Method for producing a packaging element

Abstract

A method for producing a packaging element (1) from a ready-made sheet material (2) and from a carrier material (3), having the following steps: a) making available the ready-made sheet material (2); b) connecting the ready-made material (2) to the carrier material (3), which is made available as endless material, such that a first composite (4) of the ready-made material (2) and of the carrier material (3) is generated; c) carrying out at least one conveying of the ready-made material (2) with the carrier material (3); and d) carrying out at least one processing step in which the first composite (4) is processed, such that a second composite (5) of the ready-made material (2) and of the carrier material (3) is generated that forms the packaging element (1).

Description

[0001] Method for producing a packaging element

[0002] The invention relates to a novel method for producing packaging elements and packaging.

[0003] In conventional processes for manufacturing packaging and / or packaging elements, packaging elements are regularly manufactured from pre-cut pieces of a packaging element material. One example is the production of finished trays, which are made from pre-cut pieces of flat starting material. The processing of pre-cut pieces in the production of packaging elements has the disadvantage that a transport system is required to transport the individual pre-cut pieces. Such transport systems are usually quite complex. In contrast, there are much simpler transport systems for materials that are supplied on a roll and can be processed as continuous material. Here, the continuous material itself offers a very good opportunity to be conveyed from one station to the next in a processing device by the continuous material running through the various stations.However, certain materials cannot be supplied as continuous material on a roll or this type of supply has other disadvantages.

[0004] The object of the present invention is to at least partially solve the problems described with reference to the prior art. This object is achieved by the invention according to the features of the independent claims. Further advantageous embodiments are specified in the dependent claims as well as in the description and, in particular, in the description of the figures. It should be noted that the person skilled in the art can combine the individual features in a technologically expedient manner and thus arrive at further embodiments of the invention.Described here is a method for producing a packaging element from a ready-made sheet material and a carrier material, comprising the following steps: a) providing the ready-made sheet material; b) connecting the ready-made sheet material to the carrier material, which is provided as a continuous material, so that a first composite of the ready-made sheet material and the carrier material is produced; c) carrying out at least one conveyance of the ready-made sheet material with the carrier material; and d) carrying out at least one processing step in which the first composite is processed, so that a second composite forming the packaging element is produced from the ready-made sheet material and the carrier material.

[0005] The finished flat material is flat and therefore particularly flat. When reference is made to "finished material" below, this always refers to the "finished flat material." The finished flat material preferably has no elevations or depressions (exceeding manufacturing tolerances) or indentations or bulges. The thickness of the finished flat material is uniform (within manufacturing tolerances).

[0006] In particular, the finished material forms, for example, a flat section. It is preferably a material that would also be suitable for processing as a continuous material—for example, a material that can be provided on a roll or coil, but which is finished or divided.

[0007] Preferably, the carrier material is a deep-drawable material that can be processed in the processing steps according to step d) together with the finished material and does not hinder the intended processing steps, or even facilitates them. Preferably, the carrier material is a barrier material, or preferably, the carrier material can function as a barrier or barrier layer in the packaging element produced by the method. Further details on this are provided below.

[0008] The finished flat material is, in particular, a fiber material, especially paper or cardboard. The term "finished" in this context means that the material is prepared, in particular cut, for the packaging element to be produced. If the packaging element to be produced is, for example, a tray or a lid, then the finished material is preferably a blank that has (preferably exactly) the dimensions required to produce this tray or lid. If necessary, individual pre-finished materials can also be connected to one another by a strand of the finished material. Thus, cutting does not completely separate the finished materials from the original material, but rather merely cuts out sections.Perforations or weakenings have been introduced into the starting material of the finished material, which prevent further processing of the starting material of the finished material as a continuous material because the mechanical stability required for processing as a continuous material is missing.

[0009] The term "cardboard" refers to a flat material consisting essentially of fibers (especially fibers of plant origin). In particular, it is a material made of cellulose fibers. Such a material is preferably formed by dewatering a fiber suspension. Compared to paper, a "cardboard" exhibits, in particular, increased mechanical strength. Preferably, the "cardboard" has a minimum weight per square meter of cardboard surface of 130 g / m². 2[Grams / square meter], materials with a lower weight per unit area are often referred to as paper. A cardboard can also be a composite material made of several layers of paper with a weight per unit area below 130 g / m 2 [grams / square meter]. Such a composite material may optionally also contain air and be constructed, for example, with a corrugated paper layer. Such a sheet-like material may also be formed from a fiber composite or comprise a fiber composite that is not compact but encloses open or closed pores of air.

