EP3489005B1 - Mould and method for producing packaging - Google Patents

Description

The present invention relates to the field of manufacturing packaging, in particular packaging which is at least partially made from a material that is essentially non-thermoplastically deformable.

From the EP 2 829 392 A1 a device for deep-drawing a cardboard blank into a bowl-shaped or cup-shaped object is known. Individual blanks are completely punched out of a cardboard web by means of a punching device. The punched-out individual blanks are then fed to a forming station for forming. The molding station comprises a molding die and a molding die that can be lowered into it. A fold holder is provided which can be acted upon by the molding die, so that the individual blank to be formed is clamped between the molding die and the fold holder. This is intended to ensure that the material slips in a controlled manner during deep drawing. A counter-piston, which is able to press against the underside of the individual blank, is arranged opposite the forming die. This is intended to hold the bottom of the part to be formed during deep drawing. The disadvantage of this system is that the material to be processed has to be fed to the forming station in the form of completely separated individual blanks. This means that for each part to be produced, an individual blank must be transferred to the forming station. In addition, despite the fold holder, at least smaller folds are formed during deep drawing. Because of the lowerable forming die above the forming die, it is also generally not possible for reasons of space to process the formed parts directly in the forming station.

The DE 10 2014 106 427 A1 describes a method for producing three-dimensional molded parts from a sheet of a flat, plastically deformable fiber material with a deep-drawing device which comprises a punch and an associated die. Before reaching the deep-drawing device, a relief cut is made so that a blank for the molded part is connected to the web via at least one web and is otherwise detached from the web. In the deep-drawing device, the punch is lowered and presses the blank into a drawing sleeve. A counter holder pushes the molded part out of the draw sleeve.

The DE 2 226 222 A1 describes a method for erecting cardboard blanks, which consist of a bottom field and a number of side wall fields and possibly joint fields. A stack of such cardboard blanks is made available in a magazine. Under the magazine there is a mold with a puller located under the open bottom. This has suction holes on its surface that are connected to a vacuum source. The puller can be passed up through the open bottom of the mold to grab a carton blank and then pull it down into the mold.

The DE 2 008 313 A1 describes a method of folding a scored blank of paperboard into a container. A blank, which has an approximately rectangular shape, is moved downwards by means of a vacuum plate with a number of suction cups along an arrangement of folding elements which have rods and stops.

The object of the present invention is to provide a method which allows packaging to be produced from a non-thermoplastic or only slightly thermoplastic material and which can be efficiently integrated into a higher-level work process. In addition, a corresponding molding tool should be specified.

This object is achieved by the subject matter of claims 1 or 10, respectively. The dependent claims specify advantageous embodiments of the invention.

In a method for producing a package according to one aspect of the invention, a pre-cut sheet of material is first provided. A partial area of the material sheet is incompletely punched out of the prepunched material sheet, so that the partial area is connected to a remaining area of the material sheet via a plurality of retaining lugs. The incompletely punched-out part of the area should later be used for the packaging, or a part of it, form and can be shaped accordingly. If the packaging is to be produced, for example, as a packaging tray with a rectangular base area, the partial area can be punched out as a substantially rectangular area. However, other shapes are also conceivable. For example, the packaging could be designed as a packaging tray with a round or elliptical base.

The retaining lugs are preferably positioned in such a way that the incompletely punched-out partial surface is held in several directions on the remaining surface of the sheet of material. In this way, the punched-out partial area remains in a defined orientation and position relative to the remaining area of the sheet of material.

The pre-punched sheet of material is positioned over a molding die of a molding tool, so that the incompletely punched-out partial surface of the sheet of material at least partially covers an opening of a molding recess in the molding die. The recess of the molding die is designed according to the desired shape of the packaging to be produced.

After the pre-punched sheet of material has been positioned over the forming die, the remaining surface of the material sheet is clamped against a contact surface of the forming die. For this purpose, a clamping device can act on the remaining surface of the sheet of material against the contact surface of the molding die. It is possible, but not absolutely necessary, for the remaining surface of the sheet of material to actually come into contact with the forming die. It would also be conceivable that one or more intermediate elements are provided between the contact surface of the molding die and the remaining surface of the sheet of material, as long as the remaining surface of the sheet of material is immobilized at least in some areas by the clamping relative to the contact surface.

