WO2023175550A1

WO2023175550A1 - Apparatus and method for making a container

Info

Publication number: WO2023175550A1
Application number: PCT/IB2023/052567
Authority: WO
Inventors: Andrea Bartoli; Davide CAPITINI
Original assignee: Sarong Societa' Per Azioni
Priority date: 2022-03-18
Filing date: 2023-03-16
Publication date: 2023-09-21

Abstract

Described is an apparatus (1) for making a container (C) defining at least one processing path (L). The apparatus (1) comprises a feeding station (2) configured for introducing in the processing path (L) at least one film (F) made of a cellulose-based material, a deforming station (3), positioned downstream of the feeding station (2), comprising at least one deforming device (3a) having at least one engaging surface (3b) provided with an undulating geometry and configured for engaging the film (F) in such a way as to impress, on a processing surface (A) of the film (F), the undulating geometry, and a forming station (4), positioned downstream of the deforming station (3), comprising at least one forming device (4a) configured for forming the film (F) deformed by the deforming station (3) in such a way as to define the container (C).

Description

DESCRIPTION

Apparatus and method for making a container

This invention relates to an apparatus and a method for making a container. In particular, the invention can be applied in the field of making containers for products, in particular for food, cosmetic, pharmaceutical or other types of products.

There are currently various machines for making these containers, configured for forming a film made of polycoupled material of a plastic type, fed for example from a reel, by multi-impression moulding.

Generally speaking, these machines comprise a plurality of operating stations positioned in sequence, such as, for example, a heating station, a forming station and a cutting station.

The forming station generally comprises the use of a punch which is able to form the polycoupled film of a plastic type, in such a way as to obtain the desired container, by means of forming techniques of known type which comprise specific mould dies and the blowing of air, for example by the punch itself.

In recent times, with the transition to a more sustainable industry aimed at reducing the use of plastic materials, it has been decided to use a film made of a cellulose-based material, for example paper. The film may be a material made entirely of thermoformable paper, or it may be a polycoupled material with a prevalence of cellulose-based material.

Disadvantageously, the prior art production machines have proved ineffective in uniformly forming the cellulose-based material and it has been noted that, following the forming operations, some of the containers formed could have portions with a thickness so thin that they had to be rejected immediately at the moment they were made, since they were defective and therefore unusable.

Other containers formed could, due to the same problem, break at the time of use, when handled by a consumer. In other words, irrespective of the geometry of the punch and/or of the moulds used, the prior art machines have proved to be unsuitable for use with a film made of a cellulose-based material, made, for example, entirely of thermoformable paper or polycoupled, since they are unable to form the film in a uniform manner, resulting in the breakage of the product and/or failure to reach the necessary quality level.

One of the reasons for the non-uniform deformation is due to the fact that a coefficient of elongation of the above-mentioned cellulose-based material is not fully used and it has been noted that the containers made by forming a cellulose-based film do not reach the desired quality level which can be obtained, on the other hand, with the plastic materials used previously.

The technical purpose of the invention is therefore to provide an apparatus and a method for making a container by forming a film made of cellulose- based material, which are able to overcome the drawbacks of the prior art. The aim of the invention is therefore to provide an apparatus and a method for making a container by forming a film made of a cellulose-based material, which allow containers of the desired quality to be obtained, which have a uniform distribution of the material in the container.

A further aim of the invention is to provide an apparatus and a method for making a container by forming a film made of cellulose-based material, which allow a safe production of the container, without unwanted breakages of the container, during the making or during a subsequent use by a consumer.

The technical purpose indicated and the aims specified are substantially achieved by an apparatus and a method for making a container comprising the technical features described in one or more of the appended claims. The dependent claims correspond to possible embodiments of the invention.

In particular, the technical purpose indicated and the aims specified are substantially achieved by an apparatus for making a container defining a containment space for a product, preferably a food product. The apparatus defines at least one processing path and comprises a feeding station, a deforming station and a forming station.

The feeding station is configured for introducing in the processing path at least one film made of a cellulose-based material.

The deforming station, located downstream of the feeding station, comprises at least one deforming device having an engaging surface provided with an undulating geometry, which is configured for engaging the film in such a way as to impress, on a processing surface of the film, the undulating geometry.

Preferably, the deforming device may comprise heating elements in order to heat the deforming device in such a way as to facilitate the impression of the undulating geometry on the processing surface.

The forming station, positioned downstream of the deforming station, may comprise at least one forming device configured for forming the film, deformed by the deforming device, in such a way as to define the container. Advantageously, the deforming device, that is to say, the undulating geometry formed on the engaging surface, allows the material to be deformed, that is to say, impress the undulating geometry on the film, in such a way as to redistribute the material in such a way as to fully use the coefficient of elongation of the cellulose-based material during the forming of the container by the forming device.

Advantageously, the forming device may form the film at the processing surface, on which the deforming device can impress its undulating geometry. In other words, the undulating geometry may be impressed on a surface intended to be entirely formed to define the container.

