APPARATUS FOR FORMING CONTAINERS
The invention relates to apparatuses for obtaining containers, in particular from sheet material, said containers being utilizable in many different fields, for example for food, pharmaceutical, cosmetic or detergent products.
Apparatuses for obtaining containers by thermoforming are known, in which two webs of sheet material, typically in plastic material, arranged on a substantially vertical plane and intended to create opposite walls of containers, are processed. Said webs are advanced through a pre-heating station in which they are heated to a temperature near the softening temperature of the plastic material of which they are made. At the pre-heating station, an injector blows compressed air between the two facing webs, in order to maintain the two webs separated each other. Without this injector, the two webs, which have already been heated to a temperature near the softening temperature, would tend to stick to each other.
At a subsequent forming station, a further injector blows compressed air between the two facing webs, so as to deform the previously heated webs and to shape them according to the geometry of a mould in which the webs are inserted, so as to obtain opposing cavities of containers.
Subsequently, at a sealing station the two webs are sealed along a preset outline corresponding to the edge of the container to obtain. Said outline is interrupted at a top opening, which is- subsequently used to fill the containers with a desired substance and which is successively closed by sealing.
At the sealing station there is a spacer member, shaped like a wedge, that keeps the top edges of the two webs spaced apart from one another, in such a way that, at a subsequent filling station, the insertion of a dispensing device between the two
webs is facilitated, said dispensing device being arranged for filling each container with the desired substance. The injector of the pre-heating station, the further injector of the forming station and the spacer member of the sealing station are arranged in a fixed position on the apparatus for obtaining containers. The webs to be processed are alternatively pressed against the injector, the further injector and the spacer member, or removed therefrom, by opening or closing respective pairs of opposing half-moulds that are transversally movable in relation to the advancing direction of the webs.
A defect of the above described apparatuses is that, when the two half-moulds of the pre-heating station, or of the forming station, or of the sealing station, are removed from the webs of sheet material to enable said material to be advanced through the apparatus, the sheet material can remain stuck to the injector, the further injector or the spacer member respectively. Therefore, it is quite difficult to advance the webs towards the downward stations, and in worst cases it may be necessary to stop the apparatus and to intervene manually on it.
The adherence of the sheet material of the webs to the injector, to the further injector and/or to the spacer member is mainly due to the relatively high temperature of this material and to its thin thickness due to which a "sucker effect" between the webs and the walls of the injector, the further injector and/or the spacer member can occur. This adherence, furthermore, depends on the chemical, and physical properties of the sheet material, and it is particularly favoured for particular kind of materials.
A further defect of the known apparatuses is due to the fact that the injector, the further injector and the spacer member are integral with a fixed frame of the* forming apparatus. This may create troubles whenever it is necessary to access the
pre-heating, forming and sealing stations, for example for carrying out maintenance or size-change operations for replacing the moulds used for forming containers of a certain typology with moulds to be used for forming a containers of a different typology. In these cases, the injector, the further injector and the spacer member hamper the access to the preheating and/or sealing and/or forming stations, which makes the maintenance and size-change operations difficult and increases the time required to carry out them.
WO 02/072427 discloses an apparatus for producing two rows of facing containers starting from four webs of sheet material. At the pre-heating, sealing and forming stations a wedge deflector is provided, which is crossed by a longitudinal conduit feeding two transversal conduits coming out into the forming station. The two transversal conduits come out at two adjacent faces of the wedge deflector in such a way as to inject air respectively between a first and a second web arranged for forming opposite walls of a first row of containers, and between a further first web and a further second web arranged for forming opposite walls of a further row of containers .
Between the first row and the further row of containers a vertical plate is provided, that is suitable for preventing the two central webs from coming into contact with each other, as in such a case they could be sealed together in an undesirable manner.
The main defect of the forming apparatus disclosed in WO 02/072427 is that the two transversal conduits are arranged in a respective fixed position. In consequence of this, if there are working or assembling errors in the components of the forming apparatus, undesirable situations may take place in which, for example, the vertical plate is not arranged on the medium plane identified by the two outlet conduits.
An object of the invention is to improve the known apparatuses for forming containers .
A further object of the invention is to prevent stops of the apparatuses for forming containers due to undesirable adherence of the material from which said containers are made to the components of the forming apparatus.
