GB2573732A

GB2573732A - Press system for disposable tableware

Info

Publication number: GB2573732A
Application number: GB1802663.3A
Authority: GB
Inventors: Dominic Johnson Paul
Original assignee: Individual
Current assignee: Individual
Priority date: 2018-02-19
Filing date: 2018-02-19
Publication date: 2019-11-20
Also published as: GB201802663D0

Abstract

An apparatus for producing discrete profiled articles of disposable tableware, such as paper plates, from sheet material. The apparatus comprises a plurality of closable press modules (12; Fig 2), each press module comprising a pair of opposing press members 14, 16 each having a profiled press surface (18, 20; Fig 2) arranged to close in order to form a profiled article 34 from sheet material trapped there-between. The apparatus further comprises a guide 36, 38 for guiding motion of the press modules and a drive 42, wherein the drive causes the opposing press members of one or more of the press modules to move in unison relative to the guide whilst in the closed condition. The apparatus may comprise a conveyor system having a plurality of rotors 44, 48 and a track 46 for translating a plurality of press modules along the guide whilst in the closed condition. The guide may be elongate in form and comprise a plurality of opposing guide members. The guide may have first 36 and second 38 guide members for actuating a moveable component of the press members, the moveable component being a wall or cutter (24; Fig 2).

Description

Title: Press System for Disposable Tableware

The present invention relates to the manufacture of pressed sheet articles such as articles disposable tableware, including paper plates, bowls, trays and/or other similarly-manufactured articles.

Conventional paper plates are formed by pressing sheet paper material into a plate shape having a central planar region and a circumferential rim. The resulting profile provides a degree of structural rigidity as well as serving to prevent foodstuffs sliding off the plate in use.

A conventional machine 2 for paper plate manufacture is shown in Fig. 1, into which is fed a continuous sheet feed from a roll of paper 4. The machine 2 comprises two main stations, namely a cutting station 6 and a pressing station 8. The profile of the articles to be manufactured is cut from the sheet paper at the cutting station 6 and then fed to the pressing station 8.

During formation of the plates, the cut articles of sheet material are located between opposing press members in the pressing station 8. The opposing surfaces of the press members are correspondingly profiled such that when they are brought together onto the sheet, the sheet material is deformed to conform to the interface between the opposing press members, thereby providing the threedimensional plate shape. Paper bowls and trays may be formed in a similar manner by altering the geometry of the press members accordingly.

The profiled articles 10 individually exit the pressing station 8 and are collated.

An ongoing limit on production speed is due to the need for the sheet paper cutouts to remain held in the press for a suitable dwell time at elevated temperature to ensure that the final article adequately holds the pressed profile. A dwell time in the order of two seconds has been conventionally used. If the dwell time is reduced, the structural rigidity of the final articles is compromised.

There have also been found to be productivity problems since any changeover, maintenance or repair on either the cutter, or the press member 10 results in downtime for the machine 2 as a whole. This has an impact on production rates that can be achieved using machine 10 over a longer term.

It is an object of the present invention to provide a method, apparatus and/or system for production of pressed sheet articles, such as disposable tableware and the like, which mitigates one or more of the problems associated with the prior art.

According to a first aspect of the invention there is provided apparatus for producing discrete profiled articles from sheet material, the apparatus comprising: a plurality of closable press modules, each press module comprising a pair of opposing press members arranged to close in order to form a profiled article from sheet material trapped there-between; a guide for guiding motion of the press module; and a drive, wherein the drive causes the opposing press members of one or more of the press modules to move in unison relative to the guide when in the closed condition.

The press modules may be translated and/or moved linearly in the closed condition. The opposing press members of each press module may be maintained in the closed condition by the guide whilst moving.

The press members may move together to close in a first direction and may move in unison when closed in a second direction. The second direction may be angularly offset, e.g. perpendicular, from the first direction.

The plurality of press modules may move and/or be driven/guided in unison.

The plurality of press modules may move along the guide. The guide may be elongate in form. The guide may accommodate the plurality of moving press modules concurrently, e.g. a different locations along its length.

The guide may comprise a plurality of guide members, e.g. opposing guide members for the opposing press members of the press modules. The opposing press members may each ride along a respective one of the opposing guide members.

A plurality of press modules or press members may be driven by the drive. A common drive for a plurality of press members may be provided. The drive may comprise a plurality of transmission systems. Additionally or alternatively the drive may comprise a plurality of drive units.

