EP1568451B1 - Method and apparatus for punching a filtering medium - Google Patents

Abstract

The method involves guiding a non-woven insert material i.e. polyurethane non-woven web, between a cutting die (20) and a cutter (16) i.e. knife edge seal, which has a cutting surface (44), where the web is made of thermoplastic polyurethane based on polyester and polyether. The die and the cutter are fed to each other in a direction perpendicular to a plane of the material such that the cutter is partially engaged to punched openings of the die. The material is separated under formation of the insert. The die and cutter are held at temperature at which partial melting of the material occurs. An independent claim is also included for a device for stamping out inserts from a non-woven insert material.

Description

TECHNICAL AREA

The present invention relates to a method and an apparatus for punching inserts from a liner web of a non-woven material. The invention is particularly in the field of production of coffee capsules with deposits of polyurethane nonwoven settled.

STATE OF THE ART

Especially in the food industry, containers are often provided with inserts that can perform the most diverse functions. For example, containers containing moisture-sensitive powder may be provided with a liner which absorbs the moisture and keeps the powder dry. Other containers containing liquids may be provided with self-sealing inserts so as to prevent leaking of the contents despite damage to the container. Other applications are to provide inserts which upon activation release a substance into the main space, e.g. for capsules or cups for drinking water could be the case, in which after a piercing o.ä. a disinfectant is dispensed in controlled doses.

Self-sealing inserts are also used for coffee powder capsules. There, the deposits are usually provided on the bottom of the coffee powder capsules. For coffee preparation, the capsules are pierced in the coffee machine with a needle or with 3 Stichmessem distributed on the floor surface and water is introduced through the coffee powder in the capsules. After the coffee has been prepared and the needle has been pulled out again, the coffee powder capsules remain tight due to the self-sealing insert. This avoids that when removing the coffee powder capsules leftovers of hot cooking water leak and scald the user and contamination of the capsule chamber of the coffee machine is prevented.

The containers are made of a container material web, for example a Aluminum band, shaped. They are punched out of a web and then made by forming, such as deep drawing or blow molding. The

Inserts themselves are punched out of a band-shaped pad material web before they are sealed onto the aluminum band. The stamping and insertion of deposits is, especially in self-sealing deposits, often associated with technical difficulties: self-sealing deposits have tensile stress on a high elasticity, so they puncture the hole immediately when drilling through the container wall together with the insert by their inherent elasticity. In addition, the surfaces of such self-sealing inserts have a certain adhesiveness, so that the hole edges adhere to each other in a perforation of the self-sealing inserts and reinforce the seal. The high elasticity of the liner material on the one hand means that a feed movement of the Einlagenmaterialbandes can be done only with low speed or that only low tensile forces can act on the liner material, on the other hand, together with other material properties to the fact that the punching process must be carried out typically consuming so that the punching is always guaranteed, especially at high production speeds.

However, the manufacturing process can only be made economical if the containers are provided with inserts at high clock rates and produced.

From the DE 100 32 458 A1 a punching tool for the production of apertures in workpieces made of thermoplastic material is known, in which with a frontally rotating cutting edge, can be brought in a working with a cutting insert into engagement and arranged between its cutting edge and the cutting workpiece to produce a wall breakthrough in the cutting direction penetrating locally heated punch, wherein the punch of the punching tool is formed as a one-piece, heatable cutting punch with a frontally circumferential cutting edge with a V-shaped cutting geometry. The punch can intervene as an option in a conical, widening in the direction away from the punch directional breakthrough in the cutting plate, and the punched part is then apparently ejected over this breakthrough.

PRESENTATION OF THE INVENTION

The invention is therefore an object of the invention to provide a method, or a device available, which allows a reliable and high speeds accessible punching process, even when punching deposits from a Einlagematerialbahn of a difficult to process non-woven material.

The solution to this problem is achieved in that the process in a first step, the Einlagenmaterialbahn between a punched opening having a cutting die and a punching in the punching area tapered cutting surface having corresponding cutting edge is performed, and in a second step, the cutting die and the cutting edge in one Direction substantially perpendicular to the plane of the Einlagenmaterialbahn be supplied to each other in such a way that the cutting edge partially engages in the punching opening of the cutting die and the intermediate Einlagenmaterialbahn is separated to form the insert, wherein the cutting edge and / or the Schneidmatrize be maintained at a temperature at which at least a partial melting of the deposit material takes place.

