ES2227294T3 - FOLDED CONTAINER AND MANUFACTURING METHOD OF SUCH CONTAINER. - Google Patents

Abstract

The invention relates to a folded package and a method of making a package preferably for nutritious and non-nutritious products, including foods and beverages or the like. An object of the inventon is to provide a package, where the package may be provided with a print before the package is formed, and where the forming may take place substantially by cold forming so that the print is not affected, and where the package is suitable for receiving a tight-fitting closing means. The novel and characteristic aspect of the method of making a package is that it comprises a sheet comprising at least a layer of plastics to which an amount of inorganic powder material has been added, and that the making of the package comprises at least a combination of punching of the sheet in blanks (10), folding of at least a bottom (4) and at least a side (14), welding and forming of at least a collar (22). Owing to the inorganic powder material and owing to the poor heat effect, minimum shrinkage and very high reproducibility are achieved.

Description

Folded container and manufacturing method of said container.

The invention refers to a folded container and to a method for manufacturing said container, preferably for food and non-food products, including groceries, drinks and the like, said package comprising at least one bottom and at least one side, said container being formed by the  minus one sheet

It is known, for example of the publication German DT 2641162, the fold of a container designed for storage of edible products. This container is made of a rigid cardboard material coated with a waterproof layer grease and moisture. The bottom section is folded and glued to the side piece, which is mounted by gluing the area where The ends overlap. As the ends overlap, one face from the end in the overlapping area is exposed to the side inside the container, that is, the side that comes into contact with the product to be packed Precisely because the cardboard material it is merely coated with a grease impermeable layer and to moisture, the cardboard on the end face is exposed directly, for what has not been conceived. The packaged product "attacks" the cardboard, and especially if the product is butter or margarine, which is why this container is only conceived for a short-term storage, and only for certain products.

These same problems are known in numerous known types of folded containers, as shown in the DT 2641162, in which a material is always used based substantially on cardboard, paper, cardboard or materials similar ones containing cellulose fibers as a component principal. In the joints of the material where they glue between if the overlapping ends, the contents of the container will enter contact with cardboard or cardboard without coating. This happens regardless of whether the product involved is a cardboard with a coating of a plastic substance and / or aluminum to milk preparations with cocoa or for juices, or the so-called cardboard liquid for dairy products. Also, a feature of these packages consist in that they cannot be used, for example, to butter or margarine, which contain an acid that attacks especially to cardboard exposed in overlaps.

Other types of packaging for edible products are made of a plastic substance that is shaped by extrusion / terrestrial processes.
Molding, injection molding, shape labeling or mold labeling.

Thermoformed plastic containers have a non-uniform wall thickness due to the forming process, which requires relatively extensive quality control, and in addition, the manufacturing process causes the finished container to have an unnecessarily large wall thickness in areas not subjected to strong deformations during forming. This unnecessary wall thickness constitutes, of course, an economic effort. Subsequently, the package must be provided, for example, with a cardboard label or cover provided with preprinted information, an advertisement or the like, since the material cannot be preprinted due to the
Heat and deformation.

Direct printing on the formed container provides a result too poor with the techniques of known impression, which would have an adverse effect on sales of the products of the container. Thus, this implies an additional aspect Negative and that adds cost.

In the form labeling, a label is placed preprinted in the deep drawing tool, after which, the hot plastic substance, for example, is suctioned until Take the desired shape and merge with the label. This process It is expensive, because the labels must be manufactured and handled separately, including placement in the tool Deep drawing.

In injection molding and labeling in mold, the wall thickness is very uniform, although the product It is much more expensive to manufacture in relation to a container manufactured by the thermoforming process. The problems of containers manufactured by injection molding are the same as those of the thermoformed. That is, they cannot be preprinted, and that printing should be done after forming, so that the Print quality is too low. Alternatively, must be provided with a label or a cardboard coating expensive. Mold labeling, which consists of a molding by injection with a preprinted label placed on the mold, implies the same drawbacks set forth above for the labeling in the conformal. That is, the process results expensive, because the labels must be manufactured and handled separately, including placement in the mold.

