Device and method for generating tube-like packaged object

Abstract

To provide a device and a method for packaging an article.SOLUTION: A device (10) for generating a tube-like packaged object includes: a packaging material dispenser (12); and a formation section. The formation section includes a progressive delivery folding region which has a plurality of discrete slender outer guide surfaces (50, 52, 54, 56) extending substantially in a machine direction (A). The slender outer guide surfaces are separated from each other, progressively deliver and guide the packaging material, and come into contact with an outside surface of the packaging material so as to be folded in a tube-like structure from a flat surface structure around a vertical axis. The slender guide surface can be a circular arc shape, and can be provided by a guide rod. The device can be a horizontal or vertical forming, filling, sealing type device. The packaging material (14) can be a semi-rigid packaging material such as a cardboard sheet, a carton cardboard sheet or a semi-rigid plastic.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to an apparatus and method for packaging that is particularly, but not exclusively, suitable for packaging items in tubular packages made from semi-rigid packaging materials such as paperboard, cartonboard, and semi-rigid plastics in a substantially continuous process. [Background technology]

[0002] It is known to provide so-called flow wrap packaging, which consists of a flexible tubular container sealed at both ends, usually by crimping or embossing, to provide a patterned lateral seal.

[0003] Typically, this type of flow-wrap packaging is produced by a horizontal or vertical form, fill, and seal process (HFFS or VFFS). In the HFFS process, flexible packaging film flows through a machine that folds the material around an item, then clamps and seals the edges of the folded material, and then cuts them to provide a sealed package. Such packages can be flowed relatively quickly through a suitable machine to produce many filled packages per minute. Examples of such machines include the Pack 401 Horizontal Flow Wrapper supplied by Bosch GmbH (Germany) and the Horizontal Form Fill Seal Packaging Machine 8000MH supplied by Ossid (USA).

[0004] Traditionally, flexible films used in flow-wrap packaging generally comprise polymeric materials and are relatively strong, tear-resistant, highly flexible, and have low deadfold properties. Known HFFS or VFFS processes and apparatus have been developed to take advantage of these properties when wrapping the film around the article being packaged to seal the package. In a typical arrangement, a continuous strip of film is drawn from a roll onto a former. The film engages the former on one side and conforms to the shape of the former as it is drawn along it. The former's shape changes incrementally along its length and is configured to orient the film to move in the machine direction, folding the film into a tubular structure as it passes over the former. The article to be packaged is introduced into the partially folded packaging film, whereby the film is wrapped around the article and overlapping longitudinally extending transverse edge regions are sealed together to form a longitudinal seal. Opposite regions of the film are sealed together at opposite ends of the article to form lateral edge seals, and each package is cut to separate it from a single piece of film. In some arrangements, the inner surface of the film (i.e., the surface that faces the article once the package is formed) engages the shape former, while in others the outer surface of the film engages the former.

[0005] Known HFFS flow wrap arrangements are particularly suitable for packaging substantially rigid items. Products such as candy and chocolate bars and other food products that are rigid at the temperatures encountered during packaging are often packaged in this manner. Flowable products can also be flow wrapped using HFFS arrangements if they are initially placed within a generally rigid inner container and a flow-wrapped package formed around the filled container. In this context, the term "rigid" should be understood to mean that the item is not flowable but maintains its shape during packaging. Alternatively, the term "rigid" can generally be described as being dimensionally stable during packaging.

[0006] In a typical HFFS arrangement, packaging film is pulled down from above at an inclined angle to the horizontal onto a former, which rotates the material on a horizontal flow path while simultaneously folding or wrapping it lengthwise to form a tube around the packaged item. This requires the material to be folded in multiple directions or planes simultaneously. While this is achievable with highly flexible polymeric films typically used in flow-wrap packages, it presents a challenge for semi-rigid materials with greater deadfold characteristics, as the material tends to undesirably bulge and crease when folded a significant amount in more than one direction or plane simultaneously.

[0007] It would therefore be advantageous to provide an apparatus for packaging a series of items in packages that are continuously produced from a single, substantially continuous length of packaging material that is suitable for use with a wider range of packaging materials.

[0008] It would be particularly advantageous to provide an apparatus for packaging a series of articles in packages that are continuously produced from a substantially continuous length of packaging material suitable for use with packaging materials including paperboard, cartonboard, semi-rigid plastic, or other semi-rigid packaging materials.

[0009] It would also be beneficial to provide a method for packaging a series of items in packages that are continuously produced from a substantially continuous length of packaging material suitable for use with a wider range of packaging materials.

[0010] It would also be advantageous to provide a method for packaging a series of items in packages that are continuously produced from a substantially continuous length of packaging material suitable for use with packaging materials including paperboard, cartonboard, semi-rigid plastic, or other semi-rigid packaging materials.

[0011] It is therefore an object of embodiments of the present invention to overcome or mitigate at least some of the problems of the prior art. Summary of the Invention [Means for solving the problem]

[0012] Aspects of the present invention relate to an apparatus and method for packaging articles. According to a first aspect of the invention, there is provided an apparatus for continuously producing tubular packages from an initially substantially flat, substantially continuous length of packaging material, each package enclosing, in use, one of a series of articles conveyed through the apparatus in a machine direction, the apparatus comprising: a) a packaging material dispenser arranged to dispense a substantially continuous strip of packaging material and to convey the material in a machine direction; b) a forming section through which packaging material is conveyed in a machine direction, the forming section configured to fold the packaging material from an initially flat configuration into a tubular package structure, the forming section comprising a progressive folding region having a plurality of discrete elongated external guide surfaces extending generally in the machine direction, the elongated external guide surfaces being spaced apart from one another and configured to contact an outer surface of the packaging material to progressively fold the packaging material about a longitudinal axis extending in the machine direction as the material passes through the progressive folding region.

[0013] The terms "fold," "folding," and the like, as used herein with respect to packaging material, should be understood to include arrangements in which the packaging material is wrapped, bent, or rotated, but which do not necessarily create creases in the material, unless a requirement regarding creases is expressly stated.

[0014] The apparatus can be configured for use in producing packages from semi-rigid packaging materials. The term "semi-rigid" refers to or includes materials that can be folded around an item in a package but are sufficiently rigid to exhibit deadfold characteristics. The apparatus can be configured for use in producing packages from such materials, including semi-rigid materials such as paperboard, cartonboard, cardboard, or semi-rigid polymeric materials, and combinations of laminated materials including at least one layer of such materials. When the packaging material is cartonboard, it can include multiple layers of fiber, including at least three layers of fiber. The apparatus can be configured for use in producing packages from packaging materials comprised of paperboard or cartonboard having a weight of 150 g / sqm or greater. The apparatus can be configured for use in producing packages from packaging materials comprised of paperboard or cartonboard having a weight ranging from 150 g / sqm to 250 g / sqm. When the apparatus is configured for use in manufacturing packaging from a semi-rigid polymeric material, the apparatus can be configured for use in manufacturing packaging from a semi-rigid polymeric material having a thickness of 150 μm or more, or a thickness of 200 μm or more. The apparatus can be configured for use in manufacturing packaging from packaging material that is coated or otherwise includes an adhesive or other material for creating a seal, such as a heat seal layer. The apparatus can be configured for use in manufacturing packaging from packaging material that has a printed and / or coated protective layer. The apparatus can be configured for use in manufacturing packaging from packaging material that includes a metal or metallized layer and / or a barrier layer.

[0015] The elongated outer guide surface may be of arcuate cross-section.

[0016] The elongated outer guide surface is capable of making line contact with the packaging material.