The incompletely punched-out partial area of the sheet of material is sucked by means of negative pressure onto an insert that can be moved vertically in the molding cavity of the molding die. The height-adjustable insert is in a starting position. From the starting position, the height-adjustable insert is moved further into the mold cavity along one direction of movement. This can be done with continued suction of the partial area of the sheet of material to the height-adjustable insert. The partial surface of the sheet of material is drawn into the mold recess and thus shaped into a packaging tray.

As mentioned, a sheet of material is used from which the partial area which is then used to shape the packaging is only partially made from the sheet of material is punched out. Therefore, the partial area can be fed to the molding tool together with the remaining area of the material sheet. This facilitates correct positioning over the molding die of the molding tool, even with a complicated shape of the punched-out partial surface. In particular, automated positioning over the molding die is simplified, since the remaining area of the sheet of material is available as a contact surface for holding or gripping elements.

It is also possible within the scope of the invention for several partial areas to be incompletely punched out of the sheet of material, which are then each formed into a packaging tray in an associated mold recess of the molding die with a corresponding height-adjustable insert, as described above. This makes it possible, by appropriately positioning the sheet of material, to position the material for several packaging trays over the die in a single step and then to shape the packaging trays at the same time.

Since the partial surface of the sheet of material is drawn into the mold cavity due to the suction by means of negative pressure when the height-adjustable insert is moved, the provision of a molding die, which presses the material into the mold cavity of the molding die, is not necessary (but still possible). Thus, in the case of the invention, the molded packaging tray in the die is more easily accessible from above and can be subjected to further processing steps directly in the die. For this purpose, additional devices can be provided above the die, for example.

When the height-adjustable insert is moved from the starting position further into the mold recess, the retaining lugs preferably tear off, as a result of which the partial area is separated from the remaining area of the sheet of material. Since the remaining surface of the sheet of material is clamped against the contact surface of the molding die and the partial surface of the sheet of material is sucked onto the height-adjustable insert by means of negative pressure, the retaining lugs are torn off in a controlled manner. It is generally not possible to twist the surface or the sheet of material when the retaining lugs are torn off.

Preferably, the recess in the mold has a bevel that widens in the direction of the opening. In this way, packaging trays can be formed, the side walls of which are inclined outwards in the direction of an opening in the packaging tray. The draft also makes it easier for the partial surface of the sheet of material to be drawn into the depression in the shape.

In the context of the invention, it is possible for the sheet of material to be already pre-cut. For example, pre-cut sheets of material could have been obtained from a supplier or previously produced in a separate process. Pre-cut sheets of material can be available separately. However, it would also be conceivable, for example, that a multiplicity of pre-punched sheets of material are present in an interconnected state, for example as a supply roll. The pre-cut sheets of material could then be separated from one another before being positioned above the forming die, or a pre-cut sheet of material could be positioned above the die without prior separation from the other sheets of material.

It is also conceivable that the method according to the invention comprises prepunching the sheet of material. The step of providing the prepunched sheet of material could then include the prepunching of the sheet of material, preferably by a punching station. Here, the partial area of the sheet of material can be punched out incompletely from the sheet of material, so that the partial area remains connected to the remaining area of the sheet of material via the multiple retaining lugs.

It would be conceivable that the sheet of material is already present as a separate sheet of material before the pre-punching. This could be positioned manually or automatically over the forming die after the pre-punching. However, it would also be conceivable that the sheet of material is part of a longer material web that is unrolled from a supply roll, for example. In this case, the sheet of material could first be fed to a punching station for pre-punching the sheet of material and then, for positioning the pre-punched sheet of material, be positioned by advancing the material web over the molding die of the molding tool. It would also be conceivable that a material web is fed to the punching station and the punching station separates the sheet of material from the rest of the material web at the same time as the partial area is punched out or in an additional step

The material of the sheet of material is preferably essentially non-thermoplastically deformable. However, it is entirely conceivable that the sheet of material consists of a material which comprises components which, taken by themselves, are thermoplastically deformable. If the material of the sheet of material is not thermoplastically deformable, the tearing off of the retaining lugs can take place in a particularly controlled manner. The material of the sheet of material preferably comprises natural fiber, cardboard and / or paper. In this way, inexpensive, environmentally friendly and stable packaging can be produced.