GB 2,016,227 discloses a takeaway container. The container is cut from of a sheet of a plastic or metal substance and folds up its final form, maintaining that form thanks to the fact that The sides of the container have projections that engage in the fold. The recovery property of the plastic substance Maintains the shape of the container. With the types of substance suitable plastic known for use in food products, the folding can only be partial and without pronounced folds. This It is due to this same material recovery property. When a sheet of plastic substance is folded, the sheet can be folded at most 180 degrees. At 180 degrees, both sides of the sheet they find each other. To achieve permanent deformation with pronounced folds, the material should be folded considerably more, which, of course, is not physically possible. Therefore, the container has rounded faces and soft folds In addition, the patent does not state that there may be a lid for the container. A cover or disk could not form a tight closure, since the folds are too inaccurate and by this, also the shape of the opening of the container is imprecise. Therefore, even if the overlaps are glued and performed an attempt with a lid, the container would not be suitable anymore that for content storage for several minutes instead of hours, much less days.

In addition, GB 2,273,093 discloses a container formed by folding a plastic substance, and in which the sides have projections that get caught in the fold, with which the shape is retained and fixed thanks to the recovery property of the plastic substance. The figures of document show the folds as pronounced folds, which it is not possible to obtain with known types of plastic substance by the usual folding. As mentioned above, This would require doubling more than 180 degrees. The upper opening is becomes very inaccurate, and therefore the container is not suitable for the application of a sealing cap or disc to the empty. Therefore, it is not suitable for the storage of contents that cannot be exposed to the air, which is a requirement, for example, of many types of groceries processed.

An objective of the present invention is to provide a container of a material of a substance sheet plastic, as well as a method to manufacture said container, suitable among other things for food products and not foodstuffs, including groceries and beverages or the like, where the package can be provided with a print before the container formation, and where forming can occur substantially by cold forming, such that no Affect the impression. Another objective is to provide a method and a container in which the forming can occur substantially by cold forming, and where the container It is suitable for receiving a tight fitting cover or disc. Another objective is to provide a method and a container in the It is not necessary to apply a label or similar and / or use another post process expensive. Another objective is to provide a method and a package in which the container protects the content better than known carton-based packaging, which can improve the life of the content, both in its entirety and in the store shelf, and / or it could mean that it could reduce the participation of preservatives in the composition. Other more objective is to provide a method to manufacture a container in which the package only needs to be "straightened out" (folded and joined) immediately before being filled.

The novel and characteristic aspect of the method to make a package is that it comprises a sheet with minus a layer of a plastic substance to which a certain amount of pulverized inorganic material, and in which the manufacture of the package comprises at least a combination of how  minimum the following processes:

a) At least partial punching of the sheet in die-cut pieces from one feed per roll or per sheet

b) Folding at least one bottom and at least one side

c) Welding of at least one sheet and at least one side

d) Formation of at least one necklace.

It is considered as welding a heating whereby the two ends or the two pieces merge into contact with each other, or the activation of an applied queue, called hot glued, or the application of a hot substance molten that adheres and / or seals ends or pieces together, or other similar process.

A necklace can comprise an edge, face, lateral or conformal termination that is suitable for cooperation with a lid, container, disk or other similar closure means. May use a collar to increase strength, stiffness and / or reproducibility of a container, a lid, etc.

The manufacture of a container from a sheet comprising at least one layer of a plastic substance to the that a certain amount of inorganic material has been added pulverized provides the technical effect of modifying the properties of the layer of plastic substance. The result consists in which, among other things, the modulus of elasticity and the limit of elasticity are different to tensile and compression. He folding makes material recovery result considerably lower (becomes inert), and can form pronounced folds and folds. Therefore, after a die cut suitable, the container can be folded up to take the form desired, which is fixed, for example, by welding. The welder it covers a very limited area, such that impressions, if there are, they are not affected. Due to the material of which it is composed of pulverized inorganic material and with little effect thermal, minimal shrinkage and reproducibility are achieved very high The reproducibility of the type, form and measures results Important for the quality of the container. The formation of a necklace in the container provides additional rigidity, and makes the container is suitable for receiving, for example, a cover or disc with tight fit. Since inorganic material has been added pulverized to the plastic substance, which has thus remained encapsulated, nothing happens if two faces overlap, and you get a exposed end face with respect to the product to be Contain the container

The formation of at least one collar can involve a winding, thus providing, in a way simple, a sturdy collar and stabilizer comprising several layers.