The core of the invention is therefore to support the mechanical punching process by the application of elevated temperature, and thus to facilitate the classic way only mechanically performed punching process or to improve. In the prior art, such inserts are typically punched by a ball-and-socket cutting edge which must rotate to separate with trapped liner material within the cutting die to produce sufficient release effect at all. In addition, according to the prior art, a large punching force is required to produce a sufficient effect at all. Due to the additional application of heat, the punching force can be correspondingly reduced because the smallest fibers are melted off.

Such a method can be used in particular when it is at the insert material web around a polyurethane nonwoven fabric, preferably made of a thermoplastic polyurethane based on polyester or polyether, in which case particularly preferably the cutting edge and / or the cutting die is maintained at a temperature in the range of 75 ° -90 ° C. For example in the field of the production of coffee capsules, the polyurethane nonwoven is a polyurethane nonwoven with an air permeability of more than 300 l / m ² / s and a pore size in the range of 10 to 40 μm, preferably at a thickness of in the range of 0.1 to 0.3 mm. Also, such material can be punched very efficiently with the proposed method.

According to a first preferred embodiment of the invention, the method is carried out using a cutting die having a substantially cylindrical, preferably circular-cylindrical punched opening, and wherein the cutting surface of the cutting edge with the cylinder axis at an acute angle, particularly preferably in the range of 30 to 60 ° ( preferably about 45 °) includes. Preferably, the blade is designed such that it engages upon contact of the cutting surface with the cutting die only by a few tenths of a millimeter, for example, only 1 / 10mm in the punching opening of the cutting die.

In particular, but not exclusively in the field of production of coffee capsules, it proves to be advantageous according to a further preferred embodiment of the invention to form the cutting edge as a cutting edge, which has within the cutting surface via an opening through which a stamp is guided perpendicular to the plane of the insert material web, wherein, in a third step of the method, the punch discharges the insert through the punched opening, and wherein, in particular, this removal preferably takes place on a second material web. The insert can preferably be guided through the punch opening and be brought into contact with the second material web, wherein particularly preferably the insert is connected to the second material web. However, this can not be realized, for example, not exclusively in the area of the production of coffee capsule in that the insert is connected to the second material web in a heat-sealing process, wherein particularly preferably on the side facing away from the insert the second material web is arranged a sealing heater, which is maintained at a temperature which triggers an activation of a sealing material arranged on the side of the second material web facing the insert.

In connection with the heating of the cutting edge and / or cutting die, it proves to be advantageous, according to a further preferred embodiment, to induce them inductively. However, it is also possible to use other heating methods such as electric heating, optical heating and the like. The heating should be ensured at least at the moment of merging of cutting and / or cutting die at the desired temperature, preferably in the range of 50 to 150 ° C, particularly preferably in the range of 75 to 100 ° C. Preferably, the cutting edge is kept at this temperature.

According to a further preferred embodiment, the method is a method for producing cup-shaped, provided with a liner containers (especially coffee capsules), which is characterized in that the inserts are punched out before forming the cup-shaped container, applied at the points be made at which the containers in a subsequent operation by forming, and that the cup-shaped container is then punched out of a container material web and then formed in a forming process, preferably in one step between 6 and 12 deposits, more preferably 8 deposits are punched out , The inserts are preferably punched out of a Einlagenmaterialbahn, and the Einlagenmaterialbahn and the container material web are supplied in such a way one above the other, that the deposits immediately after their punching out of the Einlagenmaterialbahn on the below resp. applied overlying container material web and can be connected to this. In this context, it proves to be advantageous if order patterns are punched out alternately from at least two Einlagenmaterialbändern, wherein the second Einlagenmaterialbahn is moved to punching in the work area.

Further preferred embodiments of the method according to the invention are described in the dependent claims.

As already mentioned, the present invention also relates to a device, in particular for carrying out a method as described above. The apparatus is provided for punching inserts from a lay-up material web of a non-woven material, and comprises a cutting die having a punch opening and a cutting edge between which the insert web is separated. The device is characterized in particular by the fact that the cutting edge has a cutting surface tapering in the punching area to the punching opening, that the cutting die and the cutting edge are mounted in a direction essentially perpendicular to the plane of the insert material web such that they can be fed to each other, wherein the cutting edge in the piercing opening of the cutting die at least partially engages and the intermediate Einlagenmaterialbahn is separated to form the insert, wherein means are arranged, by means of which the cutting edge and / or the Schneidmatrize be maintained at a temperature at which takes place at least a partial melting of the deposit material.