The apparatus may comprise a conveyor system driven by the drive. The conveyor may bear a plurality of press modules and/or press members, e.g. one press member of a plurality of press modules. The apparatus may comprise a pair of conveyors, e.g. each conveyor bearing one of the opposing press members of the plurality of press modules.

The closed press modules may follow a path between opposing guides/conveyors. The press modules may be constrained between the opposing guides/conveyors.

The press module, e.g. either or both press members thereof, may comprise a contact member for contacting/engaging the guide. The contact between the contact member(s) and guide may constrain motion of the press module when closed.

The plurality of press modules, e.g. one or more of the press members thereof, may comprise a guide follower, such as a cam follower, wheel, bearing, gear or similar member. The press modules may be supported by respective guide followers during motion. Additionally or alternatively, the guide may comprise one or more rotor, such as a wheel, roller, bearing or the like. The press modules may move over any such rotor(s).

The guide may comprise a first guide member for guiding motion of the or each press member. The guide may comprise a second guide member for guiding a moveable component of the/each press member. The first and/or second guide member may comprise a runner or rail.

The guide may define a path for the press modules. The guide may be profiled at the start of the path, e.g. so as to bring the opposing press members together in a gradual manner. The guide may be ramped and/or curved towards the start of the path, e.g. at an upstream end of the guide.

The guide may comprise a constant or straight mid section, e.g. whereby the press elements are maintained in a substantially constant closed condition along the mid section, e.g. during the press dwell time.

The guide may be shaped towards its downstream end to open the press modules by relative movement of one or both press members apart into an open condition. The downstream end of the guide may be profiled to this end, e.g. ramped or curved.

Either or both of the opposing press members may comprise a cutter, e.g. mounted on the press member. The cutter may be a profile cutter, e.g. for cutting discrete articles from the sheet material. The cutter may be of a closed profile shape in plan. The cutter may have a continuous cutting edge or knife. The cutter may be shaped to define the outer edge of an article cut form the sheet material.

The cutter may surround a press surface of the press member.

The cutter may be retractably mounted to the press member.

The cutter on one press member of each press module may oppose an opposing, and/or correspondingly-shaped, cutter member on the opposing press member.

According to a second aspect of the present invention, there is provided a method of manufacture of disposable tableware corresponding to the first aspect of the invention.

According to a third aspect of the invention, there is provided a press module for use in a press system to produce discrete profiled articles from sheet material, the press module comprising a pair of opposing press members arranged to close in order to form a profiled article from sheet material trapped there-between; a contact member arranged to contact a corresponding guide of the press system, wherein said contact member is arranged to convey the press module along the guide when the when the opposing press members are closed.

According to a fourth aspect of the invention, there is provided a press for producing discrete profiled articles from sheet material, the press comprising a pair of opposing press members each having a profiled press surface, the opposing press member being arranged to move together in order to form a profiled article from sheet material trapped between said profiled press surfaces; characterised in that at least one of said opposing press members comprises a profile cutter extending around the press surface thereof.

The profile cutter may extend from the press member beyond a depth or height of the press surface. The profile cutter may thus form a profile cut (e.g. cutting out a discrete article) in the sheet material prior to pressing the sheet material.

The profile cutter may be moveably mounted, e.g. retractably mounted, on the press member. The profile cutter may be mounted in a recess in the press member. The recess may extend around the press surface, e.g. around the perimeter thereof.

The press may be a press module according to any preceding aspect of the invention.

The skilled addressee will understand that any of the optional features defined above in relation to any one aspect of the invention may be applied to any other aspect of the invention wherever practicable.

Embodiments of the invention will be described in further detail below, by way of example only, with reference to the accompanying drawings of which:

Fig. 1 is a schematic of a paper plate forming machine according to the prior art;

Fig. 2 is schematic side view of a press module according to an example of the invention;

Fig. 3 is a schematic of apparatus for providing pressed sheet articles according to an example of the invention;

Fig. 4. shows the movement of engaging press members of a press module according an example of the invention; and,

Fig. 5 shows a plot of applied pressure alongside a schematic of an example of a press guide according to an example of the invention.

The invention derives from the determination that it is possible to feed multiple press modules in series by translating the press modules along a conveyor during the press dwell time. Thus the rate of production of pressed, e.g. paper, articles is no longer limited by dwell time and can be significantly increased depending on the number of press modules used. Further aspects of the invention derive from the integration of a cutter with the press module itself such that a separate cutting station is not required.

