EP0393804A1 - Object with low weight/volume ratio, especially packaging object, as well as process for the manufacture of material bodies for such objects and process for the manufacture of packaging objects therefrom - Google Patents

Abstract

An object (1), which serves in particular for packaging purposes, comprises a material body (10) constructed from corrugated cardboard, in which, for the positive accommodation of articles to be packaged, there is formed at least one shaped nest (11) adapted to their contours. In order simply and economically to make possible universal use of corrugated cardboard, with adaptation to different shape requirements for the widest range of different shapes of goods to be packaged, and above all a closed plane accommodation of the article to be packaged, the corrugated layers (21, 22) are to be separate from one another and interconnected by layering and are to fill completely the volume defined by the dimensions of the packaging body, the shaped nest being formed from the closed material body. <IMAGE>

Description

Field of the Invention

The invention relates to a molded part having a low volume weight, in particular a molded molded part, comprising a material body and at least one mold cavity formed therein for the particularly positive reception of objects such as packaged goods, the material body being constructed from fibrous corrugated material such as corrugated cardboard, and a method for producing one for forming a such molded part suitable material body and a method for producing molded packaging parts from such material bodies.

State of the art

Molded parts formed with mold nests, such as are used predominantly for packaging (packaging materials and aids) today, generally consist of styrene polymers and copolymers.

Such plastics require foaming in the forms provided for them, adapting to the respective application. Such packaging is light in weight and can be adapted exactly to the desired shapes and can be produced in stock. Due to their high shock absorption capacity are suitable such moldings are particularly good for the shipping and storage of shock-sensitive, especially fragile goods. A major disadvantage of using this material for molded parts, however, is that it involves relatively high raw material costs and problems with disposal. In addition, foaming agents are generally used for foaming polystyrene, which are to be degraded to an increasing extent because of their environmentally harmful properties. Finally, the recycling of polystyrene foam is extremely difficult and costly, so that its use as a packaging material is increasingly to be questioned.

Because of the difficulties in disposing of such packaging material, many companies are now trying to use blanks made of cellulose-containing material, in particular corrugated cardboard, which are easier to dispose of, whereby a wide variety of packaging systems have been developed for the different types of packaging material, but these have a relatively high weight and cost , especially through the use of corrugated cardboard covered on both sides.

In an effort to use a less expensive material for packaging, some measures can already be taken from the printed prior art to use cellulose or corrugated cardboard bodies.

For example, FR-PS 670 494 describes a molded article wound from cell wadding or pressed from cellulose wadding fragments, into which depressions are embossed. The result is a tray-shaped body, in the wells of which fruit, eggs, glass, crystal or porcelain objects or the like. while partially enclosing their contours. Due to the material used, such packaging is upholstered or cushion-like receptacles, which are relatively soft and to be suitable for shipping purposes be surrounded by stable carrier containers. The soft material has a high inherent resilience, so that, at least using the steps described, no permanent, ie sustainably stable, mold cavities can be produced, but the embossments recede at least by part of their shape as a result of the restoring forces of the material. In this respect, it is difficult to prefabricate reproducibly uniform molded packaging parts and to store them under a wide variety of conditions, even over longer periods of time, in the course of stockpiling.

Furthermore, a material body made of corrugated cardboard with annular shape nests for the form-fitting receiving and packaging of hollow cylinders is known (US Pat. No. 2,947,459). These are winding bodies in the manner of a screw, which must necessarily have a cavity in the central area. Due to their consistency in the form of a continuous wrap, in which neighboring layers are almost endlessly connected to one another, such molded packaging parts are practically bound to round, hollow packaging goods, unless one wants to accept the hollow in the central area as a recess in the packaging. When punching out parts from such coils, which may have to be made with large diameters, for the purpose of use for packaging goods which differ from round shapes, large amounts of waste have to be accepted. A stability of the embossed mold cavities can essentially only be achieved with the means described if the embossing mainly runs with the winding layering. With the exception of rings, such molded parts are not suitable for picking up and enclosing packaging goods in whole pieces, but they can essentially only be used as partial packaging.

In order to be able to package, in particular, shock-sensitive small electrical appliances such as kitchen machines in whole or at least in part with the aid of corrugated cardboard, which is inexpensive in terms of weight and disposal, there is a package kung known (DE-GM 1 818 973), which consists of the contours of the packaged goods correspond to the pre-cut corrugated cardboard blanks. These blanks are stacked on top of one another and connected to one another, with the congruence of the punched-out areas forming mold nests in which the objects to be packaged or at least particularly damage-sensitive parts thereof are received flatly.

Summary of the invention

The invention is therefore based on the object of forming molded parts of the type described at the outset as a full substitution option for polystyrene foam packaging while utilizing the advantages thereof while at the same time largely eliminating their disadvantages, such that a universal use of the material corrugated cardboard for such packaging when adapting to the different formal requirements for a wide variety of packaging goods by means of simple and inexpensive manufacturing processes and a closed, flat reception of the respective packaging goods.