However, according to a version, the forming device may form the film at a forming area, contained in the processing surface, and that is to say smaller than the deformed surface. In other words, the deforming device may impress its undulating geometry at an area outside the forming area and surrounding the forming area, for making a reserve of material which is able to act in conjunction with the forming area in such a way as to make the container “C”.

The technical purpose indicated and the aims specified are substantially achieved by a method for making a container defining a containment space for a product, preferably food, cosmetic or pharmaceutical product.

The method comprises the following steps:

- feeding at least one film made of a cellulose-based material;

- deforming the film by impressing an undulating geometry on a processing surface of the film;

- forming the container, forming the deformed film impressing the undulating geometry.

Further features and advantages of the present invention will become more apparent from the following indicative, and hence non-limiting, description of an embodiment of an apparatus and a method for making a container.

The description is set out below with reference to the accompanying drawings which are provided solely for purposes of illustration without restricting the scope of the invention and in which:

- Figure 1 and Figure 2 are schematic representations of an apparatus according to the invention, comprising a deforming device having an engaging surface provided with an undulating geometry;

- Figure 3 is a schematic view of a deformed film, in a condition prior to forming, and of a respective container obtained from it, in a condition after forming;

- Figure 4 is an enlarged schematic view, with some parts cut away for clarity, of a different deformed film, in a condition before the forming, and of a respective container obtained from it, in a condition after the forming;

- Figure 5 is an enlarged schematic view, with some parts cut away for clarity, of another different deformed film, in a condition before the forming, and of a respective container obtained from it, in a condition after the forming; - Figure 6 is a schematic view of the engaging surface of Figure 1 , provided with an undulating geometry with linear deformation zones parallel to each other;

- Figure 7 is a schematic view of a further engaging surface, made in the form of distributed spheres or hemispheres;

- Figure 8 is a schematic view of another engaging surface, with linear deformation zones concentric with each other.

With reference to the accompanying drawings, the numeral 1 denotes in its entirety an apparatus for making a container “C” which, for simplicity of description, will hereafter be referred to as the apparatus 1 .

The container “C” defines a containment space “V” for a product, for example a food product, or a cosmetic or pharmaceutical product, or of other types.

The apparatus 1 defines at least one processing path “L” and comprises a feeding station 2 configured for introducing in the processing path “L” at least one film “F” made of a cellulose-based material.

Preferably, the apparatus 1 is configured to move the film “F” along the processing path “L” with intermittent movement with a constant spacing.

The film “F” made of the cellulose-based material may be introduced using the feeding station 2 unrolling at least one reel “B”, as shown for example in Figure 1 .

The film “F” may also be introduced using the feeding station 2 feeding single sheets made of a cellulose-based material.

In other words, the film “F” may be a continuous web or a series of sheets with finished dimensions that, once introduced in the apparatus 1 , are processed until obtaining the container “C”.

The term film “F” made of a cellulose-based material means in this text the fact that the film “F” may be entirely thermoformable cellulose-based, for example it may be made of thermoformable paper and/or paperboard, or it may be a polycoupled material, with a prevalence of cellulose-based material. In the latter case, the film “F” made of polycoupled material (not illustrated) may comprise a first layer of paper and/or paperboard, a second layer of thermoplastic polymer and a third layer of paper and/or paperboard. Still more preferably, the polycoupled material may comprise a fourth layer, optionally peelable, made of thermoplastic polymer configured to come into contact with the food product. The accompanying drawings show only the first layer of paper, which may be seen as the material which defines the outside of the container “C”.

Preferably, the first layer of paper and/or paperboard is made from paper with a grammage of 50-300 gr/m2 coupled by the second layer (for example polyethylene) to the third layer of paper with a grammage of 50-300 gr/m2. The fourth layer, which is optionally peelable, may be made of polyethylene (abbreviated PE) or polypropylene (abbreviated PP) or polyactic acid (abbreviated PLA) or other plastic materials.

The term "grammage" is used to mean a value of paper and/or paperboard density, which is expressed as a value in grams per square metre.

Even though the paper and/or the paperboard has a thickness which is usually dependent on the grammage used, the thickness of the paper and/or the paperboard may vary depending on various factors, such as, for example, the type of processing performed during the production of the paper and/or the paperboard or the quantity of wood fibre present in it.

In fact, for the same grammage, there may be a high density paper and/or paperboard which has a predetermined thickness and a low density paper and/or paperboard which is thicker than the predetermined thickness.

The apparatus 1 further comprises a deforming station 3 positioned downstream of the feeding station 2.

The apparatus 1 further comprises a forming station 4 positioned downstream of the deforming station 3.

The deforming station 3 comprises at least one deforming device 3a having an engaging surface 3b provided with an undulating geometry.

The term “undulating geometry” means any geometry, without sharp edges which can potentially damage the film “F” during the deforming step. In other words, the expression “undulating geometry” means protrusions, which extend from the engaging surface 3b, without sharp edges, configured for making respective grooves and/or folds “P” on the film “F”, creating on it a corresponding undulating geometry.

The deforming device 3a (that is, the engaging surface 3b) is configured to engage the film “F” in such a way as to impress, on a processing surface “A” of the film, the undulating geometry.