According to an advantageous further development, a thermoplastic film layer is positioned over the sheet of material over the molding die. The thermoplastic film layer can be molded into the packaging tray formed from the partial surface of the material sheet, so that there is no direct contact between a product to be packaged and the packaging tray later. This is particularly advantageous if the product to be packaged has moisture which would be absorbed by the packaging tray on contact. The thermoplastic film layer is positioned over the sheet of material while the sheet of material is over the forming die. For example, the thermoplastic film layer can be positioned over the sheet of material before the partial surface of the sheet of material is drawn into the mold recess by moving the height-adjustable insert and the packaging tray is thus formed. In principle, however, it would also be conceivable that the packaging tray is first formed and the thermoplastic film layer is only then positioned over the sheet of material over the forming die. In both cases, however, the film layer can be positioned over the sheet of material as long as it is still on the forming die. It is therefore not necessary to move the packaging tray to a further work station before the thermoplastic film layer is applied.

The thermoplastic film layer is preferably formed into the packaging tray from the side of the film layer facing away from the sheet of material by using compressed air. The thermoplastic film layer is acted upon by the compressed air into the packaging tray and can lie against the interior of the packaging tray. The thermoplastic film layer is preferably held by the clamping device. The thermoplastic film layer can already be acted upon with compressed air while the partial surface of the sheet of material is drawn into the mold recess to form the packaging tray, so that the thermoplastic film layer is shaped together with the packaging tray. However, it would also be conceivable to first completely shape the packaging tray and only then to apply compressed air to the thermoplastic film layer in order to shape it into the packaging tray.

In order to simplify the shaping of the thermoplastic film layer, the film layer can be heated after positioning over the sheet of material over the forming die by means of a heating device located on the side of the film layer facing away from the forming die. The heating device can in particular be displaceable parallel to the direction of displacement of the height-displaceable insert. In order to enable the sheet of material and the thermoplastic film layer to be positioned, the heating device can be moved away from the molding die into a stowed position. After positioning the thermoplastic Film layer, the heating device can be moved from the stowed position in the direction of the molding die into a heating position in order to heat the thermoplastic film layer.

The invention also relates to a molding tool for producing a packaging from a sheet of material which has been pre-punched by incompletely punching out a partial area of the sheet of material in such a way that the partial area remains connected to a remaining area of the sheet of material via several retaining lugs. The molding tool can be designed, suitable and configured for carrying out the method according to the invention. Features described with reference to the method can be transferred to the molding tool or to a packaging machine comprising the molding tool, and vice versa.

A molding tool according to the invention comprises a molding die which comprises a mold recess with an opening and a contact surface. In addition, the molding tool includes a clamping device which is designed to clamp the remaining surface of the sheet of material against the contact surface of the molding die when the pre-cut sheet of material is positioned over the molding die in such a way that the partial surface of the sheet of material at least partially covers the opening of the molding cavity of the molding die. A height-adjustable insert is provided in the cavity of the molding die and can be moved further into the cavity from a starting position along a travel direction. The molding tool also comprises a vacuum device to which a e.g. negative pressure that can be generated by means of a vacuum pump can be applied and which is designed to suck the partial surface of the sheet of material onto the height-adjustable insert by means of negative pressure. According to an advantageous embodiment, channels with openings are provided in the height-adjustable insert through which the negative pressure device can suck in the partial surface of the sheet of material.

Preferably, the recess in the mold has a bevel that widens in relation to the opening.

The molding tool can furthermore comprise a compressed air device which is configured to act on a thermoplastic film layer positioned above the material sheet above the molding die by using compressed air from the side of the film layer facing away from the material sheet in the direction of the material sheet.

The molding tool can comprise a heating device which is designed to heat the film layer, after the film layer has been positioned over the sheet of material over the forming die, from the side of the film layer facing away from the forming die.

The heating device can be moved parallel to the direction of movement of the height-adjustable insert towards the molding die and away from the molding die.

The invention also relates to a packaging machine which comprises the described molding tool. The packaging machine can also include a punching station which is configured to pre-punch the sheet of material by incompletely punching out the partial area of the material sheet, so that the partial area remains connected to the remaining area of the material sheet via a plurality of retaining lugs.

The packaging machine can also have a conveying device which is configured to position the sheet of material pre-cut by the punching station over the molding die of the molding tool so that the partial surface of the sheet of material at least partially covers the opening of the molding recess of the molding die.

According to an example not claimed, a method for producing a packaging is provided in which, instead of the pre-punched sheet of material with the incompletely punched-out partial surface, a separate material blank is positioned over the molding die of the molding tool, which is to be formed into a packaging tray.

