Method of manufacturing a laminated packaging material and device for the method

Abstract

This invention relates to a method for manufacturing a laminated packaging material (16) from which a packaging container (10) for packaging liquid food (12) can be formed. The method includes the following steps: providing a body layer (22) of paper or paperboard or other cellulose-based material having at least one through-hole (24); providing a base layer (26) and an adhesive (30) formed therefrom or applied to its lamination side (28); positioning the body layer (22) and the base layer (26) such that the adhesive (30) faces the lamination side (32) of the body layer (22). The substrate layer (26) is arranged in front of at least one through-hole (24); and the body layer (22) and the substrate layer (26) are joined in a lamination unit (38), wherein the first lamination device (42), the substrate layer (26), the body layer (22) and the second lamination device (44) are movably arranged in the listed order, and lamination pressure (48) is generated between the first lamination device (42) and the second lamination device (44), and wherein at least one non-adhesive lamination device (46) is movably arranged between the second lamination device (44) and the body layer (22). The position of the body layer (22) and / or the position (50) of the at least one non-adhesive lamination device (46) is controlled such that at least one through-hole (24) is covered by at least one non-adhesive lamination device (46), at least as long as lamination pressure (48) is applied to at least one through-hole (24). This disclosure also relates to a corresponding device (36) for performing the method.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a laminated packaging material from which a packaging container for packaging liquid food can be formed. The invention also relates to the laminated packaging material manufactured by this method and to an apparatus suitable for performing the method. Background Technology

[0002] Single-use, single-use packaging containers for liquid foods are typically made of packaging laminates based on cardboard or cartons. These containers are commonly used to package liquid foods, such as milk or juice, sold for long-term environmental storage. The packaging materials in these known containers are typically laminates, consisting of a body layer or core layer of paper, cardboard, or other cellulose-based material, and a liquid-tight outer layer of thermoplastic. To make the packaging container airtight, particularly for aseptic packaging purposes and to make it oxygen-tight, the laminates in these containers often include additional barrier layers, such as aluminum foil or any other film with a barrier function, such as polymer-based and / or paper-based films.

[0003] On the inner side of the laminate, in other words, on the side intended to face the food contents filled in a container made from the laminate, there is typically an innermost layer applied to the barrier layer. This innermost layer may consist of one or more partial layers, such as including heat-sealable thermoplastic polymers, such as adhesive polymers and / or polyolefins. Similarly, on the outer side of the body layer, there is typically an outermost heat-sealable polymer layer.

[0004] Packaging containers are typically produced using modern high-speed packaging machines, which form, fill, and seal preforms of rolls or packaging materials. Thus, a roll of laminated packaging material can be reformed into a tube to produce packaging containers by joining the two longitudinal edges of the roll together with an overlapping seam, formed by welding the innermost and outermost heat-sealable thermoplastic polymer layers together. This tube is filled with the intended liquid food and is subsequently separated into individual packages by repeating transverse seals at predetermined distances below the level of the contents. The packages are separated from the tubes by cuts along the transverse seals and folded along pre-prepared crease lines in the packaging material to form the desired geometry, typically a parallelepiped.

[0005] Packaging containers for sensitive liquid foods (such as milk or juice) can also be produced from sheet preforms or preforms of laminated packaging material. Packaging is produced from tubular preforms of folded flat packaging laminates by first constructing the preform into an open tubular container capsule, one open end of which is closed by folding and heat-sealing an integral end plate. This closed container capsule is then filled with the food, such as juice, and the open end is closed by further folding and heat-sealing of the corresponding integral end plate. An example of packaging containers produced from sheet and tubular preforms is the traditional so-called mountain-top packaging. There is also this type of packaging with a molded top and / or nuts made of plastic.

[0006] To access the liquid food contained in a packaged container, it is typically necessary to penetrate the laminated packaging material (e.g., via a straw). Therefore, pre-formed holes providing penetration through at least some of the laminated packaging material have been well established in the relevant art. Through such straw holes or other opening structures, consumers can conveniently access the contents of the packaged container after penetrating the remaining material. These holes are provided, for example, by punching holes in the body layer or core layer before lamination, and are therefore often referred to as pre-punched holes, the inside and outside of which are then covered by an additional laminated layer.

[0007] Since pre-punching typically occurs before the lamination process, where liquids or viscous materials, such as molten layer materials or adhesives, can be used, it is necessary to prevent such materials from diffusing uncontrollably through the holes. For example, if the body layer includes through-holes and is to be applied to the base layer during lamination, any adhesive should only affect the lamination sides of the body layer and the base layer, respectively. However, when bonded under lamination pressure, such material may be forced through the holes and reach the side of the body layer opposite the lamination side. This can lead to further problems, such as material adhering to the laminating equipment disposed on that side.

[0008] For example, patent document WO2015 / 193632A1 discloses a laminating station that separates the pressure rollers of the laminating station from the through-holes included in the laminated layer using a non-adhesive belt. The belt is pressed onto the area at the hole, while lamination pressure is applied to said area. Therefore, material inside the hole can be prevented from escaping and reaching the pressure rollers.

[0009] However, the proposed system lacks flexibility and efficiency when it comes to changing the arrangement of the holes relative to the pressure rollers, as it requires interrupting the manufacturing process and readjusting the system's arrangement with respect to the belt.