According to an embodiment, shown in Figures 6, 7 and 8, the engaging surface 3b is smaller than the deforming device 3a. The processing surface “A” has a greater extension than the engaging surface 3b and there is a planar frame around the engaging surface 3b. In this way, the deforming device 3a will not impress the undulating geometry in a portion of the film “F” (that is, of the processing surface “A”) perimetric to the portion in which the engaging surface 3b acts.

In other words, the processing surface “A” is not deformed in its entirety and therefore the engaging surface 3b only affects a specific portion of the processing surface “A”.

According to a further embodiment, not illustrated, the film “F” has an overall surface which is greater than the engaging surface 3b, that is, the processing surface “A” in such a way that, after the deformation, the film “F” has a non-deformed perimeter portion in which the undulating geometry is absent. In other words, the planar frame around the engaging surface 3b may be absent if the film “F” has an overall surface greater than the engaging surface 3b.

As shown in Figures 6, 7 and 8, the engaging surface 3b may be defined by a central portion in which the undulating geometry to be impressed is present and a perimeter portion not having the undulating geometry.

In this way, after the intermittent movement of the film “F”, portions will be defined on the film “F” which are separate and spaced from each other in which the undulating geometry is defined. The forming station 4 comprises at least one forming device 4a which is configured for forming the film “F”, deformed by the deforming device 3a, in such a way as to define the container “C”.

It should be noted that Figure 1 shows, for example, a deforming device 3a provided with two engaging surfaces 3b for simultaneously impressing two respective undulating geometries on the processing surface “A” intended to make respective containers “C”, as described in more detail below. Other configurations are possible, for example there may be a plurality of engaging surfaces 3b, or a plurality of deforming devices 3a, each of them comprising one, or more, engaging surfaces 3b, if the deforming station 3 is a multi-impression type.

Preferably, the deforming device 3a may comprise heating elements in order to heat the deforming device 3a in such a way as to facilitate the impression of the undulating geometry on the processing surface “A”.

Preferably, the engaging surface 3b may have a plurality of deformation sectors, each deformation sector having an undulating geometry made according to one or more shapes and/or having a depth variable as a function of a geometry of the container “C” to be formed.

In other words, the undulating geometry may have different extensions and/or dimensions and/or have different patterns in some deformation sectors which are completely different from those of other deformation sectors as a function of the type of container “C” to be formed, that is, as a function of which walls and/or portions of the container “C” the various zones must define.

Preferably, as shown in Figure 7, the undulating geometry of the engaging surface 3b is made in the form of spheres or hemispheres distributed on the engaging surface 3b as a function of a geometry of the container “C” to be formed. Preferably, the spheres or hemispheres may have different dimensions (that is to say, depth and/or diameters) as a function of the final shape of the container “C” to be made and/or as a function of the portion of the container “C” which they will define once the forming step has been performed.

As shown in Figure 7, the spheres or hemispheres may have reduced dimensions in a perimeter portion of the engaging surface 3b relative to the dimensions of the spheres defined in the central portion of the engaging surface 3b. For example, the perimeter spheres (or hemispheres) may have a reduced diameter compared with the central spheres.

With reference to the following description, it should be noted that Figures 3, 4 and 5 show simultaneously the deformed film "F" and the container "C" obtained by forming the above-mentioned deformed film "F".

It should be noted that, after forming, the container “C” is free of surfaces with an undulating geometry, since with the forming the material deformed in the deforming station 3 is redistributed in the entire container “C”.

Figure 4 shows a film “F” on which an undulating geometry made with the above-mentioned spheres or hemispheres is impressed on the processing surface “A”.

In particular, the film “F” of Figure 4 has been deformed with a deforming device 3a wherein the engaging surface 3b (for example obtainable by means of the engaging surface of Figure 7) has an undulating geometry wherein the spheres or hemispheres have different depths, so that the folds “P” of the film “F” can have different depths.

It should be noted that the deformed film “F” of Figure 4 has concave portions or depressions in a perimeter sector of the processing surface “A” having depths reduced with respect to the spheres or hemispheres of a central sector of the processing surface “A”. In other words, the film “F” of Figure 4 has at least two deformation sectors concentric with each other wherein the perimeter sector has folds “P” provided with a reduced depth relative to the folds “P” of the central sector.

The term folds “P” is used to mean protrusions facing towards the first layer of paper made of the polycoupled material (if the film “F” is made of polycoupled material). In other words, the protrusions are defined in what, once the container “C” has been formed, will define the inner portion of the container “C”.

Preferably, as shown in Figure 6, the undulating geometry of the engaging surface 3b may be made in the form of linear deformation zones, parallel to each other and distributed on the engaging surface 3b as a function of a geometry of the container to be formed. In a manner similar to that described above, the above-mentioned linear and parallel deformation zones may have different depths or distributions as a function of the container “C” to be formed or the portions of container “C” which the various deformation sectors must form.

Figure 5 shows a film “F” on which an undulating geometry made with the above-mentioned deformation zones which are linear and parallel to each other of the engaging surface 3b of Figure 6 is impressed on the processing surface “A”. Figure 5 shows, for example, a film “F” having folds “P” having the same depth and spaced at the same spacing (on the basis of the container “C”, the folds “P” impressed may have different distances from each other).

