Device and method for manufacturing a container from fiber-containing material

Abstract

The present invention relates to a device for producing a container from a fiber-containing material, wherein the device comprises a first mold with a cavity for receiving the fibers, the first mold comprising a feed opening through which the fibers can be introduced into the cavity in a first direction by a first device such that the fibers remain on an inner surface of the cavity and form a container blank. According to the invention, the device comprises a second device that introduces a preform into the container blank in the first direction and blows it onto the container blank by means of a stretch blow molding process. The invention also relates to a method for producing a container from a fiber-containing material using such a device.

Description

[0001] The present invention relates to a device for producing a container made of fiber-comprising material according to claim 1 and to a method for producing a container made of fiber-comprising material by means of a corresponding device according to claim 9. State of the art

[0002] In recent decades, containers such as bottles in the beverage, cosmetics, and medical technology industries have been manufactured from glass or plastic materials, particularly PET. While these containers offer favorable properties for holding liquids, food, or medications, their production and use involve a high consumption of raw materials. Furthermore, the use of PET containers is not environmentally sustainable and is only possible through complex recycling processes.

[0003] Therefore, alternatives were proposed, such as using containers made from natural materials, especially fibrous materials like pulp, instead of plastic containers made from PET or similar materials.

[0004] In previous methods, an aqueous solution containing fibers is introduced into a first mold with a cavity whose surface corresponds to the shape of the container to be produced. The first mold is designed such that the fibers remain on an inner surface of the cavity, forming a container blank. For many applications, such containers then require internal coatings. To form the internal coating, the container blank is oriented with its bottom surface facing downwards, and a preform is inserted into the container blank and blown in using a stretch blow molding process.

[0005] However, these known methods have in common that the device used and the method itself are complex and time-consuming. Task

[0006] Based on the known state of the art, the technical problem to be solved is therefore to specify a device and a method for manufacturing a container from fiber-containing material that allows for more efficient manufacturing of the container. Solution

[0007] This problem is solved according to the invention by the device for producing a container made of fiber-comprising material according to claim 1 and the method for producing a container made of fiber-comprising material according to claim 9. Advantageous embodiments of the invention are described in the dependent claims.

[0008] The device according to the invention for producing a container from material comprising fibers, wherein the device comprises a first form with a cavity for receiving the fibers, wherein the first form comprises a feed opening through which the fibers can be introduced into the cavity in a first direction by a first device in such a way that the fibers remain on an inner surface of the cavity and form a container blank, is characterized in that the device comprises a second device which introduces a preform into the container blank in the first direction and blows it onto the container blank by means of a stretch blow molding process.

[0009] The fibers can be, in particular, natural fibers and especially plant components, or they can comprise such components. Preferably, the fibers are at least partially pulp. The cavity of the mold is designed such that the fibers do not penetrate the inner surface of the cavity.

[0010] This device eliminates the need to reorient or adjust the orientation of the container blank for preform injection. Consequently, the device does not require reorientation, resulting in efficient container production.

[0011] In one embodiment, the fibers can be introduced into the cavity by means of the first device in an aqueous solution comprising the fibers.

[0012] The aqueous solution need not be water-based; it can be based on any other liquid solvent. Specifically, aqueous solutions introduced into the cavity can have a water or other liquid content exceeding 90% and a fiber content of less than 10% or even less than 3%. Additionally, the aqueous solution can contain other components, such as additives to influence the chemical or physical properties of the fibers. Furthermore, the cavity of the mold is designed so that the liquid from the aqueous solution can drain from it independently of the cavity opening. The preform exerts a pressing force on the container blank, compressing it and thus creating a drying effect.

[0013] In one embodiment, the first mold can be oriented such that the container blank is formed upside down in the cavity. This results in a uniform shaping of the container on the inner surface of the cavity. The second device is designed such that the preform can be inserted into the container blank from below.

[0014] The first form can include a grid that forms at least part, preferably the entire, inner surface. The grid can preferably contribute to retaining the solid components of the aqueous solution in the cavity of the form.

[0015] In one embodiment, the first device is designed such that a vacuum or overpressure can be generated in the cavity. This allows liquid to be forced / drawn out of the container blank.