Such a method comprises the positioning of a material blank over a molding die of a molding tool, so that the material blank at least partially covers an opening of a molding recess of the molding die. The material blank is sucked by means of negative pressure onto an insert that can be moved in height in the cavity of the molding die in a starting position of the insert that can be moved in height. From the starting position, the height-adjustable insert is moved further into the mold recess along a direction of movement, the material blank being drawn into the mold recess and thus formed into a packaging tray.

With such a method, in contrast to the method in which the pre-punched sheet of material is processed with the incompletely punched-out partial surface, there is no need to clamp the material against a contact surface of the molding die. In order nevertheless to enable the material blank to be positioned easily in a suitable position above the forming die, the material blank can optionally be aligned on a positioning element. One Such a positioning element, for example in the form of positioning pins and / or positioning edges, can for example be provided or attached to the molding die.

With regard to the method in which the pre-punched sheet of material is processed with the incompletely punched-out partial area, the features described can be transferred to the method in which the material blank is processed. In particular, the features of claims 4 to 9 can be applied alone or in any combination to the method in which the material blank is processed.

The method in which the material blank is processed can also be carried out with the described molding tool. Optionally, the clamping device of the molding tool can be omitted for this and / or the positioning element described can also be provided.

Fig. 1

eine schematische Ansicht auf eine Verpackungsmaschine mit einem Formwerkzeug und einer Stanzstation gemäß einer Ausführungsform;

Fig. 2

eine schematische Draufsicht auf einen vorgestanzten Materialbogen;

Fig. 3

eine perspektivische Schemaansicht einer mit einem Verfahren gemäß einer Ausführungsform hergestellten Verpackungsschale; und

Fig. 4A - 4D

eine schematische Darstellung einer Abfolge von Betriebszuständen eines Formwerkzeugs gemäß einer Ausführungsform beim Herstellen einer Verpackung gemäß eines erfindungsgemäßen Verfahrens nach einer Ausführungsform.

Fig. 5

eine schematische Draufsicht auf Materialzuschnitte, welche in einem beispielhaften, nicht beanspruchten Verfahren zu Formvertiefungen umgeformt werden.

In the following, the invention is to be explained further on the basis of exemplary embodiments with reference to the figures. It shows

Fig. 1

a schematic view of a packaging machine with a molding tool and a punching station according to an embodiment;

Fig. 2

a schematic plan view of a pre-cut sheet of material;

Fig. 3

a perspective schematic view of a packaging tray produced by a method according to an embodiment; and

Figures 4A-4D

a schematic representation of a sequence of operating states of a molding tool according to one embodiment when producing a package according to a method according to the invention according to one embodiment.

Fig. 5

a schematic plan view of material blanks, which are formed in an exemplary, not claimed method to form depressions.

Figure 1 shows a packaging machine 1 according to an embodiment. The packaging machine 1 comprises a punching station 3 and a forming tool 5, both of which are provided on a machine frame 7. The punching station 3 comprises a punching tool upper part 9 and a punching tool lower part 11. A material web 13 is made by means of a

Transport device 15 is removed from a supply roll 17 attached to machine frame 7 and fed to punching station 3. The conveying device 15 can, for example, comprise chains of clamps guided on both sides of the material web 13 on the machine frame 7 for holding the material web 13 in a clamped manner.

The punching station 3 is configured to prepunch the material web 13. In particular, a sheet of material 19, which is part of the material web 13, is prepunched. Figure 2 shows a schematic plan view of a sheet of material 19 prepunched by the punching station 3. In the embodiment shown, this was also separated from the rest of the material web 13 during the prepunching. But this is not absolutely necessary. In addition, it would also be conceivable to feed the punching station 3 instead of the material web 13 already separated material sheets 19 for prepunching.

When pre-punching the sheet of material 19 in the embodiment shown, the punching station 3 punches four partial areas 21 by incompletely punching out of the material sheet 19, so that the partial areas 21 each remain connected to a remaining area 25 of the material sheet 19 via several retaining lugs 23. The partial areas 21 each correspond to an area which is later formed into a packaging tray 27 with the molding tool 5. In the embodiment shown, packaging trays 27 of the in Figure 3 Shown shape can be produced, that is, packaging trays 27 with a rectangular base 29 and outwardly tilted side walls 31. Of course, other shapes for the packaging tray 27 would also be conceivable, such as a packaging tray 27 with any polygon, a circle or an ellipse as the base 29 The shape of the partial surfaces 21 of the sheet of material 19 that are not to be completely punched out can be adapted to the respectively desired shape of the packaging tray 27.