This object is achieved in that the material body consists of a plurality of mutually separate, layered interconnected shaft layers which completely fill the volume determined by the external dimensions of the body, and that the mold cavity is formed from the closed material body. Depending on the material used and, if appropriate, using appropriate auxiliaries or additives, the mold cavity is designed to have a stable surface for the purpose of avoiding resetting, ie in order to maintain the mold cavity shape. The material body is intended to extend with the wave shape directed in the depth direction of the mold cavity and the mold cavity essentially by pressing or compressing the wave material in the direction of its waves be educated.

This gives a material body which is constructed from multi-layer fibrous corrugated material, the mold cavity and its shape can be predetermined in such a way that the packaged goods are enclosed by the molded packaging part with a tight fit of the mold cavity walls. The invention makes use of the surprising finding that multi-layered, ie multi-layer material made from separate, ie non-wound layers of fibrous corrugated material such as cellulose, especially corrugated cardboard, with the exercise of - when using heat and / or moisture, even relatively low - Pressure in the direction of the waves and thus contrary to the usual deformability of such material, ie in the direction of the highest resistance to deformation, in a simple manner permanent, that is to say plastically deformable and one can thus produce molded parts which, in terms of shape, size and function, are not inferior to those made of polystyrene foam and come sufficiently close in terms of weight, with the shaft arrangement according to the invention being able to accommodate high weights of packaging material even with light paper materials of low quality. The multilayer corrugated material blocks required for the molded parts can, in an advantageous manner described below, be produced in a continuous process by producing a continuous strand of material and cutting it off in the desired size in each case, that is to say both in terms of thickness, length and width and other shape, for example with regard to Curvatures are produced so that in addition to the production of smaller series, mass production with high output per unit of time and thus universal use of molded packaging parts designed and produced according to the invention is possible. In contrast to the spiral or spiral wound corrugated cardboard semi-finished bodies of the known type, the required molded part sizes can be arranged in the panel as far as possible and below Use of computer-controlled cutting and / or milling techniques that are possible today, whereas in comparison to the manufacture of polystyrene parts, no material shapes are required, but only appropriate embossing or printing tools. The molded parts according to the invention can be put together to form an overall packaging, for example for household machines, devices and complete systems of consumer electronics, but also larger machines or machine parts, to name just a few possibilities, by correspondingly coordinating the shape of several individual parts. However, they can also be used just as well as trays to be blistered with a visible surface, inserts for boxes, systems for the orderly storage of tools, cutlery, etc.

This enables you to replace the expensive and difficult-to-dispose foam material, which is environmentally harmful in its manufacture and use, with a material that brings considerable improvements with regard to the manufacture of the molded parts, their use and ultimately their disposal, and but at the same time fully meets the requirements for a short-lived packaging material that flatly and tightly encloses the packaging material. For example, corrugated material covered on one side, which is commercially available, for example, as corrugated cardboard, can be used, with different corrugation heights and gram weights depending on the type, shape and nature of the molded parts to be produced. The paper qualities that can be used can be kept relatively low, and the use of recycled waste paper can even be considered up to 100%, whereby even a paper that has been recycled several times can be used. It is important that compared to the plastic foam, the pure raw material costs for the shaft material on today's basis are less than a third. Corrugated cardboard layering is also cheaper than the volume calculation based on volume Plastic foam. Even if these advantages are offset by a possibly somewhat more complex processing technology, on the one hand the lower energy costs and much shorter cycle times (time per piece) when processing paper compared to plastic foams are significant, and on the other hand the advantages of pure recycling material and the adjustable rotting time to be considered very meaningful.

The preferred use of unilaterally covered, relatively light and low-quality corrugated cardboard, which, as indicated, is commercially available as rolled corrugated cardboard, is a further advantage in this respect. Due to the relatively low importance of this material, the large, high-performance corrugated cardboard companies have not in this area invested more. In recent years, you have mainly concentrated on the production of high-quality corrugated cardboard covered on both sides, from which folding boxes, crates or the like are produced. The invention thus opens up a new area of application for this material, especially since the modern, high-performance corrugated cardboard machines can only process paper with certain minimum requirements. In the coarse wave range, wave material is generally used today that has a weight of at least 120g. Papers with a minimum weight of 120 g are also used for the two top layers, with at least one blanket partially consisting of new cellulose. The paper of the corrugated cardboard structure must therefore have a certain stability so that it can be processed on modern systems. On the other hand, the corrugated cardboard that is preferred for the invention can be produced from much lower paper qualities. As mentioned, both the ceiling and the shaft can consist of 100% recycled waste paper. Paper with a weight of up to approx. 80g can be used for the ceiling and the shaft. Possibly. are in individual cases however, significantly lower paper qualities can also be used.