The invention has been developed for production of disposable articles of tableware, such as paper plates, trays, bowls or the like. According to aspects of the invention, the sheet material may comprise paper material. The paper material may comprise a weight of 150 to 250 or 300 gsm. The paper material may comprise a weight of 170-230 gsm, e.g. around 200 gsm. The paper material may comprise a card or card-like material. Additionally or alternatively, the paper/card material may be up to, around or exactly 1 mm thickness, e.g. greater than 0.6, 0.8 or 0.9 mm and/or less than 1.4 or 1.2 mm thickness.

Whilst the invention is well-suited to pressing of such sheet paper or card material, other sheet materials could be used. If paper/card material is used, then it is noted that the paper/card may be laminated, e.g. with a film/polymer material, on either or both sides. Substitute sheet paper/card material may also be used.

Turning to Fig. 2, there is shown a press module 12 according to an example of the invention. The press module 12 comprises first 14 and second 16 press members, which are arranged in an open configuration such that there exists a gap there-between, into which a sheet material can be fed to be pressed. The press module 12 is oriented such that the first 14 and second 16 press members are arranged one atop the other, i.e. vertically spaced, but could be differently oriented on other examples.

Press member 14 comprises a projecting press surface 18 defining one side of an article profile to be formed during pressing. Press member 16 comprises a recess 20 shaped to define the opposing side of the article profile to be formed. When the press members 14 and 16 are open, a sheet material is located between the press members, which are subsequently closed in the direction A to press the sheet material between the opposing press surfaces and thereby deform the sheet material to conform to the pressed profile.

The press surface profile(s) may comprise a base portion towards the centre of the profile and a rim formation towards the perimeter. The rim formation extends around the entire perimeter and comprises an increased depth relative to the base portion, which may be relatively flat/planar in form. The rim formation may comprise a series of angularly spaced radially-aligned grooves. Two sets of grooves may be provided for increased rigidity, e.g. with a first set of grooves being commencing radially inwardly of a second set of grooves. The different sets of grooves may be of different depth and/or radial length. The two sets of grooves may be interspersed. The depth of the grooves may increase from a radially inner end to a radially outer end of each groove. Either set of grooves may terminate at the outer edge/perimeter of the article or else radially inside the peripheral edge.

An outer rim edge or lip may be free of grooves and/or downwardly turned, e.g. to provide structural rigidity or hoop strength around the outer edge of the final product.

Either or both press member may comprise a heater 22. The combined pressure and heating of the sheet material helps ensure that the sheet material article adequately retains its pressed profile. An electric heater, e.g. a cartridge heater, may be used.

The temperature of one or both press members, e.g. a press surface thereof, may be greater than 100°C. The temperature may be greater than 120°C, 140°C or

150°C, such as for example between 150°C and 200°C. A temperature in the region of 150°C to 180°C, e.g. approximately 165°C, has been found to be suitable for pressing paper tableware.

A controller may be used to control operation of the heater. The controller may activate the heater until a predetermined threshold temperature or temperature range is achieved. The controller may monitor the temperature of the press member(s) and/or press surface(s) thereof using one or more temperature sensor and may control operation of the heater in response to the temperature readings.

Unlike the prior art example of Fig. 1, the press module 12 has an integral cutter. This is provided by way of a cutter member 24 provided on the press member 14. The opposing press member 16 has an opposing cutting surface 26, e.g. a land or supporting surface, on which the sheet material can rest during cutting.

The cutter member 24 is a profile cutter, e.g. being shaped to cut the perimeter of a discrete article from a sheet of paper material. The cutter member 24 takes the form of a closed circuit or loop in plan. In this example, the cutter member is circular in plan, i.e. to cut circular articles from the sheet feed, but could take other forms, e.g. oblong or other regular or irregular shapes, to correspond to the shape of the article to be pressed.

The opposing cutter surface 26 may be shaped to correspond to the shape of the cutter member 24 in plan, i.e. to provide a cutting surface against which the cutter can press.

The cutter member 24 has a knife edge, blade or tip, e.g. extending around the cutter profile/perimeter. The cutter member may be referred to as a knife or blade. The cutter may also be considered to be akin to a cookie-cutter or steel-rule die.

The cutter acts as a compression cutter in this example, whereby the cut is formed by the application of pressure between the cutter member 24 and the opposing surface 26 when the sheet material is located there-between.

