EP0977823A2

EP0977823A2 - Methods and apparatus and units produced by the same

Info

Publication number: EP0977823A2
Application number: EP98924163A
Authority: EP
Inventors: Andrea Bartoli; Luigi Malagoli; Luca Turci
Original assignee: Unifill International AG
Current assignee: Elopak Systems AG
Priority date: 1997-04-24
Filing date: 1998-04-21
Publication date: 2000-02-09
Also published as: WO1998047772A2; WO1998047772A3; AU7646198A

Abstract

A packaging method includes forming a container by thermowelding two strips (1) of thermoplastics and blow thermoforming at least one of the strips, (1) inserting a wick (19) between the strips (1) and through the interior of the container and filling into the container a substance, for example insecticide, perfume, deodorant or candle wax, which, in a liquid state, flows along the wick.

Description

MEHODS AND APPARATUS AND UNITS PRODUCED BY THE SAME

The invention concerns a method and apparatus and a unit produced by the same. The unit may take a number of forms, for example it may include one or more containers for emanation of volatile substances, e.g. insecticides, or it may be a packaging unit for one or more candles. DE-A-44 46 413 describes a container for an active substance, such as perfume, insecticide or the like, including a portion of sheet material drawn to provide a larger cavity and a smaller cavity, closed by respective closing layers. Between the above-mentioned cavities a wick extends, which is covered by the closing layers. The cavity in which the active substance and a portion of the wick are contained is closed by a permanent closing layer, while the other cavity, wherein the other end of the wick extends, is closed by a removable layer. To activate the device, the wick is uncovered by removal of the removable layer and the wall of the corresponding cavity is turned away from the wick in such a way that it may be brought up to a heater of an evaporator device to facilitate the emanation of the active substance. Turning the cavity wall away from the wick means that the user, after removal of the removable layer, sets the cavity wall at an angle to the position which it had originally. Because the open container is inserted into the evaporator device with the wall of the cavity projecting forwards, there is a risk of contact between the leading edge of the wall and fixed portions of the evaporator device. Filling of the active substance into the dish-like drawn portion involves the risk of the liquid being spilled beyond the flange of the drawn portion, especially if the filling is performed at other than a slow rate. Moreover, the wick becomes wet before closing with the closing layers. Thus, sealing of the closing layers to the drawn portions may be unreliable. DE-U-296 12 562 describes a container for an analogous active substance, which has a chamber wherein there is lodged a wick having an end projecting outward. The container is obtained by drawing a first sheet of plastic material to form a cavity having an edge flange, extending outward and crossed by the wick, whereon a closing and substantially plane second sheet is welded, or glued. DE-U- 296 12 562 also describes a package for containing the container mentioned above, which has a first packaging sheet element wherein a cavity is formed, which has substantially the same shape as the container and a second packaging sheet element, which is substantially plane and is attached, in a removable way, to the first packaging element. The cavity has an extension to lodge the end of the wick pro ecting from the container, holds the container when the latter is placed inside the cavity and has a plurality of seating projections which support the container flange inside the cavity. Preparatory to use, the container is removed from the package, after removing therefrom the removable sheet, and inserted into an evaporator device wherein a heater acts to facilitate the evaporation of the volatile substance. Such a complex of package and container is very complicated, bulky and requires extraction of the container from the cavity of the package. Moreover, the mixture of air and vapours of the active substance from the wick exposed m the extension stays trapped m the cavity between the container and the package and tends to condense on the inside of the package .

Candles are normally manufactured as such and then put into boxes each containing one or more candles. Candles are sold m that way to customers.

It is also known to package candles by inserting each candle into a container having substantially the shape of a bowl and then melting outer parts of the candle so that, upon cooling, the candle has closely taken up the internal shape of the bowl. Each candle includes a metal anchorage from which a wick extends upwardly. After the wick has been lit, the consumer pours candle wax in granules into the bowl in order to prevent the candle from being consumed rapidly.

The Applicants believe that refill candles for such bowl are not presently available, so that when the candle has been consumed it is necessary to replace both the candle and the bowl .

A further drawback is that, when the packaging units are stocked for a long period, a somewhat significant proportion of perfumes which are included in the wax is lost to the ambient at posphere.

In known blow-thermoforming packaging systems a flowable product is filled into containers which have been blow- thermoformed from face-to-face thermoplastic strips and which, after filling, are then sealed for delivery to customers. As a result, the content of each blow- thermoformed packaging unit is only formed of a single flowable product.

US-A-5, 121, 835 discloses a candle display package including two transparent panels which double as a mould and as a container for the candle (s) . One or each of the panels is a mould panel having one or more shaped recesses with one or more sprue passages. Wick holders, including V-shaped notches, are provided beyond opposite ends of the or each recess. The panels may be held together during moulding and thereafter by snap-fastener-type elements formed on the panels. A display graphics card may be held between the panels. In one embodiment, the panels are hinged together beyond the upper ends of a group of candle recesses, with the panels held together with the hinge lowermost and the sprue passages uppermost, and wax is poured in through the passages and allowed to set. It is desired to improve existing packaging systems, especially for such products as insecticides, deodorants, perfumes and candles . According to a first aspect of the invention, there is provided a method including forming a container utilizing first and second strips of material, said forming comprising blow-thermoforming, characterized in that a wick is located to extend between said strips and through the interior of said container.

According to a second aspect of the invention, there is provided apparatus including forming means which utilizes first and second strips of material in forming a container, said forming means comprising blow- thermoforming means, characterized in that locating means serves to locate a wick to extend between said strips and through the interior of said container.

According to a third aspect of the invention, there is provided a unit comprising a container which has been formed by utilizing first and second strips of material in blow-thermoforming, characterized in that a wick extends between said strips and through the interior of said container and that said container contains a substance which, in a liquid state, flows along said wick. Owing to these aspects of the invention, it is possible to produce wicked units relatively rapidly and relatively cheaply.