As already indicated, the material body can preferably be a molded block which is divided from a material strand and which, in opposition to the base surface, has a defined molded part surface from which the mold cavity (s) extend / extend into the interior of the body. In other words, in such a material body, the waves lie in a direction between the molded part surface and the bottom surface, and the mold cavities are produced from the molded part surface by embossing or pressing together with tools in accordance with the desired shape. However, it is equally possible that the mold cavities extend from different directions into the interior of the molded part. Depending on the desired nest depth, the waves are more or less compressed. This upsetting begins on the surface and increases according to the degree of deformation over the depth to be produced, the highest degree of upsetting always being present on the contact surface for the goods to be packaged and the lowest in the area of the bottom surface. In this respect, there is a very sensible combination between the strength of the receptacle and the shock absorption capacity of the packaging, since pressure, shocks, etc. have to be absorbed primarily from the outside of the packaging, so that the deformability is highest here.

In an expedient embodiment of the invention, adjacent corrugated layers are joined together by a common cover layer, which means that the use of the above-described corrugated cardboard material, that is corrugated cardboard covered on one side, can be realized particularly expediently. However, it is also possible to dispense with ceiling layers at least partially by means of a cross-layer arrangement or by additional stabilization or fixing of the shafts in order to save weight.

For the reasons described above, the material forming the corrugated or ceiling layers can be particularly advantageously made of fibrous material, such as waste paper, produced in recycling.

In an advantageous embodiment of the invention, the layered shaft layers which are adjacent to one another can be joined to form the material body by connection by means of their cover layers and / or by connecting means which hold the layers together at cut surfaces essentially perpendicular to the wave course, these variants of the joining of the individual layers depending on can choose the application, degree of deformation, the required shock absorption capacity, etc. Either cover layers or other laminations can be provided as connecting means which stabilize the molded part surface at least in the area of the surface of the mold cavity, which in turn can also be an additive, in particular a binder, which has a stabilizing effect. This additive can be part of the lamination and / or the shaft material. On the other hand, it can be advantageous, viewed individually or in addition, if the molded part surface is stabilized at least in the area of the cavity surface by chemical and / or physical treatment, this being entirely dependent on the type and nature of the corrugated material and / or the additives used.

If, according to a further embodiment of the invention, corrugated fiberboard is interspersed with or has a stabilizing agent as a liner, which consists of plastically deformable material and may have elastic, brittle, water-repellent and / or adhesive material properties, there is a significant additional advantage: The fact that material produced in recycling or multiple recycling has a relatively high density, results in a relatively low material consumption when diving in or other application of stabilizing agents, which may include stearin, paraffin or similar material, but especially, for example, adhesive thermoplastic material or the like, which has favorable properties with regard to processability (rapid softening and curing) and plastic deformability. To increase the stability after embossing deformation, plastically deformable material can also advantageously be used as adhesive material for shafts and ceilings. This can lead to the smoothing and stiffening of the nest surface in the course of the deformation. If one takes into account that the much spongier mixed papers, such as those used in the production of corrugated material from new cellulose, in some cases absorb far more than 100% by weight of stabilizing agents, it provides a significant advantage of the invention is that the material density of the fibrous material can be so great that the weight fraction of the stabilizing agent can only be up to a maximum of 50% of the weight of the untreated fibrous material. This, at the same time in connection with the measure that the corrugated or ceiling and cover layers can preferably consist entirely of recycled waste paper, whereby, as mentioned, the specific weight of the paper can be a maximum of 80 g, represents a considerable additional advantage of the invention Shaped part on its use as packaging aids, especially with a view to the substitution of today's very light polystyrene foam.

Since the molded parts can be cut off from the strand and the corrugated material has an uneven or corrugated or an open-pore surface whenever a separation is made in any direction transverse or perpendicular to the ceiling layers, at least one of the The outer surfaces thereof can be coated with a covering material. Coating with such a covering material does not only make the outer optical Impression improves, but also manageability, accompanied by a reduction in the risk of damage or injury. The cover material can be a hardening liquid material such as stearin, paraffin or the like, but also a cellulose-containing fibrous material, preferably recycled paper material, as well as fleece or gauze. When impregnating the molded parts with the first-mentioned material group either after the molded parts have been cut or even when these materials are used during strand production, additional advantages can be achieved in terms of deformability and durability, but also stability, while coating with recycled paper is particularly important in terms of weight ratios is cheap.

Overall, as explained above, there are several options for the surface stabilization of the fibrous material, i.e. corrugated and / or ceiling material, which can be optionally combined with one another, in a lamination, in the use of binder or additive, in use of glue between the lamination and the corrugated cardboard, in an open corrugated cardboard surface that has been treated with stabilizer material, in the use of a stabilizer between the shaft and ceiling, in the provision of a stabilizer in the shaft material and in physical processes by using water, steam and / or heat can be seen. The lamination can be carried out by spraying, dipping, applying the layer or rolling suitable material. Eroding is also possible. A surface coating without lamination of the open wave structure creates a network structure that leads to a composite effect of the material properties specified by the simple wave structure, e.g. for cross-linking.