[0010] The finished material can also be a different material—for example, a porous material made from a foam, for example. Preferably, the finished material is deformable in processing methods for producing the packaging element to create a shaped packaging element.

[0011] Preferably, the finished material has a material thickness that is greater than the material thickness of the carrier material. Preferably, the finished material is particularly suitable for forming a rigid structure of the packaging element.

[0012] The prepared material in step a) is provided, for example, using a manipulator arm that removes the material from a storage area and provides it. Any method for providing the material can be used. Preferably, the prepared material is placed on a carrier material, which is preferably provided as a continuous material from a roll or in a similar manner.

[0013] In step b), the finished material is bonded to the carrier material. This can be done, for example, by partially adhering the finished material to the carrier material. A first bond is formed between the finished material and the carrier material. The first bond is preferably a preliminary bond, which is preferably reinforced or intensified in subsequent processing steps. The first bond serves, for example, only for the relative positioning of the finished material and the carrier material to one another. The term "first bond" here means that the carrier material is bonded to one another in a first manner (with a first intensity). In subsequent processing steps, the bond between the finished material is preferably intensified or a different (if necessary,A more permanent (or more permanent) joining technique is used to join the carrier material and the finished fiber material. The composite created in subsequent processing steps is referred to here as the "second composite." The first composite and the second composite do not differ in that they are made of different materials. The carrier material and the finished material are the same in both the first composite and the second composite. Or in other words: the first composite becomes the second composite. The first composite and the second composite differ in the existing connection between the carrier material and the finished material. The first composite preferably describes a provisional or preliminary bond between the finished material and the carrier material. The second composite preferably describes a final bond between the finished material and the carrier material.The process steps are preferably carried out regularly and repeatedly at various stations for carrying out the described process, with the carrier material being continuously moved further so that between each step the carrier material is continuously moved further and the finished materials are arranged one behind the other on the carrier material at regular intervals. This creates a strip consisting of the carrier material provided as a continuous material and finished materials arranged one behind the other on it (preferably at uniform intervals). The process therefore preferably forms a continuous processing process in which the individual process steps are carried out one after the other for each packaging element to be produced, but in parallel for packaging elements processed one after the other.A machine for carrying out the described method preferably operates with a processing cycle with which the individual processing steps are each carried out simultaneously for successively processed finished materials / packaging elements. The movement of the carrier material provided as a continuous material conveys the finished material according to step c), wherein preferably a large number of individual finished materials are transported one after the other through a device for producing packaging elements from station to station. The carrier material provided as a continuous material thus serves as a transport medium. The conveyance can take place, for example, by transporting the carrier material provided as a continuous material on rollers like a type of conveyor belt. In embodiments, outer edges of the carrier material can run in guide rollers.The finished material is positioned between these outer edges in a central area of ​​the carrier material, or forms the first bond with the carrier material there. Processing stations act on the areas of the carrier material where the finished material is positioned. By using the carrier material provided as a continuous material for conveying in combination, transport and handling during the production of a packaging element with finished materials can be significantly simplified. Finished materials are characterized by the fact that they are introduced into the process described here as individual parts (each finished).Preferably, the finished materials have also been cut from another continuous material in a process step preceding the preceding step, although a first distance between adjacent cut-out materials in this additional continuous material is very small, and after joining in step b), these cut-out materials each have a larger second distance from one another on the carrier material. The finished materials can preferably be produced from this additional continuous material with very little material waste. The small first distance (where the finished materials may even be directly adjacent to one another) is advantageous for producing finished materials from the additional continuous material with little waste.The larger second distance is advantageous in order to provide sufficient space for processing the composite of prefabricated materials and carrier materials in further processing steps in d). As already explained, further processing steps take place according to step d), in which the composite of the prefabricated material and the carrier material is processed. In particular, a connection between the prefabricated material and the carrier material is intensified, for example by bonding the two materials together over a large area. This can be achieved, for example, by welding. In this way, a second composite of the prefabricated material and the carrier material is formed. The second composite is thus, for example, a welded composite. In contrast, the first composite is, for example, a temporary composite formed with a first temporary connection.A temporary connection in the first composite can, for example, be made by bonding.

[0014] The described method has advantages over other methods with regard to the transport system for the finished material, because certain materials, for example, cannot be processed from the roll as a continuous material due to their properties. This applies, for example, to finished materials that have a relatively high rigidity and therefore cannot be provided on a roll. This can also be the case, for example, because the finished materials may already be designed with ribs and / or stiffening structures before step a) that prevent them from rolling up.

[0015] Using the process described here, prefabricated blanks / partial blanks / preforms can be processed from a single web, with the web being formed by the carrier material (which is regularly required anyway in many applications). Consequently, a special transport system for prefabricated materials is unnecessary, as the carrier material strand takes over the transport.