According to a fourth aspect of the invention, there is provided a method including forming a container utilizing first and second strips of material, filling said container with a substance and locating a wick between said strips to extend through said container, whereby said substance, in a liquid state, flows along said wick, characterized in that said wick is introduced to between said strips before said substance is filled into said container.

Owing to this aspect of the invention, it is possible to avoid the substance wetting the wick before the strips are sealed together.

According to a fifth aspect of the invention, there is provided a method including utilizing first and second strips of material to form a container, filling said container with a substance and locating a wick between said strips to extend through said containers, whereby said substance, in a liquid state, flows along said wick, said container being part of a unit m which said wick is completely enclosed, characterized in that no more strips than said first and second strips are employed m providing the external walls of said completed unit. According to a sixth aspect of the invention, there is provided a unit comprising a container comprised of first and second strips of material, a substance contained by said container, and a wick extending between said strips and through said container, whereby said substance, m a liquid state, flows along said wick, said wick being completely enclosed m said unit, characterized m that no more strips than said first and second strips are employed in providing the external walls of said unit. Owing to these aspects of the invention, it is possible to simplify the manufacture and structure of such units. According to a seventh aspect of the invention, there is provided a method comprising providing candle wax means and wick means m a container formed of first and second walls joined together, characterized by injecting anchoring means into said container.

According to an eighth aspect of the invention, there is provided apparatus comprising providing means arranged to provide candle wax means and wick means in a container, and forming means arranged to form said container of first and second walls joined together, characterized m that injection means is arranged to inject fluid anchoring means into said container.

According to a ninth aspect of the invention, there is provided a unit comprising candle wax means and wick means m a container formed of first and second walls joined together, characterized by anchoring means m said container. According to a tenth aspect of the invention, there is provided a method comprising introducing a fluid anchoring substance into moulding means having walls defining an interior thereof, said anchoring substance flowing to a bottom part of said interior to an anchorage location at which said anchoring substance forms an anchorage means which causes a wick to be anchored at said anchorage location upon setting of said anchoring substance, and introducing fluid wax to above said anchorage means and around said wick between said wick and said walls. Owing to these aspects of the invention, it is possible to provide a wick anchorage in a convenient manner. In particular, with reference to the latter aspect, the provision of the anchorage can be m a manner which reliably results in the anchorage being at the bottom of the wax.

According to an eleventh aspect of the invention, there is provided a method comprising providing candle wax means and wick means m a container formed of first and second walls joined together, characterized by introducing said wick means through an opening of said container. Owing to this aspect of the invention, it is possible to provide a wicked container m an efficient manner. According to a twelfth aspect of the invention, there is provided a method wherein a distribution container is formed of first and second walls joined together along an outline of said container and first and second flowable products are filled into said container.

According to a thirteenth aspect of the invention, there is provided apparatus comprising means arranged to form a distribution container of first and second walls joined together along an outline of said container and to fill said container with first and second flowable products. According to a fourteenth aspect of the invention, there is provided a unit comprising a distribution container formed of first and second walls joined together along an outline of said container and first and second flowable products in said container.

Owing to these aspects of the invention, the range of contents which can be packaged in such units is significantly increased.

In a preferred embodiment, the unit comprises a container having a cavity containing a volatile substance, a wick extending outwardly from said cavity and intended to transfer, in a controlled manner, the volatile substance from the cavity to the ambient atmosphere, the cavity being provided with an extension projecting outwards and bounded by at least one element of removable sheet material containing the outer end zone of the wick. Advantageously, the container is obtained by thermowelding of two strips of gas-barrier sheet material along a welding edge, the appendix forming an outward extension of that edge, and thermoforming at least one of the strips to make it concave and joined; between the strips there is interposed the wick, which is preferably flat. In a further advantageous embodiment, the appendix has a gap which exposes the outer end zone of the wick, and the gap is covered by a fluid-tight removable cover. Thus, the appendix may be covered, at both its sides, by sheets of removable material, for example a peelable material which cover gaps at both sides, and thus protects the wick and isolates it from the outside environment and thereby prevents the emanation of the active substance before the opening of the unit.

In such a manner, the unit is totally closed without it having to be introduced into a package. Moreover opening is simplified because, for use, it is sufficient to remove the sheets of removable material, freeing the wick. Preferably, the wick is attached to the appendix along at least one pair of edges.

Thus, it is possible to protect the wick during insertion into an evaporation device, so eliminating the risk of damage of the wick by contact with projecting portions of the evaporator device.

In a preferred method for manufacturing containers containing one or more volatile substances, a pair of strips is thermowelded and at least one strip of the pair is thermoformed to obtain groups of containers joined by thermowelding along respective major peripheral edge zones of the containers, each container having a non-welded peripheral edge zone providing a communication between the container interior and the outside. The method then includes filling with the substance (s) , inserting wicks through the communications into the container interiors, and closing the containers; wherein, during the closing, the wick is enclosed between the strips.

In one embodiment, before the filling, a portion of the or each communication conduit is punched out, m such a way that during closing of the container (s) the outer end zone (s) of the wιck(s) stay(s), at least partially, not engaged by the strips.

In a preferred embodiment, the appendix defines a chamber m which the outer end zone of the wick is contained, the chamber being openable along a predetermined fracture line interposed between an edge zone of the chamber and the container interior.

In such a way, the container is completely closed without introducing it into a package. Moreover, opening is simplified, since, for use, it is sufficient to flex the container and the appendix about the predetermined fracture line to free the emanating end zone of the wick. In a further embodiment, there is provided a packaging unit comprising a container, and a candle m said container having wick means, said container comprising first and second walls joined together and extending over respective opposite sides of the candle.

