Method and apparatus for laminating gas-permeable containers
Patent Information
- Authority / Receiving Office
- EP · EP
- Patent Type
- Applications
- Current Assignee / Owner
- WATTTRON GMBH
- Filing Date
- 2023-08-31
- Publication Date
- 2026-07-08
Smart Images

Figure EP2023073938_06032025_PF_FP_ABST
Abstract
Description
[0001]Method and device for laminating gas-permeable containers. The invention relates to a method and a device for laminating a container with a film, wherein the container is made of a porous or perforated material, for example, a fiber-based material. Against the backdrop of the increasingly evident effects of climate change, growing environmental awareness and emerging protests against plastic pollution are gaining importance. These factors play a crucial role in the development of alternatives to glass or plastic packaging. One promising sustainable option is the use of molded fiber packaging made from renewable, recyclable, and biodegradable paper fibers.However, the biggest challenge with molded fiber packaging is that it lacks effective protection against liquids and / or gases, making it unsuitable for beverages or food. Despite numerous research projects by reputable companies in this area, there is still no adequate solution to the problem of liquid barrier or gas barrier in molded fiber packaging. However, there are several ways to create a liquid barrier. These mainly consist of applying a plastic film inside the cup. Another option is to spray a plastic coating inside the cup. However, the spraying process has the problem that the coating and cup cannot be separated after use, making the cups unsuitable for recycling and not biodegradable.Furthermore, existing laminating processes cannot prevent the laminating film from becoming excessively thin in the deep-drawn areas, allowing fibers from the formed pulp to puncture the film and create a leak in the barrier. Using a thicker film to compensate for these holes is unacceptable for both economic and environmental reasons. Furthermore, the following challenges associated with existing production processes are worth mentioning: − Heating a thin film using radiant heating is ineffective because the heat passes through the layer. − The machine's complexity is increased by the need to use a pre-stretch die.− Forming with a pre-stretching die is made more difficult by the fact that the low thermal mass of the film can lead to cooling of the film below the processing temperature or - in the case of a heated die - to sticking of the die itself. The object of the invention is to provide a method and a device for laminating a container with a film, which enables the film to be formed with the most uniform local material expansion possible and thus allows the creation of a uniform barrier, for example against liquids or gases, as well as a uniform sealing layer. This object is achieved on the method side by the features of independent patent claim 1 and on the device side by the features of independent patent claim 11. Further expedient embodiments of the invention are the subject of the dependent patent claims.To achieve this object, a method for laminating a container with a film is proposed, comprising the steps of a) providing a container made of a porous or perforated material with an opening and an interior space delimited by a container wall; b) providing a film made of a thermoplastic plastic; c) heating the film to a plasticizing temperature of the plastic; d) arranging the film over the opening; and e) laminating the film and container by molding the film into the interior space of the container by generating a pressure difference between a first air pressure prevailing on a side of the film facing away from the interior space and a second air pressure prevailing on a side of the film facing the interior space, such that the softened film is joined, i.e. permanently connected, to the container wall.The plasticization temperature of the plastic is understood to be a temperature that is higher than normal conditions (T = 293.15 K, p = 101.325 kPa), which makes the material more easily plastically deformable. Due to its reduced viscosity caused by the increased temperature, the plastic forms an at least superficial, material-tight bond with other materials onto which it is pressed. The pressure difference can advantageously be generated suddenly. When molding the film into the interior of the container, a defined material distribution is sought in order to achieve maximum barrier effect and mechanical strength with minimal material usage. At the same time, the connection between film and container achieves optically and functionally optimal results, as the film is fully bonded to the container wall without blistering, and this bond remains intact at least during the period of use, i.e.the film does not peel off on its own. The material from which the container to be laminated is made is preferably a fiber-based material such as paper, cardboard, molded fiber or the like. Alternatively, the container can be made of a foamed plastic or another material. The decisive factor is that the material of the container is an air-permeable material. Porous materials do not have a sufficient liquid and gas barrier, so that containers made from them are unsuitable for holding liquids and / or food in their unlaminated state. Using the proposed method, such a container can be made impermeable to liquids and gases in a relatively simple and cost-effective manner. It is also conceivable that a container made of a fundamentally gas-tight material is perforated as part of or prior to the proposed method in order to create gas permeability.The container can, for example, have a basic shape suitable for holding