In certain applications, it is also possible to provide such layers between layers with a wave course directed in the depth direction of the cavity have a waveform arranged perpendicular to it. For this purpose, coarser-wave material may be provided, so that certain weight advantages can result. Of course, with such a crosswise stratification, the arrangement of false ceilings can sometimes be dispensed with, since the crosswise lying shaft positions can possibly be connected to each other at their contacting shaft tips, provided that the restoring forces have been controlled by appropriate pretreatment of the shaft material.

In realizing the invention, it is even possible for the mold cavity or mold cavities to be deformed up to the degree of maximum deformability of the shaft material. In this way it is possible to produce bowls, troughs or bowls with an edge that is arched against the bowl cavity, or also flower pots and similar pressed bodies, which thus have a compressed corrugated cardboard wall and are nevertheless compact and possibly leakproof. There is a much cheaper production, especially when using recycled paper material, and without the conventional effort for drying in the usual wet suction process for such compacts. Such two-sided pressed or embossed objects can be formed with walls of different thicknesses and carry thickened areas such as beads or feet. According to the invention, such thickenings, in contrast to wet suction processes, do not require complementary cavities at the position of the convex formations, so that practical parts can be produced from cellulose material, as can otherwise only be achieved by means of plastic injection molding technology.

In a preferred embodiment of the molded part, it can consist of at least two pivoted or hinged molded part sections which, on the other hand, in the assembled state, hold a product to be packaged, the contours of which are adapted to the contours can trap between them. Such molded packaging parts are particularly useful for larger packaged goods and on the one hand allow easy opening of the packaging and removal of the packaged goods and on the other hand the use of semi-finished material pieces of a height that only corresponds to part of the height of the piece to be packaged. It is even possible that the space occupied by the packaged goods can go beyond parts of the contours of the molded part sections, as long as it is ensured that the packaged part lies overall within the outer contours of the assembled molded packaging part. As a rule, for shipping such packaging goods, which are generally palletized today, they are placed in an outer carton anyway and arranged on a pallet together with other, generally identical packaging for the purpose of storage or transport. In the case of such molded parts divided into molded part sections, the sections can preferably be connected to one another in a hinge-like manner exclusively on an outer surface by means of a common cover layer; it is therefore possible to produce a molded part base body of relatively small height, which is divided into individual molded part sections, and, by folding up sections, to produce a package overall in which a significantly higher packaged goods can be accommodated. The ceiling is used as a common connecting element.

In the manufacture of a material body which is suitable for forming the molded parts or molded part sections described above, in a further development of the inventive concept, shaft material is cut to pieces of material of essentially the same length and width, these pieces of material are layered to a block of the desired height and from this block, holding the pieces of material together, material disks of the same thickness in a plane substantially perpendicular to the dimension of the length and the waveform are separated, whereupon these disks are joined to form a continuous strand of material of any length with a height or width determined by the thickness and width of the material pieces, and material bodies of the desired length for the subsequent production of the mold nests in them are separated from this strand of material. In such a method, one-sided covered shaft material is preferably used, which can be produced on a roll and kept in stock, in order to then continuously feed it to the corresponding system during the production of the material pieces. It is also possible, however, to continuously supply corrugated cardboard covered on one side from a corrugated cardboard production system and to separate pieces of the same length from the supplied material web and to stack them up to form the block such that the width of the material web is the length of the block and the cutting length of the material pieces is the width of the block form. Optionally, the cut pieces of material can be joined together by gluing the individual shaft layers or by holding the layers while cutting and connecting the layers at the cut surfaces perpendicular to the shaft direction. Of course, both options can also be combined.

When embossing the mold cavities, depending on the previous preparation of the starting material and / or the arrangement of appropriate laminations, the procedure is usually to adjust the heat, moisture and pressure to match the respective material properties. The required temperatures result from the melting points of the aggregate. With thermoplastic materials, melting points of the order of about 60 to 160 ° C can be assumed; the lower the melting point, the lower the temperature of the embossing tool needs to be, so that one can remain sufficiently below the flash point of the corrugated material or corrugated paper. Because the temperature is too leads to the desired zonal destabilization of the shaft material, one usually gets by with relatively low pressures in order to overcome the material resistance and to switch off the material restoring forces. It is also important in this context that a generally only slight increase in the moisture content of the material leads to considerable reductions in the required embossing pressure.