It is thereby possible to improve the packaging of candles, particularly from the point of view of shortening the manufacture of packaging units including candles. Furthermore, it is possible to provide a refill candle which may be inserted into a bowl-shaped container when a previous candle in that container has been consumed. It is also possible to prevent perfumes in the candle from evaporating before use, because the walls may provide an effective isolation of the candle.

In a further preferred embodiment, there is performed a method comprising providing distribution containers with respective wick means extending therethrough, introducing fluid wax to between the wick means and the respective containers and subsequently delivering to customers packaging units formed of solidified wax obtained from the fluid wax, the wick means and the containers. In this way, the production of packaged candles can be greatly simplified.

The invention will be better understood by reference to the attached drawings, which show some embodiments and wherein:

Figure 1 is a schematic front view of an apparatus for manufacturing wicked packaging units;

Figure 2 is a section taken along line II-II of Figure 1 ; Figure 3 is a fragmentary view from the right in Figure 2; Figure 4 is a section taken along line IV-IV of Figure 1; Figure 5 is a vertical section of a container, filled with a liquid volatile substance and with a wick inserted; Figure 6 is a fragmentary view from the right in Figure 5; Figure 7 is a section taken along line VI I-VI I of Figure 6; Figure 8 is a section taken along line VIII-VIII of Figure

1;

Figure 9 is a fragmentary view from the right in Figure 8;

Figure 10 is a section taken along line X-X of Figure 1;

Figure 11 is a fragmentary view from the right in Figure

10;

Figure 12 is a front view of a filled and closed unit, in an embodiment wherein an outer end zone of the wick is contained m an appendix provided with a window-shaped gap;

Figure 13 is a view as m Figure 3, but relating to an embodiment of unit with fork-shaped gap;

Figure 14 is a section taken along line XIV-XIV of Figure 13;

Figure 15 is a front view as m Figure 12, but with the wick inserted into the fork-shaped opening of Figure 13; Figure 16 is a section taken along line XVI-XVI of Figure 15;

Figure 17 is a section as m Figure 16, but m an embodiment wherein the outer end zone of the wick is received m a seat obtained between two strips of thermoformable material and provided with a predetermined fracture line;

Figure 18 is a section as m Figure 17, but m a further embodiment wherein the seat is wide enough to receive the wick loosely;

Figure 19 is an enlarged section of the portion of the unit where the wick exits from the container, m an embodiment wherein the wick is protected by a pair of removable closing sheets;

Figure 20 is a schematic front view of a modified embodiment of the apparatus;

Figure 21 is a fragmentary section taken along line XXI- XXI of Figure 20;

Figure 22 s a fragmentary view from the right m Figure 21;

Figure 23 is a view as m Figure 22, but after welding transversely of an intermediate portion of the wick; Figure 24 is a section taken along line XXIV-XXIV of Figure 23;

Figure 25 is a section taken along line XXV-XXV of Figure 23; Figure 26 is a front view of a unit produced by the apparatus of Figure 20;

Figure 27 is a section taken along line XXVII-XXVII of Figure 26;

Figure 28 is a diagrammatic perspective view from one end of a system for producing blow-thermoformed packaging units including candles;

Figure 29 shows a diagrammatic, fragmentary, partly sectional front view of a piece of blow-thermoformed sheet material defining containers each containing a wick and an anchorage for the wick;

Figure 30 is a view similar to Figure 28 of another embodiment of the system;

Figure 31 is a view similar to Figure 29 of a piece of blow-thermoformed sheet material in the embodiment of Figure 30 and illustrating an initial phase of incorporation of a wick into a blow-thermoformed container;

Figure 32 is a view as in Figure 31, but during a later phase of incorporation;

Figure 33 is a view as in Figure 31, but at a stage at which a flowable anchoring substance has been introduced into the container;

Figure 34 shows a diagrammatic, fragmentary top view of the piece during the phase of Figure 29, with partial welding means in a open condition;

Figure 35 is a view as in Figure 34, but with the welding means in a closed condition;

Figure 36 is a front view of a packaging unit produced by the system of Figure 29;

Figure 37 is a side view of the packaging unit of Figure 36;

Figure 38 is a top view of the packaging unit of Figure 37;

Figure 39 is an elevation of a candle unit removed from the packaging unit of Figure 36; Figure 40 is a view similar to Figure 30 of a piece of blow-thermoformed sheet material defining containers each having two apertures formed in a peripheral seal of the container;

Figure 41 is a view as in Figure 40, but with the apertures receiving respective injectors delivering fluid products to a bottom part of the container;

Figure 42 is a view as in Figure 41, but at a later stage of injection, at which the injectors are withdrawn from the bottom part of the container;

Figure 43 shows a fragmentary front view of a packaging unit containing two distinct products separated along a plane extending longitudinally of the packaging unit; Figure 44 is a view as in Figure 43, but showing the products separated along a transverse plane of the packaging unit;

Figure 45 is a section taken along line XLV-XLV of Figure 44.

Referring to Figure 1, a pair of strips 1 unwound from a reel, not shown, or a sheet longitudinally folded so as co obtain a pair of opposite strips, is indexed in a feeding direction FI through a thermowelding and blow- thermoforming station 2, or a plurality of stations, fcr thermowelding and for blow-thermoforming by injecting a pressurized fluid by of suitable injecting means 3. At the station (s) 2 groups 4 of containers are formed according, for example, to the manners described in WO-A-94/08852, or in EP-A-0692364, the groups 4 of containers being severed from the strips 1 exiting from the forming station 2 by severing means (not shown) . The groups 4 are subsequently indexed in a direction F2, orthogonal to the direction FI, in which a first punching station 5, a filling station 6 for filling the containers, an introducing station 7 for introducing wicks into the containers, a closing station 8 for closing the containers, an attaching station 9 for attaching a peelable cover and a second punching station 10 to sever the individual containers from each group 4 are disposed m succession.