liquids and / or food, for example as a bowl, cup, glass, mug, plate, dish, can, jug, bottle, etc. Another important area of application of the proposed method is the functionalization of containers with regard to the sealability of the material, which can also be achieved using the proposed method. This variant is particularly advantageous for packaging goods that require no or only a slight barrier, but the container is nevertheless to be closed by sealing a lidding film. The film used for the method according to the invention consists of a thermoplastic, preferably a polyethylene or polypropylene, particularly preferably a linear or only slightly branched polyethylene or polypropylene.Advantageously, the film is single-layer and consists of only one plastic, because single-layer films are easier to recycle than multi-layer composite materials. The thermoplastic is particularly preferably biodegradable. In particular, bioplastics such as polylactide (PLA) are also referred to as plastics within the meaning of the invention. The heating of the film and the arrangement of the film over the opening (steps c and d) can take place in any order. For example, the film can first be arranged over the opening and heated on site, or alternatively, it can first be heated and then arranged over the opening in the heated state. The heating can take place in several sub-steps. For example, the film can first be preheated, then arranged over the opening and then heated further over the opening.The container can also be prepared (step a) either before or after the film has been prepared (step b), or even during or after the film has been heated (step c). According to an advantageous embodiment, the film is deformed in a defined manner by heating the film (step c) in a defined inhomogeneous manner. The temperature profile is set depending on the specific shape of the container in such a way that the material is evenly distributed during the deformation of the film, so that the thickness of the deformed film is ultimately as close as possible to the ideal state, i.e. is as equal as possible at every point. In the end, the same elongation should prevail everywhere. To this end, the more heated areas are stretched significantly at the beginning, and only when they are in contact with the wall are the remaining areas (particularly the corners) formed from the then barely formed material.By independently adjusting the temperature distribution, the viscoplastic behavior of the film used can be optimally controlled. This allows certain properties of the end product or the manufacturing process - such as air or liquid tightness, wall thickness distribution or heating time - to be physically controlled. When carrying out the method according to the invention, a sealing area can be formed on the container by sealing the film onto the edge of the base body. This forms a later sealing surface, for example for a lidding film. Locally defined heating increases the strength of the joint between film and container in the later sealing area, for example for easy opening of packaging without delamination, i.e. without parts of the lamination layer that extend beyond the sealing area undesirably detaching from the container.According to a preferred embodiment, the film is brought close to a heating device for heating (step c). Contactless heating of the film has the advantage that the heating device is not contaminated by the material of the heated film and that there is no contamination of the film material by the heating system, which would be particularly problematic in aseptic or pharmaceutical manufacturing processes. Particularly preferably, the film is brought into contact with a heating surface of a heating device for heating (step c). Direct contact with a heating surface results in a more effective and targeted transfer of heat to the film. The heating can be graduated by heating different areas of the heating surface to different intensities.In an advantageous embodiment, during heating (step c), air is sucked in through at least one flow opening arranged in the heating surface of the heating device, whereby the film advantageously comes into direct contact with the heating surface. On the one hand, this improves heat transfer from the heating surface to the film. In particular, temperature gradients can be transferred to the film with greater precision. By sucking in air through at least one flow device arranged in the heating surface, the heating device can advantageously be used as a gripper. This fixes and positions the film material, and the heating of the film can take place simultaneously with the arrangement of the film over the opening of the container, which, among other things, saves time. Such an embodiment is particularly suitable for processing film cut-outs.It can further be provided that, in order to generate the pressure difference during lamination (step e), a gas mixture is expelled through at least one flow opening arranged in the heating surface of the heating device. The gas mixture is preferably air. Advantageously, the compressed air is tempered, which optimizes the forming results. Heat can be supplied to the compressed air in at least some areas, whereby forming is more efficient in these areas. In contrast to the use of heated compressed air, unheated compressed air would cool down too quickly during expansion, which would consequently also cool the film too quickly. Furthermore, the compressed air can be cooled in at least some areas, thereby specifically creating areas in which the film material is less strongly formed.According to a further preferred embodiment, to generate the pressure difference during lamination (step e), air is sucked in on the outside of the