A still further object is to improve the apparatuses by means of which two facing rows of containers may be formed simultaneously, and reducing the incidence of any working or assembling errors during the operation of said apparatuses. Another object is to supply apparatuses for forming containers in which maintenance and size-changing operations are simplified and made more rapid.
In a first aspect of the invention, there is provided an apparatus for forming containers from web means, comprising operating means arranged for pressing opposing parts of edge portions of said web means against deflector means, characterised in that, moving means is associated with said deflector means in such a way as to move said deflector means to substantially separate .said edge portions from said deflector means.
The moving means enables the deflector means to be separated from the edge portions of the web means, whenever the web means has to be advanced through the apparatus according to this aspect of the invention. In this way adherence between the deflector means and the edge portions of the web means is substantially avoided, even if high temperatures are present and the web means has a very low thickness.
Furthermore, as the movement of the deflector means has to enable the deflector means merely to disengage from the edge portions o the web means, it is sufficient for the deflector means to perform a relatively limited stroke. This allows the dimensions of the apparatus to be kept relatively, small and
the inertia due to the movement of the deflector means to be limited.
In a second aspect of the invention, there is provided an apparatus for forming containers from web means, comprising operating means arranged for pressing opposing parts of edge portions of said web means against deflector means, characterised in that, said deflector means comprises first deflector means arranged for being inserted between first and second borders of said edge portions, and second deflector means arranged for being inserted between further first and further second borders of said edge portions.
The first deflector means and the second deflector means according to this aspect of the invention form distinct deflector means that can be operationally positioned independently of one another, taking account of any processing and/or assembling errors that can occur in the components of the apparatus .
According to a third aspect of the invention, there is provided an apparatus for forming containers, comprising operating means arranged for processing a material in such a way as • to obtain said containers therefrom, cooperating means arranged for cooperating with an edge portion of said material, characterised in that, evacuation means is further provided arranged for enabling said cooperating means to be moved away from said operating means by an amount that is substantially greater than the amount that would be strictly necessary for avoiding mechanical interferences between said cooperating means and said material.
Owing to the evacuation means, it is possible to significantly move the cooperating means away from the operating means in such a way as to access the operating means, for example to carry out maintenance or size-change operations without interfering with the cooperating means. This enables to reduce
intervention times and to increase therefore the productivity of the apparatus.
The invention will be better disclosed and carried out with reference to the accompanying drawings, which illustrate some exemplifying and not limiting embodiments of the invention, in which:
Figure 1 is a schematic front view, partially sectioned, of an apparatus for forming containers;
Figure 2 is an enlarged view like Figure 1, showing a forming station of the apparatus of Figure 1;
Figure 3 is a further enlarged schematic cross section of a portion of the forming station in Figure 2, showing an end part of first deflector means and of second deflector means;
Figure 4 is a view like Figure 3, showing the first deflector means and the second deflector means in a rest position;
Figure 5 is a perspective view showing evacuation means provided in an alternative embodiment of the apparatus in
Figure 1;
Figure 6 is an enlarged and schematic perspective view of an end portion of deflector means of the apparatus of Figure 1.
Figures 1 to 3 show operating means including a forming station 1 of a thermoforming apparatus suitable for simultaneously forming two facing rows of containers.
In the forming station 1 a central plate 2 is provided. On a first side of the central plate 2 a first web 3 and a second web 4 of sheet material are advanced. On a second side of the central plate 2, opposite to the first side, a further first web . 5 and a further second web 6 of sheet material are advanced. The webs 3, 4, 5, 6 can be unwound from four distinct reels, or from a smaller number of reels, for example one or two reels, in which case the strips unwound from the reels must be longitudinally folded in order to obtain the desired number of webs.
The second web 4 and the further second web 6 abut the central plate 2, whilst the first web 3 and the further first web 5 interact with two forming half-moulds 7 which are arranged on opposite sides of the central plate 2. The forming half-moulds 7 can translate in the direction of the arrows Fl between an open configuration in which they do not interact with the webs 3, 4, 5, 6, that can, therefore, be moved through the forming station 1, and a closed configuration, shown in Figure 3, in which the forming half-moulds 7 press the webs 3, 4, 5, 6, against the central plate 2.