In the example of Fig. 2, the cutter member 24 is moveably/retractably mounted to the oppress member 14. In the position shown in Fig. 2, the cutter member 24 projects from the press member 14 beyond the press surface 18 in its extended condition. However the cutter member 24 can retract into the press member 14. The cutter member 24 may be mounted in a recess 28 for this purpose. The cutter member 24 can slide into the recess in the direction of arrow B.

The retracting cutter 24 allows the required cut to be made, when the cutter member 24 is in its extended condition, but subsequently be retracted to allow the press surfaces 18, 20 of the opposing press members to be brought into a pressing arrangement. The cutter member 24 may be resiliently mounted for this purpose (i.e. to allow resilient retraction) or else its position may be controlled by one or more guide member/rail, along which the cutter member 24 may ride as will be described below.

Whilst a compression cutter is preferred for a number of reasons, it is possible that an interference cutter arrangement could be used, whereby the cutter member 24 overlaps the edge of the opposing cutting surface 26 such that the cutter member rides over the side/edge of the opposing cutter surface 26 when they are brought together (akin to a scissor cutting action, rather than a compression cut). In such an example, the cut would thus be formed at the interface between the adjacent edges/faces of the cutter member and cutter surface.

The on-press cutter arrangements described above are well-suited to a conveying press arrangement of the type to be described below. However it is to be noted that the conveying press system described below could also be used with a more conventional cutter station, in which discrete articles are cut from a feed of sheet material and subsequently passed into the press module 12.

In Fig. 2, the press members 14 and 16 of the press module 12, each have a contact member 30. In this example, the contact members take the form of a wheel or cam follower that can ride along a guide for the press module/members in use as will be described below. Each press member 12, 14 of Fig. 2 comprises a plurality of contact members 30 aligned substantially perpendicularly to the direction A in which the press module opens and closes.

The plurality of contact members on each press member 12, 14 may be aligned in a direction of travel if the press module 12 when closed.

Turning now to Fig. 3, there is shown a conveyor system for moving a plurality of the press modules 12 during manufacture of pressed sheet articles 34.

The system comprises opposing guides 36 and 38 for guiding motion of respective opposing press members 14 and 16 of each press module 12. The guides 36, 38 may take the form of runners or rails.

The guides 36, 38 are elongate in form and have profiled ends 36A and 38A. The profiled ends 36A and 38A are located towards the direction of feed of the sheet material 40 into the press system 32, i.e. the upstream end in the direction of flow of the sheet material in use. The profiled ends are ramped, e.g. smoothly ramped and/or curved.

The profiled ends lead to a straight guide mid section. The opposing/downstream ends of the guides 36, 38 may or may not be profiled also, e.g. in the same manner as the upstream ends.

The opposing guides 36, 38 thus collectively form a tapering guide which narrows towards a main/neck region of substantially constant width, through which press modules 12 can travel in a constrained manner.

The system 32 further comprises a drive unit 42, shown schematically, which may comprise an electric drive/motor.

The drive unit 42 drives movement of a conveyor for the press modules. The conveyor in this example comprises a pair of conveyors, each being arranged to drive movement of one of the opposing press members 14, 16 of the plurality of press modules 12 relative to the respective guide 36, 38. That is to say, each guide has its own conveyor in this example.

The conveyor(s) comprise a driven rotor 44A, 44B and a belt or track 46 forming a closed loop or circuit, which is driven by the rotor 44A, 44B.

In the example shown, the each conveyor comprises a plurality of rotors 44 and 48. The rotors are spaced apart and located at opposing ends of the conveyor such that the track 46 extends between the plurality of rotors 44, 48 and forms a closed loop around the rotors. Further rotors could be provided along the length of the conveyor as desired.

Any, any combination, or all of the rotors could be driven by the drive unit 42, e.g. by way of a suitable transmission system. Any undriven rotor(s) can passively rotate to permit the track 46 to pass thereover. In one example, one conveyor could be passive and driven by the motion imparted to the press modules by the other/driven conveyor.

The track 46 and rotors of the conveyor may comprise keying formations, e.g. corresponding teeth or castellations. This may serve to permit greater torque transfer between the rotors and the track and may also serve an indexing function to ensure one-to-one motion between the rotor and track (i.e. without slippage).

The track 46 carries a plurality of press members 14/16 at spaced locations along its length. The track may comprise suitable recesses and/or attachment formations for the press members to ensure the press members are fixedly connected to the desired location along the track length.