Preferably, the cutting die has a substantially cylindrical, preferably circular cylindrical punch opening, and the cutting surface of the cutting edge (16) forms an acute angle with the associated cylinder axis, particularly preferably in the range of 30 to 60 °, preferably in the range of 45 °.

To a direct shift resp. According to a further preferred embodiment, it is advantageous for the transfer of the insert to a second medium to form the cutting edge as a cutting edge, which has an opening within the cutting surface, through which a punch can be guided perpendicular to the plane of the insert material web. In this case, the stamp is intended to discharge the insert through the punching opening substantially immediately after the punching process, whereby preferably this removal, preferably in a linear movement (eg parallel to the relative direction of movement of the cutting and cutting die), takes place on a second material web , and wherein in particular preferably further means are provided by means of which the insert can be connected to the second material web. The funds may be a seal heating, with the help of which the deposit with the second material web in a marriage sealing process can be connected. In this case, the heat seal is particularly preferably arranged on the side facing away from the insert of the second material web, and the seal heater is maintained at a temperature which activates a sealing material disposed on the side facing the insert of the second material web (can on the insert or on the second Material web already be provided) triggers.

As already mentioned, the proposed device can be used in particular in the production of cup-shaped containers provided with a liner, such as coffee powder capsules. In this case, a Einlagenmaterialbahn, the Einlagenmaterialbahn in a work area overlapping container material web and a punching device arranged in the work area are provided, through which the deposits are punched out at arranged in a predetermined order pattern punching positions and can be applied in predetermined container positions on the container material web, preferably a feed device is present, by which the punching device and the Einlagenmaterialbahn are movable relative to each other at least at a portion of the displacement steps substantially transverse to the web direction of the Einlagenmaterialbahn. In connection with this procedure is explicit on the Swiss application CH 0739/03 from 25.04.2003 resp. referenced the associated European patent application.

According to a further preferred embodiment of the device according to the invention, the sealing stamp has means, in particular in the form of means for applying a negative pressure (eg vacuum lines with openings on the top of the stamp, wherein the vacuum is applied depending on the punching cycle in each case substantially only during the Transport takes place on a second material web), by means of which the insert between the punching and the application to the second material web can be held on the seal die.

In particular, in connection with the production of coffee capsules, it proves to be advantageous to arrange the cutting die in a first stationary plane (in a die holder), above which first stationary plane the second material web (eg container material web) and above this second material web a seal heater (for securing the inserts on the container material web) are arranged. In this case, below the first stationary plane, a cutting edge preferably designed as a ring cutting edge (designed for partial engagement in the cutting die) is displaceably mounted perpendicularly to the first stationary plane, and a sealing die is mounted so as to be axially displaceable within the annular cutting edge. Thus, when the insert material web is fed between the cutting edge and the cutting die, first the insert is punched between the cutting edge and the cutting die, and these are subsequently applied directly to the above-guided second material web in a linear movement from below, without any intermediate storage, large displacement or the like. and be connected to this with the aid of the seal heater. Subsequently, for example, a material web thus provided with the inserts can be further processed into coffee capsules in a forming process (in combination with a further punching process of the second material web).

In connection with an efficient and parallel production of a plurality of deposits or, where appropriate, a plurality of coffee capsules, it may prove advantageous to arrange a plurality of cutting dies in a first plane and to arrange a corresponding number of cutting edges in a second plane, and the first and the second level during the punching process synchronized to each other to move.

Further preferred embodiments of the device according to the invention are described in the dependent claims.

BRIEF EXPLANATION OF THE FIGURES

Fig. 1

einen axialen Teilschnitt durch eine Stanzvorrichtung gemäss der Erfindung, wobei in der rechten Hälfte die Stanze im geöffneten Zustand dargestellt ist, und in der linken Hälfte die Stanze im geschlossenen Zustand dargestellt ist, wobei gleichzeitig die Einlage bereits auf einer zweiten Materialbahn fixiert wird;

Fig. 2

einen axialen Teilschnitt analog zu Fig. 1 eines weiteren Ausführungsbeispiels einer Stanze;

Fig. 3

eine schematische Aufsicht auf eine Stanze gemäss Fig. 1 oder Fig. 2, wobei mehrere derartige Stanzvorrichtungen parallel geschaltet sind; und

Fig. 4

eine schematische Aufsicht gemäss Fig. 3, wobei weiterhin das Stanz- respektive Auftragsmuster sowie die Bemassungen im Detail dargestellt sind.