The overall advantages that can be achieved with the invention are that a corrugated material, preferably corrugated cardboard covered on one side, can be used as the starting material, which, due to the fact that it can consist of 100% recycled waste paper, entails considerable cost advantages and one has relatively high density, which causes a low absorption of stabilizing materials. The molded parts according to the invention are also considerably more environmentally friendly than conventional packaging aids of similar shape and similar purpose made of polystyrene foam, in that they can be easily disposed of, have good compostability or rotability and can also be subjected to recycling again. Compared to foams, they are easy to print and color and, due to the elimination of the casting or foaming molds, they can be produced inexpensively both in small series and in mass production, the embossing tools being cheaper to produce than foam molds. Even if the weight advantages of polystyrene foam are not fully achieved, a significant compromise can be achieved between the material costs and the physical properties, which is in favor of the molded parts according to the invention. In addition, the material to be used according to the invention is currently the lightest known natural raw material for the packaging purposes mentioned, that is to say for the production of packaging parts having mold cavities, and moreover with the possibility of disposing of one Compression - especially after moistening the material with water - to about a tenth of its volume, which leads to a reduction in packaging waste volumes in industry and household.

Figure description

• Fig. 1 eine axonometrische Ansicht eines erfin­dungsgemäßen Formteils mit ineinander über­gehenden Formnestausbildungen und teilweise weggelassener Deckschicht zur Darstellung der Wellenausrichtung,
• Fig. 2 einen Querschnitt durch ein ähnliches Form­teil mit unterschiedlich stark abgestuftem Formnest und unterschiedlichen Stauchungs­graden,
• Fig. 3 den prinzipiellen Ablauf der Herstellung eines Materialstranges zur Herstellung der erfindungsgemäßen Formteile,
• Fig. 4 in axonometrischer Darstellung eine abgewan­delte Ausführungsform eines erfindungs­gemäßen Formteils mit mehreren Formteil­abschnitten,
• Fig. 5 die Ausführungsform der Fig. 4 in verein­fachtem Längsschnitt und kleinerem Maßstab mit eingelagertem Verpackungsgut,
• Fig. 6 eine Darstellung ähnlich Fig. 4 einer weiteren Ausführungsvariante mit in Abschnitte unterteiltem Formteil,
• Fig. 7 einen Prinzip-Schnitt der Ausführungsform der Fig. 6 im kleineren Maßstab mit einge­lagertem Verpackungsgut und
• Fig. 8 eine andere Ausführungsform der Erfindung für ein bis zum Grad maximaler Verform­barkeit des Wellenmaterials verformtes Formteil.

Further advantages and embodiments or possibilities of the invention emerge from the following description of the exemplary embodiments shown in the schematic drawing. It shows

• 1 is an axonometric view of a molded part according to the invention with merging moldings and partially omitted cover layer to show the shaft alignment,
• 2 shows a cross section through a similar molded part with differently graduated mold cavities and different degrees of compression,
• 3 shows the basic sequence of manufacturing a strand of material for producing the molded parts according to the invention,
• 4 is an axonometric representation of a modified embodiment of a molded part according to the invention with several molded part sections,
• 5 shows the embodiment of FIG. 4 in a simplified longitudinal section and on a smaller scale with the packaged goods stored,
• 6 shows a representation similar to FIG. 4 of a further embodiment variant with a molded part divided into sections,
• Fig. 7 is a principle section of the embodiment of Fig. 6 on a smaller scale with stored goods and
• Fig. 8 shows another embodiment of the invention for a molded part deformed up to the maximum degree of deformability of the shaft material.

Embodiments

A molded part 1 according to the invention with a low volume weight is shown in its basic structure in FIGS. 1 and 2 and comprises a material body 10 in which one or more mold cavities 11, here in the form of a plurality of mold cavity sections 11a, b, c and d that run into one another, are arranged.

The material body 11 is formed from corrugated material or material 2, the corrugations extending according to the arrow A in the depth direction of the mold cavity 11. The corrugated material here is corrugated cardboard made from recycled paper. It is corrugated cardboard covered in one layer, in which adjacent corrugated layers 21 and 22 are joined together by a common cover layer 3, ie are connected to one another in a known manner by gluing. The corrugated material is interspersed or interspersed with a stabilizing agent that is not recognizable in the drawing, in order to give the material certain properties, possibly adapted to special applications, that have changed compared to pure corrugated cardboard, for example with regard to elasticity, brittleness, water repellency, gluing or the like . to give. The stabilizing agent can be materials such as stearin, paraffin or thermoplastic, although other substances or substances that are suitable for the purposes of use and production can also be used.

Surface 13, bottom surface 14 and side surfaces 15 of the material body 10 are covered with a cover material 4, which is either a fibrous material, e.g. Waste paper, or other coating materials such as film formers, waxes, synthetic resins or the like. can act coated.

The mold cavity 11 is formed by surface 13, i.e. here one-sided upsetting of the shaft material 2 in the shaft direction A. In other words, the material body 10 initially has a cuboid, closed shape, which is then provided with the mold cavity by embossing or other pressing with correspondingly shaped tools. As a result of the desired shape of the mold cavity, there are different degrees of deformation or compression for the various mold cavity sections 11a-d, these different degrees of compression being characterized by hatches of different densities as 12a, b, c, d (see FIG. 2). The deeper the mold cavity section in question, the higher the compression and thus the compression of the corrugated material.