[0016] It is particularly advantageous if the continuous material provided as a carrier material is a plastically deformable film. The carrier material is preferably intended to form a barrier layer in the produced packaging element, which, for example, prevents moisture from penetrating the packaging or aromas from escaping from the packaging. The carrier material is preferably suitable for forming a vapor barrier. Optionally, the carrier material can be a coated material.

[0017] It is also advantageous if the finished flat material is made of natural polymer fibers.

[0018] Preferably, the finished material or the material from which the fibers of the finished material are made and the material of the carrier material are weldable to one another. Preferably, both materials have a similar melting point. Preferably, the finished material and the carrier material are bonded to one another in step d). This particularly preferably occurs under the influence of heat. Furthermore, a welding process is particularly preferred for this purpose.

[0019] It is also advantageous to create a temporary first bond between the carrier material and the material to form the first bond. This can, for example, be an adhesive bond as mentioned above.

[0020] Furthermore, it is preferred if the first provisional connection in the first composite enables a relative positioning of predetermined first carrier material sections of the carrier material and predetermined first material sections of the finished material.

[0021] Furthermore, it is advantageous if, in step b), first connections are formed in regions to form the first composite, and wherein during at least one processing step in step d), relative movements occur between predetermined second carrier material sections of the carrier material and predetermined second material sections of the material.

[0022] In preferred embodiments, the first temporary connection is thus created only between (limited) (surface) sections of the carrier material and the finished material. Preferably, a relative displacement between further (other) surface sections of the finished material and the carrier material is still possible, which has an effect, for example, when carrying out a processing step in step d). For example, it is possible that during press forming in step d), surface sections of the finished material shift relative to the carrier material, but the first temporary connection predetermines the directions and / or areas in which such displacements can occur.

[0023] It is particularly advantageous if at least one processing step in step d) is a deformation step in which the first composite is deformed.

[0024] A particularly advantageous deformation process is realized as a deep-drawing process, in which the finished material is deformed together with the carrier material in a deep-drawing tool in order to produce, for example, a tray-shaped packaging element.

[0025] Fibre materials (particularly paper or cardboard) provided as finished sheet materials can be formed using forming processes to create tray-shaped packaging elements. Finished sheet materials are processed together with the carrier material to form a shape or a shaped body. Before step d), the finished sheet material does not form a shaped body, but rather is flat. In step d), a shaped body is formed from the finished sheet material and the carrier material. Furthermore, it is advantageous if heat is applied to the first composite during the forming of the first composite.

[0026] Preferably, a tool for performing a forming step (in particular a deep-drawing tool) has at least one heating means with which the carrier material and the finished material are heated. Particularly preferably, heat is introduced that is sufficient to thermally bond, in particular weld, the finished material and the carrier material together, at least in sections.

[0027] Preferably, a deformation process in step d) is configured such that the finished material and the carrier material are thermally bonded to one another across the entire surface of the finished material. Most preferably, after a deformation process in step d), the carrier material forms a supporting layer or a supporting layer of a sandwich structure formed from the carrier material and the finished material. The carrier material preferably encloses the sandwich structure or forms a surface of the sandwich structure. Preferably, fibers of the finished material are no longer recognizable from a surface of the sandwich structure, or the surface is formed entirely by the carrier material.

[0028] In further preferred embodiments, a finished material with two layers of a carrier material is processed into a sandwich structure. The finished (fiber) material preferably forms an inner structure that is concealed or covered on both sides by the carrier material and that spaces the two layers of carrier material apart. The distance between the two layers of the carrier material is ensured by the finished material. All layers are preferably firmly and completely connected to one another by the forming process, as intended for the finished packaging element. However, it is not excluded that the individual layers can later be mechanically separated from one another (possibly for recycling the packaging). A second layer of the carrier material can also be provided as a continuous material.However, it is also possible to provide it in pre-assembled form, whereby the other carrier material is used as continuous material for transport according to step c).

[0029] It is also advantageous if the carrier material and the finished material are at least partially welded together during the deformation of the first composite.

[0030] Furthermore, it is advantageous if at least one processing step in step d) is a punching step in which at least one separating line is introduced into the second composite.

[0031] It is also advantageous if, after step d), a step e) takes place in which the second composite is separated from the carrier material provided as a continuous material in order to form the packaging element.

[0032] The separation can be performed with or without the prior introduction of a separating line. However, it is preferred that at least one separating line be introduced first, forming a type of perforation along which the second composite is later separated from the carrier material provided as a continuous material.