[0010] Therefore, there is a need for an improved method for manufacturing laminated packaging materials and corresponding manufacturing equipment. Summary of the Invention

[0011] One object of the present invention is now to overcome, at least in part, one or more of the aforementioned limitations of the prior art. Specifically, the present invention aims to provide a method for manufacturing a laminated packaging material from which packaging containers for packaging liquid foods can be formed, a method that allows a perforated body layer to be safely and efficiently laminated to a base layer, wherein liquid, viscous, or formable adhesives or layer materials may be used. It is particularly designed to safely prevent such materials from affecting the lamination equipment.

[0012] To achieve these objectives, a method for manufacturing a laminated packaging material is provided, from which a packaging container for packaging liquid food products can be formed. The method of the present invention includes the following steps:

[0013] - Provide a body layer of paper or paperboard or other cellulose-based material having at least one through-hole;

[0014] - Provides a base layer and an adhesive formed from or applied to its lamination side;

[0015] - Position the body layer and the base layer such that the adhesive faces the laminated side of the body layer and the base layer is disposed in front of at least one through-hole;

[0016] - A body layer and a base layer are joined in a lamination unit, wherein a first lamination device, a base layer, a body layer and a second lamination device are movably arranged in the enumerated order, and lamination pressure is generated between the first lamination device and the second lamination device, wherein at least one non-adhesive lamination device is movably arranged between the second lamination device and the body layer.

[0017] According to the invention, the position of the body layer and / or the position of the at least one non-adhesive laminating device is controlled such that at least one through-hole is covered by at least one non-adhesive laminating device, at least as long as lamination pressure is applied to at least one through-hole.

[0018] Here, for the sake of a concise description of the technical principles, the disclosed features may be referred to as "at least one" in the singular form; however, this does not imply any limiting features.

[0019] The method of the present invention advantageously achieves the secure sealing of the through-hole by the non-adhesive laminating device, preventing any material (e.g., adhesive) from traveling through the through-hole to the second laminating device. Since the relative positions of the body layer and the non-adhesive laminating device are controlled, this effect can be achieved without stopping the manufacturing process, such as by readjusting the position of the non-adhesive laminating device. Therefore, the method of the present invention achieves a very high level of quality and productivity.

[0020] The body layer and the substrate layer are typically bonded in a lamination process, which can be either a dry lamination process or a wet lamination process. Preferably, the bonding can be performed in a dispersion and / or wet lamination process.

[0021] Controlling the position of the body layer and / or the position of the non-adhesive laminating device can refer to an open control loop or a closed control loop, preferably executed in real time. Position control can refer to any dimension required to describe the relative position of the through-hole and the non-adhesive laminating device. If the non-adhesive laminating device and the through-hole, for example, temporarily meet in planes parallel to each other in the laminating unit, such dimensions can include the lateral and / or longitudinal dimensions of the planes. If the non-adhesive laminating device and the through-hole, for example, temporarily approach each other in non-parallel planes, such dimensions can include the lateral and / or longitudinal dimensions of each of the planes, and may also include a vertical dimension to predict the position of the through-hole relative to the non-adhesive laminating device when lamination pressure is applied. Appropriate control techniques can be used to process such two-dimensional or three-dimensional data using suitable measures, and, if necessary, time data regarding position, velocity, and / or acceleration values. Through this disclosure, those skilled in the art will have sufficient technical knowledge to select from the above suggestions or any combination or extraction thereof to ensure that the through-hole is securely covered by the non-adhesive laminating device, thereby preventing adhesive material from traveling through the through-hole to the second laminating device.

[0022] The body layer and base layer can be introduced into the lamination unit individually or as pre-bonded combined layers. Preferably, they are introduced individually and contact each other in the lamination unit. It should be understood that, for example, through-holes can be created in the preparatory steps of the method of the invention. This also applies to applying an adhesive to or forming the base layer. Running the method of the invention as a process is not technically necessary, but is preferred. The body layer, base layer, or both layers themselves may include some liquid-resistant properties. Based on known requirements for such laminated packaging materials, one or more additional layers, such as a liquid-resistant layer or an oxygen-barrier layer, can also be applied in subsequent steps of the method of the invention.

[0023] The through-hole can preferably be used as a hole for placing a straw therein. Therefore, the through-hole can include a suitable diameter, such as about 6 mm.

[0024] Preferably, the base layer may comprise materials such as paper, paperboard or other cellulose-based materials, polymeric materials, or any combination thereof. In particular, a base layer comprising polyolefins is preferred.

[0025] The adhesive material can be selected from all materials known to be suitable for such lamination processes, preferably for wet lamination processes. The material of the base layer can itself have adhesive properties, for example, if the base layer includes a polymer layer. The adhesive can also be applied to the base layer as an additional material (e.g., as a polymer solution). The adhesive is applied at least in the areas of the through-holes to ensure liquid-resistant adhesion in those areas, for example, if the through-holes are penetrated by a pipette. It is particularly preferred to apply the adhesive to the entire laminated side of the base layer to achieve full adhesion between the body layer and the base layer.

[0026] Preferably, the lamination unit is a wet lamination unit to bond the body layer and the base layer in a wet lamination process.