The formation of at least one collar can involve the hot shaping of the shape of the collar, of so that, for example, pronounced edges can be created for your hook with, for example, a lid or a container.

In an advantageous embodiment, the package can understand several pieces, including parts with means to close the container, said parts being preferably made of the same way as described above, with what the same advantages can be achieved for all parts.

The sheet can be provided with an impression with prior to punching, so that printing can take place before straightening the container. Therefore you can printing with a quality far superior to that It is possible in a formed container. In addition, it is much less face.

Manufacturing may involve conformation in hot edges and / or double curvature faces, allowing this way get more sophisticated ways than by simply creased. By limiting the hot forming area, they remain a low level of contraction and high reproducibility.

In an advantageous embodiment, at least one side it can be initially separated from at least one fund, and also be at less folded and joined separately, after which they join the side or sides and the bottom or bottoms. In this way, they can provide more complex forms than by using sides and contiguous funds.

The stamped pieces can be stacked in a pallet with a fixation intended for the geometry involved, and that It is suitable for straightening the container immediately before filled in. In this way, considerable savings can be achieved in the transport of containers, given that the untapped containers they occupy a considerably smaller space, and it is not necessary The containers are stackable. You get the same advantage in the Packaging storage In addition, a number can be provided considerably larger packaging in the filling unit, and it is not The stores need to be replenished very frequently.

The novel and characteristic appearance of the container includes the characteristics that it is formed at least by a sheet comprising at least one layer of a plastic substance to which a certain amount of material has been added pulverized inorganic, and that the container is substantially formed by folds and welds, and that the package includes as minimum a suitable collar to receive means of closing the container. This provides a container with a minimum level of contraction, and a very high reproducibility. Since the material has been added inorganic sprayed to the plastic substance, which thus has encapsulated by him, nothing happens if two faces overlap, and an end face exposed to the product to be obtained is obtained Contain the container

The sheet may comprise at least one layer of coating of a plastic substance that can present, by For example, greater strength or firmness than the rest of the blade. OR well, for example, it can be used in the coating layer of a plastic substance another color or a better plastic substance quality.

The sheet can be provided with an impression that has been applied before forming the container, allowing this mode carry out printing with the sheet in a flat state, which allows to use known methods of high quality printing. Likewise, a lower level of process waste is achieved, given that the "lattice" generated by the subsequent die cut in the type of plastic substance involved can be reused without no problem, since printing on the "lattice".

The package can comprise various parts, including at least one part endowed with means to close the container, said parts being preferably made thereof material. In this way, all parts can be manufactured with the Same quality and the same advantages.

The folded container may comprise at least one insulating layer on the sheet, which means that, in certain types of packaging, there is no need for additional protection against sunlight, water or oxygen. This protection is incorporated simply to the sheet from which the container is folded. In addition, the part of the sheet that remains after die cutting can be reused without any problem, which has not been the case until now with the residual material from, for example, the thermoforming of containers. In the traditional methods of manufacture of a container, the material can also be reused residual, but only if there is no ink on the sheet, since it can contain free radicals The reuse problem of materials in which there is a layer of a plastic substance of lightning protection is that the protective layer Against the light it is often black and can only constitute 10% of the total thickness of the sheet, since otherwise the black color will You will see through the white outer layers. In a process of thermoforming, approximately 50% of residual material is generated from the thermoforming process. If 50% of residual material in a 10% layer, is not economically helpful, given that approximately 40% of the amount should be discarded material of the plastic substance. This happens to satisfy the Customer's desire for a 100% white tub, for example.

The sheet may comprise at least one layer of foamy or expanded plastic substance, which can be reduced the weight of the container saving material at the same time, and Get better thermal insulation.

The package may include a collar designed for a spring cover This gives the possibility to use the type usual tapas typically used in table margarines and similar products.