The invention will be explained in more detail with reference to embodiments in conjunction with the drawings. Show it:

Fig. 1

an axial partial section through a punching device according to the invention, wherein in the right half of the punch is shown in the open state, and in the left half of the punch is shown in the closed state, at the same time the insert is already fixed on a second material web;

Fig. 2

an axial partial section analogous to Figure 1 of another embodiment of a punch.

Fig. 3

a schematic plan view of a punch according to FIG. 1 or FIG. 2, wherein a plurality of such punching devices are connected in parallel; and

Fig. 4

a schematic plan view of FIG. 3, wherein further the punching respectively order pattern and the dimensions are shown in detail.

WAYS FOR CARRYING OUT THE INVENTION

Fig. 1 shows an axial schematic section through a punching device according to a first embodiment. The punching device stands on a base plate 1, on which guide columns 2 are fixed. A punching device normally comprises four such guide columns 2, but a plurality of punching devices can be guided by such a group of four guide columns 2 (see below in connection with FIGS. 3 and 4). The cover plate 4 and a die holder 11 arranged below it are fixedly arranged with respect to the base plate 1 and the guide columns 2, respectively. The cover plate 4 and the die holder 11 can be fixedly connected to the guide columns 2 for fixing, but can also be attached to other fastening devices be fixed in relation to the guide columns 2.

The punching device described in the context of this embodiment is designed, inter alia, initially to punch out a deposit 39 from a deposit material web 26 in a combined process, and to apply this deposit immediately afterwards onto a container material web 27. To ensure this direct transfer, the container material web 27 is guided above the die holder 11 and, as it were, resting on it. Below the die holder is the Insert material web 26 out.

The ultimate goal is to apply deposits to the container material web 20 and, in a subsequent process, independent of the present stamping device, to produce coffee capsules from the container material web in a forming process.

The movable elements of the punching device are now arranged below the die holder 11. In order to represent the individual process steps in a single Fig., The punching device is shown on the right half-side in the open state, and on the left half-side in the closed state immediately upon application of the liner to the sealing film 27, d. H. on the container material web. The movable elements of the punching devices comprise a lower holder 5, which is mounted displaceably via a toggle lever 24 on the guide columns 2 in the vertical direction.

As a further movable element, the upper holder 6 may be mentioned, which is also slidably mounted on the guide columns 2 in the vertical direction. The upper holder 6 can be moved relative to the lower holder 5 to a certain extent, and this relative mobility is crucial for the functioning of the stamping process.

The upper holder 6 is connected via a guide rod 10 slidably connected to the lower holder 5. The parallel to the guide columns 2 arranged guide rod 10 is fixedly connected to the upper holder 6 and is slidably guided on the lower holder 5 via a guide holder 7, in which a sliding bearing 9 is arranged. The maximum distance from the upper holder 6 and lower holder 5 is determined via an adjusting nut 30. This maximum distance is enforced by at least one cutting compression spring 23. In other words, the upper level 6 can be approximated only against the spring force of the cutting compression spring 23 to the lower level 5, and this only up to another stop, then, namely, when the guide rod 10 and the adjusting nut 30 with the surface of the lower holder 5 comes into contact.

On the upper side of the upper holder 6, an insulation 12 is first arranged, on which then a bobbin 13 is placed. Within this bobbin 13, an electric coil 14 is arranged, which serves to inductively heat a disposed above the bobbin 13 annular cutting edge 16. To control the temperature of the annular cutting edge 16, a temperature sensor 29 is also arranged. The annular cutting edge 16 is fastened on the bobbin 13 via a clamping ring 15.

The annular cutting edge 16 is designed essentially as a circular ring which is essentially cut out on the inside and whose outer surface facing the cutting die 20, the cutting surface 44, is tapered, d. H. It forms a cutting tip. The cutting surface 44 encloses an angle of 30-45 ° with the axis of the annular cutting edge 16. The cutting tip of the annular cutting edge 16 is adapted to the inner diameter of the cutting die 20 fastened to the die holder 11. The cutting die 20 is, just like the annular cutting edge 16 of a hardened metal and is replaceable and formed in the form of a circular ring. The cutting dies 20 likewise have a cylindrical central opening whose diameter is approximately 2/10 mm larger than the diameter of the cutting tip of the annular cutting edge 16. The annular cutting edge 16 thus moves easily into the cutting die 20 when the annular cutting edge 16 is brought onto the cutting die 20 , And the material to be separated is clamped on the one hand by the cutting tip and on the other hand between the cutting surface 44 and the inner edge of the cutting die 20, respectively. separated.