[0017] At least some of the elongated external guide surfaces may be symmetrically disposed about the longitudinal axis.

[0018] When considered from their upstream end to their downstream end, at least some of the elongated external guide surfaces can be angled laterally inward and in a vertical plane. The machine direction can be horizontal, and at least a portion of at least some of the elongated external guide surfaces can be angled laterally inward and upward from their upstream end toward their downstream end.

[0019] The device can include one or more elongated external guide members defining elongated external guide surfaces. In one embodiment, the device has guide members in the form of rods or the like. In one embodiment, each guide member defines at least a portion of a respective one of the elongated external guide surfaces. At least one of the guide members can comprise a cylindrical rod. In one embodiment, the guide members are supported at one end by a support member having an opening through which at least the packaging material and the articles to be packaged pass. In this embodiment, the guide members can be attached to the support member around the periphery of the opening. The guide members can be supported at both ends by respective support members. The support members can be plates.

[0020] The progressive folding region may comprise one or more elongated external guide members configured to define a cage or funnel through which the packaging material passes in use, the one or more elongated external guide members defining elongated external guide surfaces.

[0021] At least one of the elongated external guide surfaces may be discontinuous. For example, instead of using a single continuous rod to define the elongated external guide surface, a series of rods may be used to define the elongated external guide surface. This may be beneficial to reduce frictional contact between the guide surface and the packaging material. The rods in the series may be spaced apart in the machine direction and aligned along a common axis.

[0022] At least some of the elongated external guide surfaces can extend parallel to one another in a common first plane, and at least some of the other elongated external guide surfaces can extend parallel to one another in a second common plane different from the first common plane.

[0023] In one embodiment, the apparatus further comprises an article conveying arrangement for conveying a series of articles to be packaged in the machine direction and for introducing each article proximate the packaging material in succession at a position such that the packaging material is then folded around the article during use. In one embodiment, the article conveying arrangement is configured to insert each article into the partially folded packaging material at a position such that the inserted article is conveyed between the elongated external guide surface over at least a portion of the length thereof. In this embodiment, the apparatus is configured for inserting the articles into the partially folded packaging material, the packaging material being positioned between each article and the elongated external guide surface. The article conveying arrangement can be configured to insert the articles into the partially folded packaging material at an upstream end of the progressive folding region. The article conveying arrangement can comprise an elongated guide that supports the articles from below and for sliding the articles along the guide. The article conveying arrangement can also comprise a circulating drive member, such as a belt or chain, running parallel to the guide over a portion of its length. The drive member may have several drive formations (e.g., pegs) spaced along its length, each configured to engage an end of an article and move it in the machine direction along the guide so that the articles are maintained at a set distance from one another and move along the guide.

[0024] The forming section may also include at least one package former, the or each package former defining a packaging material folding channel through which packaging material is conveyed, the folding channel of the or each package former being shaped to fold the packaging material about a longitudinal axis as the packaging material passes therethrough toward the folding channel during use. The forming section may include at least one package former positioned upstream of the progressive folding region in the machine direction. The folding channel of the at least one package former may be configured to fold side regions of the initially flat packaging material out of the plane of the initially flat packaging material. When the machine direction is horizontal, the folding channel of the at least one package former may be configured to fold the side regions of the initially flat packaging material downwardly toward a central region of the packaging material. The folding channel may be generally inverted "U" shaped. The package former may include a body, the packaging material folding channel being at least partially defined by an opening through the body. The body can be a plate. The, or at least one of the package formers, can include at least one guide for directing the packaging material into or out of the opening. Alternatively, the package former can include two separate members contoured and spaced to define a packaging material folding channel therebetween.

[0025] The progressive folding region may include one or more interior guide surfaces for engaging an interior surface of the packaging material.

[0026] The apparatus can be configured to package generally block-shaped articles having opposing first and second major surfaces and opposing sides, in which case the progressive folding region can include at least one first elongated external guide surface configured to hold the packaging material proximate the first major surface of the article being transported through the progressive folding region, and a pair of second elongated external guide surfaces, each configured to hold a portion of the packaging material proximate a respective side of the article. The progressive folding region can further include a pair of third elongated external guide surfaces, each configured to progressively fold a respective side region of the packaging material proximate the second major surface of the article as the packaging material and the article traverse from the upstream end to the downstream end of the progressive folding region. When considered from the upstream end to the downstream end, each of the third elongated external guide surfaces can be angled inwardly transversely to the machine direction and in a vertical plane. When considered from the upstream end to the downstream end, each of the third elongated external guide surfaces can be angled laterally inward and upward. The apparatus can be configured to form a vertical fin seal that joins outer lateral edge regions of the packaging material together to create the package, in which case the apparatus can include a guide arrangement at the downstream end of the progressive folding region for holding the outer lateral edge portions in proximity and projecting from the second major surface of the article. The guide arrangement can include a support member, such as a plate, that defines a slot through which the outer lateral edge portions pass.

[0027] The forming section may extend over a length, measured in the machine direction, of 1 meter or more, or 1.5 meters or more, or 2 meters or more, or 3 meters or more. Alternatively, the forming section may extend over a length, measured in the machine direction, that is at least three times the length of the packages the apparatus is configured to produce, or at least four times the length of the packages the apparatus is configured to produce, or at least five times the length of the packages the apparatus is configured to produce, or at least six times the length of the packages the apparatus is configured to produce. Alternatively, the forming section may extend over a length, measured in the machine direction, that is at least seven times the width of the packages the apparatus is configured to produce, or at least eight times the width of the packages the apparatus is configured to produce, or at least nine times the width of the packages the apparatus is configured to produce, or at least ten times the width of the packages the apparatus is configured to produce.

[0028] The apparatus can be configured such that at least a portion of the packaging material travels throughout the forming section in a substantially constant plane that is substantially parallel to or includes the longitudinal axis. The forming section can be configured such that the folding direction of the packaging material at any given point along the folding section is substantially exclusively in a plane perpendicular to the longitudinal axis.

[0029] The apparatus can include one or more elongated article support members extending generally in the machine direction and configured to support articles being packaged, The one or more elongated article support members can be positioned to extend within the partially folded packaging material during use.

[0030] The apparatus can include an arrangement for scoring, debossing, and / or pre-creasing the packaging material. The arrangement for scoring, debossing, and / or pre-creasing the packaging material can be provided inline within the apparatus. The arrangement for scoring the packaging material can include mechanical die-cutting and / or laser scoring techniques. The arrangement for debossing the packaging material can include mechanical pressing techniques.

[0031] In one embodiment, the apparatus includes an arrangement for humidifying and / or heating the packaging material. This may include a device for applying steam and / or humidified hot air to the packaging material. In one embodiment, at least a portion of the package-forming section is housed within a chamber, and the apparatus includes a system for injecting steam and / or humidified hot air into the chamber. In one embodiment, a pre-treatment chamber for humidifying the packaging material is provided upstream of the package-forming section, through which the packaging material is conveyed before passing through the package former. In one embodiment, the apparatus includes one or more nozzles for directing steam and / or humidified hot air toward the packaging material.

[0032] The device may be configured for use in packaging items that are rigid.

[0033] The apparatus can be adapted for use in packaging articles having various shapes, including prismatic articles, such as block-shaped products in the form of bars, which may include candy bars, chocolate bars, and other snack-type bars or food products. The apparatus can be adapted for use in packaging articles having irregular shapes. The apparatus can be adapted for use in packaging articles comprising products disposed within a rigid container. This may consist of a flowable (e.g., non-rigid) product disposed within the container, or multiple rigid products grouped together within a container. For example, the apparatus can be adapted to package multiple products arranged in a stack within the rigid container. Such products may consist of cakes, biscuits, other food products, etc.