Each group 4 of containers exiting from the forming station 2 comprises (Figure 2) a first strip portion 11, which is substantially flat, and a second strip portion 12, wherein there has been obtained, by plastic deformation through blow-thermoforming, at least one cavity 13 intended to contain an active substance to be emanated. The strip portions 11 and 12 have been joined together by thermowelding m zones 14 bounding the perimeter of each cavity 13. Each zone 14 has an upper end portion defining an opening in the form of a conduit 15 which allows communication between the cavity 13 and the outside .

At the punching station 5, a pair of opposite punches (5') is driven to act on corresponding zones of the strip portions 11 and 12 defining each conduit 15, so as to create therein a pair of opposite window-shaped gaps 16, having substantially the same dimensions as and aligned with each other; the pair of gaps 16 has a transverse dimension less than the transverse dimension of each conduit 15.

At the filling station 6, the cavities 13 are filled with a liquid, active substance 18, which is introduced into the cavities through filling cannulae 17 inserted through the conduits 15.

In a case m which, after severing of the groups 4 from the strips 1, or after punching of the pair of gaps 16, the conduits 15 have respective outer edges which have been squashed by the severing and/or punching, there could be provided, Petween the first punching station 5 and the filling station 6, a flaring station, not shown, for flaring the edges mentioned above and comprising flaring conical spindles acting on those edges to open them at least sufficiently to prevent interference during introduction of the cannulae 17. Advantageously, each conduit 15 extends vertically, so as to act as a passage for the corresponding cannula 17 (as well as for the wick 19, as will be explained below) and assure an optimal condition of filling of the corresponding cavity 13.

After introducing the liquid substance 18 into the cavities 13 and after extracting the cannulae 17 from those cavities, each group 4 is advanced to the introducing station 7, shown m Figure 4, for inserting a wick 19 into the cavity 13 through the conduit 15. The wick 19 is obtained by unwinding of a porous wick stock 22, such as paper or a textile, permeable to the liquid substance 18, from a reel 20 and cutting thereof by shears 21 which are above the conduit 15. To ensure that the stock 22 stays m a substantially rectilinear condition which promotes the inserting thereof through the conduit 15, the stock 22 is passed through a plurality of straightening, idle and/or motorized rollers 23. The shears 21 cut the stock 22 when the free end thereof is at a certain distance from the bottom of the cavity 13, m such a way that, once cut, the wick 19 falls inside the liquid 18 and rests on the bottom of the cavity. To facilitate correct positioning of the wick 19, the bottom of the cavity is provided with an oblique guide wall 24 terminating m a seat 24', located immediately adjacent to the portion 11 and opposite to the conduit 15 and arranged to guide and receive the corresponding end of the wick after it has been cut off by the shears 21.

Figures 5 and 6 show the positioning of the wick 19 inside the cavity 13 after it has come to rest on the seat 24'. In an alternative embodiment, not shown but similar to that shown m Figure 22, the wicks are inserted through the respective conduits 15 by an inserting device, after they have been cut and stored m a suitable loader supported above each conduit 15.

Figures 8 and 9 show that, at the closing station 8 for closing groups 4, each conduit 15 is squashed so as to extend the welding zone 14 between the portions 11 and 12 and isolate the cavity 13 from direct communication with the outside. Owing to the squashing of each conduit 15, the wick 19 is gripped between the portions 11 and 12. The wick projects outwards with respect to the cavity 13 through a portion 25 of the periphery of the cavity 13. The gaps 16 are smaller than the dimensions of the wick and therefore, during squashing of the conduit 15, they frame the outer end zone 26 of the wick which projects from the cavity 13, the zone 26 thus being held firmly round its periphery by the edges of the openings 16. The gripping of the zone 26 assures stable positioning of the wick 19 inside the cavity 13.

As a consequence of the squashing of the conduit 15, the communication with the outside may take place only through the wick zone 26. Therefore, the liquid, volatile, active substance 18 tends to move from the cavity 13, wherein it is contained, to the exposed zone 26 while the substance evaporates, for example if it is heated in an evaporating device of conventional type.

To inhibit the evaporation of the substance 18 before use, downstream of the closing station 8 there is provided an attaching station 9 for covering with a pair of removable sheet elements 27 the portions of the welding zones 14 containing the gaps 16. The covering may be by a pair of removable sheet elements 27a, coupled for example m a peelable way with the portions 11 and 12 and physically independent of each other, as indicated m Figure 19, or may be a single sheet elment 27 folded longitudinally, by means for example of a folding device 29 indicated m Figure 1.

There is further advantageously provided, m the sheet element (s) 27, or 27a, at least one manually grippable edge zone 28, or 28a, to assist removal of the sheet element (s) for use. Downstream of the attaching station 9, there is provided the second punching station 10 wherein, from the groups 4, the units 30, shown in Figure 12, are cut out. Each unit

30 is provided with a peripheral weld 14 which surrounds the cavity 13 containing the liquid 18 and, in an extension 35 of the weld, has the gaps 16, which are closed by the peelable sheet elements 27, 27a.

The gaps 16 described so far have a window shape, but, as shown in Figures 13 to 16, in the welding zones 14 relating to the conduits 15 there may be fork-shaped gaps

31 open upwardly, the welding zones 14a around the gaps 31 being correspondingly fork-shaped (Figure 15) . In this case, as shown in particular in Figure 14, the conduit 15 may be shorter than when the gaps are window-shaped.

As shown in Figure 15, closing of the groups 4 results in each zone 26 being gripped at just three three sides, but it still has a very precise and secure position for insertion into an evaporating device.

Figure 17 shows a unit wherein the outer end zone of the wick 19 is incorporated between the portions 11 and 12 forming the body of the unit, in a seat 49 which entirely receives the zone 26, so as to close it off from the outside. To free the zone 26, there is provided a predetermined fracture line 50 in each of the portions 11 and 12, such as to fracture under the action of a slight bending stress exerted by the user.