In another embodiment, the package may include a collar designed for a fitted cap, and in another embodiment, Designed for a pressure cover. Therefore, the container can be used in conjunction with all usual types of tapas.

The sheet may comprise at least one layer of coating preferably comprising at least one olefin, said material being suitable for reuse.

Powdered inorganic material can preferably comprise lime and / or talc, which are cheap and also they are suitable for the addition to the plastic substance in common extruders.

The layer or layers to which material has been added inorganic powders may constitute at least 75% of the total thickness of the sheet. Therefore, an amount can be obtained relatively high pulverized material, which reduces the price. At the same time, the amount of material sprayed It favors the reproducibility of the container.

The amount of pulverized inorganic material it can constitute at least 20 percent by weight of the layer or layers, thus making the sheet foldable.

The amount of pulverized inorganic material it may preferably constitute at least 50 percent in weight of the layer or layers, which is especially favorable for the folding of the sheet, while reducing the contraction level

The invention of more complete way through the drawings that show examples of embodiments of the invention:

Figure 1 shows a section of a container creased.

Figure 2 shows a section of a container creased.

Figure 3 shows a bottom and side of a unfolded container

Figure 4 shows a section of a container folded with a fitted lid.

Figure 5 shows a section of a container folded with a spring cover.

Figure 6 shows a section of a container folded with a snap cover.

Figure 7 shows a section of a container creased.

Figure 8 shows the principle of a pallet with a fixation seen obliquely from above.

Figure 1a shows a sheet consisting of a single layer (3) of a plastic substance to which a certain amount of pulverized inorganic material. He plastic substance material can be an olefin, while the pulverized material may be, for example, lime or talc.

Figure 1b shows a sheet consisting of a single layer (3) of a plastic substance to which a certain amount of pulverized inorganic material, and that is provided with a coating layer (5) of a plastic substance On one of their faces.

Figure 1c shows a sheet consisting of a single layer (3) of a plastic substance to which a certain amount of pulverized inorganic material, and that is equipped with coating layers (5 ') and (5' ') of plastic substance on both sides.

Figure 1d shows a sheet consisting of a single layer (3) of a plastic substance as well as an insulating layer integrated (7), which may be, for example, a black pigment, a black plastic substance, aluminum foil, etc.

Figure 1e shows a sheet consisting of a single layer (3) of a plastic substance to which a certain amount of pulverized inorganic material, and that is provided with coating layers (5 ') and (5' ') of the substance plastic on both sides, and additionally provided with a layer insulator (7).

The sheet can be manufactured, for example, by lamination or coextrusion, and can comprise so many layers as required by the use of packaging itself.

Figure 2 shows a section of a container folding formed by a single sheet piece. In this embodiment, there is a folded edge from the bottom (4), said edge forming a foot (6) of the container in the transition to a side (14). Side (14) ends in a necklace (22), which in this case is formed by rolling. At the points where the sheet can have overlapping ends, which is not shown in the figure, these are welded or, for example, hot glued each. Level differences due to overlap may equalize by hot forming or chamfering. Instead of overlap, the ends can be joined edge to edge, being then soldiers or glued. The foot (6) and / or the collar (22) can set by heat input or by gluing.

Figure 3 shows a variant of a background die cut (4) and an uncut side (14), where the bottom (4) and the side (14) may be provided with an impression. When the container, immediately before filling, has to be folded, the bottom (4) and the side (14) are arranged in a folding machine and fold, so that one edge bends down from the bottom (4), and the side (14) bends up and moves around the bottom (4). When the container has been folded, it melts or hot glued, for example, by welding cushions which can be mounted in connection with the folding machine. After completing the joint, the package is ready for use and can Be driven to a filling station.

The bottom (4) and the side or sides (14) they can, likewise, be folded or partially welded, followed by a folding and an additional soldier, in the same way that can be partially formed throughout the process a collar or one foot, as well as edges and / or double curvature faces. The process constituent can be combined in numerous ways according to the invention, which depends solely on the concrete design selected for the container.