[0034] The apparatus can be configured to package an article made up of more than one product piece.

[0035] The equipment may be a horizontal form-fill-seal machine.

[0036] The equipment may be a vertical form-fill-seal machine.

[0037] According to a second aspect of the present invention there is provided an apparatus for producing tubular packages from an initially substantially flat, substantially continuous length of packaging material, each package enclosing, in use, one of a series of articles conveyed through the apparatus in a machine direction, the apparatus comprising: a) a packaging material dispenser arranged to dispense a substantially continuous strip of packaging material and to convey the packaging material in a machine direction; b) a forming section through which packaging material is conveyed in the machine direction, the forming section configured to fold the packaging material from an initially flat configuration into a tubular package structure that encloses the item, the forming section comprising a progressive folding region having a plurality of guide members that define a cage or funnel through which the packaging material passes in use, the guide members defining a plurality of discreet elongated external guide surfaces extending generally in the machine direction, the elongated external guide surfaces being spaced apart from one another and configured to contact an outer surface of the packaging material to progressively fold the packaging material about a longitudinal axis extending in the machine direction as the packaging material passes between the guide surfaces.

[0038] The elongated outer guide surface may be of arcuate cross-section.

[0039] The elongated outer guide surface is capable of making line contact with the packaging material.

[0040] This device according to the second aspect of the invention may have any of the features of the device according to the first aspect described above.

[0041] According to a third aspect of the present invention there is provided a method for continuously producing tubular packages from an initially substantially flat, substantially continuous length of packaging material, each package enclosing one of a series of articles conveyed in a machine direction, the method comprising: a) dispensing a substantially continuous strip of packaging material and conveying the packaging material in a machine direction; b) folding the packaging material into a tubular structure by passing the packaging material in a machine direction through a forming section configured to fold the packaging material from its initially flat configuration into a tubular package structure that encircles the item, at least a portion of the forming section comprising a plurality of discrete elongated external guide surfaces extending generally in the machine direction, the elongated external guide surfaces being spaced apart from one another and configured to contact an outer surface of the packaging material to progressively fold the packaging material about a longitudinal axis extending in the machine direction as the material passes between the guide surfaces.

[0042] The method according to the third aspect of the invention may be carried out using an apparatus according to either the first or second aspect described above.

[0043] In one embodiment, the method includes conveying a transport article to be packaged through at least a portion of the forming section, the packaging material being positioned between the article and an exterior elongated outer guide surface.

[0044] The plurality of discrete, elongated external guide surfaces extending generally in the machine direction can be part of a progressive folding region of the forming section, and the method can include passing the packaging material through a package former before the packaging material enters the progressive folding region, the package former defining a packaging material folding channel through which the packaging material is conveyed, the folding channel being shaped to fold the packaging material about a longitudinal axis as the packaging material passes therethrough toward the folding channel. The folding channel can be configured to fold side regions of the initially flat packaging material out of the plane of the initially flat packaging material. When the machine direction is horizontal, the folding channel of at least one package former can be configured to fold the side regions of the initially flat packaging material downwardly relative to a central region of the packaging material. The method may include passing the packaging material through a series of package formers before the packaging material enters the progressive folding area, the shape of the packaging material folding channel of each package former in the series changing such that the packaging material passing through each package former in the series is successively folded about a longitudinal axis as it passes toward and through the folding channel.

[0045] The article may be a rigid article. The method may include folding packaging material around the article in succession. The method may include folding packaging material around the article in succession so that the packaging material conforms to the cross-sectional shape of the article. The method may be configured for use in packaging articles having various shapes, including prismatic articles, such as block-shaped articles in the form of bars, which may include candy bars, chocolate bars, and other snack-type bars or food products. The method may be adapted for use in packaging articles having irregular shapes. The method may be adapted for use in packaging articles comprising a product disposed within a rigid container. This may consist of a flowable (e.g., non-rigid) product disposed within the container, or multiple rigid products grouped together within the container. For example, the method may be adapted to package multiple products arranged in a stack in a rigid container. Such products may consist of cakes, biscuits, other food products, etc. Each article may comprise more than one product part. Each article may comprise a rigid container into which the product is introduced.

[0046] The packaging material may be a semi-rigid material. The term "semi-rigid" refers to a material that can be folded around an item during packaging but is sufficiently rigid to exhibit deadfold properties. The packaging material may include any one or more selected from the group consisting of paperboard, cartonboard, cardboard, or semi-rigid polymeric materials, combinations of such materials, and laminated materials including at least one layer of such materials. If the packaging material is cartonboard, it may include multiple layers of fiber, including at least three layers of fiber. The packaging material may be composed of paperboard or cartonboard having a weight of 150 g / sqm or greater. The packaging material may be composed of paperboard or cartonboard having a weight ranging from 150 g / sqm to 250 g / sqm. Alternatively, if the packaging material is a semi-rigid polymeric material, it may have a thickness of 150 μm or greater, or 200 μm or greater. The packaging material may be coated or otherwise provided with an adhesive or other material to create a seal, such as a heat seal layer. The packaging material can be printed and / or coated onto a protective layer. The packaging material can include a metal or metallized layer, and / or a barrier layer.

[0047] The method can include introducing the packaging material into the package former section in a direction angled by 20 degrees or less, or 10 degrees or less, or 5 degrees or less with respect to a plane parallel to or containing the longitudinal axis. If the longitudinal axis is horizontal, the method can include introducing the packaging material into the package former section in a direction angled by 20 degrees or less, or 10 degrees or less, or 5 degrees or less with respect to the horizontal. The method can include passing the packaging material through the package former section in a substantially constant plane. The method can comprise folding the packaging material substantially exclusively in a plane perpendicular to the longitudinal axis at any given point within the folding section.

[0048] The method may be carried out in a horizontal form-fill-seal machine.

[0049] The method can be carried out in a vertical form-fill-seal machine.

[0050] The method can include sealing opposing lateral edge regions of the packaging material together to form a longitudinal seal after the material has been folded around each item. The method can include forming a fin-type seal or a wrap-type longitudinal seal.

[0051] An opposing method can include sealing portions of packaging material together at opposite ends of the article after the packaging material has been wrapped around the article to form the edge seals.

[0052] The method may include scoring, debossing, and / or pre-creasing the material.

[0053] The method may include treating the packaging material by moistening and / or heating the packaging material. The method may include treating the packaging material with steam and / or moistened hot air.

[0054] The method may include forming a seal on the package using ultrasonic and / or radio frequency sealing techniques.

