the carrier material in certain areas. A first composite of the manufactured material and the carrier material is formed. The first composite is preferably a preliminary composite, which is preferably reinforced or intensified in subsequent processing steps. The first composite, for example, only serves to position the manufactured material and the carrier material relative to one another. The term “first composite” here means that the carrier material is connected to one another in a first manner (with a first intensity). In subsequent processing steps, the connection between the manufactured material is preferably intensified or a different (possibly more permanent) connection technique is also developed for connecting the carrier material and the manufactured fiber material. The composite created in subsequent processing steps is referred to here as the “second composite”. The first composite and the second composite do not differ in that they consist of different materials. The carrier material and the manufactured material are the same in the first composite and the second composite. Or in other words: the first group becomes the second group. The first composite and the second composite differ in the respective connection between the carrier material and the manufactured material. The first composite preferably describes a provisional or provisional composite of the manufactured material with the carrier material. The second composite preferably describes a final composite of the manufactured material with the carrier material. The process steps are preferably carried out regularly and repeatedly in different stations for carrying out the method described, with the carrier material being moved further and further, so that between each implementation of the steps the carrier material is constantly moved further and the prepared materials are arranged one behind the other on the carrier material at regular intervals. The result is a band consisting of the carrier material provided as an endless material and assembled materials, which are arranged one behind the other (preferably at uniform distances). The method therefore preferably forms a continuous processing process in which the individual process steps for each individual packaging element to be produced are carried out one after the other but parallel to one another for packaging elements processed one behind the other/sequentially. Preferably, a machine for carrying out the method described works with a processing cycle with which the individual processing steps are carried out simultaneously for ready-made materials/packaging elements processed one after the other.

By moving the carrier material provided as an endless material, the manufactured material is conveyed according to step c), with a large number of individual manufactured materials preferably being transported one after the other from station to station through a device for producing packaging elements. The carrier material provided as an endless material thus serves as a transport medium. The promotion can take place, for example, by transporting the carrier material provided as endless material on rollers like a kind of conveyor belt. In embodiments, outer edges of the substrate may ride in guide rollers. The assembled material is positioned between these outer edges on a central region of the carrier material or forms the first composite there with the carrier material. Processing stations act on the areas of the carrier material in which the manufactured material is positioned. By using the carrier material provided as an endless material for conveying in combination, transport and handling during the production of a packaging element with ready-made materials can be significantly simplified. Fabricated materials are characterized by the fact that they are introduced into the process described here as individual parts (each fabricated). Preferably, the assembled materials have also been separated from a further endless material in a process cut upstream, although a first distance between adjacent separated materials in this further endless material is very small and after connecting in step b) these separated materials each have a larger ßeren second distance from each other on the carrier material. The assembled materials can preferably be produced from this further endless material with very little material waste. The small first distance (at which the prefabricated materials may even directly adjoin one another) is advantageous in order to produce prefabricated materials with low waste from the further endless material. The larger second distance is advantageous in order to provide sufficient space for processing the composite of manufactured materials and carrier materials in further processing steps in d).

As already stated, further processing steps take place according to step d), in which the composite of the manufactured material and the carrier material is processed. In particular, a connection between the manufactured material and the carrier material is intensified, for example by the two materials being cohesively connected to one another over a large area. This can be achieved, for example, by welding. In this way, a second composite of the manufactured material and the carrier material is formed. The second composite is therefore, for example, a welded composite. In contrast, the first composite is, for example, a provisional composite, formed with a first provisional connection. A provisional connection in the first composite can, for example, be designed as an adhesive bond.

The method described has advantages over other methods in relation to the transport system of the manufactured material, because certain materials cannot be processed from the roll as endless material, for example due to their properties. This applies, for example, to manufactured materials that have a relatively high rigidity and therefore cannot be provided on a roll. This can also apply, for example, because the assembled materials may already be formed with ribs and/or stiffening structures before step a) that prevent them from rolling up.

By means of the method described here, ready-made blanks/partial blanks/preforms can be processed from a web, the web being formed here by the carrier material (which is regularly required anyway in many applications). As a result, there is no need for a special transport system for manufactured materials, since the material strand of the carrier material takes over the transport.

It is particularly advantageous if the endless material provided as a carrier material is a plastically deformable film.