In the embodiment shown, the punching station 3, as mentioned, in each case incompletely punched out four partial areas 21 from a sheet of material 19. During the further processing of the sheet of material 19 by the molding tool 5, which is described below, four packaging trays 27 can be produced at the same time. It would of course also be conceivable to punch any other number of partial areas 21 incompletely from the sheet of material 19. In particular, it would also be conceivable to incompletely punch out only a partial area 21 from a sheet of material 19 and to produce the packaging trays 27 individually.

After the prepunching, the sheet of material 19 is transferred to the forming tool 5 for further processing. In particular, the pre-cut sheet of material 19 is over a Forming die 33 of the forming tool 5 positioned. In the embodiment shown, this takes place by further conveying the sheet of material 19 by means of the conveying device 15.

The molding tool 5 comprises the molding die 33 and a cover part 35. Figure 4A shows a detail of the forming station 5 in an open operating state. In the open operating state, the molding die 33 and the cover part 35 are spaced apart from one another in such a way that the sheet of material 19 can be positioned between the molding die 33 and the cover part 35. In Figure 4A the sheet of material 19 was already positioned over the molding die 33 by means of the conveying device 15 in such a way that the incompletely punched-out partial surfaces 21 of the sheet of material 19 each at least partially cover an opening 37 of an associated molding recess 39 of the molding die 33. A thermoplastic film layer 41 was also positioned over the sheet of material 19 on the side of the sheet of material 19 facing away from the molding die 33. In the embodiment shown, the thermoplastic film layer 41 is pulled off a corresponding supply roll 43 of the molding tool 5 (see FIG Figure 1 ).

After the prepunched sheet of material 19 and the thermoplastic film layer 41 have been positioned between the molding die 33 and the cover part 35 of the molding tool 5, the molding tool 5 is closed by moving the molding die 33 and the cover part 35 towards one another. The resulting operating situation is in Figure 4B shown. At its end facing the molding die 33, the cover part 35 comprises a clamping device 45 which, in the embodiment shown, is designed as a grid which essentially corresponds to the shape of the remaining surface 25 of the sheet of material 19. In the closed state of the molding tool 5, the clamping device 45 clamps the remaining surface 25 of the sheet of material 19 against a contact surface 47 of the molding die 33. The thermoplastic film layer 41 above the sheet of material 19 is also clamped by the clamping device 45 against the contact surface 47 of the molding die 33 and thus immobilized . In the closed state of the molding tool 5, an airtight interior space is preferably defined by the molding die 33 and the cover part 35 together with the sheet of material 19 clamped therebetween and the thermoplastic film layer 41 clamped between them.

The molding tool 5 comprises height-adjustable inserts 49, one of which is in each case in a molding recess 39 of the molding die 33. The inserts 49 are each along a direction of travel V within the shape recesses 39 adjustable in height. The direction of travel V is parallel to the direction along which the molding die 33 and the cover part 35 of the molding tool 5 are moved relative to one another in order to close or open the molding tool 5. In the Figures 4A and 4B the height-adjustable inserts 49 are each shown in a starting position which corresponds to a maximally extended position. In the starting position, a mounting plate 51 of a height-adjustable insert 49 lies essentially at a height at which it is flush with the opening 37 of the corresponding molding recess 39 of the molding die 33. The height-adjustable inserts 49 each comprise channels 53 which end in openings formed in the holding plate 51 which face the sheet of material 19. The channels 53 are connected to a vacuum device 55 which is designed to suck the partial surfaces 21 of the sheet of material 19 to the holding plate 51 of the respective height-adjustable insert 49 by means of a vacuum applied through the channels 53. After the molding tool 5 has been closed, the partial surfaces 21 are in each case sucked in at least regionally by the vacuum device 55 on the corresponding height-adjustable insert 49 and held there.