[0055] A further aspect of the present invention comprises using an apparatus according to either the first or second aspect of the invention described above to produce packaging using the method of the third aspect of the invention described above. The present invention provides, for example, the following items. (Item 1) 1. Apparatus for continuously producing tubular packages from an initially substantially flat, substantially continuous length of packaging material, each package enclosing, in use, one of a series of articles conveyed in a machine direction through the apparatus, the apparatus comprising: a) a packaging material dispenser arranged to dispense a substantially continuous length of packaging material and convey said material in said machine direction; b) a forming section through which the packaging material is conveyed in the machine direction, the forming section configured to fold the packaging material from an initially flat configuration into a tubular package structure, the forming section comprising a progressive folding region having a plurality of discrete elongated external guide surfaces extending generally in the machine direction, the elongated external guide surfaces being spaced apart from one another and configured to contact an outer surface of the packaging material to progressively fold the packaging material about a longitudinal axis extending in the machine direction as the material passes through the progressive folding region. (Item 2) Item 1, wherein at least some of the elongated external guide surfaces can be angled laterally inward and perpendicular to the machine direction when considered from the upstream end to the downstream end. (Item 3) Item 3. The device of item 2, wherein the device comprises one or more guide members defining the elongated external guide surface. (Item 4) Item 4. The apparatus of item 3, wherein at least one of the guide members comprises a cylindrical rod. (Item 5) 5. The apparatus according to claim 3 or 4, wherein at least some of the guide members are supported at one end by a plate having openings through which at least the packaging material and the articles to be packaged pass. (Item 6) 6. The apparatus of any one of items 3 to 5, wherein the elongate outer guide member is configured to define a cage or funnel through which the packaging material passes in use. (Item 7) 7. The apparatus of any one of claims 1 to 6, wherein the apparatus conveys a series of articles to be packaged in the machine direction, and further comprises an article conveying arrangement for successively positioning each article proximate the packaging material at a position such that, in use, an inserted article is conveyed between the elongated external guide surfaces through at least a portion of the progressive folding region, the packaging material being positioned between the article and the elongated external guide surfaces. (Item 8) 8. The apparatus of any one of claims 1 to 7, wherein the forming section comprises at least one package former, the or each package former defining a package folding channel through which the package material is conveyed, the folding channel of the or each package former being shaped to fold the package material about the longitudinal axis as the package material passes therethrough toward the folding channel during use. (Item 9) Item 10. The apparatus of item 8, wherein at least one package former is positioned upstream of the progressive folding region in the machine direction and configured to fold side regions of the package material out of the plane of the initially flat package material. (Item 10) 10. The apparatus of any one of items 1 to 9, wherein the apparatus is configured to package generally block-shaped articles having opposing first and second major surfaces and opposing sides, and the progressive folding region comprises at least one first elongated external guide surface configured to hold the packaging material proximate a first major surface of an article being conveyed through the progressive folding region, and a pair of second elongated external guide surfaces, each second elongated external guide surface configured to hold a portion of the packaging material proximate a respective side of the article. (Item 11) Item 11. The apparatus of item 10, wherein the progressive folding region further comprises a pair of third elongated external guide surfaces, each configured to progressively fold a respective side region of the packaging material adjacent the second major surface of the article as the packaging material and article traverse from the upstream end to the downstream end of the progressive folding region. (Item 12) 12. The apparatus of claim 10 or 11, wherein the apparatus is configured to produce packages in which outer lateral edge regions of the packaging material are sealed together to form a vertical fin seal, and wherein the apparatus comprises a guide arrangement at a downstream end of the progressive folding region for holding the outer lateral edge portions of the packaging material in proximity. (Item 13) 13. The apparatus of any one of the preceding claims, wherein the progressive folding region extends in the machine direction over a length of 1 m or more, or over a length of 1.5 m or more, or over a length of 2 m or more. (Item 14) 14. The apparatus of any one of claims 1 to 13, wherein the apparatus is configured such that at least a portion of the packaging material advances through the forming section in a substantially constant plane that is substantially parallel to the longitudinal axis. (Item 15) 15. The apparatus of any one of items 1 to 14, wherein the packaging material is a semi-rigid packaging material. (Item 16) 1. A method for producing a continuous series of tubular packages from an initially substantially flat, substantially continuous length of packaging material, each package enclosing one of a series of articles conveyed in a machine direction, the method comprising: a) dispensing a substantially continuous strip of packaging material and conveying said packaging material in said machine direction; b) folding the packaging material into a tubular structure by passing the packaging material in a machine direction through a forming section configured to fold the packaging material from its initially flat configuration into a tubular package structure, at least a portion of the forming section comprising a plurality of discrete elongated external guide surfaces extending generally in the machine direction, the elongated external guide surfaces being spaced apart from one another and configured to contact an outer surface of the packaging material to progressively fold the packaging material about a longitudinal axis extending in the machine direction as the material passes between the guide surfaces. (Item 17) Item 17. The method of item 16, wherein the packaging material is a semi-rigid packaging material. (Item 18) 18. The method of claim 16 or 17, wherein the packaging material comprises any one or more selected from the group comprising paperboard, cartonboard, cardboard, or semi-rigid plastic. (Item 19) 19. The method of any one of items 16 to 18, wherein the method includes conveying an article to be packaged through the progressive folding region with the packaging material positioned between the article and the elongated external guide surface. (Item 20) 20. The method of any one of items 16 to 19, wherein the method includes maintaining at least a portion of the packaging material in a substantially constant plane as it passes through the forming section. [Brief explanation of the drawings]

[0056] In order that the invention may be more clearly understood, certain embodiments thereof will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] 1 is a perspective view of one embodiment of an apparatus for producing packages in accordance with aspects of the present invention, showing the apparatus with a length of packaging material extending through a package-forming section of the apparatus. [Figure 2] 2 is an alternative perspective view of the apparatus of FIG. 1 further showing a length of packaging material extending through the forming section of the apparatus. [Figure 3] 2 is a perspective view of the progressive folding region forming portion of the package forming section of the apparatus of FIG. 1 viewed from one side of the apparatus, further showing the apparatus with a strip of package material extending through it; FIG. [Figure 4] FIG. 4 is a perspective view similar to that of FIG. 3 but from the other side of the device. [Figure 5] 2 is a perspective view of the apparatus of FIG. 1, but showing the single piece of packaging material not extending through the forming section. [Figure 6] 6 is a perspective view of the progressive folding area of ​​the apparatus of FIG. 5, viewed from the upstream end toward the downstream end, illustrating how the articles to be packaged are conveyed through the progressive folding area. [Figure 7] FIG. 7 is a perspective view of the downstream end of the progressive folding region shown in FIG. 6. [Figure 8] FIG. 7 is a plan view from above of the progressive folding area shown in FIG. 6. [Figure 9] 2 is a view of the upstream end of a first support plate comprising a portion of the progressive folding area of ​​the apparatus of FIG. 1; [Figure 10] 2 is a perspective view of the downstream end of a package former that is part of the package forming section of the apparatus of FIG. 1. [Figure 11] 11 is a perspective view illustrating how a strip of packaging material is folded as it passes through the package forming section of the apparatus of FIGS. 1-10. FIG. DETAILED DESCRIPTION OF THE INVENTION

[0057] An embodiment of an apparatus 10 and method for producing packages according to aspects of the present invention will be described with reference to the accompanying drawings. In the description and claims, references to the "outer surface of the packaging material" mean the surface of the packaging material that is outermost when the packaging material is formed into a package. In contrast, references to the "inner surface of the packaging material" mean the surface that is innermost in the finished package and faces the packaged items.

[0058] Apparatus 10 includes a packaging material dispenser, generally designated 12, arranged to dispense a continuous, initially flat strip of packaging material 14 in a package conveying or machine direction, the direction of which is indicated by arrow A in FIG. 2.

[0059] The apparatus is particularly adapted for use with semi-rigid packaging materials. The term "semi-rigid" refers to or includes materials that can be folded around an item in a package but are sufficiently rigid to exhibit deadfold characteristics. The packaging materials can include paperboard, cartonboard, cardboard, or semi-rigid polymeric materials, combinations of such materials, and laminated materials containing at least one layer of such materials. Cartonboard generally contains multiple layers of fiber, and may contain at least three layers of fiber. The packaging material can be comprised of paperboard or cartonboard having a weight of 150 g / sqm or greater, particularly a weight in the range of 150 g / sqm to 250 g / sqm. However, the apparatus 10 can also be adapted for use with other semi-rigid materials, including semi-rigid polymeric materials having a thickness of 150 μm or greater or a thickness of 200 μm or greater.