As shown in Figure 18, according to a further embodiment, the zone 26 of the wick 19 is contained in a chamber 51 obtained from the pair of sheet portions 11 and 12. In such a case there is provided, to promote opening, a predetermined fracture line 50a, which is located in an intermediate location of the chamber 51, spaced above the base thereof. Such an arrangement of the fracture line 50a prevents folding of the wick, during the slight bending stress on the portions 11 and 12 necessary to free the wick, and thus prevents its insertion into the evaporating device being problematic, or its emissive capacity being compromised.

Referring to Figure 20, the apparatus shown therein differs from that of Figure 1 m that the severed groups (104) are indexed into a station 107a for inserting wicks 119 into the containers and for intermediate welding, a filling station 106 for filling the containers, a closing station 108 for closing the containers, and a punching station 110 to sever the units 160 from each group 104. Each group 104 of containers exiting from the forming station 2 comprises (Figure 21) a first strip portion 111, which is substantially plane, and a second strip portion 112, wherein there has been obtained, by blow- thermoforming, at least one cavity 113 suitable to contain an active substance to be emanated. The portions 111 and 112 are joined together by thermowelding m zones 114 defining the perimeters of the cavities 113, apart from openings 115, located m the upper parts of the portions 111 and 112 to create communication between the cavity 113 and the outside.

At the inserting and intermediate welding station 107a, through the opening 115 of each cavity 113 there is introduced a porous wick 119, obtained by unwinding of a wick stock 122 from a reel 120 by means of rollers 123. Clamping means 162 insert the wick through the opening 115 until its free lower end 164 arrives near the bottom of the cavity 113. The clamping means 162 are provided with holding elements 163 which maintain the wick 119 positioned m the cavity 113 while welding means 166 squash intermediate parts of the portions 111 and 112 m such a way that, from the cavity 113 a chamber 168 is separated, wherein the emanating end 164 is received. The intermediate welding means 166 are formed by a pair of welding bars 170 one of which is advantageously covered with a resilient body 172. The resilient body 172 is preferably positioned at the same side as the second portion 112, i.e. the one which has been blow- thermoformed, to ensure the necessary sealing between the cavity 113 and the chamber 168 at the intermediate portion of welding. The welding bars 170 are moved in the directions indicated by arrows F3 and deform intermediate parts of the portions 112 from the position indicated in chain lines in Figure 21 to the position shown in full lines .

The welding bars 170 are preferably coupled with pneumatic, or hydraulic, driving means so as to ensure that the necessary sealing is obtained, in particular adjacent the longitudinal edges of the wick 119, when the liquid substance to be emanated is introduced into the cavity 113.

After the welding bars 170 have performed the intermediate welding 174 of the portions 111 and 112, the holding elements 163 of the clamping means 162 can release the wick 119. Thus, the wick is inserted already cut into the cavity 113 and simply released by the holding elements 163 when the execution of the intermediate welding 174 has been completed. In this way the wick 119 is stably maintained positioned in the cavity 113 throughout the time necessary to fix it between the portions 111 and 112. At the subsequent filling station 108, into the cavities 113 there is injected an active substance 118 in the liquid state, which is introduced into the cavities by means of filling cannulae 117 inserted through the openings 115.

At the subsequent welding station 108, end welding means 176 close the openings 115 of the cavities 113, isolating the substance 118 contained therein. The end welding means 176 comprise a further pair of welding bars 178 analogous to the welding bars 170, but which may be without a resilient body, because the wick 119 is not interposed between the portions 111 and 112 in this zone of welding. Moreover, the further welding bars 178 are shaped in such a way as to create, while they are performing the end welding 114a, also a seat 124' for that internal end 179 of the wick 119 which is opposite to its emanating end and which stays in contact with the substance 118. For use, the unit 160 is opened by holding with the hands the part of the unit defining the cavity 113 and the part of the unit defining the chamber 168, and folding the latter in the directions indicated by the arrow F4 (in Figure 27) around a predetermined fracture line 180 which is located between the intermediate welding 174 and the chamber 168 to sever the unit along the fracture line 180, to free the emanating end 164 wherefrom the substance 118 may evaporate into the ambient atmosphere.

The predetermined fracture line may be formed by an incision in one or both of the sheets 111 and 112, and may be obtained by conventional tools, such as cutting knives, for example disposed before the forming station 2 and not shown.

Since the unit 160, when opened, may be inserted into a conventional evaporator device with the seat 124' at the lower end, it is advisable that the internal end 179 be on the seat 124' so as to ensure that the wick is soaked in the liquid substance 118 until the substance 118 is completely consumed.

Instead of providing the seat 124', it is possible to clamp the internal end 179 in end welding 114a. It is to be noted that, since the dimensions of the chamber 168 are very small, before opening of the unit 160, the emanating end 164 would allow no more than a negligible quantity of liquid substance 118 to evaporate - in practice just that quantity which would saturate the volume of the chamber 168 - and therefore the units 160 may be stored for long periods without loss of content owing to evaporation.

Referring to Figures 28 and 29, the system comprises a pair of opposing strips 202 which are face-to-face with each other and which are indexed through heating and forming means 204 m the direction of arrow FI . The strips 202 travel through the heating and forming means 204 m a vertical condition parallel to each other. The heating and forming means are provided with cavities into which the strips 202, once heated, are expanded to form containers 206 welded along respective peripheral seals 208 and defining groups of containers. The strips 202 are expanded by means of pressurized forming fluid, such as pressurized air, which is injected between the strips 202 via inflation conduits 212. Severing means 214 are located downstream of the heating and forming means to sever from the strips 202 each piece 210 containing a group of containers .