After the incompletely punched-out partial surfaces 21 have been sucked onto the respective height-adjustable insert 49, the height-adjustable inserts 49 are moved along the direction of movement V from the starting position into the mold depressions 39. Here, the partial surfaces 21 of the sheet of material 19 are drawn into the shaped depressions 39 and thus each formed into a packaging tray 27. Figure 4C shows the situation after the height-adjustable inserts 49 have been completely retracted. Because the incompletely punched-out partial surfaces 21 were sucked into the inserts 49 when the inserts 49 were moved in, the partial surfaces 21 became when pulled into the respective mold recess 39 by engagement with side walls of the mold recess 39, in particular with bevels 57 of the mold recesses 39, which are located in Widen in the direction of the openings 37 of the recesses 39, shaped to form packaging trays 27. Since the remaining surface 25 of the sheet of material 19 is clamped against the contact surface 47 of the molding die 33 when the height-adjustable insert 49 is retracted, the retaining lugs 23 tear off when the partial surfaces 21 are pulled into the recesses 39 and the packaging trays 27 are separated from the remaining surface 25 of the sheet of material 19 .

In the cover part 35 of the molding tool 5, a heating device 59 is provided, which can be moved parallel to the direction of movement V of the height-adjustable inserts 49 towards the molding die 33 and away from the molding die 33. In the Figures 4A and 4B the heating device 59 is shown in a stowed position in which it is at a maximum within the cover part 35 has moved away from the molding die 33. After the molding tool 5 has been closed, the heating device 59 is moved from the stowed position onto the molding die 33 into a heating position, which is in the Figures 4C and 4D is shown. How out Figure 4C As can be seen, the heating device 59 is in the heating position adjacent to the thermoplastic film layer 41 and can heat it in such a way as to improve the deformability of the film layer 41.

After the packaging trays 27 have been formed by pulling the incompletely punched-out partial surfaces 21 into the molding depressions 39, the heated thermoplastic film layer 41 is formed into the packaging trays 27 by using compressed air from the side of the film layer 41 facing away from the molding die 33. For this purpose, the molding tool 5 can comprise a compressed air device 61 which can introduce compressed air into the interior of the cover part 35 of the molding tool 5. As a result of the increase in pressure within the cover part 35, the thermoplastic film layer 41 is molded into the packaging trays 27, as in FIG Figure 4D shown. The packaging trays 27 are provided with an inner layer of film. The provision of such a film layer is not absolutely necessary, however, and the thermoplastic film layer 41 could also be completely omitted. The thermoplastic film system 41 could alternatively also be connected to the packaging tray 27 in a separate work station downstream of the molding tool 5.

As an alternative not claimed, it would also be conceivable, instead of the incompletely punched-out partial surfaces 21 of the prepunched sheet of material 19, to shape completely cut-out material blanks 71 into packaging trays 27. Figure 5 shows, by way of example, four such material blanks 71 which have a shape such that packaging trays 27 of the FIG Figure 3 can be shaped from them.

The material blanks 71 can be positioned over the molding die 33 of the molding tool 5 in such a way that they each at least partially cover an opening 37 of a molding recess 39 of the molding die 33. In order to facilitate the correct positioning of the material blanks 71, positioning elements 73 can be provided on the molding die 33, with which the material blanks 71 can be aligned. Such positioning elements 73 are in the Figures 4A to 4D shown in dashed lines as a possible modification. When processing completely separated material blanks 71, there is no need to clamp the material against the contact surface 47 of the molding die 33, the clamping device 45 of FIG Forming station 5 can therefore be omitted as a modification. Otherwise, a forming station 5 of the type described above can be used.

After positioning, the material blanks 71 are each sucked by means of a vacuum by the vacuum device 55 onto the vertically movable insert 49 in the associated mold recess 39 of the molding die 33. The inserts 49 are then each moved from the starting position along the direction of travel V into the mold recess 39, the respective material blank 71 being drawn into the mold recess 39 and thus formed into a packaging tray 27.

It is also conceivable to position a thermoplastic film layer 41 over the material blanks 71 over the molding die 33 and additionally, optionally, to shape the thermoplastic film layer 41 into the packaging trays 27 using compressed air from the compressed air device 61.

Claims (16)

1. A method for producing a packaging, comprising the following steps:

   providing a prepunched material sheet (19) from which a subarea (21) has been punched out incompletely such that the subarea (21) is connected to a residual area (25) of the material sheet (19) through a plurality of retaining lugs (23);

   positioning the prepunched material sheet (19) on top of a female die part (33) of a forming tool (5) such that the subarea (21) of the material sheet (19) covers an opening (37) of a forming cavity (39) of the female die part (33) at least partially;

   clamping the residual area (25) of the material sheet (19) in position against a contact surface (47) of the female die part (33);

   sucking the subarea (21) of the material sheet (19) by means of a vacuum onto an insert (49), which is vertically movable in the forming cavity (39) of the female die part (33), at a starting position of the vertically movable insert (49); and