[0027] The term "movably arranged" does not mean that the first laminating device, base layer, body layer, and second laminating device must be arranged in this order with direct physical contact with each other (although it may be), but rather that the lamination pressure propagates between the components in this order. This also applies to the arrangement of the non-adhesive laminating device and the second laminating device, however, where the body layer is in direct physical contact with the non-adhesive laminating device to seal the through-holes in the adhesive on the side of the body layer opposite its lamination side. However, it is preferable to arrange the aforementioned components in the following order with direct physical contact with each other: first laminating device, base layer, body layer, non-adhesive laminating device, and second laminating device. Thus, the body layer can at least partially and simultaneously be in direct contact with the second laminating device. This applies to areas of the second laminating device not extended into by the non-adhesive laminating device. This is because the non-adhesive laminating device does not necessarily separate the entire surface of the second laminating device from the body layer, but is preferably limited to the area of ​​the through-holes.

[0028] The term "non-adhesive lamination device" refers to any technical means suitable for covering through-holes and preventing adhesive from escaping from the through-holes on one side of the body layer opposite the lamination side, or at least preventing adhesive from escaping from the through-holes on one side of the body layer opposite the lamination side, from adhering to a second lamination device, particularly when lamination pressure is applied. Preferably, the non-adhesive lamination device may comprise a material such as polytetrafluoroethylene (PTFE), also known as "TEFLON". The brand is known, or it includes other materials with similar properties that make it resistant to adhesion.

[0029] In a preferred embodiment of the method of the present invention, the body layer includes a plurality of through holes, and furthermore, a plurality of non-adhesive laminating devices are movably arranged between the second laminating device and the body layer, wherein the position of the body layer and / or the position of each non-adhesive laminating device is controlled such that each non-adhesive laminating device covers the through hole at the corresponding position, at least as long as lamination pressure is applied to the corresponding through hole.

[0030] This further increases the flexibility of the method of the present invention. The vias can be arranged in one or more rows on the body layer, for example. For example, each non-adhesive laminating device can be controlled based on the position of the vias in one of these rows. The vias in the rows can be at least partially periodic or may not provide any periodicity. The vias can be arranged in groups randomly, at equal intervals, or at varying distances, and their size and shape can vary.

[0031] In a preferred embodiment of the method of the present invention, each of the first and second laminating devices includes a laminating roller to transmit laminating pressure, and the position of the body layer and / or the position of the non-adhesive laminating device is controlled at least in a direction parallel to the axis of rotation of the laminating roller. For example, the laminating roller may include a pressure roller and a cooling roller.

[0032] In a preferred embodiment of the method of the present invention, the non-adhesive laminating apparatus includes a non-adhesive strip guided on the laminating rollers included in the second laminating apparatus.

[0033] Based on, for example, the cylindrical geometry of a laminating roller, the movement of the control belt along the geometry to change its position can be conveniently achieved.

[0034] Preferably, for any of the tape, laminated packaging material, or any additional material used to manufacture the laminated packaging material, one or more additional rollers, such as tension rollers, idle rollers, cooling rollers, or storage rollers, are used.

[0035] The belt can be driven by one or more such additional rollers and / or laminating rollers of a second laminating device.

[0036] Using rollers for the second lamination unit and for the drive belt reduces the difficulty of synchronizing the movement of the belt and the material used for laminating packaging materials, for example, when exposed to lamination pressure.

[0037] Preferably, there are eight belts of the type described above, arranged adjacent to each other in a direction parallel to the axis of rotation of the laminating roller. Preferably, each of the eight belts is movable within a range of 30 cm in this direction. Preferably, the two outermost belts have a wider width than the other belts arranged between them, meaning that the middle belts are narrower than the edge belts respectively.

[0038] In a preferred embodiment of the method of the present invention, the position of the belt in a direction parallel to the rotation axis of the laminating roller is controlled by an actuated guide member that applies a positioning force to the belt in a direction parallel to the rotation axis of the laminating roller.

[0039] If the belt is guided on laminating rollers that may rotate simultaneously, the positioning force can easily change the belt's position on the laminating rollers.

[0040] For example, the belt itself can be driven by an electric motor, which can also be used to generate the positioning force. Preferably, each belt has at least one individually controlled actuator, such as an electric motor. Further, as an example, the actuated guide member can include a guide sleeve for guiding the belt, or may have any other structure to transmit the positioning force. The actuated guide member, such as the guide sleeve, is preferably designed relative to the fact that the belt can be driven in a direction transverse to the direction of the positioning force, which can be, for example, the machine direction described in more detail below. For this purpose, the actuated guide member may include bearings to compensate for relative movement between the belt and the guide structure.

[0041] Preferably, the actuated guide member may have at least one or more guide rollers supported on a separate support for each belt. Preferably, the support and thus the actuated guide member are equipped with a dedicated motor to be driven in the direction of the positioning force and / or transverse to the direction of the positioning force. All guide members may be driven individually in the direction of the positioning force on a single slide or track. More than one slide or track may also be available to support a group of guide members and belts respectively. Alternatively, more than one slide or track may be available, each slide or track supporting one guide member and belt respectively.

[0042] In a preferred embodiment of the method of the present invention, the method is a continuous or discontinuous flow process running along the machine direction, and wherein the position of the body layer and / or the position of the non-viscous laminating device is controlled at least in a direction transverse to the machine direction.

