WO2021195713A1 - Apparatus and method for thermoforming a material - Google Patents
Apparatus and method for thermoforming a material Download PDFInfo
- Publication number
- WO2021195713A1 WO2021195713A1 PCT/AU2021/050303 AU2021050303W WO2021195713A1 WO 2021195713 A1 WO2021195713 A1 WO 2021195713A1 AU 2021050303 W AU2021050303 W AU 2021050303W WO 2021195713 A1 WO2021195713 A1 WO 2021195713A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- product
- sheet
- mould
- cellulose
- sheets
- Prior art date
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/10—Forming by pressure difference, e.g. vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/56—Coatings, e.g. enameled or galvanised; Releasing, lubricating or separating agents
- B29C33/60—Releasing, lubricating or separating agents
- B29C33/62—Releasing, lubricating or separating agents based on polymers or oligomers
- B29C33/66—Cellulose; Derivatives thereof
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/18—Thermoforming apparatus
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/30—Moulds
- B29C51/36—Moulds specially adapted for vacuum forming, Manufacture thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/42—Heating or cooling
- B29C51/421—Heating or cooling of preforms, specially adapted for thermoforming
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
- B29C51/46—Measuring, controlling or regulating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C2791/00—Shaping characteristics in general
- B29C2791/004—Shaping under special conditions
- B29C2791/006—Using vacuum
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2001/00—Use of cellulose, modified cellulose or cellulose derivatives, e.g. viscose, as moulding material
Definitions
- the invention relates to an apparatus and a method for thermoforming a material.
- the invention relates to an apparatus and a method for thermoforming a cellulose-containing material.
- other materials that have similar characteristics that have made it difficult to thermoform the materials into commercially useful products
- Cellulose is an organic compound that is found in the cell walls of plants. The material was discovered in the 1800’s and was used to produce the first successful thermoplastic polymers.
- Cellulose is a biodegradable and sustainable material and is therefore considered more environmentally friendly than petrochemical-derived polymers.
- Cellulose is typically produced by first grinding plant matter into a pulp and adding a solvent, such as acetone, to the pulp and leaving the mixture for around 24 hours. The mixture is then spread out onto a stainless-steel conveyor belt and a plasticizer, such as vinegar, is added to the mixture. Heat and air pressure is then applied to remove the acetone from the mixture to leave only the cellulose material behind in a film form. The acetone is collected and reused.
- Thermoforming is a manufacturing process where a polymer (also referred to herein as a plastic) sheet is heated to a pliable forming (softening) temperature and then moulded to form a specific shape. Polyethylene terephthalate (PET) is a commonly used polymer for thermoforming for the manufacture of packaging.
- a solvent such as acetone
- a plastic material may undergo a phase transformation, due to the application of strain, known as strain crystallization.
- strain crystallization the initially disordered, i.e. amorphous, molecular structure becomes more ordered, i.e. crystalline.
- This process changes the mechanical properties of the material and increases its hardness. Once a material has become crystalline, it is generally accepted that the material has lost its thermoplastic properties and will no longer thermoform into a desired shape.
- the crystallization of PET occurs at a rate which is gradual enough to draw shapes having deep cavities, making it suitable for thermoforming a range of different packaging articles.
- cellulose is not capable of being thermoformed into a shape having deep cavities (cavities with a depth to width ratio greater than 0.1). This is because, unlike PET, cellulose crystallizes too quickly for known thermoforming technology. In addition to the above, heated cellulose is difficult to transport to a mould while hot, as it sags under its own weight when heated.
- thermoforming a material comprising cellulose to produce moulded articles having suitably deep cavities It is desirable to provide a method for thermoforming a material comprising cellulose to produce moulded articles having suitably deep cavities.
- the invention is a method for thermoforming a cellulose-containing material to form a product that has a product wall of the cellulose-containing material, the method including the steps of: i) heating a sheet of the material to be within a softening range of the material; ii) moving the heated sheet and/or a mould having a mould wall defining a profile of the product relative to each other so that the sheet is in an operative position to be formed into a product in the mould; and iii) heating an opposite surface of the sheet to a surface of the sheet facing the mould to maintain the temperature of the sheet within the softening range of the material; and iv) using air pressure and/or vacuum to form the heated sheet against the mould wall to form the product.
- the sheet may be any suitable thickness, width and length.
- the sheet may be up to 200 microns in thickness.
- the sheet may be up to 150 microns in thickness.
- the sheet may be up to 120 microns in thickness.