[0033] By introducing a dividing line, the composite consisting of the carrier material as a continuous material and the finished materials is divided into individual packaging elements. The introduction of dividing lines preferably takes place relatively far towards the end of a process for producing packaging elements. The introduction of dividing lines is preferably one of the last steps and very preferably the last step in the production of the packaging element and optionally even in the production of a packaging formed with the packaging element. In embodiments, the dividing line is introduced as a line that divides the carrier material provided as a continuous material into individual sections, each of which has a finished material and in each of which a finished material together with the carrier material forms a second composite or a packaging element.

[0034] In further embodiments, the dividing line is formed circumferentially around the finished flat element or the second composite or the packaging element. Preferably, a frame made of carrier material remains around the finished flat element or the second composite or the packaging element. The finished packaging element is preferably punched out of the continuous material along the dividing line. A circumferential dividing line around the finished packaging element is used primarily in embodiments of the described method in which outer regions / edges / edges of the carrier material provided as continuous material are used for transport and, for example, run on rollers.

[0035] Furthermore, it is advantageous if at least one processing step in step d) is a filling step in which a packaging element volume of the packaging element formed in a previous processing step is filled with a product.

[0036] It is particularly preferred that a filling step or filling takes place before individual packaging elements are separated from one another or from the carrier material provided as a continuous material. Preferably, the filling step also takes place before separating lines are introduced. The carrier material provided as a continuous material thus serves, in particular, also during filling as a transport medium, with which the packaging element formed from the finished flat element and the barrier medium is transported from one processing station to the next processing station, etc.In particular, in step d) where a deformation step using heat has taken place, a predetermined cooling time or standing time may optionally take place after the deformation step and before the filling step, which is realized, for example, by a cooling section through which the packaging element passes after a deformation step and after a filling step.

[0037] It is also advantageous if, at least in one processing step in step d), a closure element is applied to a packaging element volume of the packaging element formed in a previous processing step.

[0038] It is particularly preferred that a closure element is also applied before individual packaging elements are separated from one another. It is also particularly preferred that a closure element is also applied before the dividing lines are introduced.

[0039] Most preferably, a material for forming the closure elements is also provided as a continuous material. Preferably, when dividing lines are introduced and / or during separation, the closure element material provided as a continuous material is also separated or divided into individual closure elements assigned to each packaging element or each package. Particularly preferably, when dividing lines are introduced or during separation, the packaging is already firmly closed. This means that the closure element is preferably already permanently connected to the packaging element (e.g., by circumferential gluing or welding) when the separation occurs or when dividing lines are introduced.

[0040] Also described here is a composite packaging element consisting of a support layer of material and a carrier material supported by the support layer, manufactured according to the described method. The composite packaging element is a packaging element that forms a composite of various materials, namely the finished material, which is, for example, a fiber material and / or a porous material, and the carrier material. Such a composite packaging element preferably has high mechanical stability and can also be produced efficiently using the method described here.

[0041] It should be noted that the particular advantages and design features described in connection with the method described above are also applicable and transferable to the composite packaging elements described below.

[0042] Also to be described here is an apparatus for producing described composite packaging elements using the described method.

[0043] It should be noted that the particular advantages and design features described in connection with the method described above are also applicable and transferable to the device described below.

[0044] The described device preferably has a plurality of stations through which the carrier material is conveyed as a continuous material, wherein the stations are configured to carry out the individual process steps. The device further comprises means for conveying the carrier material provided as a continuous material with the finished materials arranged thereon.

[0045] The invention and the technical context of the invention are explained in more detail below with reference to the figures. The figures show preferred embodiments to which the invention is not limited. It should be noted that the figures, and in particular the proportions depicted in the figures, are only schematic. It shows:

[0046] Fig. 1 : a schematic representation of an apparatus for carrying out the described method.

[0047] The device 16 shown in Fig. 1 has a plurality of stations 17. The carrier material 3 is provided as a continuous material and passes through the individual stations 17 one after the other. In a first station 17, steps a) and b) take place. The finished sheet-like material 2 is provided and preferably positioned on the carrier material 3 such that first carrier material sections 7 and first material sections 8 abut one another. In these sections, a first provisional connection 6 is preferably created between the carrier material 3 and the finished sheet-like material 2, so that a first composite 4 is formed. The first composite 4 preferably does not yet comprise a connection between the finished sheet-like material 2 and the carrier material 3 over the entire area.Rather, second carrier material sections 9 and second material sections 10 are preferably also provided, in which the carrier material 3 and the finished sheet material 2 are only adjacent to each other, but are still movable relative to each other. Such relative movements can then occur during further processing in subsequent stations 17.