[0043] Machine orientation refers to the fact that laminated packaging materials are typically manufactured in a flow process with a material supply orientation (in other words, it is machine orientation).

[0044] In a preferred embodiment of the method of the present invention, after the body layer and the base layer are joined, the laminated packaging material is guided via at least one subsequent roller, which includes a non-adhesive laminating device covering the through-holes, provided that the subsequent roller is in contact with the through-holes.

[0045] The non-adhesive laminating device for the subsequent rollers can be designed and configured similarly to the preceding description, and therefore can also be controllable to ensure that it matches the position of the through-hole.

[0046] Based on this, it can be ensured that, for example, adhesives that have not yet reached a sufficient degree of hardening will not adhere to subsequent rollers.

[0047] In a preferred embodiment of the method of the present invention, the sensor detects the position of the through-hole on the body layer, and controls the position of the body layer and / or the position of the non-adhesive laminating device based on the detected position of the through-hole.

[0048] This significantly increases the process stability and flexibility of the method of the present invention in changing the position of the through hole.

[0049] In a preferred embodiment of the method of the invention, the non-adhesive laminating device is cleaned by a cleaning device before and / or after contacting the through-hole. Preferably, the cleaning device is arranged at a location where the non-adhesive laminating device (e.g., the belt) has passed the first and second laminating devices. In one embodiment, the cleaning device is located behind the pressure roller, where the belt exits the roll gap defined by the pressure roller.

[0050] The cleaning device ensures that any impurities or unavoidable residues of the adhesive material applied to the non-adhesive laminating device are removed before the non-adhesive laminating device comes into contact with the body layer and the second laminating device again. Therefore, it is particularly preferable to combine the cleaning device with the wet lamination process.

[0051] The cleaning device can preferably be combined with an actuated guide member. For example, such a cleaning device can be combined with a guide sleeve for the belt. Preferably, the guide sleeve includes a cleaning device that cleans the belt when it is driven transversely to the direction of the positioning force, for example toward a second laminating device, or in a particular example, along the machine direction.

[0052] The cleaning device may have a scraper or similar structure to scrape off any excess adhesive that may remain on the non-adhesive laminating device (preferably a belt). Additionally, a collection container may be provided to collect excess adhesive, particularly the scraped-off adhesive.

[0053] Furthermore, the non-adhesive laminating device, preferably a belt, can be exposed to a cleaning bath, such as by immersion in a cleaning bath. The cleaning bath preferably contains water and alcohol. Most preferably, the cleaning bath is applied after the use of a scraper.

[0054] After the cleaning bath, the non-stick laminating device is dried, preferably with a belt. Drying is preferably carried out by a suitable heat treatment method.

[0055] In a preferred embodiment of the method of the present invention, after bonding the body layer and the base layer, at least one additional layer is applied to the laminated packaging material, which includes the innermost liquid-tight layer for direct contact with the food contained in the packaging container formed by the packaging material and / or the outermost liquid-tight layer, and is adapted to constitute the exterior of the packaging container.

[0056] Depending on the target product, especially packaging containers for liquid foods, other layers such as oxygen barriers can also be applied as additional layers.

[0057] Another aspect of the invention relates to a laminated packaging material manufactured according to the inventive method of the invention.

[0058] Another aspect of the invention relates to a packaging container comprising a laminated packaging material according to the invention.

[0059] Another aspect of the invention relates to an apparatus for manufacturing laminated packaging materials, which can form packaging containers for packaging liquid food. The apparatus includes a laminating unit configured to receive a body layer having at least one through-hole and a base layer having an adhesive formed on or applied to its laminating side. The laminating unit includes a first laminating device and a second laminating device configured to form a laminating cavity therebetween and apply laminating pressure to the body layer and the base layer if the layer is introduced into the laminating cavity. The laminating unit also includes at least one non-adhesive laminating device, which, if introduced into the laminating cavity, is movably arranged between the second laminating device and the body layer.

[0060] According to the invention, the position of the body layer and / or the position of the at least one non-adhesive laminating device is controllable, such that at least one through-hole is covered by at least one non-adhesive laminating device, at least as long as lamination pressure is applied to at least one through-hole.

[0061] In a preferred embodiment of the apparatus of the present invention, the apparatus is adapted to and can be configured to perform the inventive method according to the present disclosure. Even more preferably, the apparatus of the present invention is configured to perform the method of the present invention.

[0062] Therefore, all device-related features disclosed regarding the method of the present invention are also disclosed herein as analog features in possible embodiments of the apparatus of the present invention. The same applies to other embodiments regarding the method-related features disclosed regarding the apparatus of the present invention.

[0063] Preferably, the lamination unit of the device of the present invention is a wet lamination unit.

[0064] Preferably, the device of the present invention includes a sensor configured to detect the location of a via on the body layer, wherein the location of the body layer and / or the location of the non-adhesive laminating device can be controlled based on the detected via location. Even more preferably, the sensor is configured in this manner.

[0065] In a preferred embodiment of the apparatus of the present invention, the apparatus is configured to manufacture laminated packaging material using a continuous or discontinuous flow process that runs along the machine direction, and wherein the position of the body layer and / or the position of the non-adhesive laminating device is controllable at least in the direction transverse to the machine direction.