Within the annular cutting edge 16, ie in the central bore of the punch, now also a seal stamp 17 made of plastic or a plunger 21 is arranged, which is also mounted displaceably in the vertical direction. This the plunger 21 is first performed on the lower side in the guide holder 7 of the lower holder 5 in a sliding bearing. Against the stop of an adjusting nut 25 of the plunger 21 is clamped over a seal-compression spring 22 upwards, ie the plunger 21 can be moved against the spring force of the seal-compression spring 22 against the lower holder 25 down. In the area of the annular cutting edge 16 at the head of the plunger 21 is the Seal 17 arranged, and this is firmly connected to the plunger 21. In the region of the annular cutting edge 16, the sealing stamp 17 has a shoulder which engages in a corresponding shoulder formed by the bobbin 13 and the annular cutting edge 16, so that the unit of sealing stamp 17 and ram 22 only reach the upper holder 6 until this paragraph is reached can be inserted. In the illustrated in the right half-plane open position of the punch of the sealing die 17 is adjusted via the adjusting nut 25 such that the upper level of the seal punch 17 comes to lie substantially in a plane with the cutting tip of the annular cutting edge 16.

Within the plunger 21 and in particular within the seal punch 17, a system of vacuum lines is provided, which is acted upon on the underside of the plunger 21 via a vacuum port 28 with vacuum. The vacuum lines open at the upper-side inner surface of the sealing die 17 in small holes, and serve to hold the punched insert 39 during their transport up to the container material web 27 on the seal 17 stamp.

Immediately above the cutting die 20 and between die holder 11 and cover plate 4, a sealing heater 18 is arranged coaxially with the movable just described below arranged elements of the punch. This heat seal 18 is attached via an insulation 19 on the cover plate 4. The sealing heater 18 is substantially formed as a cylindrical punch, which is electrically maintained at a temperature which allows sealing of the inserts 39 with the container material web 27. In this case, the sealing heater 18 is arranged above the container material web 27 such that a distance of approximately ½ mm remains between the container material web 27 and the sealed heater 18.

The individual elements lower holder 5, upper holder 6 and plunger 21 with seal stamp 17 attached thereto are in other words adjustable relative to each other displaceable and movable, and the mobility will be described below with reference to the description of the operation in a punching operation.

As already mentioned, the punching device is shown in the open state on the right side. In this open state, the annular cutting edge 16 of the Cutting die 20 spaced.

Between these two elements, the insert material web 26 is guided, preferably so that it touches neither the cutting die 20 nor the annular cutting edge 16. As an insert material web in this case is a web of non-woven of polyurethane Estane ^® having a basis weight of 50 grams per square meter.

Above the die holder 11, a sealing film 27 and a container material web is guided. It is a metal track resp. a sheet of, for example, aluminum, which is already provided with a coating which allows application and simultaneous securing of the inserts 39 to the container material web 27 by simple local heating (typically the coating is an acrylic based heat sealing lacquer). For this purpose, the coating must be present on the container material web 27 at least on the side facing away from the sealing heater 18. The container material web 27 is guided at a distance from the sealing heater 18, it should remain at least a distance of 1/2 mm between seal heater and container material web.

If both the container material web 27 and the insert material web 26 have reached the desired position, the entire unit, as shown in the right half-plane of FIG. 1, is moved upwards via the toggle lever 24. After a corresponding displacement, first a contact between the annular cutting edge 16 (and optionally the surface of the sealing stamp 17) with the insert material web 26 will take place. Since the insert material web 26 is flexible, it is pressed upwards against the further displacement of the sealing punch 17 and annular cutting edge 16 and finally against the cutting die 20. At the moment in which the insert material web 26 is pressed between the annular cutting edge 16 and the cutting dies 20, a separation of the insert material web will take place to form the inserts 39. On the one hand, this separation takes place due to the mechanical separation effect between annular cutting edge 16 (respectively cutting surface 44) and cutting die 20, but on the other hand, according to the invention, a more extensive separation effect is achieved the heating of the annular cutting edge 16 is reached. Namely, the ring cutter 16 is maintained at a temperature of 75-90 ° C or more at least at the moment of punching, and accordingly, thin fibers which are not sufficiently separated by the mechanical action are separated by the heat.