[0016] Furthermore, the first form can be designed in such a way that heat can be introduced into the cavity. This allows any remaining liquid to be removed from the container blank.

[0017] Furthermore, the device can be designed such that the container blank is arranged in the first form when the second device inserts the preform into the container blank in the first direction. This allows the device to be designed compactly.

[0018] In another embodiment, the device may comprise a transfer unit and a second mold comprising a second cavity. The device is configured such that the container blank can be inserted from the first mold into the second cavity of the second mold via the transfer unit without changing the orientation of the container blank. Furthermore, the second device inserts the preform into the container blank in the first direction when the container blank is positioned in the second mold. This allows the container to be further processed in the second mold. The dimensions of the second cavity may also differ slightly from the dimensions of the first cavity.

[0019] Furthermore, the arrangement of the first facility relative to the first form and the arrangement of the second facility relative to the second form can be simplified.

[0020] Furthermore, the second mold can be designed in such a way that heat can be introduced into the second cavity. For this purpose, the second mold can be heated. This allows any remaining liquid to be removed from the container blank.

[0021] It can also be provided that the second form includes a porous structure that forms at least part, preferably all, of the inner surface of the second cavity. The porous structure can preferably contribute to retaining the solid components of the aqueous solution in the second cavity of the second form. Furthermore, excess air, as well as water and water vapor, can be dissipated through the porous structure.

[0022] The inventive method for producing a container from fiber-containing material by means of a device comprising a first form with a cavity for receiving the fibers, wherein the first form comprises a feed opening through which the fibers can be introduced into the cavity in a first direction by means of a first device in a container blank manufacturing step, so that the fibers settle on the inner surface of the cavity and the container blank is formed, is characterized in that the method comprises a coating step, wherein this comprises, by means of a second device, the insertion of the preform in the first direction into the container blank and the blowing of the preform into the container blank by means of a stretch blow molding process.

[0023] This method eliminates the need to reorient the container blank for blowing in the preform. Therefore, the process is efficient.

[0024] It may be provided that the container blank manufacturing step includes a flow step comprising a flow of fibers in an aqueous solution, encompassing the flow of fibers through the feed opening in the first direction to the inner surface of the cavity by means of the first device.

[0025] It may be provided that the first form is oriented in such a way that the container blank is formed upside down in the cavity.

[0026] Furthermore, it may be provided that after the inflow step, a negative pressure or positive pressure is created on the cavity by the first device, so that liquid is forced out of the container blank and discharged from the mold.

[0027] In one embodiment of the method, the container blank is arranged in the first mold when the coating step is carried out.

[0028] In another embodiment of the method, it is provided that the method includes a transfer step between the flow step and the coating step, wherein this includes transferring the container blank from the first mold into the second cavity of the second mold by the transfer unit without changing the orientation of the container blank.

[0029] It may be provided that heat is introduced into the second mold before or during the coating step.

[0030] It can be provided that the stretch blow molding process of the coating step generates a pressure between 0.1 and 40 bar in the preform, which presses the preform against the container blank and the container blank against the inner surface of the cavity or the inner surface of the second cavity. This allows liquid to be forced out of the container blank while an internal coating is applied. Furthermore, a higher temperature of the preform compared to the container blank can dry the container blank. Brief description of the characters Fig. 1a to 1g Schematic view of the process steps of a first embodiment of the method for producing a container from fiber-comprising material using a first embodiment of the device for producing the container. Fig. 2a to 2f Schematic view of the process steps of a second embodiment of the method for producing a container from fiber-containing material using a second embodiment of the device for producing the container. Detailed description of the characters

[0031] The Fig. Figures 1a to 1g show a schematic view of the process steps of a first embodiment of the method for producing a container from fiber-containing material, which is carried out using a first embodiment of the device for producing the container. The device comprises a first mold 101 with a cavity 102 for receiving the aqueous solution containing the fibers. The first mold 101 includes a feed opening 103 through which the aqueous solution can be introduced into the cavity 102 in a first direction 104 by a first device, which is not shown in the figures, such that the fibers remain on an inner surface of the cavity 102 and form a container blank 105. These process steps are shown in the Fig. 1a and Fig. 1b shown. According to the invention, the device comprises a second unit which inserts a preform 106 in the first direction 104 into the container blank 105, as shown in the Fig. 1d and Fig. 1e is shown, and these are blown onto the container blank 105 by means of a stretch blow molding process, as shown in Fig. 1f is shown.