In an embodiment not shown, the central plate 2, instead of being delimited by flat surfaces, is provided with recesses that act as further forming half-moulds suitable for shaping the second web 4 and the further second web 6. In this way containers are obtained that are delimited by two walls that are both shaped, rather than being delimited by one shaped wall and by one flat wall.
The device for moving the forming half-moulds 7 between the open and closed configuration is illustrated in Figure 1, showing that each forming half-mould 7 is fixed to a pair of stems 8, that are fixed to a respective connecting member 9. On each connecting member 9 a respective roller 10 is fixed engaging in a track of a corresponding cam 11, not shown. The rotational movement of the cams 11 as shown by the arrows F3 is converted, by the rollers 10 and the connecting members 9, into an alternating straight movement of the stems 8, which are slideable inside respective bushes 12, and therefore in an opening and closing movement of the forming half-moulds 7. Above the forming half-moulds 7 there is provided deflector means comprising a first wedge deflector 13 and a second wedge deflector 13', that are suitable for being interposed respectively between edge portions of the first web 3 and of the second web 4, and of the further first web 5 and of the further second web 6. The first deflector 13 and the second
deflector 13' may extend longitudinally through one or more adjacent operating stations, for example through one or more pre-heating stations arranged upstream of the forming station 1, and through one or more sealing stations arranged upstream or downstream of the forming station 1.
The central plate 2 can also have a similar structure and can extend longitudinally not only through the forming station 1, but also through one or more adjacent operating stations. In the forming station 1, the first deflector 13 and the second deflector 13' are provided with respective injection conduits 14, 14', that come out near respective flat surfaces 41, 41' of the deflectors 13, 13', as shown in Figure 3. The injection conduits 14, 14' are connected to respective longitudinal conduits 39, 39' suitable for feeding an operating fluid. The latter may comprise compressed air, which can be possibly heated.
The operating fluid passes from the longitudinal conduits 39, 39' into the injection conduits 14, 14' and is then injected respectively between the first web 3 and the second web 4 and between the further first web 5 and the further second web 6. In this way, it is possible to obtain on the first web 3 and on the further first web 5 cavities 15 and further cavities 15' of the two rows of facing containers. In the same time, inlets 16 and further inlets 16' are also obtained on the first web 3 and on the further first web 5 respectively. The inlets 16 and the further inlets 16' will be subsequently used for filling the cavities 15 and the further cavities 15' with the desired substances .
As shown in Figure 2, the first deflector 13 and the second deflector 13' are mounted on a support block 17 by means of fixing screws 18. Bushings 19 are interposed between the fixing screws 18 and the support block 17, the bushings 19 being made of an elastomeric material, for example rubber, and exerting a cushioning action. By means of the bushing 19, the
position of the first deflector 13 and of the second deflector 13' with respect to the support block 17 can be adjusted to a certain extent.
The deflector means is associated with moving means so configured as to move the deflector means in the direction of the arrow F2, between a raised rest position, shown in Figure 4, and a lowered work position shown in Figures 2 and 3. In the rest position, the first deflector 13 and the second deflector 13' are still positioned inside the inlet 16 and the further inlet 16', but they do not exert any pressure on the webs 3, 4, 5, 6 and merely have a guide function when the webs 3, 4, 5, 6 are advanced through the forming apparatus. In the work position, the first deflector 13 and the second deflector 13' press the first web 3 and the further first web 5 against the forming half-moulds 7, and the second web 4 and the further second web 6 against the central plate 2. On the first deflector 13 and on the second deflector 13' seal means is provided, the seal means including a first gasket 20, which may be in the form of a member made of elastomeric material having a circular cross section. The first gasket 20 extends along the deflectors 13, 13' parallely to the advancing direction of the webs 3, 4, 5, 6 and is housed in an appropriate seat obtained in the first deflector 13 and in the second deflector 13' . The seal means ensures that, when the first deflector 13 and the second deflector 13' are positioned in the work position to inject the operating fluid, the webs 3, 4, 5, 6 are pressed against the corresponding walls of the forming half-moulds 7 and of the central plate 2 so as to prevent leaks of the operating fluid.