One of the conveyors carries a corresponding one of the opposing press members 14 for each press module 12. The other conveyor carries the other of the opposing press members 16 for each press module 12. The two conveyors move in unison (e.g. from the common single drive 42 or else using a plurality of commonly controlled drives) such that the opposing press members of each press module also move in unison.

The two conveyors and/or driven rotors 44A, 44B are contrarotating.

The spacing of the press members on the opposing tracks 46 is also equal. Thus as the press members are moved with their respective conveyors, they are brought together in the region of the guide 36.

The contact members 30 (i.e. the guide followers) on each press member 14, 16 ensure that the press members follow the path defined by each guide 36, 38. Thus the motion of the press members is constrained.

In use, the drive unit 42 drives rotation of the rotors 44A, 44B and accordingly the press members carried by the track of each conveyor. The direction of motion is shown by arrows C.

The opposing press members 14 and 16 of each press module 12 are thus brought together as they pass around roller 48A, 48B and along the internal/opposing side of each conveyor. The press members 14,16 are separated as they pass around the roller 44A, 44B and around the external/outward-facing side of each conveyor. The conveyors can run continuously at either constant or correspondingly-variable speed such that opposing pairs of press members are continually brought together and separated as they pass around the conveyor circuit/loop.

The opposing guides 36, 38 serve to closely constrain motion of the opposing press members as they are brought into, and during, contact (i.e. during closing of the press module and pressing of the article therein). The contact members 30 on each press member thus ride along the respective guide member 36, 38.

During operation, the sheet material 40 is fed, e.g. from a roll 50, into the space between the opposing guides 36, 38, i.e. between the opposing conveyors, such that it becomes trapped between the opposing press members 14, 16, whereby the sheet material is cut by cutter 24 and pressed between opposing press surfaces 18, 20. The sheet material is held in the press module 12 during pressing for the duration of the movement of the closed press module between the guides 36, 38. At the end of the guides, the conveyors separate the respective halves of the press module to open the press such that the pressed article 34 can be removed/ejected. The continuous flow of the conveyor means that press modules are continually being closed, constrained in the closed condition and opened in succession to form a continuous flow of pressed articles 34.

The profiled plates 34 once formed start cooling once the press members 14, 16 are opened and the paper plates 34 are ejected and allowed to cool further under ambient air.

If the press modules are arranged to operate by opening and closing in a vertical direction, the lower press member 16 may comprise an ejection mechanism, e.g. by way of a moveable floor plate or ejector pin(s) to eject the pressed article after the press module has opened. However vertical opening and/or horizontal movement of the press modules during pressing are not essential and other orientations could be used if practicable.

A static knife 52 is used to cut the waste sheet material stream, i.e. from which the articles have been cut, downstream of the pressing process. The knife cuts the waste sheet material longitudinally in the direction of travel, preferably generally centrally, which helps with management of the resulting waste. In other examples, slitting of the sheet material could be performed further upstream by a static knife and/or by a knife carried on the press modules.

Fig. 4 shows an example of how guide members can be brought together in a controlled manner by suitable profiling of the either or both guides 36, 38. In the left-hand image of Fig. 4 the press members 14 and 16 are obliquely oriented as they are brought together such that a leading edge of each press member in the direction of travel, D, is closer together than a trailing edge.

In the middle image of Fig. 4, a leading portion of the cutter 24 has been brought into contact with the opposing cutting surface of the opposing press member. The initial contact is made at the leading edge only whilst the opposing press members 14 and 16 remain obliquely angled.

The oblique angle between the press members 14 and 16 is reduced until the press surfaces are fully engaged, i.e. contacting either side of the sheet material in the press.

The angled/sloped shape of either or both guides in the region 36A/38A shown in Fig. 3 can be used to achieved the desired gradual closing of the press module and applied pressure. The gradual closing action beneficially causes a progressive cut by the cutter, instead of a perpendicular cut, which could cause greater contact forces and/or lead to increased likelihood of cutting errors.

The movement of retracting cutter 24 can be controlled in unison with the closing action of the press members in certain examples of the invention. For example, where the guide may comprise two rails, one for the gross movement of the press member, and another for the actuation of the cutter 24. The two guides may be shaped differently, or offset, e.g. particularly during engagement of the press members. In this way the motion of the cutter can be controlled in a different, but related, manner to that of the press member as a whole.