As shown in Figure 8, the undulating geometry of the engaging surface 3b may also be made in the form of linear deformation zones concentric with each other and distributed on the engaging surface 3b, as a function of a geometry of the container “C” to be formed.

In a manner similar to that described above, the concentric zones may have different depths and/or different distances between one zone and another. The embodiments described above relate to the engaging surfaces 3b as well as to the undulating geometries defined on the film “F”. The above- mentioned embodiments are only some of the possible embodiments and it should be noted that on the basis of the type of container “C” to be made the same can be combined with each other or be made with totally different shapes and distributions provided they always have the undulating geometry, without sharp edges.

Preferably, as shown in Figure 1 , the deforming device 3a may be made in the form of a plate which can be pressed against the film “F”. Preferably, as shown in Figure 2, the deforming device 3a comprises a first half-mould 3c and a second half-mould 3d opposite to each other and movable towards each other to engage with the film “F” (the first half-mould 3c, or the second half-mould 3d, may be fixed and the other half-mould 3d, or 3c, may be movable, or both the half-moulds 3c, 3d may be movable). The first half-mould 3c and the second half-mould 3d comprise undulating geometries which are complementary to each other. In other words, the first half-mould 3c and the second half-mould 3d may be represented in the form of female and male shells or comprising portions of undulating geometry defined as protuberances and/or portions of undulating geometry defined as recesses complementary to the respective protuberances of the opposite half-mould (3c or 3d).

Preferably, the first half-mould 3c and the second half-mould 3d are made in the form of plates having the engaging surface 3b provided with the undulating geometry. For example, the latter may be made as a thin plate applied to mould with a greater thickness making the opposite half-mould 3c, or 3d.

According to a variant embodiment not illustrated, the deforming device 3a may comprise a pair of rollers opposite to each other and counter-rotating (not illustrated in the accompanying drawings). The rollers are configured for receiving the film “F” and engaging it. The pair of rollers comprises a first roller and a second roller, each comprising respective engaging surfaces having undulating geometries complementary to each other in the same way as described above for the embodiment with the opposite half-moulds 3c and 3d.

If the reel “B” is mounted in an idle fashion in the feeding station 2, the rollers can pull the film “F” from the reel “B” during deformation of the film “F”, which in this case will be reshaped, without stretching and without thinning its thickness. In other words, if the counter-rotating rollers engage the film “F” and the reel “B” is configured for feeding the film “F”, if required by the rollers, the geometry of the film “F” may be varied and the density of the film “F” per unit length may increase.

If, on the other hand, the reel “B” is not mounted in an idle fashion, the counter-rotating rollers will vary the geometry of the film “F” but the film “F” can be stretched and elongated so that the density of the film “F” per unit length can reduce.

It should be noted that all the above applies to the rollers and that is to say, the rollers can also have one or more engaging surfaces provided with undulating geometries, if the rollers make a multi-impression deforming device.

Advantageously, the deforming device 3a is able to impress the undulating geometry on the film “F” in such a way as to better redistribute the cellulose- based material which makes up the film “F” so as to be able to make full use of the deformability.

In other words, the processing surface “A” of the cellulose-based film “F” is deformed to obtain the final surface which, after the individual deformations made by the undulating geometry of the engaging surface 3b, will have a greater extension than the original processing surface “A” of the film “F”. In other words, the deformation obtained using the deforming device 3a makes it possible to obtain a film “F” with an extension greater than the initial one, and therefore with fibres better distributed, which guarantees a forming with a more uniform deformation.

For this reason, with the deformation, the cellulose-based film “F” can be stretched (if its density decreases), or enriched (if its density increases), distributing in both cases in a more uniform manner the fibres of the material and therefore using for the most part (but not completely) the elongation coefficient, so that once the forming for obtaining the container “C” is applied, the elongation coefficient of the cellulose-based material can be completely used.

It should be noted that the undulating geometry impressed in the film “F” in the deforming station 3 is no longer present in the container “C” formed, since the forming stabilises the fibres of the cellulose-based film “F” and makes the thickness of the formed container “C” uniform, flattening the undulating geometry.

It should be noted that the deformation allows fibres of the cellulose-based film “F” to be involved which would otherwise have been only marginally affected by the forming, for example, the zones of the film “F” with a thickness which would not have been modified after the forming (for example because they were intercepted by front planar parts of a forming punch oriented perpendicularly to a moulding direction).

The deforming station 3 therefore involves the entire surface “A” for processing the film “F” which is deformed, an involvement which would not occur in the absence of this station.

By redistributing by deforming the material which makes up the film “F”, before the forming, it may be noted that all the walls of the container “C” formed reduce uniformly in thickness, and the deformation therefore affected all the walls in a uniform manner.

This guarantees a robust container “C”, without thin parts that are not subject to undesired breakages.

The undulating geometry is therefore defined by protrusions which do not have sharp edges. These protrusions must be defined above all in the parts which are most unlikely to deform when stretching the film “F”, during the forming for making the container “C”.