The central plate 2 is supported at the bottom by fixing means 22 comprising an U-shaped internal member 23 supported by an external member 24, which is also U-shaped, and which is in turn connected to a frame 25 of the forming apparatus. Between the fixing means 22 and the central plate 2 a gap is provided,
in such a way that the central plate 2 floats, i.e. it has a preset possibility of movement in the direction of the arrow Fl. This possibility of movement is very useful inasmuch as the central forming half-moulds 7, in their movement to approach the central plate 2 till they engage with the webs to be formed, may accidentally knock against said plate, for example because of mechanical working defects or because of incorrect adjustment of the position of the members making up the forming apparatus. In particular, the longitudinal axis X of the central plate 2 may not coincide with the ideal opening and closing axis of the forming half-moulds 7, in such a way that one of the two forming half-moulds 7 gets closer than required to the central plate 2 whilst the other forming half- mould 7 remains excessively f r away from the central plate 2. In this way impacts are generated between one of the forming half-mould 7 and the central plate 2, in which case the gap existing in the fixing means 22 gives the central plate 2 a certain possibility of movement. Therefore, a violent impact of the half-moulds 7 against the central plate 2 is avoided and damage or breakage of the mechanical pieces in this zone of the forming apparatus is prevented. In this way, furthermore, the central plate 2 is pushed close to the forming half-mould 7 from which it would otherwise be excessively far. In this position-adjusting movement the first deflector 13 and the second deflector 13' can follow the central plate 2 owing to the bushings 19 made of elastomeric material that enable a certain movement of the first deflector 13 and of the second deflector 13' in relation to the support block 17. This assures good forming of the containers on both sides of the central plate 2.
It should also be noted that the containers formed on the two sides of the central plate 2 may be the same, or may have shape and/or dimensions that are different from one another, or may also be filled with different substances.
As shown in Figure 1, the support block 17 is fixed to a support plate acting as a lid 26, which is hinged in a fulcrum C on the frame 25. The lid 26 is movable between a closed position A, in which the first deflector 13 and the second deflector 13' are close to the forming half-moulds 7 and can cooperate with the latter, and an open position B, in which the lid 26 enables the first deflector 13 and the second deflector 13' to be removed from the forming station 1 by an amount that is significantly greater than that which would be strictly necessary for avoiding mechanical interferences with the webs 3, 4, 5, 6.
Figure 5 shows a further embodiment of the forming apparatus, in which a single row of containers is produced from two facing webs. In this case, there is a sole deflector 13a that is fixed to the lid 26 and that is movable between the closed position A indicated by the broken line and the open position B indicated by the continuous line.
The deflector 13a is delimited at the bottom by a flat surface 41 in which is obtained a plurality of holes 27, 27a into which come out corresponding injection conduits, arranged for supplying an operating fluid, fed by a plurality of flexible pipes 28, to a pre-heating station 29, to a sealing station 30 and to the forming station la.
In particular, first holes 27 are provided for supplying the operating fluid into the pre-heating station 29 and into the heat-sealing station 30. In these two stations, the operating fluid is fed at a relatively low pressure and has the function of preventing the facing webs, that have already been heated to a temperature near softening temperature, from sticking to one another in undesired zones. Further holes 27a supply the operating fluid at a relatively high pressure between the facing webs in the forming station la, so as to deform said webs for shaping them according to the geometry of the forming half-moulds arranged in the forming station la.
Along the deflector 13a are provided pointed members 42 through which, in the lowered work position of the deflector 13a, the operating stations la, 29, 30 can be substantially hermetically closed. As shown in Figure 6, each pointed member 42 is equipped with a further gasket 43, extending along the perimeter of the respective pointed member 42 in the direction identified by the axis X.
Owing to the first gasket 20 and to the further gaskets 43 in the lowered work position of the deflector 13a the operating fluid can be prevented from flowing out from the zone delimited by the pointed members 42. In particular, in the work position the forming station la is substantially hermetically closed in relation to the adjacent stations in such a way as to prevent leaks of the operating fluid at relatively high pressure. The pre-heating station 29 and sealing station 30 must, on the other hand, be substantially hermetically closed in relation to the adjacent stations but may communicate with one another since they both are crossed by the operating fluid at relatively low pressure. For this reason, in the boundary region between the pre-heating station 29 and the sealing station 30 no pointed member is provided. It should be noted that the sealing station 30 could be arranged downstream of the forming station la rather than upstream of it.