[0066] Other objects, features, aspects and advantages of the invention will become apparent from the following detailed description and the accompanying drawings. Attached Figure Description

[0067] Embodiments of the invention will now be described by way of example with reference to the accompanying schematic diagrams, wherein:

[0068] Figure 1 An embodiment of a packaging container for packaging liquid food is shown;

[0069] Figure 2 An embodiment of a laminated packaging material that can form a packaging container is shown in cross-sectional view;

[0070] Figures 3-4 An embodiment of a method for manufacturing laminated packaging materials and an apparatus for manufacturing laminated packaging materials is shown;

[0071] Figure 5 It shows Figure 4 Alternative implementations of the illustrated device, particularly regarding different designs of the slide;

[0072] Figure 6 An implementation scheme for the cleaning device is shown. Detailed Implementation

[0073] refer to Figure 1 An embodiment of a packaging container 10 for liquid food 12 is shown. For example, a packaging container production machine 14, not further specified, can convey laminated packaging material 16 (see also...). Figures 2-4 The packaging container 10 can be manufactured from the laminated packaging material 16. The packaging container 10 can be exemplarily manufactured by filling with liquid food 12 and then cutting and sealing the laminated packaging material 16 using a corresponding cutting and sealing device 18. The scope of the invention covers the packaging container 10 of the invention made in this manner from the laminated packaging material 16 of the invention, as referenced... Figures 2-4 Further description.

[0074] To further describe the purpose of this invention, Figure 1 The machine orientation 20 is defined in the figure below and will be referenced thereto. Machine orientation 20 refers to the fact that the laminated packaging material 16 is typically manufactured in a process having a material supply direction (in other words, it is machine orientation 20).

[0075] Figure 2 The laminated packaging material 16 of the present invention is shown in more detail. The laminated packaging material 16 comprises a body layer 22 of paper or cardboard or other cellulose-based material. At least one through-hole 24 is provided in the body layer 22. The body layer 22 is bonded to a base layer 26, the lamination side 28 of which includes an adhesive 30 that bonds the base layer 26 to the lamination side 32 of the body layer 22. By way of example only, the adhesive 30 is a polymer solution applied to the lamination side 28, which... Figure 2The laminated packaging material 16 shown is already dry. It should be noted that the material of the base layer 26 itself can also provide adhesive properties, for example, if it is provided in the form of a molten polymer material. If the base layer 26 itself provides adhesive properties, then it is not necessary to separately apply adhesive 30 to the laminated side 28. It can be seen that adhesive 30, or in other embodiments, the material of the base layer 26, has already entered the through-hole 24 to some extent. This can be the lamination pressure 48 applied to the body layer 22 and the base layer 26 to bond them together (see...). Figure 3 The result is that, for example, as long as the adhesive 30 is not yet dry, such lamination pressure 48 can cause the adhesive 30 to rise in the through-hole 24 and reach the side 34 of the body layer 22 opposite to its lamination side 32 (compare). Figure 3 However, this is undesirable. When the lamination pressure 48 decreases, the height level of the adhesive 30 in the through-hole 24 sinks again and can lead to the structural features shown. This sinking effect is enhanced as the adhesive 30 dries, which may cause the volume of the adhesive 30 to shrink even further. The laminated packaging material 16 of the present invention is produced by the method of the present invention as described below.

[0076] Figure 3 The apparatus 36 of the present invention, with reference to the manufacture of laminated packaging material 16, is illustrated schematically (also comparatively). Figures 4-6 The method of the present invention for manufacturing laminated packaging material 16. Figure 3 The lamination unit 38 of the device 36 is schematically shown in the diagram. The method of the present invention mainly includes the following steps:

[0077] In the first step, a body layer 22 is provided, which includes at least one through-hole 24.

[0078] In the second step, a base layer 26 is provided, characterized by an adhesive 30 formed therefrom or applied to its lamination side 28.

[0079] In the third step, the body layer 22 and the base layer 26 are positioned such that the adhesive 30 faces the laminated side 32 of the body layer 22, and the base layer 26 is disposed in front of at least one through-hole 24.

[0080] It should be understood that these steps can be performed in any order, as long as the adhesive 30 faces the lamination side 32 of the body layer 22 and the base layer 26 is disposed in front of at least one through-hole 24 at the end of step three. These three steps can be performed before introducing the respective components into the lamination cavity 40 of the lamination unit 38 or before entering the lamination unit 38. The body layer 22 and the base layer 26 can be introduced into the lamination unit 38 without contacting each other or already in contact, which respectively means, for example, pre-bonded but not pressed together.

[0081] More importantly, in the fourth step, the body layer 22 and the base layer 26 are joined in the lamination cavity 40, as... Figure 3 As shown. The body layer 22 and the base layer 26 preferably enter the laminating unit 38 along the machine direction 20 of the apparatus 36 of the present invention; however, this is not necessary and is only used to better illustrate the preferred mode for performing the method of the present invention. The machine direction 20 of the apparatus 36 of the present invention can be... Figure 1 The packaging container production machine 14 shown is aligned with the machine direction 20, therefore the same reference numerals are used to simplify this description. The packaging container production machine 14 can also be combined with the apparatus 36 of the present invention.