After reaching the contact between annular cutting edge 16 and cutting die 20, the upper holder 16 is fixed with respect to the die holder 11 in its position. Since now the toggle lever 24 further presses the lower holder 5 against the force of the spring 23, the plunger 21, respectively, arranged at the top seal stamp 17, on which the vacuum 3, the now ejected insert 39 is fixed by the central opening of the annular cutting edge 16 and through the central opening of the cutting die 20 through the container material web 27 is moved. The container material web 27 is pressed by the force of the punch 17 against the sealing heater 18, this state is now shown on the left side of Fig. 1. The sealing heater 18, which is held at a temperature of about 160 ° or depending on the melting point of the sealing medium, now causes the insert between the punch 17 and container material web 27 and seal heater 18 is pressed and heated, so that arranged on the container material web 27 Coating at least partially melts and leads to a firm connection between liner and container material web 27. The pressure applied is determined by the sealing pressure spring 22. The toggle lever is stretched out in this position, and a further rotation then leads again to a movement apart of the punch. Container material web 27 and insert material web 26 can now be moved to the next required position.

A further embodiment of a punching device is indicated in Fig. 2, wherein corresponding parts are designated the same as in Fig. 1. Accordingly, only the essential differences between Fig. 1 and 2 will be discussed below. In this case, the die holder 11 and the cover plate 4 are not attached to the guide columns 2, but rather to further support columns 33. The guide columns 2 are bounded at their upper end by a closure plate 34, on which typically the insert material web 26 is guided. As already above mentioned, the annular cutting edge 16 and the cutting die 20 are replaceable provided in the event of wear. On the one hand to simplify the interchangeability of these two elements, and on the other hand to adjust the guidance of the insert material web 26, the cover plate 4 can be tilted upwards over a first axis of rotation 31 and equally the die holder 11 via a second axis 32nd

FIG. 3 now shows a plan view of a device in which 8 inserts 39 are punched out simultaneously and synchronously by means of 8 punching devices as shown in FIG. 1 and FIG. 2, respectively. In Fig. 3 is visible how the container material web 27 is transported in a first main feed direction 35, and the insert material web in a second main feed direction 36, which is perpendicular to the first feed direction 35. In addition, two insert material webs 40 and 41 are guided parallel to each other and traversed according to a specific pattern (see Fig. 4). With regard to the method for the sequential processing of individual punching positions in the insert material web 40, reference should be made to the US Pat CH 0739/03 referenced in detail. In Fig. 3 also visible is the respective diameter 38, which then leads in the downstream forming process to the actual coffee capsules. When a portion of the first liner web 40 has been developed, both webs of liner are shifted to a second position such that the first lower and unprocessed liner web 41 is available for the next die sequence while the first liner web 42 is in the upper position in the direction 36 can be removed.

The details of this method are shown schematically in FIG. At the top, the container material web 27, which is completely filled with inserts 39, is shown, it becomes visible how the container material web, which has a width a of approximately 469 mm, is fitted with inserts 39 under maximum material utilization (the diameter 38 is 63.5 mm). This is represented by the displacement pattern as it is represented in the middle section by the sequence of digits within the Einlagematerialbahn 43 is indicated, with simultaneous optimal utilization of the material of the insert material web 43 achieved. For this purpose, the centers of the inserts 39 are spaced in the feed sheet 43 by g = 24.75 mm in the feed direction 35, and by d = 28.58 mm in the feed direction 36. The axes of the individual punching devices are spaced in the feed direction 35 by f = 99 mm and in Feed direction 36 by e = 114.32 mm, the individual punching positions are arranged symmetrically offset. The insert material webs have a width b = 204 mm, and the width c available for the two webs 42 and 43 is 706.25 mm.

The method used allows to perform 85 punches per minute.

LIST OF REFERENCE NUMBERS

1

baseplate

2

guide column

3

vacuum line

4

cover plate

5

lower holder

6

upper holder

7

guide holder

8th

leadership

9

bearings

10

guide rod

11

die holder

12

Isolation (material)

13

bobbins

14

electric coil

15

clamping ring

16

serrated

17

seal

18

seal Heating

19

heater

20

cutting die

21

tappet

22

Seal spring

23

Cutting-pressure spring

24

toggle

25

adjusting

26

Filter fleece, insert material web

27

Sealing film, container material web

28

vacuum connection

29

temperature sensor

30

adjusting

31

Rotary axle for 4

32

Rotation axis for 11

33

support column

34

End plate

35

Feed direction of 27

36

Feed direction of 26

37

Diameter insert

38

Diameter of container material in container material web

39

inlay

40

first deposit material web (active)

41

second insert material web (passive)

42

first deposit material web (passive)

43

second insert material web (active)

44

Cutting area of 16

45

Punch opening of 20

Claims (26)