The undulating geometry described above can be adjusted, thus reducing a depth of the protruding portions which define it. In other words, if it noted during processing that it is not possible to obtain the desired distribution of the fibres, the individual protrusion can be reshaped to accentuate or decrease it. In other words, it is possible to perform a permanent adjustment of the undulating geometry as a function of the specific container “C” to be obtained.

The forming device 4a comprises a forming punch and a respective forming die, which are movable towards each other between an open die condition and a closed die condition along a moulding direction. Preferably, the forming punch comprises blowing elements, not illustrated, suitable for releasing a fluid which may be air, or water vapour. The release of fluid may occur when the forming punch, or the forming die, intercepts the film “F” and is at least partly inserted in the forming die. In other words, when the forming punch, or the forming die, intercepts the film “F” and presses it against the respective forming die, or against the forming punch, each forming punch can release a jet (that is, a flow) of fluid (air and/or water vapour) in order to better distribute the material of the film “F” against the respective forming die, obtaining a complete and more defined forming.

It should be noted that the fluid may be steam, or air under pressure with a low moisture content, which can be released by the punch at different times. A jet of water vapour could be released by the punch before the closed die configuration, for preparing the cellulose-based film “F” to be formed, but also after forming, in order to stabilise the shape of the container “C” just formed.

It should be noted that, if the deforming device 3a is provided with two, or more, engaging surfaces 3b for simultaneously impressing two, or more, undulating geometries on the processing surface “A”, intended to make respective containers “C”, the forming station 4 comprises respective two, or more, forming devices 4a, as shown in Figure 1 , for also achieving a multi-impression forming.

However, the multi-impression forming having a plurality of forming devices 4a in the forming station 4 may also occur with a deforming device 3a provided with a smaller number of engaging surfaces 3b, with respect to the number of forming devices 4a, if the speed with which each deforming device 3a impresses the respective undulating geometries on the processing surface “A” is greater than that of the forming station 4.

The forming device 4a, acting on the deformed processing surface “A”, is able to accompany the material in such a way that it adopts the desired shape of the container “C”. In other words, the action of the forming device 4a allows the film “F” to be formed which, as shown in the schematic drawings of Figures 3, 4 and 5, passes from a flat shape to a format in which the container “C” defining the containment space “V” for the product is formed.

The forming device 4a is configured to form the deformed film F at the processing surface “A”.

A control system (not illustrated) is configured for feeding the film “F” in the processing path “L” in such a way as to position correctly, that is to say, position centred, the processing surface “A” at the forming device 4a.

Preferably, the forming station 4 also comprises a pressing device (not illustrated) configured for protecting a peripheral portion of the processing surface “A” of the film “F” and for locking the processing surface “A” in such a way as to define, during the forming of the container “C” by means of the forming device 4a, a perimeter ring “C1 ” of the container “C”. The perimeter ring ‘CT is an element of the container ‘C’ on which to seal a covering element designed to close the containment space ‘V’, at least partly, before or after inserting the product.

Preferably, the forming device 4a may be shaped in such a way as to form the deformed film “F”, and, for example, may have a perimeter edge which, during forming, allows the above-mentioned perimeter ring “C1 ” to be obtained.

In other words, the processing surface “A” which is impressed with the undulating geometry is that which is located inside the perimeter ring “C1 ” and is therefore intended to be subsequently formed.

Alternatively, according to a version not illustrated, the forming device 4a may be configured to form an area for forming the deformed film “F” contained in the processing surface “A”. In other words, the engaging surface 3b is configured for impressing the undulating geometry in an area outside the forming area and surrounding the forming area, for making a reserve of material which is able to operate in conjunction with the forming area in such a way as to make the container “C”.

In this case, the control system is configured for feeding the film “F” in the processing path “L” in such a way as to position correctly, that is to say, position centred, the forming area located inside the processing surface “A” at the forming device 4a.

Optionally, the engaging surface 3b may impress the undulating geometry also at the forming area.

In this case, the forming station 4 comprises a version of the pressing device, configured to come into contact with an inner portion of the processing surface “A”, delimiting the forming area, in such a way as to define, during a forming of the container “C” by means of the forming device 4a, the perimeter ring “C1 ” of the container “C.

However, in this case, the pressing device, although making contact with the film “F”, allows a sliding.

The forming station 4 comprises a further pressing device, surrounding externally the pressing device, configured for locking an outer portion of the processing surface “A” of the film “F”. The outer portion surrounds the inner portion of the processing surface “A” and the forming device 4a is configured for forming the forming area using the sliding through the pressing device of the deformed film “F”. In this case, the pressing device also performs the function of eliminating any possible wrinkles of the film “F”, when the latter slides and is in contact.

Advantageously, according to this version, the undulating geometry is also impressed outside the forming area, that is to say, in the outer area, between the inner portion and the outer portion, which surrounds the forming area.

In the outer area, the processing surface "A" may have a final surface of extension greater than the original processing surface "A" of the film "F" and with fibres better distributed, thanks to the individual deformations impressed on it by the deforming device 3a.