[0082] In essence, the lamination unit 38 includes a first lamination device 42 and a second lamination device 44. A base layer 26 and a body layer 22 are arranged between the first lamination device 42 and the second lamination device 44. At least one non-adhesive lamination device 46 is disposed between the second lamination device 44 and the body layer 22. With the described arrangement, the components are movably arranged in the following order: the second lamination device 44, at least one non-adhesive lamination device 46, the body layer 22, the adhesive 30 or the adhesive lamination side 28 of the base layer 26, the base layer 26, and the first lamination device 42. The first lamination device 42 and the second lamination device 44 generate a lamination pressure 48 between them, thereby bonding the body layer 22 and the base layer 26. The lamination pressure 48 can cause the adhesive 30 (or, in some embodiments, the material of the lamination side 28) to rise in the through-hole 24. However, due to the at least one non-adhesive lamination device 46, the through-hole 24 is suitably sealed on the side 34 of the body layer 22 opposite to its lamination side 32.

[0083] According to the invention, the position 50 of the at least one non-adhesive laminating device 46 is controlled such that at least one through-hole 24 is covered by at least one non-adhesive laminating device 46, at least as long as lamination pressure 48 is applied to at least one through-hole 24. Alternatively or in combination, the position of the body layer 22 is controlled such that at least one through-hole 24 is covered by at least one non-adhesive laminate, at least as long as lamination pressure 48 is applied to at least one through-hole 24.

[0084] Therefore, it is ensured that even if the different components involved in the method of the present invention change their relative positions, the through hole 24 is always properly sealed on the side 34 of the body layer 22.

[0085] The following describes in more detail some optional but preferred embodiments of the method and apparatus 36 of the present invention. First, it should be noted that the body layer 22 and the substrate layer 26 are typically bonded in a lamination process; however, the lamination process can be implemented in various ways, such as a dry lamination process or a wet lamination process. Preferably, the bonding can be performed in a dispersion and / or wet lamination process.

[0086] In the illustrated example, the method of the present invention is operated as a continuous or discontinuous flow process along the machine direction 20, wherein the position 50 of the non-viscous laminating device 46 is controlled at least in the direction 52 transverse to the machine direction 20. The relative position of the non-viscous laminating device 46 and the body layer 22 can also be controlled along the machine direction 20, for example by controlling the speed 54 of the non-viscous laminating device 46. It can also be controlled in a vertical direction, for example parallel to the lamination pressure 48, such as... Figure 3 As shown.

[0087] Preferably, each of the first laminating device 42 and the second laminating device 44 includes a laminating roller 56. The laminating roller 56 is rotatable 58 and preferably conveys the laminated packaging material 16 along the machine direction 20. The laminating roller 56 can preferably transmit laminating pressure 48 and can be driven or thermally controlled according to process requirements.

[0088] The position 50 of the non-adhesive laminating device 46 can be controlled at least in a direction 52 parallel to the axis of rotation 60 of the laminating roller 56. The same applies if correct positioning is achieved by moving the position of the body layer 22.

[0089] Preferably, one laminating roller 56 can be a pressure roller 62, and the other laminating roller 56 can be a cooling roller 64.

[0090] The non-adhesive laminating device 46 preferably comprises a non-adhesive tape 66, and even more preferably, is composed of... It is formed and guided on the laminating roller 56 included in the second laminating device 44.

[0091] Below, please refer to another source. Figure 4 According to Figure 3 The view AA defined by the cutting line A in the figure shows a preferred embodiment of the method of the present invention and the apparatus 36 of the present invention.

[0092] In this view AA, the lamination cavity 40 can be seen from below, which means that the view points to the interior of the partially cut body layer 22 and the inside of its side 34 opposite the lamination side 32 of the body layer 22.

[0093] from Figure 4 As can be seen from the image, the body layer 22 preferably includes a plurality of through holes 24. For clarity, in Figure 4 Some of the through holes are marked only by reference numeral 24 in the attached figure.

[0094] More preferably, a plurality of non-adhesive laminating devices 46 are used and are each included by the device 36 of the present invention. Preferably, as described above, all said non-adhesive laminating devices 46 are movably arranged between the second laminating device 44 and the body layer 22.

[0095] The position 50 of each non-adhesive laminating device 46 is preferably controlled such that each non-adhesive laminating device 46 covers the through-hole 24 at the corresponding position 50, at least as long as the lamination pressure 48 is applied to the corresponding through-hole 24. Alternatively or in combination, the position of the body layer 22 is controlled. Since the different through-holes 24 do not need to be exposed to the lamination pressure 48 simultaneously, it is obviously preferable to control the position 50 of each non-adhesive laminating device 46 independently.

[0096] As described above, the non-adhesive laminating device 46 preferably includes a belt 66, and the belt 66 is preferably guided on the laminating roller 56 of the second laminating device 44. The belt 66 may also be guided or driven by one or more additional rollers 68. Preferably, eight such belts 66 are arranged along the axis of rotation 60 of the laminating roller 56; for clarity, only some of these belts are shown and designated by reference numerals. This also applies to other features repeatedly included in the device 36, and are therefore shown exemplarily only in the accompanying drawings.

[0097] Preferably, each of the eight bands 66 is movable within a range of 30 cm along the axis of rotation 60. Preferably, the width of the two outermost bands 67 is greater than that of the other bands 66 arranged between them, which means that the middle bands are narrower than the edge bands 67 respectively.