- the invention extends to arrangements in which the sheet is a stack of a plurality of sheets, with a second sheet on top of a first sheet and so on.
- sheets of cellulose-containing material that are greater than 150 microns may not biodegrade quickly enough in some situations and this is a potential issue.
- the applicant has found that the use of two or more sheets, typically two sheets, typically sheets that are less than 150 microns, in a stack with one sheet on top of the other sheet in the operative position in step ii) makes it possible to form the product in steps iii) and iv) as a single unified sheet.
- step ii) providing a lower sheet in the operative position in step ii) with openings through the sheet thickness, for example being formed as perforations, can facilitate heat transfer to an upper sheet or sheets of the stack and contribute to forming the product.
- the product may include the lower and the upper sheet being secured together via sections of the upper sheet being forced into the perforations during step iv) and thereby holding the sheets together.
- step i) may include heating a stack of a plurality of sheets, with a second sheet on top of a first sheet and so on to be within the softening range of the material.
- step ii) may include moving the heated stack of sheets and/or a mould defining a profile of the product relative to each other so that the stack of sheets is in the operative position to be formed into the product in the mould.
- step iii) may include heating an opposite surface of the stack of sheets to the surface of the stack facing the mould to maintain the temperature of the stack of sheets within the softening range of the material.
- step iv) may include using air pressure and/or vacuum to form the heated stack of sheets into the mould to form the product.
- At least one of the sheets may have openings extending through the sheet to facilitate transfer of vacuum or air pressure to the sheets in the stack.
- the product may be any suitable product.
- the product may be a packaging product, such as a food tray, having a base and a side wall extending upwardly from the base and defining a compartment.
- a packaging product such as a food tray, having a base and a side wall extending upwardly from the base and defining a compartment.
- the method produces the packaging product with a draw depth to width ratio of greater than 0.1.
- the method produces the packaging product with a draw depth to width ratio of between 0.1 and 5.0.
- the heating in steps (i) and/or (iii) may be conducted by any suitable heat source.
- heating in steps (i) and/or (iii) are conducted using a radiant heat source.
- a radiant heat source is that it reduces the possibility of the contact between the sheet of material and the heat source.
- the softening range of the cellulose material is between 110-140 °C.
- the mould is chilled to be at a temperature below ambient temperature.
- the mould may be chilled to be at a temperature at or below 10 °C.
- the air pressure is produced via a vacuum device removing air from the mould.
- the air pressure is produced by blowing air.
- the material may be any suitable cellulose-containing material.
- the material may be 100% by weight cellulose or a blend of cellulose and other materials, such as plastic materials.
- the material may be at least 90% by weight cellulose.
- the material may be at least 95% by weight cellulose.
- the invention is not confined to a cellulose-containing material and extends to other materials that have similar characteristics that have made it difficult to thermoform the materials into commercially useful products.
- the invention is particularly suitable for materials exhibiting high strain crystallisation rates.
- the method and the apparatus may be adapted to be used with materials having a range of different crystallisation rates by controlling the parameters of the second heating device, i.e. temperature, power, energy, duration, etc.
- the invention is also an apparatus for thermoforming a cellulose-containing material to form a product that has a product wall of the cellulose-containing material, the apparatus comprising: a mould having a mould wall that defines a profile of the product; a heat source; and a source of air pressure and/or a vacuum-forming device, wherein, in use the heat source is adapted to heat a sheet of the cellulose-containing material to be within a softening range of the material whilst air pressure from the source of air pressure and/or the vacuum-forming device forms the heated sheet against the mould wall to form the product.
- the apparatus may be adapted for thermoforming a stack of a plurality of sheets of the cellulose-containing material, typically two sheets, with a second sheet on top of a first sheet and so on.
- the apparatus may include a feed assembly for forming the stack of the sheets and feeding the stack to the mould.
- the invention is also a thermoformed product that includes a product wall made from a cellulose-containing material.
- the product wall may include at least two sheets of the cellulose-containing material that are thermoformed together.
- At least one of the sheets may have openings, such as perforations, and cellulose-containing material from an adjacent sheet may be in the openings as a consequence of thermoforming the product and thereby contribute to holding the sheets together.
- the product may be a packaging product, such as a food tray, having a base and a side wall extending upwardly from the base and defining a compartment.
- a packaging product such as a food tray, having a base and a side wall extending upwardly from the base and defining a compartment.
- the packaging product may have a draw depth to width ratio of greater than 0.1.