The material present in the outer area, surrounding the forming area, may be thus involved and act in conjunction in the forming of the container “C” since the pressing device allows the sliding of the film “F” during the forming, whilst the further pressing device locks the film “F” during the forming.

In other words, the processing surface “A” impressed with the undulating geometry, which is that located outside the forming area, may operate in conjunction with the forming area for making the reserve of material which the forming punch can intercept and pull between it and the forming die.

The perimeter ring “C1 ” is formed by the pressing device at the end of the forming and may be used for sealing together the two half-containers.

The forming device 4a can be optionally preheated so as to improve the forming of the film “F”.

If the forming device 4a is heated, the forming punch and/or the forming die may be heated.

It should also be noted that if the heating of the forming punch and/or the forming die are present, they may advantageously operate in conjunction with any water vapour emitted by the forming punch for stabilising and/or defining the shape of the container “C”.

The apparatus 1 may comprise at least one heating station 5 interposed between the feeding station 2 and the deforming station 3 and configured for pre-heating the at least one film “F”. The heating station 5 is configured for heating the portion of film “F” intended to become the inside of the container “C” (that is, the inner portion intended to come into contact with the product).

According to an embodiment of the apparatus 1 , shown in Figure 2, the apparatus 1 may define at least two processing paths “L” for respective films “F” made of polycoupled material.

According to this embodiment, the feeding station 2 is configured for feeding respective films “F” in the two processing paths “L”. According to this configuration, the films “F” are specular to each other in such a way that the materials defining the inner portion of the container “C” are the same.

Moreover, the deforming station 3 comprises at least one deforming device 3a which differs from the deforming device 3a of Figure 1 since it is configured to impress respective undulating geometries on both the films Preferably, the deforming device 3a may be shaped in such a way as to have a fixed central portion and two portions movable towards the fixed portion designed to intercept the film “F” and impress the undulating geometry. For example, in Figure 2, the half-moulds 3c define the movable portions of the deforming device 3a whilst the half-moulds 3d define the fixed portion.

In a manner similar to that described above, the deforming station 3 may be provided with several deforming devices 3a, each of which may be provided with one or more engaging surfaces 3b for each processing path “L”, for making a multi-impression deformation.

Moreover, according to this embodiment, the forming station 4 can comprise at least one forming device 4a, comprising a forming punch and a relative forming die, configured for defining respective half-containers.

It should be noted that, as already mentioned above, in the case of a multiimpression moulding the apparatus 1 can comprise a plurality of forming devices, each corresponding to a respective engaging surface 3b; or that, alternatively, the apparatus 1 can comprise a greater number of forming devices, with respect to the engaging surfaces 3b, if the speed at which each deforming device 3a impresses the respective undulating geometry on the processing surface “A” is greater than that of the forming station 4.

For each processing path "L" a half-container is defined (in the same way as described in the embodiment of Figure 1 for the container "C") which defines an actual portion (or half-shell) of the container "C" to be made. The half-container is preferably provided with the above-mentioned perimeter ring “C1 ” obtained by means of the pressing device or by means of the specially formed forming device 4a.

According to this embodiment, the apparatus 1 also comprises conveyor means 6 configured for conveying the two processing paths “L” (that is, the respective films “F”) in such a way that the respective half-containers face each other. During such conveying of the half-containers the respective perimeter rings “C1 ” (if present) also face each other.

According to the embodiment of Figure 2, the apparatus 1 also comprises a sealing station 7 comprising at least one sealing device 7a for sealing together the half-containers to form the container “C”.

If present, the sealing device 7a is configured for sealing together the respective perimeter rings “C1 ” facing each other of the two half-containers, thus obtaining the desired container “C”.

Preferably, both in the embodiment of Figure 1 and in the embodiment of Figure 2, the apparatus 1 may comprise a preforming station (not illustrated)) positioned between the deforming station 3 and the forming station 4. The preforming station is provided with a preforming device, made in the form of a forming punch such as that present in the forming station 4 but without the forming die.

In this preforming station, a first forming step is performed on the processing surface “A” using the forming punch and a pressing device which locks the film “F” on an outer mould without the forming die.

In this way, the preforming device, acting on the processing surface “A”, makes it possible to avoid the possible elastic return of the deformed film “F” on which the undulating geometry has been impressed. In other words, the preforming advantageously prevents the cellulose fibres from returning to their “original” shape after the actual forming. For this reason, the preforming prevents the production of a container “C” (or the portion of container “C”) which is not completely formed.

Alternatively, the preforming which is performed prior to the actual forming of the film “F” may be performed in the forming station 4, in which only the forming punch of the forming device 4a is used to preform the processing surface “A” on which the undulating geometry has been previously impressed.

For example, the forming punch can interact with the film “F” performing a first stroke wherein the forming punch stops before inserting inside the forming die, achieving the preforming, and a second stroke wherein the forming punch performs its normal stroke in the forming die to achieve the actual forming.

Alternatively, in the forming station 4 there may be locking means which can be positioned in a reversible fashion in an inlet portion of the forming die to prevent access of the forming punch in the forming die.