It has been found to be surprising that the aforementioned compression of the corrugated cardboard to form nests in the manner shown, that is to say by deformation in the direction of the shaft A, means that the restoring forces of the corrugated material in the compression area can be overcome, that is to say they can no longer be effective, but instead the material "remains" in the deformed state, ie it behaves plastically and does not deform back. This creates a possibility for the formation of very form-fitting mold nests, in which correspondingly shaped parts can be securely embedded in a form-fitting manner for shipping and storage. As can be seen from the right-hand partial illustration of the arrangement of the shaft material, the volume weight of such a shaped body is relatively low, and it is the lower, the lighter shaft material and the less coarser or higher waves are used. The total packaging weight can be calculated in a simple manner from the geometric starting body, since although the material is compressed locally or zonally, the weight does not increase, based on the overall body.

The compression leads to the consolidation of that part of the surface that comes into contact with the stored goods, while no deformation takes place in the region of the side walls and, above all, the bottom surface 14, so that the corrugated material retains its shock absorption properties to the full extent , So the function of the molded body as a packaging part is fully guaranteed.

A molded part 1 or material body 10 is in the raw state, i.e. prior to the formation of the mold cavity 11, separated as a mold block from a strand of material which, if necessary, can be continuously introduced into a corresponding machine and the production of which is shown in principle in FIG. 3 proceeds essentially as follows:

Pieces of material of the desired length are cut from a unilaterally covered corrugated material that can be drawn off from one or more rollers, either in opposite directions, in order to achieve the highest possible frequency and thus a large material output, or in one direction. These are then glued, heat sealed or the like. stacked on top of each other to achieve a multi-layer blank. The stacking is carried out in a known manner and need not be explained in more detail here.

The length L of such a blank 5, as shown as a raw material for the processing shown in Fig. 3 in principle, depends on the width of the output corrugated material as it is drawn off the roll, while its width B depends the length of the sections and its height H depends on the number of layers or layers placed on top of one another. It is therefore possible to produce the dimensions of this blank 5 as required, ie the processing purpose and size of the desired molded part. In the blank 5, the waveform A is, as indicated, in the direction of the length L, the parallel lines in the partial sections indicating the ceiling layers 3.

Starting from this blank 5, indicated by a dashed line S, "disks" 51 are cut off, which are folded over according to the arrow 1 and thus have a standing wave in this position, as can be seen in the right, partially cut part of the disk 51. The thickness S ₁ (= height) of these discs can be chosen depending on the later use. These disks 51 are continuously glued to one another with their end faces 52 determined by a ceiling layer, so that a continuous corrugated cardboard material strand 6 with a "standing wave" results. In this the dashed line indicates the gluing point of the penultimate glued pane 51; this glue point is actually imperceptible, since it represents the same corrugated cardboard connection as the other corrugated ceiling connections.

The height S₁ of the material strand 6 is shown in Fig. 1 for purposes of easier comparison, and it can be seen that molded part 1 or material body 10 can be cut continuously from this material strand 6 and fed to further processing to form the mold cavities.

The above describes a method which is advantageous in many respects for producing molded blocks with a standing shaft from a running roll material of corrugated cardboard covered on one side, in order to produce the molded parts according to the invention therefrom.

The continuous strand of material 6 and / or the molded parts 1 separated from it can of course be subjected to a wide variety of treatment stages. This is also the basis for the construction of the processing system, which includes, for example, one or more stations for warm air supply, coating, glue application, paper lamination (application of cover layers), etc., a station for casting liquid cover or stabilizing material, a hot air supply, a cold air supply and / or can include an embossing station. All of these stations, by themselves or in combination with others, serve both to refine - in particular the outer surfaces - and to adjust the structure of the corrugated material (if necessary) of the molded part 1 to be separated from the material strand 6. the warm air supply for faster drying, etc. used for lamination of the starting material with water-soluble adhesive, a coating station for applying glue for the purpose of a subsequent paper top coat, the coating station for applying material to make a paper cover impermeable or otherwise, the pouring station for applying stabilizing agents, a Hot air station, which is preferably arranged in the form of nozzles, for removing excess stabilizing agent from the channels, for example excess stearin, paraffin or the like, and a cold air station is required in order to solidify material such as paraffin or stearin more quickly. Of course, it is also conceivable to use an immersion process or the like instead of a cast coating.

The decisive factor in all of this is that a deformable material can be produced from corrugated material in the form of shaped blocks in the simplest, quickest, and least expensive manner, which can be permanently deformed against the natural direction of the corrugated material. It is particularly favorable for pricing that waste paper, that is, cellulose material obtained in recycling, is used Det can be, which is relatively short-fiber, so that its absorbency is limited and subsequent finishing steps such as the introduction of stabilizing agents do not lead to an excessive, but within reasonable limits weight increase.

As shown in FIGS. 4 to 8, molded parts of various structures and degrees of deformation can be produced from a strand of material produced in this way.