1. Method of punching inserts (39) out of an insert material web (26) of a non-woven material, wherein
   in a first step the insert material web (26) is guided between a die-plate (20) having a punching aperture (45) and a corresponding cutting edge (16) having a cutting surface (44) that in the punching region tapers towards the punching aperture (45),
   and in a second step the die-plate (20) and the cutting edge (16) are guided towards one another in a direction substantially at right angles to the plane of the insert material web (26) in such a way, wherein the cutting edge (16) engages partially into the punching aperture (45) of the die-plate (20) and the insert material web (26) situated therebetween is cut to form the insert (39), and wherein the cutting edge (16) and/or the die-plate (20) are held at a temperature, at which an at least partial melting of the insert material occurs,
   characterized in that
   the cutting edge (16) takes the form of an annular cutting edge, which inside the cutting surface (44) has an opening, through which a plunger (17) may be guided at right angles to the plane of the insert material web (26), and that in a third step the plunger (17) removes the insert (39) through the punching aperture (45),
   wherein this removal is effected onto a second material web (27).
2. Method according to claim 1, characterized in that the insert material web (26) is a polyurethane non-woven, preferably of a thermoplastic polyester- or polyether-based polyurethane, and that particularly preferably the cutting edge (16) and/or the die-plate (20) is held at a minimum temperature in the region of 75°- 90°C.
3. Method according to claim 2, characterized in that the polyurethane non-woven is a polyurethane non-woven having an air permeability of more than 300 1/m²/s and a pore size in the region of 10 to 40 µm, preferably with a thickness of in the region of 0.1 to 0.3 mm.
4. Method according to one of the preceding claims, characterized in that the die-plate (20) has a substantially cylindrical, preferably circular-cylindrical punching aperture (45), and cutting surface (44) of the cutting edge (16) forms with the cylinder axis an acute angle, particularly preferably in the region of 30 to 60°.
5. Method according to one of the preceding claims, characterized in that the insert (39) is guided through the punching aperture (45) and brought into contact with the second material web (27), wherein particularly preferably the insert (39) is joined to the second material web (27).
6. Method according to claim 5, characterized in that the insert (39) is joined to the second material web (27) in a heat-sealing process, wherein particularly preferably at the side of the second web (27) remote from the insert (39) a heat-sealing device (18) is disposed, which is held at a temperature that triggers an activation of a sealing material disposed at the side of the second material web (27) facing the insert (39).
7. Method according to one of the preceding claims, characterized in that the cutting edge (16) and/or the die-plate (20) is held inductively at the desired temperature and/or at least at the moment, when the cutting edge (16) and/or the die-plate (20) are brought together, is heated inductively up to the desired temperature preferably in the region of 50 to 150°C, particularly preferably in the region of 75 to 100°C.
8. Method according to one of the preceding claims for the manufacture of bowl-shaped containers provided with an insert (39), characterized in that prior to forming of the bowl-shaped containers the inserts (39) are punched out, deposited at the points where the containers in a subsequent operation are produced by forming, and that the bowl-shaped containers (39) are then punched out of a container material web (27) and then formed in a forming process, wherein preferably in one step between 6 and 12 inserts (39), particularly preferably 8 inserts (39) are punched out.
9. Method according to claim 8, characterized in that the bowl-shaped containers are coffee powder capsules.
10. Method according to one of claims 8 or 9, characterized in that the inserts (39) are punched out of an insert material web (26), and that the insert material web (26) and the container material web (27) are fed one above the other in such a way that the inserts (39) immediately after being punched out of the insert material web (26) are deposited onto the container material web (27) situated above and/or below and are joined thereto.
11. Method according to one of claims 8 to 10, characterized in that the inserts (39) are punched out of an insert material web (26) by a punching apparatus at punching positions disposed in a predetermined order pattern and the punched-out inserts (39) are deposited at order positions disposed in the order pattern onto a container material web (27), which at least in the region of the punching apparatus is guided so as to overlap the insert material web (26) in a working area, wherein the containers are then manufactured from the container material web (27) in the region of the order positions, wherein particularly preferably between successive order patterns that are to be punched out the insert material web (26) and the punching apparatus are moved relative to one another at least by some of the displacement increments substantially in a direction (35) transversely of the take-off direction (36) of the insert material web (26).
12. Method according to claim 11, characterized in that a plurality of order patterns are punched out along a path extending in direction (35) transversely of the take-off direction (36) of the insert material web (26) before the punching apparatus and the insert material web (26) are moved in take-off direction (36) relative to one another.