[0060] The packaging material 14 is initially wound on a supply roll 16, and the packaging material dispenser 12 includes a mechanism for drawing the packaging material from the roll in a machine direction A. This mechanism typically includes one or more rollers 18, 20, 22, as known in the art, for guiding and supporting the packaging material along a desired path and for maintaining a desired tension in the packaging material.

[0061] During normal use, packaging material is dispensed from a continuous roll 16 during a run of packages until the required packages are completed or the roll is depleted, at which point the roll is replaced and the process repeated. References herein to a "continuous" or "substantially continuous" roll of packaging material should be understood in this context. The apparatus can have more than one supply roll that can be used alternatively to allow packaging material to be replaced with minimal downtime.

[0062] The apparatus 10 is a HFFS-type packaging machine, in which the packaging material dispenser 12 guides packaging material from a supply roll 16 into a generally horizontal flow path in the machine direction A, resulting in an initial planar configuration of the packaging material, indicated at 24. The apparatus 10 includes a forming section 26 configured to gradually collapse the packaging material from its initial planar configuration into a tubular structure that surrounds the target item 11. Depending on the shape and nature of the item being packaged and the type of packaging material used, the packaging material may be tightly wrapped around the item to conform to the cross-sectional shape of the item. However, in some applications, the packaging material may be formed into a tubular structure that surrounds the item, usually in relatively close proximity, but not necessarily conforming to its cross-sectional shape. This may be the case when the packaging material is too rigid to conform to the shape of the item and / or when the item is irregularly shaped. It should be understood that the term "tubular" does not imply that the packaging structure is cylindrical, such that the packaging material can be folded into any shape required to encase a particular item. This includes, for example, but is not limited to, tubular structures that are polygonal in cross section, and may be rectangular, triangular, or hexagonal in cross section.

[0063] The term "cross direction" is used herein to refer to a direction perpendicular to the machine direction A in a horizontal plane, with respect to the packaged articles, the apparatus 10, and the packaging material, while the term "longitudinal direction" is used to refer to a direction generally aligned with or parallel to the machine direction A.

[0064] In this embodiment, the apparatus 10 is configured to package generally block-shaped items 11, such as chocolate bars, having a generally rectangular prism shape with opposing front and rear major surfaces, opposing minor sides, and opposing ends. Accordingly, the package-forming section 26 is arranged to fold the packaging material to form a package having a generally planar main front wall region 28, opposing minor side wall regions 30, a generally planar main rear wall region 32 opposite the front wall region 28, and a vertical seal 34. The planar rear wall region 32 is defined by separate portions 32a, 32b of packaging material, one on each side of the vertical seal. In this embodiment, the vertical seal 34 is a fin seal, although the apparatus and method can be modified to produce a lap seal. Furthermore, as noted above, the disclosed apparatus 10 and method can be adapted to form packages of a variety of different shapes using the underlying principles taught herein.

[0065] The forming section 26 is arranged to fold the packaging material about a longitudinal axis X extending generally horizontally in the machine direction A, as illustrated in FIG. 11 . The forming section 26 includes a package former 36, the details of which can be best seen in FIG. 10 . The package former 36 has a plate 38 extending perpendicular to the machine direction A, which in this case is longitudinal. The plate 38 has an opening 40 through which the packaging material is drawn. The opening 40 defines a packaging material folding channel, the inner and outer edges of which engage the inner and outer surfaces, respectively, of the packaging material. The opening 40 is thus in the form of a narrow groove having a depth substantially equal to or slightly greater than the thickness of the packaging material 14. The slot has a linear upper section 40a extending horizontally in the transverse direction and a pair of downwardly depending side sections or legs 40b, one at one end of the upper section 40a. The side sections 40b extend at an obtuse angle relative to the upper section 40a such that the side sections 40b flare outward from their upper ends to their lower ends. The slot 40 then has a generally inverted "U" shape through which the packaging material passes. As the packaging material 14 is drawn toward and through the slot 40 of the package former 36, the side regions 14a of the material fold downward, thereby defining the central front wall region 28 of the package and beginning to form the side wall regions 30, creating fold lines 42 at the intersections of the front wall region 28 and each side wall region 30.

[0066] The package former 36 also has a package material guide 44 extending in the machine direction A from the downstream face of the plate 38. The guide has an outer surface 46 that conforms to the shape of the inner edge of the slot 40 so that the inner surface of the package material 14 contacts the guide 44 after passing through the slot 40, and is in the form of a sheet-like member. This supports the package material 14 internally as the side regions 14a are folded, helping to create a clean fold.

[0067] The package forming section 26 includes a progressive folding area 26a downstream of the package former 36 in which the package material 14 is further folded about the longitudinal axis X in a progressive, rather than continuous, manner to define a tubular structure. The progressive folding area includes a number of discrete, elongated, external guide surfaces extending generally in the machine direction for contact with the outer surface of the package material 14. The guide surfaces are configured to gradually and progressively guide the package material from the inverted "U" shape in which it enters the progressive folding area 26a into a tubular structure that surrounds the target item.

[0068] In this embodiment, there are six elongated external guide surfaces, each provided by a corresponding right cylindrical guide member 50, 52, 54, 56, 58, 60, with its longitudinal axis aligned substantially in the machine direction. The guide members 50, 52, 54, 56, 58, 60 each define a guide surface where they contact the packaging material. When the guide members are cylindrical, the packaging material makes line contact with the outer surface of each guide member at a point around its circumference, such that the contact surface between the packaging material and the guide member is relatively small. The guide members 50, 52, 54, 56, 58, 60 extend between and are supported by a first support plate 62 at the upstream end of the progressive folding region and a second support plate 64 located at the downstream end. The support plates 62, 64 extend transversely to the machine direction A, which in this case is longitudinal, and each define a respective opening 66, 68 through which, in use, the packaging material 14 and the articles 11 to be packaged pass. As can be seen in Figures 5, 6, 7, 8, and 9, guide members are mounted to each of the support plates 62, 64 with their ends extending through the respective openings 66, 68 and their outer peripheries projecting into the cross-sectional area defined by the openings, such that the packaging material 14 engages the outer surface of the guide member rather than the support plate.

[0069] The opening 66 in the upstream support plate 62 is generally inverted "U" shaped, with two vertically aligned legs 66a, 66b joined by an upper bridge section 66c that extends horizontally transverse to the machine direction A. The bridge section 66c is sized to allow the packaging material and the articles to be packaged to pass between the various guide members, the upstream ends of which are tapered to allow the packaging material 14 to be guided against the outer surfaces of the guide members without being damaged.

[0070] The opening 68 in the downstream support plate 64 has a generally rectangular main portion 68a through which an item to be enclosed in the packaging material 14 can pass. In this embodiment, the apparatus is configured to produce a package having a vertical fin seal 34 formed by joining together opposing outer lateral edge portions 14b of the packaging material. To assist in creating the fin seal, a slot 68b depends downwardly at the center of the lower edge of the main portion, through which the opposing outer lateral edge portions 14b of the packaging material are pulled. The packaging material passes through the slot 68b but, unlike the package former 36, otherwise contacts the second support plate 64 where the support plates 62, 64 do not engage the packaging material 14.

[0071] The bridge section 66c of the opening 66 in the upstream support plate 62 and the rectangular main portion 68a of the opening 68 in the downstream support plate are aligned with one another in a generally common horizontal plane.

[0072] Both support plates 62, 64 are mounted to a horizontal support surface 69 to which package former 36 is also mounted. However, support plates 62, 64 and package former 36 may be mounted to any suitable support structure. In fact, it should be noted that guide members 50, 52, 54, 56, 58, 60 need not be mounted to support plates 62, 64 at all, but may be supported by any suitable means.