Wicks 216 extend between the strips 202 so that, at the location where the containers 206 are to be formed, the wicks 216 extend along the heating and forming means 204, whereby, when each piece 210 is severed from the strips 202, each container 206 includes a wick 216. Advancing means (not shown) advance each piece 210 m a direction indicated by arrow F2 to an injection station 218, m which flowable anchoring means 220 are injected into the containers 206 through injectors 222. The injectors 222 are inserted into the containers 206 through an aperture 223 of the peripheral seal 208. The anchoring means occupy only a bottom portion 224 of each container and solidify around the corresponding part of the wick 216. Experiments have been successfully carried out in which cement, particularly "white cement", has been used as flowable anchoring means. The expression "white cement" means a cement which does not substantially include Fe, l. e. Portland cement (having less than 0,2% of Fe) or a cement containing a substantial proportion of Alumina (at least 35% of A1₂0₃) .

Each wick 216 extends m a container 206 transversely of the direction F2 from one edge 226 of each piece 210 to the opposite edge 228 and is welded between the strips 202 at correspondingly opposite locations of the peripheral seal 208.

Advancing means advance the pieces 120 from the injection station 218 to a filling station 230, where filling tubes 232 introduce liquid candle wax into the containers 206 through the openings 223. After filling, welding means 234 seal each container 206 by closing and sealing the opening 223. The pieces 210 are then transferred to a cutting station 236 m which individual containers 206 are cut from the pieces 210.

Referring now to Figures 30 to 35, the difference compared to the embodiment of Figure 28 is that the wicks (here referenced 216a) are inserted after blow-thermoforming of the containers 206. The advancing means advance the pieces 210 to a wick insertion station 237 m which a wick 216a is inserted into each container 206. The insertion station 237 comprises insertion means 238 internally provided with a wick 16a initially having an end portion 217 projecting from a free end 240 of the insertion means 238, which is movable from an inoperative position outside the container 206 to an operative position - shown in Figure 31 - m which the end portion 217 is positioned into a recess 242 of the container 206 opposite to a further aperture 244 of the seal 208 through which the insertion means 238 is inserted. The insertion station 237 is further provided with clamping means 246 which, when the end portion 217 is positioned in a recess 242, clamp the end portion 217 by squashing together opposite recess wall portions of the container 206 so as to embed the end portion 217 m the peripheral seal 208.

The insertion means 238 are then withdrawn from the container 206 while leaving the wick 216 m the container. Gripping means 252 clamp together wall portions 248 defining the further aperture 244 so as to embed into the seal 208 a corresponding intermediate wick portion. The gripping means 252 are provided with indentations 254 corresponding to the wall portions of each container 206 defining the aperture 223 so as not to squash those wall portions when brought into a closed condition. Thus the wick 216a is positioned in a stable manner in the container 206 and the aperture 223 is left open. Cutting means 250 provided in the insertion station 237 cut each wick 216a immediately above the closed, further aperture 244. The piece 210 is then advanced to the injection station 218 and thence to the filling station 230 and finally to the cutting station 236.

Referring to Figures 36 to 39, an individual container 206 is shown, comprised of opposite concave wall portions 258 welded together in a peelable manner along a peripheral seal 208, the container 206 containing a wick 216, a candle wax body 256, and anchoring means 220 occupying a substantial portion of the bottom part of the container. The wall portions 258 comprise flaps 260 which are not welded, so as to facilitate opening of the container 206 by pulling apart the flaps 260.

As shown in Figures 40 to 42, a piece 210a includes a container 206a of a group of containers which each comprise a plurality of openings 223a wide enough to receive filling tubes 232a therethrough, each filling tube 232a delivering a pasty product A, B into the container 206a. As the filling tubes 232a are withdrawn from the container 206a in the direction of arrow F3, the products A, B are distributed vertically one beside the other, as shown in Figure 42, along a separation plane S. The products A, B may be incompatible with one another so as not to mix one with the other when simultaneously put into the container 206a by the filling tubes 232a. Thus, after sealing of the container 206a, the content of the final packaging unit comprises two distinct products. In Figures 44 and 45 a packaging unit is shown in which a container 206b contains two products A, B which are disposed one on the other with respect to the direction F3 along which the filling tubes are movable. In this embodiment, the product A, which occupies the bottom part of the container 206b, may be introduced into the container at a first product-filling station, while the product B is inserted at a subsequent filling station. There may be only one opening 223a, so that the filling tube 232a from which the product B is delivered may pass through the same opening 223a as does the filling tube of the product A.

The possibility of including different products, such as A and B, into the same container 206a, 206b may be considered as an alternative in the manufacture of known products, such as food products, e.g. ice creams having a plurality of flavours, or may give rise to new products, such as multi-layer detergents or deodorants.

Claims

1. A method including forming a container utilizing first and second strips of material, said forming comprising blow-thermoforming, characterized m that a wick is located to extend between said strips and through the interior of said container.

2. A method according to claim 1, and including filling into said container a substance which, m a liquid state, flows along said wick.

3. A method according to claim 2, and including sealing said first and second strips of material together throughout the periphery of said container m a liquid- tight manner except where said wick extends through said periphery.

4. A method according to claim 3, wherein said wick extends through said periphery at a first end zone only.

5. A method according to claim 3, or 4, wherein said sealing comprises heat- and pressure-sealing.

6. A method according to any one of claims 3 to 5, wherein said sealing fixes at least one discrete portion of said wick relative to said container.

7. A method according to claim 6, wherein said at least one discrete portion comprises an intermediate portion of said wick nearer to one end zone than to the opposite end zone of said wick.

8. A method according to any one of claims 3 to 7, wherein said sealing comprises a step of sealing around a major portion of said periphery and leaving an unsealed opening over a minor, upper portion of said periphery, and a subsequent step of sealing at said opening.

9. A method according to claim 8, and including introducing said wick through said opening.

10. A method according to claim 9, and including, after said introducing, severing said wick from wick stock.

11. A method according to claim 10 as appended to claim 6, wherein said severing is performed after said sealing.

12. A method according to any one of claims 9 to 11, and including providing m the interior of said container a recess which limits movement of the opposite end zone of said wick relative to said container.