- the packaging product may have a draw depth to width ratio of between 0.1 and 5.0.
- Figure 1 shows a step-by-step diagram of a prior art thermoforming apparatus and cycle
- Figure 2 shows a step-by-step diagram of a thermoforming apparatus and cycle according to an embodiment of the invention.
- Figure 3 shows a step-by-step diagram of a thermoforming apparatus and cycle according to another, but not the only other possible, embodiment of the invention.
- Figure 1 shows a step-by-step diagram of a prior art thermoforming apparatus and cycle used to thermoform a plastic material.
- thermoforming apparatus comprises:
- moulding device 20 having a mould 22 that has an internal cavity 26 bounded by internal walls of the mould 22, with the cavity defining the shape of a product;
- thermoforming cycle has three steps: ‘a’; ‘b’; and ‘c’ as follows.
- step ‘a’ a sheet of plastic material 12a is heated within a softening range of the material by applying heat using the heat source 10 - see Figure 1(a).
- step ‘b’ the now heated sheet of plastic material 12b is transported by the sheet holding/transporting device 14 to the forming device 20 and positioned on top of the mould 22 above the internal cavity 26, as illustrated in Figure 1(b).
- step ‘c’ air is drawn from the internal cavity 26, as shown by the arrows 24 in Figure 1(c), to generate a negative pressure (i.e. partial vacuum) within the internal cavity 26.
- the partial vacuum draws the heated sheet of plastic material 12 into the internal cavity so that the sheet of plastic material 12 contacts the internal walls of the mould 22 and thereby conforms to the shape defined by the internal walls.
- the mould is typically chilled below ambient temperature. When the sheet of plastic material 12 contacts the internal walls, the plastic material cools and solidifies into the product shape.
- steps ‘b’ and ‘c’ are applied to a sheet of cellulose material
- a heated sheet of cellulose material 12 is drawn out from the sheet and the material undergoes a phase transformation, due to the application of strain.
- the initially disordered, i.e. generally amorphous, molecular structure becomes more ordered, i.e. crystalline.
- This process changes the mechanical properties of the cellulose material and increases resistance to the forming action as the sheet of cellulose material is being drawn out.
- the prior art thermoforming apparatus and cycle shown in Figure 1 (and other prior art thermoforming apparatus and cycles known to the applicant) is not suitable for thermoforming cellulose material.
- thermoforming apparatus and cycle such as that described in relation to Figure 1
- the suitability of a material for use in a thermoforming apparatus and cycle is largely dependent on the rate at which crystallization occurs in the material.
- the crystallization of PET occurs at a rate which is gradual enough to draw shapes having deep cavities, making it a suitable material for thermoforming.
- the crystallization of cellulose occurs at a much higher rate, making it less suitable for thermoforming processes.
- Figure 2 shows a step-by-step diagram of a thermoforming apparatus and cycle for thermoforming cellulose material according to a first embodiment of the invention.
- the apparatus for thermo forming comprises: a first heat source 110, a moulding device 120 having (a) a mould 122 that has an internal cavity 128 bounded by internal walls of the mould 122, with the cavity defining the shape of a product, and (b) a second heat source 126; and a sheet holding/transporting device 114 that is configured to hold the perimeter of a sheet of plastic 112 and to transport the sheet.
- the first and second heat sources 110, 126 are radiant heat sources.
- thermoforming cycle according to the first embodiment of the invention, has three steps: ‘a’; ‘b’; and ‘c’ as follows.
- step ‘a’ a sheet of cellulose material 112a is heated, within a softening range of the material, by applying heat to a surface of the sheet of cellulose material 112a using the first heat source 110.
- step ‘b’ the now heated sheet of cellulose material 112b is transported by the sheet holding/transporting device 114 to the moulding device 120 and positioned on top of the mould 122 above the cavity 128.
- step ‘c’ air is drawn out of the internal space 128 as shown by the arrows 124 to form a negative pressure (i.e. vacuum) within the internal space 128.
- the heated sheet of cellulose material is drawn into the mould by the negative pressure and contacts and adopts the shape defined by the internal walls of the mould.
- the mould is chilled below ambient temperature, typically at or below 10 °C, using cold water. As a consequence, when the cellulose material contacts the internal walls of the mould, the cellulose material cools and solidifies into the product shape.
- the second heat source 126 applies heat to a surface of the heated sheet of cellulose material.