[0073] The apparatus 10 includes an article conveying arrangement for conveying a series of articles 11 to be packaged in a machine direction A through at least a portion of the package forming section 26. The article conveying arrangement sequentially positions each article proximate the packaging material 14 in a position such that the packaging material 14 is subsequently folded into a tubular structure surrounding each article as the packaging material and articles progress through the package forming section. In this embodiment, the article conveying arrangement is configured to introduce the articles 11 into the partially folded packaging material downstream of the package former 36 at the beginning of the progressive folding region 26a. The article conveying arrangement includes an article support structure for supporting each article from below and extending from the upstream support plate 62 toward the downstream support plate 64. As best seen in FIG. 8 , the article support structure includes a pair of elongated article support rods 70, 72 that extend horizontally and parallel to each other from the upstream support plate 62 to a support pillar 74 positioned midway between the upstream support plate 62 and the downstream support plate 64. At their upstream ends, the support rods 70, 72 are attached to the upstream support plate 62 adjacent the lower edge of the bridge section 66c and protrude through the plate 62. The outer peripheries of the support rods protrude above the lower edge of the bridge section 66c of the opening 66. A third article support rod 73 extends horizontally downstream of the support pillars 74 and is centered between and aligned with the longitudinal axes of the upstream support rods 70, 72. All support rods are of the same diameter and are positioned in a common plane. Although not shown, the article transport arrangement includes a suitable system for continuously delivering articles to be packaged to the upper bridge section 66c of the opening 66 of the upstream support plate 62 so that the articles are received at the tops of the upstream article support rods 70, 72. A drive mechanism for sliding the articles 11 along the support rods 70, 72, 73 is also provided. The drive mechanism can take any suitable form as known in the art, such as a recirculating chain or belt having spaced drive formations (e.g., pegs) at the upstream end that engage each article in turn and push the articles along the support rods 70, 72, 73.The drive mechanism is adjusted to move the articles 11 along the support rods 70, 72, 73 at regular intervals relative to one another and in synchronization with the packaging material 14 as the articles are conveyed through the package forming section 26.

[0074] In the drawings, article support rods 70, 72, 73 are shown in dashed lines to more clearly distinguish them from rod-like guide members 50, 52, 54, 56, 58, 60. It should be recognized that other arrangements for supporting articles as they move through progressive folding region 26a may be employed.

[0075] The six elongated outer guide members 50, 52, 54, 56, 58, 60 include a pair of first or upper guide members 50, 52 aligned with their longitudinal axes extending parallel to one another in a common horizontal plane in the machine direction. The upper guide members 50, 52 are spaced apart transversely relative to the machine direction A, one on each side of the longitudinal axis X, and are positioned to hold the front wall region 28 of the packaging material adjacent to the upper major surface 76 of the article 11. The upper guide members 50, 52 are each attached to the upstream support plate 62 adjacent an upper edge of the bridge section 66c of the opening 66, with their outer peripheries projecting below the upper edge of the bridge section 66c. The minimum vertical distance between the outer peripheries of the upper guide members 50, 52 and the outer peripheries of the article support rods 70, 72, 73 is substantially the same as or slightly greater than the combined thickness of the packaging material 14 and one of the articles 11. The upper guide members 50, 52 are similarly connected to the downstream support plate 64 at locations proximate the upper edge of the main portion 68a of the opening 68, with their outer peripheries projecting below the upper edge.

[0076] The second pair of guide members 54, 56 are aligned with their longitudinal axes extending parallel to one another in a second common horizontal plane in the machine direction. The second pair of guide members, which may be referred to as side guide members, are positioned below the first pair 50, 52 and are spaced further apart to hold the downwardly depending region 14a of the packaging material 14 in intimate contact with opposite sides of the article 11. The side guide members 54, 56 are connected to the support plates 62, 64 adjacent respective side edges of the bridge section 66c of the opening 66 in the upstream support plate and respective side edges of the main portion 68a of the opening 68 in the downstream support plate 64. The minimum horizontal distance between the perimeters of the side guide members 54, 56 is equal to or slightly greater than the combination of the width of the article 11 and twice the thickness of the packaging material 14.

[0077] A final pair of lower guide members 58, 60, one on each side of the central longitudinal axis of the package-forming section, are positioned below the second pair of guide members 54, 56 and spaced transversely relative to the machine direction A. The lower guide members are configured to fold upwardly the side edge regions 14a of the package material as it travels longitudinally from the upstream end to the downstream end of the progressive folding region 26a to form the lower rear wall regions 32 of the tubular package and fin seal 34. To accomplish this, the lower guide members 58, 60 are each longitudinally aligned with a locus of points on the package material where folds 78 are formed on either side between the respective lower rear wall sections 32a, 32b and the laterally outer edge regions 14b as the package material travels between the upstream and downstream support plates. Thus, each of the lower guide members 58, 60 is aligned with its longitudinal axis slanted upwardly and laterally inwardly in the direction from its upstream end to its downstream end, but the longitudinal axis of the lower guide members 58, 60 can still be said to extend generally in the machine direction A. At their downstream ends, each lower guide member 58, 60 is attached to the downstream support plate 64 adjacent the lower edge of the main opening portion 68a proximal to the central slot 68b. At their upstream ends, each lower guide member 58, 60 is attached to the upstream support plate 62 adjacent the outer edge of its respective leg portion 66a, 66b of the opening 66, partway down the leg. The outer periphery of each lower guide member 58, 60 projects inward of its respective leg portion 66a, 66b of the opening 66 so that the respective side region 14a of the packaging material engages the lower guide member.

[0078] To begin operation of the apparatus 10, the leading edge of the packaging material 14 can be manually fed through the slot 40 of the package former 36, guided through the progressive folding region 26a, and inserted through the openings 66 and 68 in the upstream and downstream support plates within the guide members 50, 52, 54, 56, 58, 60, with the outermost lateral edge region 14b of the packaging material being fed through the slot 68b in the downstream support plate. Once manually fed through the forming section 26 and any downstream equipment, the leading end portion of the packaging material can be withdrawn in the machine direction A at a steady state by a packaging material dispenser, which can include means for driving the packaging material at any suitable location in the line.

[0079] During steady-state operation, the packaging material 14 automatically conforms to the shape of the opening 40 in the package former 36, causing the side regions 14a to fold against the upper front wall region 28 as they are drawn toward and through the package former 36. This folding action continues as the packaging material approaches the upstream support plate 62, with the side regions 14a extending substantially vertically downward as the packaging material reaches and passes through the opening 66 in the upstream support plate 62.

[0080] The packaging material is conveyed in a steady state through the package-forming section 26, and the articles 11 to be packaged are introduced into the partially folded packaging material 14 through the openings 66 in the upstream support plate 62 at the start of the progressive folding region 26a. In the progressive folding region 26a, the front wall region 28 of the packaging material is positioned between the upper guide members 50, 52 and the upper major surfaces of the articles 76. Thus, the front wall region 28 is held in contact with or at least in close proximity to the upper major surface 76 of each article by the upper guide members. Upper portions of the side regions 14a of the packaging material are positioned below the opposing sides of the articles inside the side guide members and are held in contact with or at least in close proximity to the sides of the articles by the respective side guide members 54, 56.