container wall. Since the material of the container is permeable to air, air is thus sucked out of the interior of the container through the container wall. It can further be provided that the container wall is perforated in at least one place in order to create a flow opening in the container wall suitable for suction. To generate the pressure difference between the first air pressure prevailing on the side of the film facing away from the interior of the container and a second air pressure prevailing on the side of the film facing the interior, the expulsion of compressed air from at least one flow opening arranged in the heating surface and the suctioning of air through the container wall can be combined.According to a further preferred embodiment, at least during lamination (step e), a suction device is arranged on the outside of the container wall, at least partially covering the container wall and having at least one flow opening for sucking in air. Advantageously, air can be sucked out of the interior of the container through the container wall via the suction device. According to an advantageous embodiment, the film is provided in the form of a blank whose shape essentially corresponds to the shape of the opening. The blank can be removed from a storage device and transported, for example, by the heating device itself. This takes place, for example, by suction via at least one flow opening arranged in the heating surface of the heating device. Alternatively, the blank can be provided via a separate feed device.According to another alternative embodiment, the film is provided as a film web. Heating (step c) occurs only locally in an area of the film web whose shape essentially corresponds to the shape of the opening. After lamination (step e), the area bonded to the container is cut or punched from the web (step f).The object is further achieved by a device for carrying out a method according to the invention, comprising o a delivery device for delivering a film made of a thermoplastic material into the region of an opening of a container made of a porous or perforated material with an interior space defined by a container wall; o at least one heating device designed to heat the film to a temperature above a plasticizing temperature of the plastic; and o at least one pressure generating device for generating a pressure difference between a first air pressure prevailing on a side of the film facing away from the interior space and a second air pressure prevailing on a side of the film facing the interior space. The delivery device for delivering the film is designed to deliver film blanks and / or to deliver a film web.A feeding device for feeding film blanks can, for example, be designed as a gripper. A feeding device for feeding a film web can be designed as a clamp pull-off device or in the form of a chain feed. Furthermore, the device can have a film storage device in which prefabricated film blanks are kept ready. The pressure generating device is part of a forming station in which the film is formed. The heating of the film by the at least one heating device can take place before or in the forming station. Alternatively, the heating of the film can already take place during transport or during the feeding of the film web or film blank. The heating device has at least one heating surface. Advantageously, the film can be brought into direct contact with the heating surface and can thus be heated efficiently and precisely.The heating device can, for example, have a plate-shaped carrier substrate with a front side and a back side, which consists of an electrically non-conductive ceramic material, and on whose front side, which forms the heating surface, at least one heating conductor is arranged. For example, at least two heating conductors can be arranged on the heating surface, which can be controlled independently of one another. The front side of the carrier substrate has one or more heating conductors arranged thereon, which can, for example, be arranged in one plane (next to one another) or in several planes (one above the other), i.e. the front side of the heating element faces the material to be heated. In addition, it can be provided that at least one sensor conductor for temperature measurement is arranged on the heating surface. For example, a sensor conductor can be assigned to each heating conductor in order to be able to control the heating conductors individually.To contact the heating conductor or sensor conductor arranged on the front side of the carrier substrate, the carrier substrate can have through-holes coated with or filled with electrically conductive material, for example, through which the at least one heating conductor and / or the at least one sensor conductor are electrically contacted from the rear side of the carrier substrate through the carrier substrate. The at least one heating conductor and / or the at least one sensor conductor can be produced using thick-film printing technology. Alternatively or additionally, it can be provided that the at least one heating conductor and / or the at least one sensor conductor consist of an electrically conductive ceramic material. The at least one heating conductor and / or the at least one sensor conductor can advantageously be produced using thick-film printing technology.Particularly advantageously, the heating conductor(s) and / or the sensor conductor(s) can be made of an electrically conductive ceramic material. For this purpose, an electrically conductive ceramic slurry can be printed in the form of conductor tracks onto an electrically non-conductive, flat ceramic substrate, which can be in the form of a green compact or fired ceramic, for example. Producing the heating conductors