4 shows a molded part 1 composed of three molded part sections 1a, 1b, 1c with the (left) section 1c in the open and the (right) section 1b in the folded-up state which forms the finished packaging. The molded sections are hinged to one another via the cover material 4 of the lamination. The mold nests 11 of these molded part sections 1a, 1b, 1c are designed to accommodate a cuboid-shaped piece of packaging material 7, which can be seen in FIG. 5, so that, as can be seen from the left-hand part, the packaging material 7 can be inserted into the central molded part section 1a in the opened state . The molded part sections are then folded up by 90 °, as indicated by the position of the right molded part section 1b, so that in the assembled state, which is shown in principle in FIG. 5, the packaged goods 7 are firmly enclosed. In order to keep the molded part 1 in a position fixed for storage and transport, it is, as can also be seen from FIG. 5, surrounded by a carton 8. The molded part sections are formed on the raw part separated from the material strand 6 in accordance with the total length of the three sections with regard to their desired contact contours and the molded nest sections by embossing, so that they lie tightly against one another and the packaged goods 7 in the assembled state of the molded package part in the molded nest 11 securely and flat and can record between them without displacement. Of course, the oblique-angled contact edges could also be separated or Cutting process are generated.

6 and 7 show a variant compared to FIGS. 4 and 5, in which the hinge-like articulation of the molded part sections 1a, 1b, 1c separated by a cut in the dash-dot line E takes place over the cover layer 4 arranged along the free upper edges of the mold cavities . As can be seen from FIG. 7, the packaged goods 7 are not completely accommodated within the molded part sections, but instead form, as can be seen at the bottom left and right, free spaces into which the packaged goods can protrude. With this embodiment one saves in relation to that of FIGS. 4 and 5 molding material while accepting a partial exposure of the packaging goods; however, it must be taken into account that a cardboard box or other rewinder is provided in any case, so that the packaged goods, if no special edge protection is required, can be stored and transported with sufficient impact protection. In the event that special security is required here, the cavities 81 could still be filled with suitable filler material, but this is avoided if possible for reasons of the lowest possible transport weight.

Any suitable measures such as cold or hot forming can be considered for the deformation or embossing of the mold cavities as well as other recesses and recesses, depending entirely on the starting material and any measures taken in the course of finishing, in particular the additives and lamination materials used , judges.

The molded parts produced in the manner set out above are not limited in their application to packaging purposes, but it is also possible to produce moldings for other areas of application, if and where it is important to substitute light, but expensive and / or non-environmentally compatible materials; so you can this way the starting material for corrugated cardboard compacts or for completely, partially or not at all press-formable, but by cutting, sawing, milling or the like. Provide shaping workpieces that can be used, for example, as documents for digging arrangements, as fillers and inserts, as packs in thermal or noise insulation, etc. In such cases, appropriate shaping measures will be used.

Finally, Fig. 8 shows in principle the possibility of the maximum deformability of the shaft material of a material body 10 for the production of a trough or a shell 9 indicated by dash-dotted lines, here the embossing in two directions, indicated by the arrows II and III, from above and below he follows. The material can be compressed to different extents, in order to meet the requirements placed on the shape of such a shell for a relatively thin-walled bowl part 91 with a relatively thick bead 92 and feet 93 raised downwards.

As can be seen, it is not a major problem not only to deform the idea on which the invention is based, namely a shaped body which is designed in a "standing" shaft and is deformed in the direction of the shafts, but rather such a deformation from both sides, seen in the direction of the wave. Such two-sided deformed molded parts can, as mentioned, be used for a wide variety of purposes.

Finally, it should be mentioned that the embossing deformations do not necessarily have to be formed only in the form of nests provided with a closed, circumferential edge, but it is equally possible to apply them in the edge region of the material body to form recessed grips or other indentations.

Claims (31)