13. A method according to claim 12, wherein said recess is provided opposite said opening.

14. A method according to claim 12, wherein said recess is provided by deforming said opening while closing said opening during said sealing.

15. A method according to claims 6 and 12, wherein said at least one discrete portion comprises said opposite end zone .

16. A method according to any one of claims 2 to 15, and further comprising introducing into said container a flowable product.

17. A method according to claim 16, wherein said flowable product constitutes anchoring means.

18. A method according to claim 17, wherein said flowable product comprises cement.

19. A method according to any one of claims 2 to 18, wherein said wick is introduced to between said strips before said substance is filled into said container.

20. A method according to claim 6, 7, or 15, or any one of claims 8 to 14, or 16 to 19, as appended to claim 6, wherein the discrete portion, or one of the discrete portions, of said wick is fixed between said strips before said substance is filled into said container.

21. A method according to any preceding claim, wherein said container is part of a unit in which said wick is completely enclosed and no more strips than said first and second strips are employed in providing the external walls of said unit.

22. A method according to claim 4, or any one of claims 5 to 20 as appended to claim 4, and including forming, through said material, outwardly of said periphery, a gap over which said first end zone extends and whereby said first end zone may communicate with the ambient atmosphere.

23. A method according to claim 22, and including removably covering said gap with a fluid-tight cover to prevent said wick from communicating with said atmosphere.

24. A method according to claim 4, or any one of claims 5 to 21 as appended to claim 4, and including forming outwardly of said periphery a chamber loosely containing said first end zone.

25. A method according to claim 24, and including providing adjacent said chamber a line of weakness in said material for fracturing to permit removal of said chamber.

26. A method according to any one of claims 2 to 20, or any one of claims 22 to 25, or claim 21 as appended to claim 22, wherein said substance is an insecticide, a deodorant or a perfume.

27. A method according to any one of claims 2 to 20, or any one of claims 22 to 25, or claim 21 as appended to claim 22, wherein said substance is candle wax.

28. A method including forming a container utilizing first and second strips of material, filling said container with a substance and locating a wick between said strips to extend through said container, whereby said substance, m a liquid state, flows along said wick, characterized m that said wick is introduced to between said strips before said substance is filled into said container.

29. A method according to claim 28, wherein a discrete portion of said wick is fixed between said strips before said substance is filled into said container.

30. A method according to claim 28, or 29, and including sealing said first and second strips of material together throughout the periphery of said container m a liquid- tight manner except where said wick extends through said periphery.

31. A method according to claim 30, wherein said wick extends through said periphery at a first end zone only.

32. A method according to any one of claims 28 to 31, and including, after the introduction of said wick to between said strips, severing said wick from wick stock.

33. A method according to claim 32 as appended to claim 29, wherein said severing is performed after said discrete portions have been fixed beween said strips.

34. A method including utilizing first and second strips of material to form a container, filling said container with a substance and locating a wick between said strips to extend through said containers, whereby said substance, m a liquid state, flows along said wick, said container being part of a unit m which said wick is completely enclosed, characterized m that no more strips than said first and second strips are employed m providing the external walls of said unit.

35. A method according to claim 34, and including sealing said first and second strips of material together throughout the periphery of said container m a liquid- tight manner except where said wick extends through said periphery.

36. A method according to claim 35, and including forming outwardly of said periphery a chamber loosely containing a first end zone of said wick.

37. A method according to claim 36, and including providing adjacent said chamber a line of weakness m said material for fracturing to permit removal of said chamber.

38. A method comprising providing candle wax means and wick means m a container formed of first and second walls joined together, characterized by injecting anchoring means into said container.

39. A method according to claim 38, wherein said anchoring means comprises cement.

40. A method comprising providing candle wax means and wick means in a container formed of first and second walls joined together, characterized by introducing said wick means through an opening of said container.

41. A method according to claim 40, and further comprising positioning said wick means at one end thereof into a recess portion in the interior of said container opposite to said opening.

42. A method according to claim 41, and further comprising, after said positioning, clamping said one end by bringing together respective opposite container wall portions of said first and second walls at said recess portion.

43. A method according to any one of claims 40 to 42, and further comprising, after said introducing, gripping a portion of said wick means by bringing together respective opposite container wall portions of said opening.

44. A method according to claim 43, wherein, no earlier than said gripping, cutting means cuts said wick means immediately outside said container.

45. A method comprising introducing a fluid anchoring substance into moulding means having walls defining an interior thereof, said anchoring substance flowing to a bottom part of said interior to an anchorage location at which said anchoring substance forms an anchorage means which causes a wick to be anchored at said anchorage location upon setting of said anchoring substance, and introducing fluid wax to above said anchorage means and around said wick between said wick and said walls.

46. A method according to claim 45, and further comprising inserting said wick through an opening of said moulding means .

47. A method according to claim 46, and further comprising positioning said wick at one end thereof into a recess portion in the interior of said moulding means opposite to said opening.

48. A method according to claim 47, and further comprising, after said positioning, clamping said one end by bringing together respective opposite portions of said walls at said recess portion.

49. A method according to claim 47 or 48, and further comprising, after said positioning, gripping a portion of said wick by bringing together opposite wall portions of said opening.

50. A method wherein a distribution container is formed of first and second walls joined together along an outline of said container and first and second flowable products are filled into said container.

51. A method according to claim 50, wherein said first and second flowable products are filled through respective openings in said container.

52. A method according to claim 50, or 51, wherein, after the filling with said first and second products, said container is sealed so that said container becomes substantially fluid-tight throughout its outline.

53. Apparatus including forming means which utilizes first and second strips of material in forming a container, said forming means comprising blow-thermoforming means, characterized in that locating means serves to locate a wick to extend between said strips and through the interior of said container.