and, if present, the sensor conductors using thick-film printing technology is cost-effective and also allows the heating conductors and sensor conductors to be manufactured either in a single process step or in steps within one and the same process.The through-hole plating of the heating conductor(s) and / or the sensor conductor(s) can be achieved simultaneously by injecting the slurry into holes or bores in the carrier substrate during printing, creating vias that can be used to electrically contact the heating conductor(s) and / or the sensor conductor(s) from the back of the carrier substrate. After a subsequent drying step, the ceramic substrate printed with ceramic conductor tracks can then be fired as usual. It can advantageously be provided that at least two heating conductors can be controlled independently of one another.Depending on the arrangement of the two or more heating conductors relative to one another, this can result in the heating device generating an adjustable temperature field viewed across its front side, or enabling compensation for varying degrees of heat dissipation by setting a very uniform temperature profile over a larger area, making the heating output selectable to be greater or lesser, etc. The heating device can in particular have two or more separately controllable heating circuits. Advantageously, this allows different areas of a film to be heated to different intensities. For example, areas further inside can be heated less intensely than edge areas of the film. The heater can particularly advantageously have a surface coating, for example a non-stick coating made of PTFE or the like, in order to reduce the risk of the softened film sticking.The heating surface of the heating device can further have at least one flow opening for sucking in and / or expelling air. In a preferred embodiment, the heating surface of the heating device and control electronics for controlling the heating device are arranged as close to each other as possible, for example by accommodating the control electronics in a housing that also supports the heating surface. The control electronics can be arranged, for example, directly behind the heating surface or separated by a thermal insulation element. This creates a compact heating device and thus reduces integration effort. Advantageously, a film blank can be held on the heating surface via a flow opening for sucking in air, allowing the heating device to function as a gripper.By means of a heating device designed in this way, a film blank can be removed from a storage unit and transported to a container to be laminated, wherein the film blank can be heated by the heating device during transport. By expelling compressed air from the flow opening arranged in the heating surface, the heated film can then be formed into the container. In addition, one or more separate flow openings for expelling air and one or more separate flow openings for sucking in air can be arranged in the heating surface. It can further be provided that the device has a plurality of heating devices. These can each have at least one flow opening for sucking in and / or expelling air in their heating surfaces and can be arranged in a cascade or rotation manner in order to increase the productivity of the device.The device preferably further comprises a suction device which at least partially covers the container wall and which has at least one flow opening for sucking in air. It can be provided that the suction device has a plurality of flow openings for sucking in air, which are evenly distributed over its inner surface. This allows the suction of air from the interior of the container to take place more evenly than with only one flow opening. According to a preferred embodiment, the device further comprises a second delivery device for delivering a container made of a porous or perforated material with an opening and an interior space delimited by a container wall. It can be provided, for example, that the second delivery device is designed as a conveyor belt or as a cell chain or as a robot (e.g. as a so-called "pick and place" robot).Furthermore, a storage area for containers can be provided, from which individual containers can be removed and fed to the second delivery device. According to an alternative embodiment, the second delivery device is designed as part of a fill-seal system (which is fed with containers which are filled and sealed in the system) or a form-fill-seal system (in which containers are formed which are filled and sealed in the system). Accordingly, the device is designed as a retrofit module for an existing FS system (fill-seal system) or an FFS system (form-fill-seal system) and, as such, can be integrated into the FS system or the FFS system in such a way that the delivery of a container to be laminated takes place via a delivery device of the FS system or FFS system.In the first case, the containers are prepared by the FS system as gas-permeable blanks, which are laminated by the proposed device as a retrofitted module of the FS system and then filled and sealed by the FS system. In the second case, the gas-permeable blank is manufactured by the FFS system, this blank is laminated by the proposed device as a retrofitted module of the FFS system and then filled and sealed by the FFS system. The heating device can be designed particularly advantageously for use in the food sector, i.e. designed to be easy to clean, made of inert material and liquid-tight. The invention is explained in more detail below with reference to exemplary embodiments and associated drawings. Fig. 1: shows a schematic representation of part of the device according to the invention during the preparation and heating of a film; Fig.Fig. 2: a