[0032] The first form 101 can comprise a grid 109 that forms at least part, preferably completely, of the inner surface of the cavity 102, as shown in the figures. The grid 109 is designed such that the fibers flowing into the cavity 102 with the aqueous solution are deposited on the grid 109, and the liquid of the aqueous solution exits the cavity 102 through it and is drained away. For this drainage, the first form 101 can, for example, have several drainage channels (not shown).

[0033] The first form 101 can also be oriented such that the container blank 101 is formed upside down in the cavity 102, as shown in the figures. This ensures a uniform distribution of the fibers and prevents the base of the container from becoming too thick.

[0034] Furthermore, the first device can be configured to generate a vacuum or overpressure on the cavity 102. This allows liquid to be forced out of the container blank 105 and the structure of the container blank 105 to be solidified on the inner surface of the first mold 101. If the vacuum or overpressure is applied to the first mold 101 while at least some of the fibers forming a fiber component of the container have not yet deposited on the inner surface of the cavity 102 in the aqueous solution, this can serve to form the bottom surface of the container blank 105.

[0035] According to the Fig. In the embodiment of the method shown in Figure 1, the container blank 105 is removed from the first mold 101 after being pressed out by the negative or positive pressure and inserted into a second cavity 107 of a second mold 108. The device includes a transfer unit (not shown) for this purpose. The transfer step by the transfer unit is performed by Fig. 1c schematically depicted. Here, the transfer unit can be designed such that the container blank 105 can be inserted through the transfer unit from the first mold 101 into the second cavity 107 of the second mold 108 without changing the orientation of the container blank 105.

[0036] In the second form 108, heat can then be applied to the container blank, as described in the Fig. 1d, Fig. 1e and Fig. Figure 1f shows the heat. The heat is schematically indicated in the figures by black arrows. This allows additional liquid to be removed from the container blank 105.

[0037] Furthermore, the second device introduces the preform 106 in the first direction 104 into the container blank 105 within the second mold 108, as shown in the Fig. 1d and Fig. 1e is shown. The preform 106 is then blown onto the container blank 105 by means of a stretch blow molding process, as shown in Fig. 1f is shown.

[0038] The second form 108 can comprise a porous structure 110 that forms at least a partial, preferably a complete, inner surface of the second cavity 107, wherein the second form is also designed such that excess liquid can be drained from it and / or evaporate due to heat. The porous structure 110 can be designed to withstand the pressure during the stretch blow molding process.

[0039] Through the stretch blow molding process, shown in Fig. 1f, a pressure between 0.1 and 40 bar can be generated in the preform 106, which presses the preform 106 against the container blank and the container blank against the inner surface of the second cavity 107. Due to the pressure and heat, liquid can then also be removed from the container, and the container with the inner coating can then be removed from the second form 108 for use or further processing, as described in Fig. 1g is shown.

[0040] The in the Fig. The second embodiment of the method shown in 2a to 2f, or the second embodiment of the device used, differs from the first embodiment in that the preform 106 is blown into the container blank 105 inside the first form 101 by means of the second device.

[0041] For this purpose, as in the first embodiment of the process, aqueous solution is first introduced by a first device, which is not shown in the figures, through a feed opening 103 of the first mold 101 into a cavity 102 of the first mold 101 in such a way that the fibers remain on an inner surface of the cavity 102 and form a container blank 105. These process steps are described in the Fig. 2a and Fig. 2b shown.

[0042] The first form 101 of the second embodiment can comprise a grid 109 that forms at least part, preferably completely, of the inner surface of the cavity 102, as shown in the figures. The grid 109 is designed such that the fibers flowing into the cavity 102 with the aqueous solution are deposited on the grid 109, and the liquid of the aqueous solution exits the cavity 102 through it and is drained away.