It should be emphasized here that, of course, Other forms may be provided as needed or desired. The which is contemplated here is not only how the sheet is formed with a bottom (4) and a side or side (14), but also one more level general in terms of packaging design. According to the invention, Packaging can be made in all possible ways, such as circular, oval, conical, rectangular shapes, etc.

Also, as shown in figures 4, 5 and 6, packages (2) designed for various types can be manufactured of covers (18), (20).

Figure 4 shows a package comprising a called fitted cover (16). This guy has the advantage that the closure can be airtight, and that the enclosed air contributes to the container stabilization. In addition, the insertion of a disc with a lid fitted if the sheet is equipped with a insulating layer (7). A bottom (4) has a curved edge towards below which folds a side (14). On the point bottom, side (14) and bottom (4) hook and form jointly one foot (6). The side (14) and the bottom (4) are welded or glue each other on the foot (6). The side (14) has a top necklace-shaped termination (22). The necklace (22) can be formed by winding and subsequent conformation in hot. The winding causes the sheet to have at least two layers, so that there is enough material to work with in the hot shaping This allows hot forming a given collar (33) suitable for receiving, for example, a top. On the other hand, the package can, of course, comprise also a lid or part of a lid.

Figure 5 shows a package comprising a called spring cover (20). In the embodiment shown, a bottom (4) has a curved edge down that engages with an edge of a side (14) correspondingly curved, to end of forming a foot (6). The side (14) and the bottom (4) are welded or glue each other on the foot (6). At the top, the side (14) is provided with a collar (22) suitable to receive a spring cover (20). The necklace (22) can acquire its shape by hot shaping in order to achieve greater precision in the position of the active edge of the collar (22).

Figure 6 shows a package comprising a called pressure cap (21). In the embodiment shown, a bottom (4) has a curved edge down that engages with an edge of a side (14) correspondingly curved, for form a foot (6). The side (14) and the bottom (4) are welded or glue each other on the foot (6). On the top, the side (14) is provided with a collar (22) suitable for receiving a cap under pressure (21). The necklace (22) can acquire its shape by hot shaping in order to achieve greater precision.

The caps (18), (20), (21) can be made of the same way and the same material as the sides (14) and the bottom (4), that is, by a combination of die cut, folding, welding and folding of at least one collar.

Figure 7 shows a variant of the package that It is precisely suitable for use as a lid. The container it comprises a bottom (4) connected to a side (14), being formed said side (14) down with a collar (22) formed by rolled up

Figure 8 shows a preferred embodiment of a pallet (24) with a fixation (26). The pallet (24) is designed to be fixed in connection with a die cutting process, a folding process and a filling process. It is provided with one or, as shown here, several fixings (26) conceived for the particular geometry in which the part is manufactured die cut (10) involved. The die cut pieces (10) can be bottoms (4) and / or sides (14) that can be contiguous. Fixing (26) can be adjustable so that the pallet (24) can be adjusted to other die cut pieces (10). The pallet (24) can be used in filling areas where there are often requirements strict with respect to the pallet. What is contemplated here is, by For example, the pallet must be able to be cleaned safely. In the figure, the pallet (24) is provided with a bottom (28) that can rise in such a way that the top die cut pieces (10) They are always at the same height. Instead of pieces die cut (10), the sheet can be in the form of a roll, where the shape of the bottoms (4) and / or the sides (14) is partially stamped That is, between the roll and the funds (4) and / or lateral (14) there are several weak connections that they can break easily in the machine that must "straighten" the container

The folded container may be formed by a sheet that has been punched into pieces of a rolled material or in sheet shape before being folded, which makes it possible to have the material stored in a form suitable for the rest of the production steps The sheet can be composed of several layers optionally rolled sheet or coextruded, while Other sheets may be rolled.

In one embodiment, the package may be manufactured from a mono-sheet of a plastic substance Mono-sheet is understood as a product with the desired properties formed by a material cheap and in which the residual material can be used again with ease.

The package may also be formed from a sheet of a plastic substance consisting of several layers. Is therefore it is possible to use a sheet consisting, for example, of a inner layer, an insulating layer of aluminum foil and a layer external The layered structure can thus adapt to the purpose for which the container is conceived.