schematic representation of a part of the device according to the invention during the forming of the film into the interior of the container; Fig. 3: a longitudinal section through a container laminated using the method according to the invention; Fig. 4: a simplified representation of the process sequence for lamination with film blanks; Fig. 5: a simplified representation of the process sequence for lamination with a film web; and Fig. 6: a further simplified representation of the process sequence for lamination with a film web. The drawings show the device only schematically to the extent necessary to explain the invention. They make no claim to completeness or to scale. Figures 1 and 2 show a schematic representation of a part of the device according to the invention, respectively during the preparation and heating of a film 2 (Fig. 1) and during the forming of the film 2 into the interior 1.3 of the container 1 (Figure 2). The film 2 is brought into contact with the heating surface 3.1 of a heating device 3. The heating surface 3.1 has a plurality of flow openings 4, which in the present embodiment are evenly distributed over the heating surface 3.1. Air is sucked in through at least some of the flow openings 4, whereby the film 2 is brought into direct contact with the heating surface 3.1. The suction through the flow openings 4 is illustrated by arrows in Figure 1. By creating a temperature field 8 in the heating surface 3.1, the film is heated. As soon as the heated film 2 is arranged in the region of the opening 1.1 of a container 1, air is expelled through at least some of the flow openings 4 in the heating surface 3.1 (illustrated by arrows in Figure 2). This can be done through the same flow openings 4 through which the suction previously took place, or through other flow openings 4 which are also in the heating surface 3.1 are arranged. At the same time, air is sucked out of the interior 1.3 of the container 1 through the container wall 1.2 of the container 1 (also indicated by arrows). By expelling compressed air from the flow openings 4 of the heating surface 3.1 and simultaneously sucking air through the container wall 1.2, a pressure difference is created between a first air pressure, which prevails on the side of the film 2 facing away from the interior 1.3, and a second air pressure, which prevails on the side of the film 2 facing the interior 1.3, so that the softened film 2 is pressed / sucked against the container wall and joined to the container wall 1.2. Figure 3 shows a longitudinal section through a container 1 that has been laminated using the method according to the invention. The opening 1.1 of the container 1 and the container wall 1.2 can be seen. The film 2 is connected to the container wall 1.2 and thus lines the interior 1.3 of the container 1.The film 2 was also sealed in an enlarged edge area of the container 1, thereby forming, for example, a sealing area 9 for a possible cover film. Figure 4 shows a simplified representation of the process sequence for lamination with film cut-outs, while Figures 5 and 6 show simplified representations of the process sequence for lamination with a film web. In the exemplary embodiments in Figures 4 and 5, a plurality of containers 1 are held in a storage 10 for containers 1 and transported via a container feed device 13 to a suction device 5. The suction device 5 has a recess whose shape essentially corresponds to the shape of the container 1 and is thus suitable for receiving a container.In the exemplary embodiment shown in Figure 4, film blanks 2 made of a thermoplastic material are held in a storage 11 for film blanks and transported individually by a feed device 6 into the area of the opening of a container positioned in the suction device 5. There they are heated by a heating device 3 and then, by generating a pressure difference between two air pressures on the two opposite sides of the film, formed into the container 1 positioned in the suction device 5 and joined to the container wall. The finished laminated containers are transported away via a transfer unit 12 for further storage or processing. In the exemplary embodiment shown in Figure 5, the film 2 is provided in the form of a film web and transported by a feed device 6 into the area of the suction device 5.As described for the embodiment shown in Figure 4, the film is heated in the area above the opening of a container positioned in the suction device 5 and then formed into the container. Since the film is now joined to the container wall, the container remains adhered to the film 2. The laminated container is transported by the transfer unit 12 to a downstream, not shown, work unit, in which, for example, the laminated container can be cut or punched out of the film web, or another subsequent process such as filling the container can take place.The embodiment shown in Figure 6 differs from the embodiment shown in Figure 5 only in that the containers 1 are not delivered from a storage device (reference numeral 10 in Figures 4 and 5), but are supplied externally, for example directly from a container production line. The delivery device 13 for the containers 1 is designed here, for example, as a "pick and place" robot, which transports the containers 1 directly to the suction device 5. Method and device for laminating gas-permeable containers List of reference numerals 1 Container 1.1 Opening of the container 1.2 Container wall 1.3 Interior of the container 2 Film 3 Heating device 3.1 Heating surface 4 Flow opening in the heating device 5 Suction device 6 Feed device for film 7 Pressure generation device 8 Temperature field 9 Sealing area 10 Storage for containers 11 Storage for film cuts 12 Transfer unit 13 Feed device for containers.