Alternatively, the pressing device may be used to prevent access of the forming punch to the forming die. Advantageously, the above-mentioned apparatus 1 (in the various embodiments) comprising the deforming station 3 makes it possible to obtain a container "C" made of a cellulose-based material having fibres uniformly distributed in such a way as to avoid undesired breakages during use due to portions thinner than others.

Moreover, the apparatus 1 , by means of the deforming operation, allows the fibres to be evenly distributed before the forming operation, thus preventing unwanted breakages during the operation.

Advantageously, the undulating geometry (without sharp edges) allows the film “F” to be deformed without the risk of breaking it.

Advantageously, the engaging surface 3b has an undulating geometry distributed and shaped in such a way as to obtain the best possible distribution of the fibres, as a function of the final shape of the container "C" to be obtained.

The invention also relates to a method for making a container “C” defining a containment space “V” for a product, preferably a food, cosmetic or pharmaceutical product.

The method is preferably implemented by means of the above-mentioned apparatus 1 and, therefore, the steps described below are to be understood as performed in the individual stations of the apparatus 1 .

The method comprises a first step of feeding at least one film “F” made of cellulose-based material.

The feeding step is preferably performed by unrolling at least one reel “B” of the cellulose-based material or feeding single sheets of the film “F”. Preferably, the feeding step is performed by preparing a film “F” made of thermoformable cellulose-based material, or a polycoupled material with a prevalence of cellulose-based material, comprising a first layer of paper, a second layer of thermoplastic polymer and a third layer of paper. Preferably, the polycoupled material comprises a fourth layer of thermoplastic polymer which is peelable.

The method also comprises a step of deforming the cellulose-based film “F” by impressing an undulating geometry on a processing surface “A” of the film “F”. The deforming step is performed taking into account the final geometry (that is, the shape) of the container “C” to be made.

The method also comprises a step of forming the container “C” which can be obtained by forming the film “F”, previously deformed by impressing on it the undulating geometry.

The method also comprises the step of forming the deformed film “F” at the processing surface “A” on which the undulating geometry is impressed.

Alternatively, the method may comprise the step of forming a forming area of the deformed film “F”, which is contained in the processing surface “A”, and impressing the undulating geometry at least outside said forming area, for making a reserve of material which is able to operate in conjunction with the forming area for making the container “C”.

In exactly the same way as described above, the method may also be implemented using the embodiment of the apparatus 1 illustrated in Figure 2. For this reason, the method may comprise feeding at least two cellulose- based films “F” in respective processing paths “L” and deforming and then forming both the films “F”. At this point, the method comprises conveying the two paths with the two half-containers facing each other and then sealing them to each other in such a way as to obtain the specific container “C”.

Preferably, the method also comprises a step of preheating the film “F”. The step is performed before the deforming step and preheating a portion of the polycoupled material suitable for entering into contact with the product with the container “C” formed.

Preferably, the method may comprise a preforming step performed before the forming step and after the deforming step. In this preforming step, a first step is performed for forming the film “F” at the processing area “A” in order to avoid the possible elastic return of the area on which the undulating geometry has been impressed.

The advantages discussed above for the apparatus 1 are also valid with regard to the method just described.

For this reason, the invention is able to overcome the drawbacks of the prior art.

Advantageously, the step of deforming the cellulose-based film “F” which is performed by impressing an undulating geometry on a processing surface “A” of the film “F” allows the fibres of the film “F” to be uniformly distributed during the step of forming the container, which follows the deformation previously applied.

In this way, the invention makes it possible not to damage the film “F” and/or the cellulose-based container “C” during the operations described above, and to make the container “C” robust, which can therefore be handled by a consumer without the risk of breakage.

Claims

1 . An apparatus (1 ) for making a container (C) defining a containment space for a product, preferably a food product, said apparatus (1 ) defining at least one processing path (L) and comprising:

- a feeding station (2) configured for introducing in said processing path (L) at least one film (F) made of a cellulose-based material;

- a deforming station (3), located downstream of said feeding station (2), comprising at least one deforming device (3a) having at least one engaging surface (3b) provided with an undulating geometry and configured for engaging said film (F) in such a way as to impress, on a processing surface (A) of the film (F), said undulating geometry; and

- a forming station (4), located downstream of the deforming station (3), comprising at least one forming device (4a) configured for forming said film (F), deformed by said deforming device (3a), in such a way as to define said container (C).

2. The apparatus (1 ) according to claim 1 , wherein the undulating geometry is made in the form of spheres or hemispheres distributed on said engaging surface (3b) as a function of a geometry of the container (C) to be formed.

3. The apparatus (1 ) according to claim 1 , wherein said undulating geometry is made in the form of zones of linear deformation parallel to each other and distributed on said engaging surface (3b) as a function of a geometry of the container (C) to be formed.

4. The apparatus (1 ) according to claim 1 , wherein said undulating geometry is made in the form of zones of linear deformation concentric with each other and distributed on said engaging surface (3b) as a function of a geometry of the container (C) to be formed.