[0048] Preferably, the finished sheet-like material 2 with the carrier material 3 is conveyed between the individual stations 17 according to step c). Three stations 17 are also shown here, in which further processing steps according to step d) of the described method take place. In the first station 17, seen from the left, the first composite 4 passes through a forming tool 18, in which the first composite 4 is formed and, during the forming process, preferably a second composite 5 is also formed, in which the carrier material 3 and the finished sheet-like material 2 are preferably connected to one another over the entire surface of the finished sheet-like material 2. In further processing steps 14 (not shown separately here), for example, a product 13 can be introduced into a packaging element volume 12.Next, a station 17 is shown in which a closure element 15 is applied to the packaging element using a closure tool 19. Subsequently, a station 17 is shown in which separating lines 11 are introduced using a separating tool 20 and in which the packaging element 1 is separated from the carrier material 3 provided as a continuous material. All stations 17 shown in Fig. 1 are examples. The structure of a device 16 for carrying out the described method can also vary. What is essential is that the packaging element 1 or the precursor of the packaging element 1 (finished flat material 2, first composite 4, second composite 5) is conveyed with the aid of the carrier material 3 provided as a continuous material.

[0049] List of reference symbols

[0050] 1 packaging element

[0051] 2 ready-made material

[0052] 3 Carrier material

[0053] 4 first association

[0054] 5 second compound

[0055] 6 first connection

[0056] 7 first carrier material sections

[0057] 8 first material sections

[0058] 9 second carrier material sections

[0059] 10 second material sections

[0060] 11 Dividing line

[0061] 12 packaging element volume

[0062] 13 Product

[0063] 14 further processing steps

[0064] 15 locking element

[0065] 16 Device

[0066] 17 stations

[0067] 18 mold tool

[0068] 19 Locking tool

[0069] 20 cutting tools

Claims

Claims: A method for producing a packaging element (1) from a prefabricated sheet material (2) and a carrier material (3) comprising the following steps: a) providing the prefabricated sheet material (2); b) joining the prefabricated sheet material (2) with the carrier material (3), which is provided as a continuous material, so that a first composite (4) of the prefabricated sheet material (2) and the carrier material (3) is produced; c) carrying out at least one conveying of the prefabricated sheet material (2) with the carrier material (3); and d) carrying out at least one processing step in which the first composite (4) is processed so that a second composite (5) forming the packaging element (1) is produced from the prefabricated sheet material (2) and the carrier material (3).A method according to claim 1, wherein the continuous material provided as the carrier material (2) is a plastically deformable film. A method according to any one of the preceding claims, wherein the finished sheet material (2) is formed from natural polymer fibers. A method according to claims 1 to 3, wherein in step b) a temporary first connection (6) is made between the carrier material and the finished sheet material to form the first composite (4). A connection according to claim 4, wherein the first temporary connection (6) enables the relative positioning of predetermined first carrier material sections (7) of the carrier material (3) and predetermined first material sections (8) of the finished sheet material (2).

6. Method according to one of the preceding claims, wherein in step b) to form the first composite (4) first connections (6) are formed area by area and wherein during at least one processing step in step d) relative movements occur between predetermined second carrier material sections (9) of the carrier material (3) and predetermined second material sections (10) of the finished planar material (2).

7. Method according to one of the preceding claims, wherein at least one processing step in step d) is a deformation step in which the first composite (4) is deformed.

8. Method according to claim 7, wherein heat is applied to the first composite (4) during the deformation of the first composite.

9. Method according to claim 7 or 8, wherein during the deformation of the first composite (4) at least partial welding of the carrier material (3) and the prefabricated planar material (2) takes place.

10. Method according to one of the preceding claims, wherein at least one processing step in step d) is a punching step in which at least one separating line (11 ) is introduced into the second composite (5).

11. Method according to one of the preceding claims, wherein after step d) a step e) is carried out in which the second composite (5) is separated from the carrier material (3) provided as a continuous material in order to form the packaging element (1 ).

12. Method according to one of the preceding claims, wherein at least one processing step in step d) is a filling step in which a packaging formed in a previous processing step is The packaging element volume (12) of the packaging element (1) is filled with a product (13).

13. A method according to any one of the preceding claims, wherein at least in one processing step in step d) a closure element (15) is applied to a packaging element volume (12) of the packaging element (1) formed in a previous processing step.

14. A packaging element (1) consisting of a support layer made of prefabricated planar material (2) and a carrier material (3) supported by the support layer, manufactured according to a method according to any one of claims 1 to 13.

15. A device for manufacturing packaging elements (1) according to claim 14, wherein the device is configured to carry out the method according to any one of claims 1 to 13.

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