The carrier material is preferably intended to form a barrier layer in the packaging element produced, which, for example, prevents moisture from penetrating into the packaging or aromas from escaping from the packaging. The carrier material is preferably suitable for forming a vapor barrier. If necessary, the carrier material can be a coated material.

It is also advantageous if the manufactured material is made from natural polymer fibers.

Preferably, the manufactured material or the material from which the fibers of the manufactured material are made and the material of the carrier material can be welded together. Both materials preferably have a similar melting point. The manufactured material and the carrier material are preferably connected to one another in step d). This is particularly preferably done under the influence of heat. Further A welding process is particularly preferably used for this purpose.

It is also advantageous if a provisional first connection is made between the carrier material and the material to form the first composite. This can be, for example, an adhesive connection already mentioned as an example above.

In addition, it is preferred if the first provisional connection in the first composite enables a relative positioning of predetermined first carrier material sections of the carrier material and predetermined first material sections of the assembled material.

In addition, it is advantageous if in step b) to form the first composite, first connections are formed in regions and relative movements occur between predetermined second carrier material sections of the carrier material and predetermined second material sections of the material during at least one processing step in step d).

In preferred embodiment variants, the first provisional connection is therefore only created between (limited) (surface) sections of the carrier material and the assembled material. A relative displacement to one another is preferably possible between further (other) surface sections of the manufactured material and the carrier material, which has an effect, for example, when carrying out a processing step in step d). For example, it is possible that during press forming in step d) surface sections of the manufactured material shift relative to the carrier material, but the first provisional connection specifies in which directions and/or areas such shifts can occur.

It is particularly advantageous if at least one processing step in step d) is a deformation step in which the first composite is deformed.

A deformation process is particularly advantageously implemented as a deep-drawing process, in which the assembled material is deformed together with the carrier material in a deep-drawing tool in order to produce, for example, a shell-shaped packaging element

It is also advantageous if heat is applied to the first composite during the deformation of the first composite.

A tool for carrying out a deformation step (in particular a deep-drawing tool) preferably has at least one heating means with which the carrier material and the manufactured material are heated. Particularly preferably, heat is introduced which is sufficient to thermally connect the assembled material and the carrier material to one another, in particular to weld them, at least in sections.

Preferably, a deformation process in step d) is set up so that the manufactured material and the carrier material are thermally connected to one another over the entire surface of the manufactured material. Very particularly preferably, after a deformation process in step d), the carrier material forms a support layer or a support layer of a sandwich structure, which is formed from the carrier material and the manufactured material. The carrier material preferably closes off the sandwich structure or forms a surface of the sandwich structure. Fibers of the manufactured material are preferably no longer recognizable from a surface of the sandwich structure or the surface is completely formed by the carrier material.

In further preferred embodiments, a manufactured material with two layers of a carrier material is processed into a sandwich structure. The assembled (fiber) material preferably forms an internal structure which is covered or covered on both sides by the carrier material and which spaced the two layers of carrier material apart from one another. The distance between the two layers of the carrier material is guaranteed by the manufactured material. All layers are preferably firmly and completely connected to one another through the deformation process, as intended for the finished packaging element. However, it cannot be ruled out that the individual layers can later be separated mechanically (if necessary for recycling of the packaging). A second layer of the carrier material can also be provided as a continuous material. However, it is also possible to provide it in ready-made form, with the other carrier material being used as a continuous material for transport according to step c).

It is also advantageous if the carrier material and the assembled material are at least partially welded during the deformation of the first composite.

Furthermore, it is advantageous if at least one processing step in step d) is a punching step in which at least one dividing line is introduced into the second composite.

It is also advantageous if step d) is followed by step e), in which the second composite is separated from the carrier material provided as an endless material in order to form the packaging element.

The separation can be done with or without the prior introduction of a dividing line. However, it is preferred that at least one dividing line is introduced first, which forms a type of perforation along which the second composite is later separated from the carrier material provided as an endless material.

By introducing a dividing line, the composite of the carrier material as endless material and the assembled materials is divided into individual packaging elements. The introduction of dividing lines preferably takes place relatively far at the end of a process for producing packaging elements. The introduction of dividing lines is preferably one of the last steps and most preferably the last step in the production of the packaging element and possibly even in the production of a packaging formed with the packaging element.