- the invention allows materials containing cellulose to be deep drawn by depth to width ratios of greater than 0.1 and in some cases as much as 5.0.
- Figure 3 shows a step-by-step diagram of the thermoforming apparatus and cycle for thermoforming cellulose material according to a second embodiment of the invention.
- thermoforming apparatus shown in Figure 3 comprises: a first heat source 210; a moulding device 220 having (a) a mould 222 with external walls that define a shape of a product, (b) a base 224 forming an internal channel 226 therebetween, and (c) a second heat source 230; and a sheet holding/transporting device 214 that is configured to hold the perimeter of a sheet of plastic material 212 and to transport the sheet.
- thermoforming cycle according to the second embodiment of the invention functions in much the same way as the first embodiment with the exception that the mould 222 is a positive pressure mould.
- a sheet of cellulose material 212 is pressed onto the external walls of the mould 222 and adopts the shape defined by the external walls.
- the mould is chilled below ambient temperature, typically at or below 10 °C, using cold water. As a consequence, when the cellulose material contacts the external walls, the cellulose material cools and solidifies into the product shape.
- Another advantage of the invention is that the components which enable the invention to work with cellulose material, in particular the second heating device, can be easily retrofitted into an existing thermoforming apparatus with very few modifications.
- thermoforming materials containing cellulose Whilst the invention is particularly useful for thermoforming materials containing cellulose, it is by no means limited to these materials.
- the method and apparatus of the invention is particularly suitable for materials exhibiting high strain crystallisation rates.
- the method and apparatus may be adapted to be used with materials having a range of different crystallisation rates by controlling the parameters of the second heating device, i.e. temperature, power, energy, duration, etc.
- the first and second heat sources described in the above embodiments are radiant heat sources.
- radiant heat sources are particularly suitable for thermoforming material containing cellulose because they can be effectuated from a distance and as such, reduce the possibility of contact between the sheet of material and the heat source.
- Radiant heat sources include convective, dielectric heating and the like.
- heat sources may be used.
- contact heating may be used, such as in situations where the material has a low tackiness when in the softening range.
- thermoforming a cellulose containing material involving the use of air pressure to create a vacuum.
- thermoforming method could be performed by blowing air against a surface of the sheet to force it against the mould, i.e. positive air pressure.
- thermoforming method of the invention could be performed without using air pressure at all, for example by using solely the contact pressure from the mould itself.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Blow-Moulding Or Thermoforming Of Plastics Or The Like (AREA)
Abstract
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Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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AU2021247418A AU2021247418A1 (en) | 2020-04-03 | 2021-04-01 | Apparatus and method for thermoforming a material |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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AU2020901039 | 2020-04-03 | ||
AU2020901039A AU2020901039A0 (en) | 2020-04-03 | Apparatus and method for thermoforming a material | |
AU2021900432A AU2021900432A0 (en) | 2021-02-19 | Apparatus and method for thermoforming a material | |
AU2021900432 | 2021-02-19 |
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WO2021195713A1 true WO2021195713A1 (en) | 2021-10-07 |
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PCT/AU2021/050303 WO2021195713A1 (en) | 2020-04-03 | 2021-04-01 | Apparatus and method for thermoforming a material |
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AU (1) | AU2021247418A1 (en) |
WO (1) | WO2021195713A1 (en) |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100143695A1 (en) * | 2007-06-27 | 2010-06-10 | Masanori Ogawa | Automobile floor back covering material and process for producing the same |
US20150056562A1 (en) * | 2013-08-22 | 2015-02-26 | Lydia KLEFFMANN | Candle magazine |
US20190070819A1 (en) * | 2016-03-18 | 2019-03-07 | Pulpac AB | Method for manufacturing a cellulose product, cellulose product forming apparatus and cellulose product |
-
2021
- 2021-04-01 WO PCT/AU2021/050303 patent/WO2021195713A1/en active Application Filing
- 2021-04-01 AU AU2021247418A patent/AU2021247418A1/en active Pending
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US20100143695A1 (en) * | 2007-06-27 | 2010-06-10 | Masanori Ogawa | Automobile floor back covering material and process for producing the same |
US20150056562A1 (en) * | 2013-08-22 | 2015-02-26 | Lydia KLEFFMANN | Candle magazine |
US20190070819A1 (en) * | 2016-03-18 | 2019-03-07 | Pulpac AB | Method for manufacturing a cellulose product, cellulose product forming apparatus and cellulose product |
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AU2021247418A1 (en) | 2022-12-08 |
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