5. The apparatus (1 ) according to any preceding claim, wherein said engaging surface (3b) has a plurality of deformation sectors, each deformation sector having an undulating geometry made according to one or more shapes and/or having a depth variable as a function of a geometry of the container (C) to be formed.

6. The apparatus (1 ) according to any preceding claim, wherein said deforming device (3a) comprises a first half-mould (3c) and a second halfmould (3d) opposite each other and movable relative to each other to engage the sheet (F), said first half-mould (3c) and said second half-mould (3d) comprising undulating geometries complementary to each other.

7. The apparatus (1 ) according to claim 6, wherein said first half-mould (3c) and said second half-mould (3d) are made in the form of plates having the engaging surface (3b) provided with the undulating geometry.

8. The apparatus (1 ) according to any one of claims 1 to 5, wherein said deforming device (3a) comprises a pair of rollers opposite each other and counter-rotating, said rollers being configured for receiving the film (F) and engaging it, wherein the pair of rollers comprises a first roller and a second roller each comprising respective engaging surfaces (3b) having undulating geometries complementary to each other.

9. The apparatus (1 ) according to any preceding claim, also comprising a heating station (5) interposed between said feeding station (2) and said deforming station (3) and configured for preheating said at least one film (F).

10. The apparatus (1 ) according to any preceding claim, wherein the forming device (4a) is configured to form the deformed film (F) at the processing surface (A).

1 1. The apparatus (1 ) according to claim 10, wherein said forming station (4) further comprises a pressing device configured to protect a perimeter portion of said processing surface (A) of the film (F) and for locking said processing surface (A) in such a way as to define, during a forming of said container (C) by means of said forming device (4a), a perimeter ring (C1 ) of the container (C); and wherein said forming device (4a) is configured for forming the deformed film (F) delimited by said perimeter ring (C1 ).

12. The apparatus (1 ) according to any one of claims 1 to 9, wherein the forming device (4a) is configured for forming a forming area of the deformed film (F) contained in the processing surface (A), said engaging surface (3b) being configured for impressing said undulating geometry at least outside said forming area.

13. The apparatus (1 ) according to claim 12, wherein said forming station (4) comprises a pressing device, configured to come into contact with an inner portion of the processing area (A) allowing a sliding of the film "F", delimiting the forming area, in such a way as to define, during a forming of said container (C) by means of said forming device (4a), a perimeter ring (C1 ) of the container (C); and a further pressing device, surrounding the outside of the pressing device, configured for blocking an external portion of the processing surface of the film (F), surrounding the outside of the inner portion; and wherein the forming device (4a) is configured for forming said forming area by means of a sliding through the pressing device of the deformed film (F).

14. The apparatus (1 ) according to any preceding claim, wherein said apparatus (1 ) defines at least two processing paths (L) for respective films (F) of cellulose-based material and wherein:

- said feeding station (2) is configured for feeding respective films (F) in the two processing paths (L);

- said deforming station (3) comprises at least one deforming device (3a) configured for impressing respective undulating geometries on said films (F);

- said forming station (4) comprises at least one forming device (4a) configured for defining respective half-containers; said apparatus (1 ) further comprising:

- conveying means (6) configured for conveying said processing paths (L) in such a way as to face together respective half-containers;

- a sealing station (7) comprising at least one sealing device (7a) for sealing together said half-containers forming said container (C).

15. The apparatus (1 ) according to any preceding claim, wherein said forming device (4a) is also configured for preforming said film (F) before the forming of the film (F).

16. The apparatus (1 ) according to any one of claims 1 to 14, comprising a preforming station, positioned between the deforming station (3) and the forming station (4), and comprising a preforming device configured to preform said film (F), deformed by said deforming device (3a).

17. A method for making a container (C) defining a containment space (V) for a product, preferably a food product, said method comprising the steps of:

- feeding at least one film (F) made of a cellulose-based material;

- deforming said film (F) by impressing an undulating geometry on a processing surface (A) of the film;

- defining said container (C) forming said deformed film (F), said film (F) being deformed by impressing said undulating geometry.

18. The method according to claim 17, wherein said feeding step is performed by unrolling at least one reel (B) of cellulose-based material or feeding single sheets of said film (F).

19. The method according to claim 17 or 18, wherein said feeding step is performed by preparing a film (F) made of cellulose-based material, for example a thermoformable paper-based material, or a polycoupled material comprising a first layer of paper, a second layer of thermoplastic polymer, a third layer of paper, preferably said polycoupled material comprising a fourth peelable layer of thermoplastic polymer.

20. The method according to any one of claims 17 to 19, comprising a step of preheating the film (F), said step being performed before the deforming step and preheating a portion of the cellulose-based material suitable for entering into contact with said product with the container (C) formed.

21. The method according to any one of claims 17 to 20, and comprising the step of forming the deformed film (F) at the processing surface (A).

22. The method according to any one of claims 17 to 20, and comprising the step of forming a forming area of the deformed film (F), which is contained in the processing surface (A), and impressing the undulating geometry at least outside said forming area.

23. The method according to any one of claims 17 to 22, comprising a preforming step performed before the step of forming the container (C) and after the step of deforming the film (F).