[0098] Preferably, the position 50 of each belt 66 in a direction parallel to the rotation axis 60 of the laminating roller 56 is controlled by an actuated guide member 70, which applies a positioning force 72 to the belt 66 in that direction. This can be achieved by... Figure 4 And others Figure 5 As seen in the image, a belt 66 is exemplarily shown located on the lower right side. Preferably, the actuated guide member 70 may have at least one or more guide rollers 68, which are supported on a separate support member 69 for each belt 66. Preferably, the support member 69 and thus the actuated guide member 70 are equipped with a dedicated motor 71 to be driven in the direction of the positioning force 72 and / or transverse to the direction of the positioning force 72. All guide members 70 may be individually driven in the direction of the positioning force 72 on a single slide or track 73, as exemplarily shown. Figure 4 As shown.

[0099] The non-adhesive laminating device 46 preferably passes through the cleaning device 74 before and / or after contacting the through-hole 24 (see also...). Figure 6 Clean it.

[0100] Preferably, the cleaning device 74 is arranged at a position where the non-adhesive laminating device 46 (e.g., belt 66) has passed the first laminating device 42 and the second laminating device 44. In one embodiment, the cleaning device 74 is located behind the pressure roller 62, where the belt 66 exits the roll gap defined by the pressure roller 62.

[0101] The cleaning device 74 can be integrated with the actuated guide member 70 or with another suitable component of the device 36. It can also be provided as a separate unit. An exemplary implementation of the cleaning device 74 as a separate unit... Figure 6 It is shown in the figure and will be described further below.

[0102] See further Figure 4 To significantly improve control over the relative position between the non-adhesive laminating device 46 and the body layer 22, a sensor 76 may be present. The sensor 76 can detect the position 78 located at the through-hole 24 on the body layer 22, which is exemplarily shown in… Figure 4 The upper left. The position 50 of the non-adhesive laminating device 46 can then be controlled based on the detected position 78 of the through hole 24. Correct alignment can also be achieved by moving the position of the body layer 22 relative to the non-adhesive laminating device 46.

[0103] It should be understood that after the bonding of the body layer 22 and the base layer 26, the laminated packaging material 16 may be guided through one or more subsequent rollers (not shown), which may also include non-adhesive laminating devices 46 to cover the through-hole 24, provided that the subsequent rollers are in contact with the through-hole 24. The subsequent rollers and the corresponding non-adhesive laminating devices 46 may include one or more features described in this disclosure and may, but not necessarily, perform the lamination function. For example, the subsequent rollers may be used for purposes of cooling, storing, or conveying the laminated packaging material 16.

[0104] Figure 5 It shows Figure 4 Alternative embodiments of the device 36 shown are presented, particularly with regard to different designs of the slides 73 and 75. Therefore, Figure 5 Only the portion of device 36 with guide member 70 is shown in the figure, and the upper part of the device is cut off in the figure.

[0105] As can be seen, there may be more than one slide or track 73, 75. Slide 75 may each carry a set of guide members 70 and a belt 66. There may also be more than one slide or track 73, 75, each of which carries a guide member 70 and a belt 66, as exemplarily shown at slide 73.

[0106] Turn now Figure 6An embodiment of the cleaning device 74, provided as a separate unit, is shown. An exemplary belt 66 is partially shown as a non-adhesive laminating device 46 that may have just passed over the pressure roller 62. It can be seen that, in this case, residual adhesive 30 may be present on the belt 66. To remove the adhesive 30, the cleaning device 74 may have a scraper 80 or a similar structure to scrape off any excess adhesive 30 that may remain on the belt 66.

[0107] A collection container 82 may be present to collect this excess adhesive 30, particularly the scraped-off adhesive 30. Furthermore, the strip 66 may be exposed to a cleaning bath 84, for example, by immersion in said cleaning bath 84. The cleaning bath 84 preferably contains water and alcohol. Most preferably, the cleaning bath 84 is applied after the use of the scraper 80.

[0108] After cleaning bath 84, belt 66 is dried, which is preferably achieved by a suitable heat treatment device 86. As shown, residual liquid 88 is thus removed before belt 66 is guided back to the lamination process, as indicated by the direction of movement 90. Based on this, it is particularly preferable to combine the cleaning device 74 with the wet lamination process.

[0109] Generally, the cleaning device 74 can be implemented in various ways, as long as it ensures that any impurities or unavoidable residues of the adhesive 30 applied to the non-adhesive laminate 46 are removed before the non-adhesive laminate 46 is brought into contact with the body layer 22 and the second laminate 44 again.

[0110] As can be seen from the above description, although various embodiments of the present invention have been described and illustrated, the present invention is not limited thereto, but may be practiced in other ways within the scope of the subject matter defined in the appended claims.