It should furthermore be noted that also in the apparatus arranged for forming two rows of facing containers shown in Figures 1 to 4, each deflector 13, 13' can have a structure that is completely analogous to the structure of the deflector 13a shown in Figures 5 and 6.
The lid 26 can be actuated between the open position and the closed position as will be explained in detail below, either when two facing rows of containers or when a single row of containers are manufactured.
As shown in Figure 5, the lid 26 is provided with a knob 31, which can be used to lock or unlock the lid 26 in relation to the frame 25, the knob 31 being fixed to the end of a pin 32 that is slideable inside a housing 36 obtained in the lid 26. The housing 36 is provided, in its central region, with an opening 37 that enables the pin 32 to be accessed from the outside of the housing 36. In the closed position A, the portion of the pin 32 emerging from the opening 37* shapingly engages a groove 33 obtained on a rocker arm 34 fitted onto the frame 25.
As shown in Figure 1, the moving means associated to the deflector 13a includes, in this case, a pneumatic cylinder 35, from which a stem 40 protrudes. The stem 40 is arranged for actuating the rocker arm 34 so that when the lid 26 is in the closed position A, the injector means can be moved between the work position, in which the webs 3, 4, 5, 6 are tightened against the forming half-moulds 7 or against the central plate 2, and the rest position, in which said webs can slide in relation to the components of the forming station. During operation, the lid 26 is normally in the closed position A, in which the deflectors 13, 13a and/or the second deflector 13' are arranged in the zone occupied by the forming half-moulds 7, or by analogous half-moulds provided in the pre-heating station or in the sealing station. The pin 32 is engaged in the groove 33 and the knob 31 is rotated into such a position to lock the lid 26 on the frame 25.
When the operating fluid has to be blown between the webs of sheet material, the stem 40 exits from the pneumatic cylinder 35 in such a way as to move downwards the end of the rocker arm 34 provided with the. groove 33. The rocker arm 34 moves downwards the pin 32 and then the deflector 13, 13a and possibly the second deflector 13' , that are rigidly coupled with the pin 32 by means of the lid 26. In this way the
deflectors - press the webs of sheet material against the central plate 2 and the half-moulds.
At the end of the injection phase of the operating fluid, the stem 40 re-enters in the pneumatic cylinder 35 so that the end of the rocker arm 34 provided with the groove 33 is moved upwards. The deflector 13, 13a and possibly the second deflector 13' are also moved upwards, thereby enabling the webs of sheet material to be advanced through the forming apparatus .
If in an operating station such as the forming station 1, la, the pre-heating station 29 or the sealing station 30, maintenance or size-changing operations are required, for example replacement of the half-moulds, the knob 31 is rotated into such a position as to enable the pin 32 to slide along the housing 36 for disengaging from the groove 33. At this point the lid 26, assisted by the gas spring 38, can be raised in the open position B, together with the deflector 13, 13a and possibly the second deflector 13' that are rigid with it. These deflectors are then evacuated outside the zone occupied by the operating stations 1, la, 29, 30, which enables said stations to be easily accessed to perform the required maintenance or replacement operations.
The lid 26 and the devices connected to it can furthermore be evacuated from the zone occupied by the operating stations 1, la, 29, 30, without physically disconnecting any component of the forming apparatus. In fact, the lid 26 remains connected to the frame 25 near the fulcrum C even in the open position B, and no components have to be removed from the forming apparatus and then be reassembled on it. In this way there is a guarantee that components of the forming apparatus are not lost during maintenance operations regarding the operating stations 1, la, 29, 30, inasmuch as said components always remain connected in some way to the frame 25.
Obviously, before raising the lid 26 to the open position B, the half-moulds 7 must have been distanced from one another by moving them in the direction of the arrow Fl in such a way as to avoid interference between the deflector 13, 13a and possibly the deflector 13', and the half-moulds 7. It should be noted that the lid 26, movable between the closed position A and the open position B, can be associated not only with deflector means of a thermoforming apparatus for thermoforming sheet material, but in general with any means arranged for cooperating with an edge portion of a material from which containers are obtained, for example in blow thermoforming machines for blow thermoforming plastic material and obtain bottles therefrom.