[0081] As the packaging material enters the opening 66 in the upstream support plate 62, the side regions 14 a project downwardly beyond the lower guide members 58, 60. The packaging material below the lower guide members 58, 60 includes outer lateral edge regions 14 b that form the fin seal 34 in the finished package. As the packaging material and articles progress through the progressive folding region 26 a, the lower guide members 58, 60 are operable to cause the side regions 14 a of the packaging material to fold inwardly and upwardly on both sides to form rear wall sections 32 a, 32 b of the tubular package that are held in contact with or adjacent to the lower major surface of each article as it approaches the downstream support plate 64. However, the outer lateral edge regions 14b of the packaging material are constrained to protrude downwardly when held within the slots 68b, causing the material to fold about the fold lines 78 between the outer lateral edge regions 14b and the respective rear wall sections 32a, 32b as the packaging material approaches and passes through the downstream support plate 64.

[0082] The article support rods 70, 72, and 73 support the articles from below as they move from the upstream support plate 62 to a position near the downstream support plate 64. The downstream ends of the support rods 73 are positioned at a point where the packaging material 14 can be wrapped around the articles 11 sufficiently tightly so that the packaging material itself can support and transport through the openings 68 in the downstream support plate 64 without the need for additional support. However, in some applications, support for the packaged articles can be provided externally from below the packaging material after it is folded to enclose the articles. As the packaging material 14 exits the downstream support plate 64, the lateral outer edge regions 14b are sealed together to form the vertical fin seals 34, and the packaging material is crimped together and sealed at both ends of each article 11 to form lateral end seals, thereby holding each article in a closed, generally sealed package. The packaging material 14 is cut to separate each successive package from the remainder of the packaging material, and the fin seals 34 can be folded over onto one side. Any suitable mechanism can be used to create the fin seals 34 and lateral seals, and mechanisms can be used that are similar to those used in conventional HFFS equipment, such as sealing rollers, crimp bars, etc.

[0083] The apparatus 10 can be operated in a substantially continuous manner to successively package several articles 11 at a relatively high rate until the supply roll 16 is depleted, at which point the supply roll is replaced and the process is repeated.

[0084] It should be noted that the packaging material dispenser 12 aligns the packaging material 14 generally parallel to a longitudinal axis X about which the material is folded before contacting the package former 36, and that the packaging material passes through the forming section 26 in a substantially constant plane parallel to the axis X. Specifically, the upper front wall region 28 moves in substantially the same plane through the package forming section 26. In this embodiment, where the apparatus is a HFFS apparatus, the packaging material enters a generally horizontal flow path before engaging the package former 36 and continues to traverse a generally horizontal path throughout the forming section 26. As a result, at any given time, the packaging material 14 is folded to a significant extent about the longitudinal axis X in only one direction or plane as it passes through the forming section 26. This is particularly beneficial for semi-rigid packaging materials, reducing the tendency of the material to bulge or buckle. It will be appreciated that when producing packages of different shapes, the upper front wall region 28 may not be present, but at least a portion of the package material passes through the entire forming section in a substantially constant plane, whereby the package material is folded a significant amount in only one direction or plane at any given time. Regardless of the shape of the package being formed, it is beneficial if the forming section is configured so that the package material is folded only about a generally longitudinal axis parallel to the direction in which the package material is conveyed.

[0085] It will be appreciated that the packaging material 14 need not be maintained strictly in the same plane throughout the package-forming section 26, provided that any changes in the angle of the packaging material in the machine direction A are relatively small and do not result in unwanted ridges and folds. In fact, it has been found that in some applications it may be beneficial to direct the packaging material 14 onto the package former 36 at a slight angle relative to the horizontal to control tension in the material. However, the angle is significantly smaller than that used in conventional flow wrap apparatus and methods, typically no more than 20 degrees, or no more than 10 degrees, or no more than 5 degrees relative to the plane comprising the longitudinal axis X. Testing of the HFFS apparatus has found that it may be beneficial to direct the packaging material onto the package former 36 at a slight angle from below upward, with the lower edge of the roller 18 positioned slightly below the upper horizontal portion 40a of the opening 40 of the package former 36.

[0086] The package forming section 26 is configured to minimize frictional contact with the package material. In this regard, the package former 36 contacts the package material only at a discreet location as it passes through the opening 40, and the elongated guide members 50, 52, 54, 56, 58, and 60 each make line contact with the package material 14. Because the elongated external guide surfaces are spaced apart, the level of friction generated is significantly less than that produced by a conventional former of a significant length having a relatively wide, continuous surface through which all or most of the package material is extracted. Thus, unlike conventional formers, the elongated external guide surfaces of the package former 36 and the progressive folding region define discontinuous guide surfaces rather than continuous surfaces that contact a significant surface area of ​​the package material. Maintaining low frictional contact between the equipment and the packaging material in the package forming section 26 is particularly beneficial for use with semi-rigid packaging materials, such as paperboard and cartonboard, where the length of the forming section 26 is expected to be longer than that used in conventional flow-wrap HFFS equipment designed for use with flexible packaging films. When used with semi-rigid packaging materials, the forming section 26 of the apparatus 10 according to the present invention may have a length (as measured in the machine direction A) of 1 meter or more, or 1.5 meters or more, or 2 meters or more, or 3 meters or more. Alternatively, the length of the forming section can be related to the length and / or width of the packages being produced, with the length of each package measured longitudinally from lateral end seal to lateral end seal and the width measured transversely. In this regard, the longitudinal direction of the package is parallel to the machine direction A as the package is conveyed through the apparatus. When considered in terms of the length of the package, the forming section 20 may have a length that is at least three times the length of the package, or at least four times the length of the package, or at least five times the length of the package, or at least six times the length of the package, while when considered in terms of the width of the package, the forming section 20 may have a width that is at least seven times the width of the package, or at least eight times the width of the package, or at least nine times the width of the package, or at least ten times the width of the package.Nevertheless, the length of the forming section 20 is generally kept to a minimum consistent with the need to produce bales of acceptable quality, and in some applications the length of the forming section may be shorter than the examples given above.

[0087] The use of guide members 50, 52, 54, 56, 58, 60 in the form of cylindrical rods is a particularly useful method of providing discreet elongated external guide surfaces that minimally contact the packaging material 14. However, it will be appreciated that the elongated external guide surfaces can be provided by other means. For example, an arcuate guide surface can be provided by a convex surface pressing into a sheet of material or against the edge of a bar or other elongated member, which need not be cylindrical. Indeed, while elongated external guide surfaces that are arcuate in cross section are particularly useful, this is not required, and the elongated external guide surfaces can have any suitable shape so long as they do not damage the packaging material. The guide members can be in the form of, for example, rod-like members that are polygonal in cross section and contact the packaging material at corner regions between two adjacent surfaces. It should also be understood that the various elongated external guide surfaces need not be formed by the same guide member, and that a variety of different guide members can be used in the apparatus 10. Furthermore, it is not required that each elongated external guide surface be provided by a discreet guide member. Two or more guide surfaces may be provided on a common guide member, which may take the form of a contoured member defining multiple, but spaced apart, elongated external guide surfaces along its length.

[0088] The elongated external guide surfaces need not be continuous throughout the entire progressive folding region 26a, but may be discontinuous in the machine direction. For example, rather than each elongated external guide surface being defined by a single guide rod, each elongated external guide surface may be defined by a series of rods spaced apart in the machine direction. Typically, each series of rods is aligned on a common axis. This helps further reduce frictional contact with the packaging material. It will be appreciated that similar arrangements for discontinuous guide surfaces can be made regardless of the type of guide member used to form each elongated external guide surface. Furthermore, the apparatus 10 may have more than one progressive folding region 26a arranged in series in the machine direction, each having a set of elongated external guide surfaces for progressively folding the packaging material.