[0043] Subsequently, the first device can be removed from the feed opening 103, for example, turned away, and a second device can be connected to the first form 101, which, according to the invention, introduces a preform 106 in the first direction 104 into the container blank 105, as shown in the Fig. 2c and Fig. 2d is shown, and these are blown onto the container blank 105 by means of a stretch blow molding process, as shown in Fig. 2e is shown.

[0044] This is done according to the second embodiment of the process, while the container blank 105 is in the first form 101.

[0045] The grid 109 of the first mold 101 can be designed to withstand the pressure during the stretch blow molding process. Accordingly, the container blank 105 can be located within the grid 109 during the stretch blow molding process and remain there when the first setup is exchanged for the second setup. Alternatively, the first mold 101 could be opened before the preform 106 is inserted, and the grid 109 removed. In this case, the container blank 105 would be pressed against an inner surface of the first mold 101 outside the grid 109 during the stretch blow molding process.

[0046] Generally, the first form can be 101, as in the Fig. 2c, Fig. 2d and Fig. 2e shown, also arranged in such a way that this heat is introduced into the cavity 102 of the first form 101, while the preform 106 is introduced into the container blank 105 and stretch blown onto it.

Claims

[1] Device for producing a container from material comprising fibers, wherein the device comprises a first form with a cavity for receiving the fibers, wherein the first form comprises a feed opening through which the fibers can be introduced into the cavity in a first direction by a first device such that the fibers remain on an inner surface of the cavity and form a container blank, characterized by that the device comprises a second device which introduces a preform into the container blank in the first direction and blows it onto the container blank by means of a stretch blow molding process. [2] Device according to claim 2, wherein the fibers can be introduced into the cavity by means of the first device in an aqueous solution comprising the fibers. [3] Device according to claim 1 or 2, wherein the first form is oriented such that the container blank is formed upside down in the cavity. [4] Device according to one of claims 1 to 3, wherein the first form comprises a grid that forms at least partially, preferably completely, the inner surface of the cavity. [5] Device according to one of claims 1 to 4, wherein the first device is designed such that a negative pressure or positive pressure can be generated on the cavity. [6] Device according to any one of claims 1 to 5, wherein the device is designed such that the container blank is arranged in the first form when the second device introduces the preform into the container blank in the first direction. [7] Device according to any one of claims 1 to 5, wherein the device comprises a transfer unit and a second form comprising a second cavity, wherein the device is designed such that the container blank can be inserted through the transfer unit from the first form into the second cavity of the second form without changing the orientation of the container blank, and wherein the second device introduces the preform into the container blank in the first direction when the container blank is arranged in the second form. [8] Device according to claim 7, wherein the second form comprises a porous structure that forms at least partially, preferably completely, an inner surface of the second cavity. [9] Method for producing a container from fiber-containing material using a device comprising a first form with a cavity for receiving the fibers, wherein the first form comprises a feed opening through which the fibers can be introduced into the cavity in a first direction by a first device in a container blank manufacturing step, so that the fibers settle on the inner surface of the cavity and the container blank is formed, characterized by that the process includes a coating step, wherein this includes, by means of a second device, the insertion of the preform in the first direction into the container blank and the blowing of the preform into the container blank by means of a stretch blow molding process. [10] Method according to claim 9, wherein the container blank manufacturing step comprises a flow step comprising a flow of fibers in an aqueous solution comprising the fibers through the feed opening in the first direction by means of the first device to the inner surface of the cavity. [11] Method according to claim 9 or 10, wherein the first form is oriented such that the container blank is formed upside down in the cavity. [12] Method according to one of claims 9 to 11, wherein after the inflow step a negative pressure or positive pressure is generated on the cavity by the first device, so that liquid is forced out of the container blank and discharged from the mold. [13] Method according to any one of claims 9 to 12, wherein the container blank is arranged in the first form when the coating step is carried out. [14] Method according to any one of claims 9 to 12, wherein the method comprises a transfer step between the flow step and the coating step, wherein the transfer step comprises transferring the container blank from the first mold into the second cavity of the second mold by the transfer unit without changing the orientation of the container blank. [15] Method according to any one of claims 9 to 14, wherein the stretch blow molding process of the coating step generates a pressure between 0.1 and 40 bar in the preform, which presses the preform against the container blank and the container blank against the inner surface of the cavity or the inner surface of the second cavity.

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