Claims

1. A method for manufacturing a laminated packaging material (16), wherein the laminated packaging material (16) can be used to form a packaging container (10) for packaging a liquid food (12), the method comprising the following steps: Provide a body layer (22) of paper or paperboard or other cellulose-based material having at least one through hole (24); Provides a base layer (26) and an adhesive (30) formed from or applied to its laminated side (28); Position the body layer (22) and the base layer (26) such that the adhesive (30) faces the laminated side (32) of the body layer (22) and the base layer (26) is disposed in front of the at least one through hole (24); The body layer (22) and the base layer (26) are joined in a lamination unit (38), wherein a first lamination device (42), the base layer (26), the body layer (22), and a second lamination device (44) are movably arranged in the listed order, and lamination pressure (48) is generated between the first lamination device (42) and the second lamination device (44), and wherein at least one non-adhesive lamination device (46) is movably arranged between the second lamination device (44) and the body layer (22). The feature is that the position of the body layer (22) and / or the position (50) of the at least one non-adhesive laminating device (46) is controlled such that the at least one through hole (24) is covered by the at least one non-adhesive laminating device (46), at least as long as the lamination pressure (48) is applied to the at least one through hole (24); Each of the first laminating device (42) and the second laminating device (44) includes a laminating roller (56) to transmit the laminating pressure (48), and the position of the body layer (22) and / or the position (50) of the non-adhesive laminating device (46) is controlled at least in a direction parallel to the rotation axis (60) of the laminating roller (56). The non-adhesive laminating device (46) includes a non-adhesive tape (66) guided on the laminating roller (56) included in the second laminating device (44); The position (50) of the non-adhesive tape (66) in a direction parallel to the rotation axis (60) of the laminating roller (56) is controlled by an actuated guide member (70), which applies a positioning force (72) to the non-adhesive tape (66) in a direction parallel to the rotation axis (60) of the laminating roller (56).

2. The method according to claim 1, wherein the body layer (22) includes a plurality of through holes (24), and furthermore, a plurality of non-adhesive laminating devices (46) are movably arranged between the second laminating device (44) and the body layer (22), wherein the position of the body layer (22) and / or the position (50) of each non-adhesive laminating device (46) is controlled such that each non-adhesive laminating device (46) covers the through hole (24) at the corresponding position (50) at least as long as the lamination pressure (48) is applied to the corresponding through hole (24).

3. The method according to claim 1 or 2 is a continuous or discontinuous flow process running along the machine direction (20), wherein the position of the body layer (22) and / or the position (50) of the non-viscous laminating device (46) is controlled at least in a direction (52) transverse to the machine direction (20).

4. The method according to claim 1 or 2, wherein after joining the body layer (22) and the base layer (26), the laminated packaging material (16) is guided via at least one subsequent roller including a non-adhesive laminating device covering the through-hole (24), provided that the subsequent roller contacts the through-hole (24).

5. The method according to claim 1 or 2, wherein the sensor (76) detects the position (78) of the through hole (24) on the body layer (22) and the position (50) of the body layer (22) and / or the position (50) of the non-adhesive laminating device (46) can be controlled based on the detected position (78) of the through hole (24).

6. The method according to claim 1 or 2, wherein, The non-adhesive laminating device (46) is cleaned by the cleaning device (74) before and / or after contacting the through hole (24).

7. A laminated packaging material (16) manufactured by the method according to any one of claims 1-6.

8. A packaging container (10), comprising the laminated packaging material (16) according to claim 7.

9. An apparatus (36) for manufacturing a laminated packaging material (16) from which a packaging container (10) for packaging a liquid food (12) can be formed, the apparatus (36) comprising a laminating unit (38) configured to receive a body layer (22) having at least one through-hole (24) and a base layer (26) having an adhesive (30) formed thereon or applied to its laminating side (28), wherein the laminating unit (38) comprises a first laminating device The laminating unit (42) and the second laminating device (44) are configured to form a laminating cavity (40) therebetween and apply laminating pressure (48) on the body layer (22) and the base layer (26) if the layers (22; 26) are introduced into the laminating cavity (40), and wherein the laminating unit (38) further includes at least one non-adhesive laminating device (46) movably arranged between the second laminating device (44) and the body layer (22) if introduced into the laminating cavity (40), characterized in that, The position of the body layer (22) and / or the position (50) of the at least one non-adhesive laminating device (46) is controllable such that the at least one non-adhesive laminating device (46) covers the at least one through hole (24), at least as long as the lamination pressure (48) is applied to the at least one through hole (24). Each of the first laminating device (42) and the second laminating device (44) includes a laminating roller (56) to transmit the laminating pressure (48), and the position (50) of the body layer (22) and / or the position (50) of the non-adhesive laminating device (46) is controlled at least in a direction parallel to the rotation axis (60) of the laminating roller (56); wherein the non-adhesive laminating device (46) includes a non-adhesive strip (66) guided on the laminating roller (56) included in the second laminating device (44); wherein the position (50) of the non-adhesive strip (66) in a direction parallel to the rotation axis (60) of the laminating roller (56) is controlled by an actuated guide member (70) which applies a positioning force (72) to the non-adhesive strip (66) in a direction parallel to the rotation axis (60) of the laminating roller (56).

10. The apparatus (36) according to claim 9, which is adapted to and configured to perform the method according to any one of claims 1 to 6.

11. The apparatus (36) according to claim 9 or 10, comprising a sensor (76) configured to detect the position (78) of the through hole (24) on the body layer (22), wherein the position of the body layer (22) and / or the position (50) of the non-adhesive laminating device (46) can be controlled based on the detected position (78) of the through hole (24).

12. The apparatus (36) according to claim 9 or 10, wherein the apparatus (36) is configured to manufacture the laminated packaging material (16) by a continuous or discontinuous flow process running along the machine direction (20), and wherein the position of the body layer (22) and / or the position (50) of the non-adhesive laminating device (46) is controllable at least in the direction (52) transverse to the machine direction (20).

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