Fig. 5 shows an example of cutter and/or press movement, wherein the upper lines 54 and 56 depict guide paths or motion paths for the cutter 24 (in phantom) and the press member (e.g. the upper press member 14) respectively. The lower graph shows a schematic plot of the applied pressure ‘p’ between the press members over time ‘t’ or travel distance ‘d’ along the guide through the pressing operation.

It can be seen that the cutter is extended at point 58, i.e. in advance of the engagement between the press members. Then as the press member 14 is moved towards the opposing press member 16 along the sloping guide path portion of path 56, the cutter comes into contact with the sheet material to perform the desired contour cut.

Then the cutter starts to retract whilst the press member 14 advances further towards the opposing press member, i.e. to avoid excessive loading on the cutter. A point 60 it can be seen that the cutter is retracting whilst the press member is advancing along path 56. The cutter is fully retracted and the press member fully advanced such that the cutter is removed from interfering with full engagement between the press surfaces of the press members at point 62. This position is then held for the press dwell time as the closed press module travels along the guide, until the press members disengage at point 64.

The gradual loading of the press member up to point 62 is shown in the pressure plot of Fig. 5. The press loading is generally constant during the dwell time. The disengagement of the press members at 64 need not be so gradual but could be the reverse of the loading portion of path 56 if desired.

In Fig. 3, the guide is shown as being a generally smooth rail. However in other examples the guide could be toothed, or otherwise textured to ensure a mechanical/frictional engagement between the guide followers 30 and guide. The guide followers 30 could be similarly textured or toothed. In other examples, the conveyor system could comprise multiple rotors, e.g. rollers, drums or gear wheels, in close succession and the press member/module could rise along the rotors, with or without the use of a track. The rotors could collectively provide the guide, e.g. a rolling guide, in such examples.

In further example, the guide follower on the press member(s) could comprise a static projection or guide section, rather than a wheel.

A rack and pinion type arrangement could be used if the press member(s) are driven by contact with driven gear wheels, rather than smooth rollers.

In the above examples, the conveyor comprises a common belt/track for controlling movement of the plurality of press modules/members in a common manner. However other arrangements are also available. For example, a plurality of rotors of the conveyor system could be individual driven and/or independently controlled without the need for the belt/track. Additionally or alternatively, each press could potentially have its own individual drive/motor on board the press module so that the press modules/members are self-propelled.

In further examples of the invention, the opposing press members 14, 16 could comprise a coupling, keying, latching or locking arrangement to hold the press members in the closed condition whilst moving through the conveyor. This may be useful in embodiments in which only a single conveyor is used, instead of the two conveyors shown in Fig. 3. A coupling between the closed press members may enable a single drive or single conveyor to move the closed press modules along the guide.

Using the invention, a plurality of press modules can be conducting a pressing operation simultaneously, such that the production rate can be increased beyond the inverse of the dwell time. This a production rate of greater than 30 articles per minute is feasible, for example in the region of 50 or 60 or more articles per minute (e.g. a production frequency of better than 1 Hz) can be achieved without adversely shortening dwell time in a way that could reduce product quality.

Using the translating press system of the kind described herein, the dwell time of the press in the closed condition can be extended or shortened to suit the desired quality of the pressed article with minimal impact on the maximum production rate that can be achieved.

It is also feasible that different articles, i.e. articles formed of the same sheet material but having different shape, could be produced in the same run, thereby offering increased flexibility for the operator. Thus every press module need not be identical for a given production run.

The path/guide followed by the press modules can be lengthened or shortened to accommodate greater/fewer press modules. Furthermore the speed at which the press modules move along the track can be altered. This the system allows far greater flexibility over dwell time and/or production rates.

Whilst the above description discloses an apparatus and system for paper plate manufacture, it will be appreciated that the same system and apparatus can be used for other types of disposable tableware, such as bowls and/or trays, which require cutting and/or pressing from a sheet material. The shape of the pressing surfaces and press settings may be altered according to the desired article of tableware to be manufactured.

Furthermore, whilst the substrate of the articles of kitchenware is referred to herein as ‘paper’ it is intended that this encompasses heavier paper materials, such as 5 card.

It is also envisaged that the sheet material could be printed and/or laminated prior to cutting and pressing.

Claims

1. Apparatus for producing discrete profiled articles from sheet material, the apparatus comprising:

a plurality of closable press modules, each press module comprising a pair

5 of opposing press members arranged to close in order to form a profiled article from sheet material trapped there-between;

a guide for guiding motion of the press modules; and a drive, wherein the drive causes the opposing press members of one or more of the press modules to move in unison relative to the guide whilst in the 10 closed condition.