54. Apparatus according to claim 53, and including filling means arranged to fill into said container a substance which, in a liquid state, flows along said wick.

55. Apparatus according to claim 54, and including sealing means which serves to seal said first and second strips of material together throughout the periphery of said container in a liquid-tight manner except where said wick extends through said periphery.

56. Apparatus according to claim 55, wherein said sealing means comprises heat- and pressure-sealing means.

57. Apparatus according to claim 55, or 56, wherein said sealing means serves to fix at least one discrete portion of said wick relative to said container.

58. Apparatus according to claim 57, wherein said locating means and said sealing means are arranged at a common station.

59. Apparatus according to any one of claims 55 to 58, wherein said sealing means comprises first sealing means arranged to seal around a major portion of said periphery and to leave an unsealed opening over a minor, upper portion of said periphery, and second sealing means which serves to seal at said opening.

60. Apparatus according to claim 59, and including inserting means which serves to insert said wick through said opening.

61. Apparatus according to claim 60, and including severing means arranged to sever said wick from wick stock.

62. Apparatus according to any one of claims 54 to 61, and further comprising introducing means which serves to introduce a flowable product into said container.

63. Apparatus according to any one of claims 55 to 61, or claim 62 as appended to claim 55, and including gap- forming means arranged to form, through said material, outwardly of said periphery, a gap over which a first end zone of said wick extends and whereby said first end zone may communicate with the ambient atmosphere.

64. Apparatus according to claim 63, and including covering means which serves removably to cover said gap with a fluid-tight cover to prevent said wick from communicating with said atmosphere.

65. Apparatus according to any one of claims 55 to 61, or claim 62 as appended to claim 55, and including chamber- forming means arranged to form outwardly of said periphery a chamber for loosely containing a first end zone of said wick.

66. Apparatus according to claim 65, and including weakening means arranged to provide adjacent said chamber a line of weakness in said material for fracturing to permit removal of said chamber.

67. Apparatus comprising providing means arranged to provide candle wax means and wick means in a container, and forming means arranged to form said container of first and second walls joined together, characterized in that injection means is arranged to inject fluid anchoring means into said container.

68. Apparatus according to claim 67, and further comprising filling means arranged to fill said container with said candle wax means after operation of said injection means.

69. Apparatus comprising means arranged to form a distribution container of first and second walls joined together along an outlineof said container and to fill said container with first and second flowable products.

70. Apparatus according to claim 69, wherein said means includes first introducing means and second introducing means arranged to introduce the respective first and second products into said container.

71. A unit comprising a container which has been formed by utilizing first and second strips of material in blow- thermoforming, characterized in that a wick extends between said strips and through the interior of said container and in that said container contains a substance which, in a liquid state, flows along said wick.

72. A unit according to claim 71, wherein said first and second strips of material are sealed together throughout the periphery of said container in a liquid-tight manner except where said wick extends through said periphery.

73. A unit according to claim 72, wherein said wick extends through said periphery at a first end zone only.

74. A unit according to claim 72 or 73, wherein the seal at said periphery fixes at least one discrete portion of said wick relative to said container.

75. A unit according to claim 74, wherein said at least one discrete portion comprises an intermediate portion of said wick nearer to one end zone than to the opposite end zone of said wick.

76. A unit according to any one of claims 71 to 75, and including, in the interior of said container, a recess which limits movement of an inner end zone of said wick relative to said container.

77. A unit according to claims 76 and 74, wherein said at least one discrete portion comprises said inner end zone.

78. A unit according to any one of claims 71 to 77, and further comprising a flowable product in said container.

79. A unit according to claim 78, wherein said flowable product constitutes anchoring means.

80. A unit according to claim 79, wherein said flowable product comprises cement.

81. A unit according to any preceding claim, wherein said wick is completely enclosed in said unit and no more strips than said first and second strips provide the external walls of said unit.

82. A unit according to claim 73, or any one of claims 74 to 80 as appended to claim 73, and including, through said material, outwardly of said periphery, a gap over which said first end zone extends and whereby said first end zone may communicate with the ambient atmosphere, and a fluid-tight cover removably covering said gap to prevent said wick from communicating with said atmosphere.

83. A unit according to claim 73, or any one of claims 74 to 81 as appended to claim 73, and including, outwardly of said periphery a chamber loosely containing said first end zone .

84. A unit according to claim 83, and including, adjacent said chamber, a line of weakness in said material for fracturing to permit removal of said chamber.

85. A unit according to any preceding claim, wherein said substance is an insecticide, a deodorant or a perfume.

86. A unit according to any one of claims 71 to 84, wherein said substance is candle wax.

87. A unit according to claim 86 as appended to claim 72, wherein said strips are peelable apart around said periphery.

88. A unit comprising a container comprised of first and second strips of material, a substance contained by said container, and a wick extending between said strips and through said container, whereby said substance, in a liquid state, flows along said wick, said wick being completely enclosed in said unit, characterized in that no more strips than said first and second strips are employed in providing the external walls of said unit.

89. A unit according to claim 88, wherein said first and second strips of material are sealed together throughout the periphery of said container in a liquid-tight manner except where said wick extends through said periphery.

90. A unit according to claim 89, and including, outwardly of said periphery, a chamber loosely containing a first end zone of said wick.

91. A unit according to claim 90, and including, adjacent said chamber, a line of weakness in said material for fracturing to permit removal of said chamber.

92. A unit comprising candle wax means and wick means in a container formed of first and second walls joined together, characterized by anchoring means in said container .

93. A unit according to claim 92, wherein said anchoring means comprises cement.

94. A unit comprising a distribution container formed of first and second walls joined together along an outline of said container and first and second flowable products in said container.

95. A unit according to claim 94, wherein said container is substantially fluid-tight throughout its outline.