In embodiments, the dividing line is introduced as a line which divides the carrier material provided as an endless material into individual sections, each of which has a manufactured material and in which a manufactured material together with the carrier material forms a second composite or a packaging element.

In further embodiment variants, the dividing line is formed all around the assembled flat element or the second composite or the packaging element. A frame made of carrier material preferably remains around the assembled flat element or the second composite or the packaging element. The finished packaging element is preferably punched out of the endless material along the dividing line in the manner of a punch. A circumferential dividing line around the finished packaging element is used primarily in embodiment variants of the method described, in which outer areas/edges/edges of the carrier material provided as endless material are used for transport and, for example, run on rollers.

Furthermore, it is advantageous if at least one processing step in step d) is a filling step in which a packaging element volume of the packaging element formed in a previous processing step is filled with a product.

It is particularly preferred that a filling step or filling takes place before individual packaging elements are separated from one another or from the carrier material provided as endless material. The filling step preferably takes place in particular before dividing lines are introduced. The carrier material provided as an endless material therefore serves as a transport medium, in particular during filling, with which the packaging element formed from the assembled flat element and the barrier medium is transported from one processing station to the next processing station, etc.

In particular, in which a deformation step using heat has taken place in step d), a predetermined cooling time or standing time can optionally take place after the deformation step and before the filling step, which is realized, for example, by a cooling section which cools the packaging element after a deformation step and after a Filling step happens.

It is also advantageous if, at least in one processing step in step d), a closure element is applied to a packaging element volume of the packaging element formed in a previous processing step.

It is particularly preferred that a closure element is also applied before individual packaging elements are separated from one another. Particularly preferably, the application of a closure element also takes place before the introduction of dividing lines.

Very particularly preferably, a material for forming the closure elements is also provided as an endless material. When introducing dividing lines and/or during separation, the closure element material provided as endless material is preferably separated or divided into individual closure elements assigned to each packaging element or each packaging. Particularly preferably, the packaging is already tightly closed when dividing lines are introduced or during separation. This means that the closure element is preferably already permanently connected to the packaging element (for example by circumferential gluing or welding) when the separation takes place or when dividing lines are introduced.

Also to be described here is a composite packaging element consisting of a support layer made of material and one of the support layer supported carrier material produced according to the method described.

The composite packaging element is a packaging element which forms a composite of different materials, namely the assembled material, which is, for example, a fiber material and/or a porous material, and the carrier material. Such a composite packaging element preferably has high mechanical stability and can also be produced efficiently using the method described here.

It should be pointed out that the special advantages and design features described in connection with the method described above can also be applied and transferred to the composite packaging elements described below.

Also to be described here is a device for producing the composite packaging elements described using the method described.

It should be pointed out that the special advantages and design features described in connection with the method described above can also be applied and transferred to the device described below.

The device described preferably has a plurality of stations through which the carrier material is conveyed as an endless material, the stations being set up to carry out the individual process steps. The device also has means for conveying the carrier material provided as an endless material with the assembled materials arranged thereon.

• 1: eine schematische Darstellung einer Vorrichtung zur Durchführung des beschriebenen Verfahrens.

The invention and the technical environment of the invention are explained in more detail below with reference to the figures. The figures show preferred exemplary embodiments to which the invention is not limited. It should be particularly noted that the figures and in particular the size relationships shown in the figures are only schematic. It shows:

• 1 : a schematic representation of a device for carrying out the method described.

The ones in the 1 Device 16 shown has a plurality of stations 17. The carrier material 3 is provided as an endless material and passes through the individual stations 17 one after the other. Steps a) and b) take place in a first station 17. The assembled material 2 is provided and preferably positioned on the carrier material 3 in such a way that first carrier material sections 7 and first material sections 8 rest against one another. In each of these sections, a first provisional connection 6 is preferably created between the carrier material 3 and the manufactured material 2, so that a first composite 4 is formed. The first composite 4 preferably does not yet include a connection between the assembled material 2 and the carrier material 3 over the entire surface. Rather, there are also preferably second carrier material sections 9 and second material sections 10 in which the carrier material 3 and the manufactured material 2 only lie against one another but are still movable relative to one another. Such relative movements can then occur in further processing in subsequent stations 17.