Claims
Method and device for laminating gas-permeable containers Claims 1. Method for laminating a container (1) with a film (2), comprising the steps of a) providing a container (1) made of a porous or perforated material with an opening (1.1) and an interior space (1.3) delimited by a container wall (1.2); b) providing a film (2) made of a thermoplastic plastic; c) heating the film (2) to a temperature above a plasticizing temperature of the plastic; d) arranging the film (2) over the opening (1.1); and e) laminating the film (2) and container (1) by molding the film (2) into the interior space (1.3) of the container (1) by generating a pressure difference between a first air pressure prevailing on a side of the film (2) facing away from the interior space (1.3) and a second air pressure prevailing on a side of the film (2) facing away from the interior space (1.3).3) facing side of the film (2), so that the softened film (2) is joined to the container wall (1.2).
2. The method according to claim 1, wherein the film (2) is deformed in a defined manner by heating the film (2) in step c) in a defined inhomogeneity.
3. The method according to claim 1 or 2, wherein the film (2) is brought close to a heating device (3) for heating in step c).
4. The method according to claim 1 or 2, wherein the film (2) is brought into contact with a heating surface (3.1) of a heating device (3) for heating in step c).
5. The method according to claim 4, wherein during heating in step c), air is sucked in through at least one flow opening arranged in the heating surface (3.1) of the heating device (3).
6. The method according to claim 4 or 5, wherein, to generate the pressure difference during lamination in step e), a gas mixture is expelled through at least one flow opening (4) arranged in the heating surface (3.1) of the heating device (3).Method according to one of claims 1 to 6, wherein, to generate the pressure difference during lamination in step e), air is sucked in from the outside of the container wall (1.2).
8. Method according to claim 7, wherein, at least during lamination in step e), a suction device (5) is arranged on the outside of the container wall (1.2), at least partially covering the container wall (1.2), said suction device having at least one flow opening for sucking in air.
9. Method according to one of claims 1 to 8, in which the film (2) is provided in the form of a blank whose shape substantially corresponds to the shape of the opening (1.1).
10. Method according to one of claims 1 to 8, in which the film (2) is provided as a film web, the heating in step c) takes place only locally in a region of the web whose shape substantially corresponds to the shape of the opening (1.1), and after lamination in step e) f) the region joined to the container (1) is cut or punched from the web.
11. Device for carrying out a method according to one of claims 1 to 10, comprising o a delivery device (6) for delivering a film (2) made of a thermoplastic material into the region of an opening (1.1) of a container (1) made of a porous or perforated material with an interior space (1.3 delimited by a container wall (1.2); o at least one heating device (3) with a heating surface (3.1) which is designed to heat the film (2) to a temperature above a plasticizing temperature of the plastic; and o at least one pressure generating device (7) for generating a pressure difference between a first air pressure prevailing on a side of the film (2) facing away from the interior space (1.3) and. a second air pressure prevailing on a side of the film (2) facing the interior (1.3).
12. The device according to claim 11, wherein the heating device (3) comprises a plate-shaped carrier substrate with a front side and a back side, which consists of an electrically non-conductive ceramic material, on whose front side, which forms the heating surface (3.1), at least one heating conductor is arranged.
13. The device according to claim 11 or 12, wherein at least two independently controllable heating conductors are arranged on the heating surface (3.1).
14. The device according to one of claims 11 to 13, wherein at least one sensor conductor for temperature measurement is arranged on the heating surface (3.1). 15.Device according to one of claims 12 to 14, wherein the carrier substrate has through-holes coated with or filled with electrically conductive material, through which the at least one heating conductor and / or the at least one sensor conductor are electrically contacted from the rear side of the carrier substrate through the carrier substrate.
16. Device according to one of claims 12 to 15, wherein the at least one heating conductor and / or the at least a sensor conductor is produced using thick-film printing technology.
17. Device according to one of claims 12 to 16, wherein the at least one heating conductor and / or the at least one sensor conductor consists of an electrically conductive ceramic material.
18. Device according to one of claims 11 to 17, wherein the heating surface (3.1) has at least one flow opening (4) for sucking in and / or expelling air.
19. Device according to one of claims 11 to 18, further comprising a suction device (5) which at least partially covers the container wall (1.2) and has at least one flow opening for sucking in air.
20. Device according to one of claims 11 to 19, further comprising a second delivery device for delivering a container made of a porous or perforated material with an opening and an interior space delimited by a container wall. 21.Apparatus according to claim 20, wherein the second feed device is designed as part of a fill-seal system or a form-fill-seal system.