The package may comprise means for electronic identification, for example a microchip. The container it can also comprise means of closing the container, for example a lid, disc or filling seal, etc.

Claims (22)

1. Method for manufacturing a package, preferably for food and non-food products, including groceries and beverages or the like, said package comprising at least one bottom (4) and at least one side (14), said package being formed by at least one sheet, characterized in that the sheet comprises at least one layer (3) of a plastic substance to which a certain amount of pulverized inorganic material has been added, and because the manufacture of the package comprises at least a combination of at least the following processes: a) at least partially cut the sheet into die cut pieces (10) from a roll feed or per sheet b) fold at least one bottom (4) and at least one lateral (14) c) weld at least one bottom (4) and at least one lateral (14) d) form at least one collar (22) suitable for Receive means to close the container. 2. Method for manufacturing a package according to claim 1, characterized in that the formation of at least one collar (22) comprises a winding. 3. Method for manufacturing a container according to claim 2, characterized in that the formation of at least one collar (22) comprises hot forming of the shape of the collar. 4. Method for manufacturing a package, according to one or more of claims 1 to 3, characterized in that the package comprises several parts, including parts with means for closing the package, said parts being preferably manufactured in the same manner as described above in one or more of claims 1 to 3. 5. Method for manufacturing a package, according to one or more of claims 1 to 4, characterized in that the sheet is provided with a print before punching. Method for manufacturing a package, according to one or more of claims 1 to 5, characterized in that the manufacturing comprises hot forming of edges and / or double curvature faces. 7. Method for manufacturing a package according to one or more of claims 1 to 6, characterized in that the face or faces (14) are initially separated from the bottom or bottoms (4), and are folded and joined at least partially separately, after which the face or faces (14) is joined with the bottom or bottoms (4). Method for manufacturing a container, according to one or more of claims 1 to 7, characterized in that stamped pieces (10) are stacked on a pallet (24) with a fastener (26) designed for the geometry involved, and because the package straightens immediately before filling. 9. Folded container, preferably for food and non-food products, including groceries and beverages or the like, said package comprising at least one bottom (4) and at least one side (14), said package being formed substantially by at least one sheet, characterized in that the sheet comprises at least one layer (3) of a plastic substance to which a certain amount of pulverized inorganic material has been added, and because the package is substantially formed by folding and welding, and because the package comprises as at least one collar (22) suitable for receiving means of closing the container. 10. Folded container according to claim 9, characterized in that the sheet comprises at least one coating layer (5) of a plastic substance. 11. Folded container according to one of claims 9 or 10, characterized in that the sheet is provided with an impression that is applied before the formation of the package. 12. Folded container according to one or more of claims 9 to 11, characterized in that the package comprises several parts, including at least one part provided with means for closing the package, said parts being preferably made of the same type of material. 13. Folded container according to one or more of claims 9 to 12, characterized in that the sheet comprises at least one insulating layer (7). 14. Folded container according to one or more of claims 9 to 13, characterized in that the sheet comprises at least one layer of an expanded plastic substance. 15. Folded container according to one or more of claims 9 to 14, characterized in that the collar (22) is designed for spring covers (20). 16. Folded container according to one or more of claims 9 to 14, characterized in that the collar (22) is designed for fitted lids (18). 17. Folded container according to one or more of claims 9 to 14, characterized in that the collar (22) is designed for pressure caps (21). 18. Folded container according to one or more of claims 9 to 17, characterized in that the sheet comprises at least one coating layer (5) preferably comprising at least one olefin. 19. Folded container according to one or more of claims 9 to 18, characterized in that the pulverized inorganic material preferably comprises lime and / or talc. 20. Folded container according to one or more of claims 9 to 19, characterized in that the layer or layers (3) constitute at least 75 percent of the total thickness of the sheet. 21. Folded container according to one or more of claims 9 to 20, characterized in that the amount of pulverized inorganic material constitutes at least 20 percent by weight of the layer (3). 22. Folded container according to one or more of claims 9 to 21, characterized in that the amount of pulverized inorganic material preferably constitutes at least 50 weight percent of the layer (3).