1. molded part of low volume weight, in particular packaging molded part, comprising a material body and at least one mold cavity formed therein for in particular the positive reception of objects such as packaged goods, the material body being constructed from fibrous corrugated material such as corrugated cardboard, characterized in that the material body (10) consists of a A plurality of mutually separate, layered interconnected shaft layers (21, 22) exist which completely fill the volume determined by the external dimensions of the body, and that the mold cavity (11) is formed out of the closed material body. 2. Molding according to claim 1, characterized in that the mold cavity (11) is surface-stable. 3. Molding according to claim 1 or 2, characterized in that the material body (10) with in the depth direction of the mold cavity (11) directed wave course (A) and the mold cavity is formed by an embossed compression or compression of the shaft material substantially in the direction of its waves . 4. Shaped part according to one of claims 1 to 3, characterized in that the mutually adjacent layered shaft layers (21,22) by connection by means of their cover layers (3) or shaft crests and / or by connecting means (4) which the layers on cut surfaces hold together essentially perpendicular to the wave course (A), are joined together to form the material body (10). 5. Molding according to one of claims 1 to 4, there characterized in that the molded part surface is stabilized at least in the area of the surface of the mold cavity (11) by a lamination (4). 6. Molding according to one of claims 1 to 5, characterized in that the molding surface is stabilized at least in the region of the mold surface by an additive, in particular a binder. 7. Molding according to claim 6, characterized in that the additive is part of the lamination and / or the shaft material. 8. Molding according to one of claims 1 to 7, characterized in that the molding surface is stabilized at least in the area of the mold surface by chemical and / or physical treatment. 9. Molding according to one of claims 4 to 8, characterized in that the lamination and / or the additive consist of a plastically deformable material. 10. Molding according to one of claims 4 to 7, characterized in that the lamination or the additive has elastic, brittle, water-repellent and / or adhesive material properties. 11. Molding according to claim 10, characterized in that the additive stearin, paraffin or the like. Material is. 12. Molding according to claim 10, characterized in that the aggregate adhesive thermoplastic material or similar Material is. 13. Shaped part according to one of claims 6 to 12, characterized in that the material density of the wave material is so large that the weight fraction of the additive is a maximum of 50% of the weight of the untreated shaft material. 14. Shaped part according to one of claims 1 to 13 of unilaterally covered corrugated material, characterized in that corrugated and ceiling material (21, 22; 3) consist of recycled fibrous material such as waste paper. 15. Molding according to claim 14, characterized in that the m² weight of the paper is a maximum of 80g. 16. Shaped part according to one of claims 1 to 15, characterized in that the material body (10) is a molded block of an endlessly generated strand of material. 17. Molding according to one of claims 1 to 16, characterized in that mold cavities extend from different directions into the interior of the molding. 18. Shaped part according to one of claims 1 to 17, characterized in that between layers with in the depth direction (A) of the mold cavity (11) directed wave course are provided with those arranged perpendicular to the wave course. 19. Molding according to one of claims 1 to 18, characterized in that the mold cavity / the mold cavities to the degree of maximum Ver formability of the shaft material is / are deformed. 20. Shaped part according to one of claims 1 to 19, characterized in that it consists of at least two pivoted or hinged molded part sections (1a, 1b, 1c). 21. A molded part according to claim 20, characterized in that the molded part sections (1a, 1b, 1c) in the assembled state hold a packaged item (7), the contours of which include an adapted cavity between them. 22. A molded part according to claim 20 or 21, characterized in that the space occupied by the packaged goods (7) extends beyond parts of the contours of the molded part sections (1a, 1b, 1c). 23. Shaped part according to one of claims 20 to 22, characterized in that the shaped part sections (1a, 1b, 1c) are connected to one another in a hinge-like manner only on an outer surface by means of a common cover layer (4). 24. A method for producing a material body suitable for forming a molded part according to one of claims 1 to 23, characterized in that shaft material is cut to pieces of material of substantially the same length (L) and width (B), these pieces of material into a block (5) desired height (H) layered and from this block holding together the material pieces material discs (51) of the same thickness (S₁) in a plane (S) substantially perpendicular to the dimension of the length (L) and the waveform are separated, whereupon these discs (51) to a continuous strand of material (6) of any length with the thickness (S₁) and the width (B) of the material pieces of certain height (S₁) or width (B) put together and this material strand material body of the desired length for the subsequent production of the mold nests are separated in them. 25. The method according to claim 24, characterized in that it is carried out using wave material covered on one side. 26. The method according to claim 24 or 25, characterized in that it is carried out with continuous feeding of the shaft material. 27. The method according to claim 25 and 26, characterized in that corrugated cardboard covered on one side is fed continuously from a corrugated cardboard production system and pieces of the same length are separated from the supplied material web and are stacked to form the block (5) such that the width of the material web is the length (L) of the block and the cut length of the material pieces form the width (B) of the block. 28. The method according to any one of claims 24 to 27, characterized in that the cut pieces of material are glued together with the aid of the wave crests of each piece with its adjacent to the block (5). 29. The method according to any one of claims 24 to 28, characterized in that the cut pieces of material by suitable mechanical and / or pneumatic support with loose lying on top of the material block (5) are joined and the material disks (51) are separated from it while maintaining the holder, whereupon they are connected to one another continuously or intermittently to form the material strand (6) by connecting their layers on the cut surfaces perpendicular to the shaft direction. 30. A process for the production of a molded part according to one of claims 1 to 23 using a material body produced according to one of claims 24 to 29, characterized in that the at least in the region of the surface (s) having the cavity openings is impregnated with a corrugated material additive, impregnated or otherwise suitably provided material bodies using at least some of the physical parameters heat, moisture and pressure with the appropriate setting of these parameters in relation to the shaft material and the aggregate in the direction of the waves to the desired cavity depth with - at least zone by zone - destabilization the wave structure is deformed and then dried and / or cooled. 31. The method according to claim 30, characterized in that the setting of the temperature according to the melting point of the additive takes place at a sufficient distance from the flash point of the shaft material.

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