Preferably, the prepared material 2 with the carrier material 3 is transported between the individual stations 17 according to step c). Three stations 17 are also shown here, in which further processing steps according to step d) of the method described take place. In the first station 17 seen from the left, the first composite 4 passes a mold 18, in which the first composite 4 is formed and during the shaping a second composite 5 is preferably also formed, in which the carrier material 3 and the manufactured material 2 are preferably formed are connected to one another over the entire surface of the manufactured material 2. In further processing steps 14 (not shown separately here), for example, a product 13 can be introduced into a packaging element volume 12. Next, a station 17 is shown, in which a closure element 15 is applied to the packaging element 1 using a closure tool 19. A station 17 is then shown, in which dividing lines 11 are introduced with a separating tool 20 and in which the packaging element 1 is separated from the carrier material 3 provided as endless material. Alone 1 Stations 17 shown are examples. The structure of a device 16 for carrying out the method described can also differ. It is essential that the packaging element 1 or the precursors of the packaging element 1 (assembled material 2, first composite 4, second composite 5) are transported using the carrier material 3 provided as an endless material.

Reference symbol list

1

Packaging element

2

manufactured material

3

Carrier material

4

first association

5

second compound

6

first connection

7

first carrier material sections

8th

first material sections

9

second carrier material sections

10

second material sections

11

parting line

12

Packaging element volume

13

product

14

further processing steps

15

Closure element

16

contraption

17

Stations

18

molding tool

19

Locking tool

20

Separation tool

Claims (15)

Method for producing a packaging element (1) from a manufactured material (2) and a carrier material (3), comprising the following steps: a) Providing the assembled material (2); b) connecting the assembled material (2) to the carrier material (3), which is provided as an endless material; so that a first composite (4) is created from the manufactured material (2) and the carrier material (3); c) carrying out at least one transport of the assembled material (2) with the carrier material (3); and d) Carrying out at least one processing step in which the first composite (4) is processed so that a second composite (5) forming the packaging element (1) is produced from the assembled flat material (2) and the carrier material (3). Procedure according to Claim 1 , wherein the endless material provided as carrier material (2) is a plastically deformable film. Method according to one of the preceding claims, wherein the manufactured material (2) is formed from natural polymer fibers. Procedure according to Claim 1 until 3 , wherein in step b) to form the first composite (4), a provisional first connection (6) is produced between the carrier material and the manufactured material. Connection to Claim 4 , wherein the first provisional connection (6) enables a relative positioning of predetermined first carrier material sections (7) of the carrier material (3) and predetermined first material sections (8) of the assembled material (2). Method according to one of the preceding claims, wherein in step b) to form the first composite (4), first connections (6) are formed in regions and wherein during at least one processing step in step d), relative movements between predetermined second carrier material sections (9) of the carrier material (3 ) and predetermined second material sections (10) of the manufactured material (2). Method according to one of the preceding claims, wherein at least one processing step in step d) is a deformation step in which the first composite (4) is deformed. Procedure according to Claim 7 , whereby heat is applied to the first composite (4) during the deformation of the first composite. Procedure according to Claim 7 or 8th , wherein during the deformation of the first composite (4), the carrier material (3) and the assembled material (2) are at least partially welded. Method according to one of the preceding claims, wherein at least one processing step in step d) is a punching step in which at least one dividing line (11) is introduced into the second composite (5). Method according to one of the preceding claims, wherein step d) is followed by step e), in which the second composite (5) is separated from the carrier material (3) provided as an endless material in order to form the packaging element (1). Method according to one of the preceding claims, wherein at least one processing step in step d) is a filling step in which a packaging element volume (12) of the packaging element (1) formed in a previous processing step is filled with a product (13). Method according to one of the preceding claims, wherein at least in one processing step in step d) a closure element (15) is applied to a packaging element volume (12) of the packaging element (1) formed in a previous processing step. Packaging element (1) consisting of a support layer made of manufactured material (2) and a carrier material (3) supported by the support layer, produced according to a method according to one of Claims 1 until 13 . Device for producing packaging elements (1). Claim 14 , wherein the device is set up to carry out the method according to one of Claims 1 until 13 .

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