   moving the vertically movable insert (49) from the starting position along a displacement direction (V) further into the forming cavity (39), whereby the subarea (21) of the material sheet (19) is drawn into the forming cavity (39) and thus formed into a packaging trough (27).
2. The method according to claim 1, wherein, during the movement of the vertically movable insert (49) from the starting position further into the forming cavity (39), the retaining lugs (23) tear and the subarea (21) is thus separated from the residual area (25) of the material sheet (19).
3. The method according to one of the preceding claims, wherein providing the prepunched material sheet (19) comprises prepunching the material sheet (19) by incompletely punching out the subarea (21) of the material sheet (19), so that the subarea (21) remains connected to the residual area (25) of the material sheet (19) through the plurality of retaining lugs (23).
4. The method according to one of the preceding claims, wherein the forming cavity (39) comprises forming incline (57), which widens in the direction towards the opening (37).
5. The method according to one of the preceding claims, wherein the material of the material sheet (19) is essentially not thermoplastically deformable.
6. The method according to one of the preceding claims, wherein the material of the material sheet (19) comprises natural fibers, cardboard and/or paper.
7. The method according to one of the preceding claims, wherein a thermoplastic film layer (41) is positioned on top of the material sheet (19) on top of the female die part (33).
8. The method according to claim 7, wherein the thermoplastic film layer (41) is formed-in into the packaging trough (27) by applying compressed air from the side of the film layer (41) facing away from the material sheet (19).
9. The method according to claim 7 or 8, wherein, after positioning of the film layer (41) on top of the material sheet (19) on top of the female die part (33), the film layer (41) is heated by means of a heating unit (59) provided on the side of the film layer (41) facing away from the female die part (33).
10. A forming tool (5) for producing a packaging from a material sheet (19), which, by incompletely punching out a subarea (21) of the material sheet (19), has been prepunched such that the subarea (21) remains connected to a residual area (25) of the material sheet (19) through a plurality of retaining lugs (23), comprising:

    a female die part (33) comprising a forming cavity (39) with an opening (37) and a contact surface (47); and

    a clamping unit (45), which is configured for clamping the residual area (25) of the material sheet (19) in position against the contact surface (47) of the female die part (33), when the prepunched material sheet (19) has been positioned on top of the female die part (33) such that the subarea (21) of the material sheet (19) covers the opening (37) of the forming cavity (39) of the female die part (33) at least partially, wherein

    the forming cavity (39) of the female die part (33) has provided therein a vertically movable insert (49), which is movable from a starting position of the vertically movable insert (49) along a displacement direction (V) further into the forming cavity (39), and

    the forming tool (5) further comprises a vacuum unit (55), which is configured for sucking the subarea (21) of the material sheet onto the vertically movable insert (49) by means of a vacuum.
11. The forming tool according to claim 10, wherein the forming cavity (39) comprises a forming incline (57), which widens in the direction towards the opening (37).
12. The forming tool according to claim 10 or 11, which additionally comprises a compressed-air unit (61) configured for acting on a thermoplastic film layer (41), which is positioned on top of the material sheet (19) on top of the female die part (33), in the direction towards the material sheet (19) by applying compressed air from the side of the film layer (41) facing away from the material sheet (19).
13. The forming tool according to claim 12, which additionally comprises a heating unit (59) configured for heating the film layer (41), after the film layer (41) has been positioned on top of the material sheet (19) on top of the female die part (33), from the side of the film layer (41) facing away from the female die part (33).
14. The forming tool according to claim 13, wherein the heating unit (59) is movable towards the female die part (33) and away from the female die part (33) parallel to the displacement direction (V) of the vertically movable insert (49).
15. A packaging machine (1), comprising:

    a punching station (3) configured for prepunching the material sheet (19) by incompletely punching out the subarea (21) of the material sheet (19), so that the subarea (21) remains connected to the residual area (25) of the material sheet (19) through the plurality of retaining lugs (23); and

    the forming tool (5) for producing a packaging from the material sheet (19), according to one of the claims 10 to 14.
16. The packaging machine according to claim 15, which additionally comprises a conveying unit (15) configured for positioning the material sheet (19), which has been prepunched by the punching station (3), on top of the female die part (33) of the forming tool (5) such that the subarea (21) of the material sheet (19) covers the opening (37) of the forming cavity (39) of the female die part (33) at least partially.

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