13. Method according to claim 11 or 12, characterized in that in a direction (35) transversely of the take-off direction (36) of the insert material web (26) more order patterns are punched out in succession than in take-off direction (36), wherein preferably a plurality of inserts (39) of an order pattern, which are arranged offset in direction (36) of the insert material web (26) substantially one after the other, optionally transversely of the feed direction of the insert material web (36), are punched out simultaneously.
14. Method according to one of claims 8 to 13, characterized in that the order patterns are punched out alternately from at least two insert material strips (42, 43).
15. Method according to claim 14, characterized in that the second insert material web for the punching-out operation is moved into the working area.
16. Apparatus for punching inserts (39) out of an insert material web (26) of a non-woven material, comprising a die-plate (20) having a punching aperture (45) and a cutting edge (16), between which the insert material web (26) is cut, wherein
    the cutting edge (16) has a cutting surface (44), which in the punching region tapers towards the punching aperture (45),
    wherein the die-plate (20) and the cutting edge (16) are mounted in a direction substantially at right angles to the plane of the insert material web (26) in such a way that they may be guided towards one another,
    wherein the cutting edge (16) engages at least partially into the punching aperture (45) of the die-plate (20) and the insert material web (26) lying therebetween is cut out to form the insert (39),
    wherein means (13, 14) are disposed, with the aid of which the cutting edge (16) and/or the die-plate (20) are held at a temperature, at which an at least partial melting of the insert material occurs,
    characterized in that
    the cutting edge (16) takes the form of an annular cutting edge, which inside the cutting surface (44) has an opening, through which a plunger (17) may be guided at right angles to the plane of the insert material web (26), and that the plunger (17) is provided for removing the insert (39) through the punching aperture (45) after the punching process, wherein this removal is effected in a linear motion, onto a second material web (27).
17. Apparatus according to claim 16, characterized in that the die-plate (20) has a substantially cylindrical, preferably circular-cylindrical punching aperture (45), and cutting surface (44) of the cutting edge (16) forms with the cylinder axis an acute angle, particularly preferably in the region of 30 to 60°.
18. Apparatus according to one of claims 16 or 17, characterized in that means (18) are provided, with the aid of which the insert (39) may be joined to the second material web (27).
19. Apparatus according to claim 18, characterized in that the means (18) are a heat-sealing device, with the aid of which the insert (39) may be joined to the second material web (27) in a heat-sealing process, wherein particularly preferably the heat-sealing device (18) is disposed at the side of the second material web (27) remote from the insert (39), and the heat-sealing device (18) is held at a temperature that triggers an activation of a sealing material, which is disposed at the side of the second material web (27) facing the insert (39).
20. Apparatus according to one of claims 18 or 19, characterized in that the apparatus is designed to manufacture bowl-shaped containers provided with an insert (39), such as coffee powder capsules, wherein an insert material web (26), a container material web (27) that overlaps the insert material web (26) in a working area, and a punching apparatus, which is disposed in the working area and by means of which the inserts (39) may be punched out at punching positions disposed in a predetermined order pattern and may be deposited in specific container positions on the container material web (27), wherein preferably a feed device is provided, by means of which the punching device and the insert material web (26) may be set in motion relative to one another at least by some of the displacement increments substantially transversely of the web direction (36) of the insert material web (27).
21. Apparatus according to claim 20, characterized in that the web direction (36) of the insert material web (27) extends substantially at right angles to the web direction (35) of the container material web (27).
22. Apparatus according to claim 20 or 21, characterized in that two insert material webs (27) are provided, substantially parallel and disposed preferably side by side.
23. Apparatus according to claim 22, characterized in that the two insert material webs (27) are designed to be feedable in web direction independently of one another.
24. Apparatus according to one of claims 18 to 23, characterized in that the sealing plunger (17) has means (3), particularly in the form of means of applying a partial vacuum, by means of which the insert (39) between being punched and deposited onto the second material web (27) may be held on the sealing plunger (17).
25. Apparatus according to one of claims 18 to 24, characterized in that the die-plate (20) is disposed in a first stationary plane, that above this first stationary plane the second material web (27) and above this second material web (27) a heat-sealing device (18) are disposed, that below the first stationary plane a cutting edge (16) in the form of an annular cutting edge is mounted displaceably at right angles to the first stationary plane, and that a sealing plunger (17) is mounted so as to be axially displaceable inside and relative to the annular cutting edge (16).
26. Apparatus according to one of claims 16 to 25, characterized in that in a first plane a plurality of die-plates (20) are disposed, and in a second plane a corresponding number of cutting edges (16) are disposed, and that the first and the second plane during the punching process are moved in synchronism relative to one another

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