2. Apparatus according to claim 1, wherein the guide is elongate in form and the one or more press module is translated along the guide by the drive whilst in the closed condition.

3. Apparatus according to Claim 1 or 2, wherein the drive and guide are arranged to move the press members together to close the one or more press module in a first direction and to move the press members in unison when closed in a second direction, the second direction being angularly offset, e.g.

20 perpendicular, from the first direction.

4. Apparatus according to any preceding claim, wherein the guide accommodates a plurality of moving press modules concurrently and the plurality of press modules are driven in unison relative to the guide.

5. Apparatus according to Claim 4, wherein the guide is elongate in form and the guide accommodates the plurality of moving press modules concurrently at spaced locations along its length.

30

6. Apparatus according to any preceding claim, wherein the guide comprises a plurality of opposing guide members for the opposing press members of the press

26 04 18 module, wherein the opposing press members each ride along a respective one of the opposing guide members.

7. Apparatus according to any preceding claim, wherein the drive comprises a 5 common drive for a plurality of press modules.

8. Apparatus according to any preceding claim, comprising a conveyor system driven by the drive.

10 9. Apparatus according to Claim 8, wherein the conveyor bears a plurality of press modules and/or press members.

10. Apparatus according to Claim 8 or 9, comprising a pair of opposing conveyors, each conveyor bearing one of the opposing press members of the or

15 each press module.

11. Apparatus according any preceding claim, comprising a pair of opposing guides, wherein movement of the closed press modules is constrained between the opposing guides.

12. Apparatus according to any preceding claim, wherein either or both of the opposing press members comprises a contact member arranged to engage the guide.

25

13. Apparatus according to any preceding claim, wherein the guide comprises a first guide member for guiding motion of the or each press member and a second guide member for actuating a moveable component of the or each press member whilst said press member is along the first guide member.

30

14. Apparatus according to Claim 13, wherein the moveable component comprises a wall or cutter of the press member.

26 04 18

15. Apparatus according to any preceding claim, wherein the guide comprises a runner or rail.

16. Apparatus according to any preceding claim, wherein the guide is shaped to

5 define a path of travel for the press modules, the guide being ramped or curved at an upstream section of the path so as to bring the opposing press members together in a gradual manner, and the guide comprising a straight section following the upstream section whereby the press elements are maintained in a substantially constant closed condition along the straight section during a press

10 dwell period.

17. Apparatus according to Claim 17, wherein the guide is shaped towards a downstream section to open the press modules by guiding one or both press members apart into an open condition.

18. Apparatus according to any preceding claim, wherein either or both of the opposing press members comprises a profile cutter mounted on the press member and surrounding a press surface of the press member.

20 19. Apparatus according to Claim 18, wherein the cutter is retractably mounted to the press member.

20. A method of manufacture of disposable tableware comprising: providing a plurality of closable press modules, each press module

25 comprising a pair of opposing press members;

bringing the opposing press members of each press module into a closed condition at a first location with a sheet material trapped there-between in order to form a profiled article from the sheet material;

moving the press modules when closed along a guide during a press dwell 30 time; and opening the opposing press members of each press module to remove the profiled article therefrom at a second location spaced from the first location by the guide.

26 04 18

21. A method according to Claim 20, wherein the plurality of press modules are closed and opened in a continuous or conveyor-like fashion such that a first press module is closed whilst one or more further press module is moving along the

5 guide in the closed condition.

22. A method according to any one of Claim 20 or 21 wherein a plurality of the closed press modules move along the guide concurrently in flow series.

10

23. A method according to any one of Claims 20 to 22 comprising carrying the opposing press members of each press module on opposing conveyors.

24. A press module for use in a press system to produce discrete profiled articles from sheet material, the press module comprising:

15 a pair of opposing press members arranged to close in order to form a profiled article from sheet material trapped there-between;

a guide follower arranged to engage a corresponding guide of a conveyor press system, wherein said guide follower is arranged to convey the press module along the guide when the when the opposing press members are closed.

25. A press module according to Claim 24, wherein the press members comprise opposing profiled press surfaces arranged to form the profile of the article when the sheet material is trapped therebetween, and at least one of said opposing press members comprises a profile cutter extending around the press

25 surface thereof.