[0089] Although all of the elongated external guide surfaces in the described embodiments are straight in the machine (longitudinal) direction, any one or more of the elongated external guide surfaces can be curved in the machine (longitudinal) direction. For example, one or more of the elongated external guide surfaces can be provided on a guide member that is curved along its length. Such a curvature can be useful in allowing packaging material to be fed onto the guide surface without being damaged or causing specific folding motion of the packaging material.

[0090] As noted above, it is not necessary for the apparatus to include support plates 62, 64 at one or both ends of the progressive folding region, as the guide members defining the elongated outer guide surfaces can be supported by any suitable support structure. Furthermore, one or more guide members can be adjustably mounted to a support to allow adjustment of the progressive folding region 26a. At the downstream end, alternative arrangements of slots 68b for guiding the outer lateral edge regions 14b of the packaging material can be used. For example, the outer lateral edge regions 14b can pass between rollers or other alternative guide arrangements to hold them in a desired orientation at the downstream end of the progressive folding region 26a. It should also be noted that, with appropriate reconfiguration, an apparatus according to the present invention can be adapted to produce packages having a vertical lap seal rather than a fin seal.

[0091] In further modifications, the package-forming section 26 need not include a package former 36 upstream of the progressive folding region 26a. Rather, the progressive folding region 26a can be used exclusively to guide the folding of the packaging material from an initially planar configuration into a tubular structure. For example, the progressive folding region can be modified to perform an initial fold of the side region 14a against the front wall region 28. This can be achieved by modifying some or all of the upstream guide members to provide this initial fold and / or the use of additional guide surfaces extending generally in the machine direction. In some cases, this may be necessary to support the packaging material on its inner surface as the side region 14a is folded, which can be achieved by additional guide members for engaging the inner surface of the packaging material at appropriate locations. However, it is also within the scope of the present invention for the apparatus to include more than one package former 36, each defining a packaging material folding channel 40 that can be positioned upstream or downstream of the progressive folding region 26a. When there are two or more packages arranged in series in the machine direction, the package material folding channels of the series of package formers may change shape during use such that the package material passing through the series of package formers is gradually folded about the longitudinal axis as the package material passes through the series of package formers.

[0092] The elongated external guide members 50, 52, 54, 56, 58, 60 can be said to form a cage or funnel that surrounds the packaging material and defines discrete, elongated external guide surfaces that gradually and progressively fold the packaging material into a tubular structure. It will be noted that although there are corresponding guide members and guide surfaces on each side of the apparatus (i.e., on either side of the central longitudinal axis X of the progressive folding region), a strictly symmetrical arrangement may not be necessary depending on the nature of the package and packaging material 14 being formed.

[0093] The packaging material 14 may be scored or debossed to aid in folding. Scoring and debossing reduces the thickness of the packaging material, creating lines of weakness that allow the material to fold more easily. Some of the score / debossed lines may extend longitudinally (i.e., in the machine direction or transport direction A), while some may extend transversely or at an angle between the two.

[0094] The packaging material 14 may be pre-scored / debossed before being wound onto the supply roll 16. Alternatively, or in addition, the apparatus 10 may include one or more arrangements for in-line scoring / debossing the packaging material after it is drawn from the supply roll. The scoring / debossing arrangements may be provided upstream of the package former 36. The scoring arrangements may include the use of mechanical die-cutting techniques and / or laser scoring. In-line debossing may be performed using mechanical pressing techniques, such as by passing the packaging material between a pair of rollers or wheels that compress the material.

[0095] Alternatively, or in addition, the packaging material 14 may be pre-creased. Pre-creasing involves partially folding or manipulating the packaging material so that it has a permanent tendency to bend along a given line. The packaging material 14 may be pre-creased before being wound onto a supply roll, and / or the apparatus may include an arrangement for pre-creasing the packaging material in-line but outside of the package forming section 26. This may be done, for example, by passing the packaging material between a pair of male and female die components that create a localized crease.

[0096] The packaging material can be scored, debossed, or pre-creased longitudinally at locations that will form corners of the finished package. For example, if the package has a generally rectangular cross-section for packaging chocolate bars or other block-shaped items 11 as in the described embodiment, the packaging material 14 can be scored or creased longitudinally where the material will be folded between the side regions 30 and the front and rear wall regions 28, 32 a, 32 b, respectively, and / or between the rear wall sections 32 a, 32 b and their respective outer lateral edge regions 14 b.

[0097] In the illustrated embodiment, the items 11 are introduced into the partially folded packaging material 14 from the bottom. However, it should be appreciated that this process can be reversed, with the items 11 being fed from the top side of the packaging material in a leading feed arrangement. The described principals discussed herein can also be applied to VFFS apparatus and methods.

[0098] The packaging material 14 can be sealed to form a finished package by any suitable means, depending on the type of material and other packaging requirements. For example, the packaging material can be sealed using an adhesive, such as, but not limited to, heat-sealable polyethylene (PE), PE-EVA blends, PE-EVA ionomer blends, heat-sealable polylactic acid copolymers, or cold sealing. The packaging material can be heat-sealed, for example, using ultrasonic or radio frequency techniques, or using pressure when cold sealing is used. Indeed, any suitable sealing technique known in the art can be used. The packaging material can have a pre-applied sealing material or can include a heat-sealable layer as part of the laminate. Alternatively, or in addition, the apparatus 10 can incorporate a system for applying adhesive or other sealing material to the packaging material 14 after it is unwound from the supply roll 16 at any suitable position in the series. The packaging material 14 can also be printed and / or coated with a protective layer, such as a coating of lacquer. Thus, references to packaging materials including paperboard, cartonboard, cardboard, or paper, semi-rigid polymeric materials, etc., should be understood to include combinations of such materials, laminates including at least one layer of such materials, and packaging materials to which an adhesive or other material to form a seal may be applied, which may be printed or coated onto a protective layer. The packaging material may also include a metal or metallized layer to provide barrier properties and / or enable inductive heating. Other suitable barrier layers may also be included in the packaging material.

[0099] The apparatus and method of the present invention are particularly suited to packaging items that maintain their shape when the packaging material is formed into a tube around the item or product during packaging. Such items are considered rigid compared to flowable items that conform to the shape of the package. Rigid products can be packaged directly using the apparatus and method of the present invention without any internal packaging, although internal packaging can be used if desired. This includes a wide range of products, including block-shaped products in bar form, which may include candy bars, chocolate bars, and other snack-type bars. However, non-block-shaped products can also be packaged using the apparatus and method of the present invention. For example, prismatic chocolate or candy products other than blocks can be packaged using the apparatus and method of the present invention. This can include elongated products shaped as triangular or hexagonal prisms. Irregularly shaped confectionery products can also be packaged using the apparatus and method of the present invention. This can include, for example, products shaped into animals or other characters. Other foods that are solid at the temperatures experienced during packaging can also be packaged using the apparatus and method of the present invention. For example, some cheeses, cakes, and biscuits can be packaged using the apparatus and method of the present invention. Products that are not rigid or sufficiently robust by themselves for direct packaging can be placed into substantially rigid containers and flow-wrapped packages formed around the filled container using the apparatus and / or method of the present invention. While the apparatus and method of the present invention are particularly suitable for packaging food products, they are not limited to such use and can be adapted to package any suitable product.

[0100] It should also be understood that reference to articles packaged in accordance with the apparatus or method of the present invention is intended to cover circumstances in which more than one product piece is packaged together in a single package. For example, it is known to package two or more chocolate bars in a single package, and the apparatus and method of the present invention can be adapted in this manner to package multiple products together in a single package, with each group of products packaged in a single package being considered one "article."

[0101] The above-described embodiment is described by way of example only. Many modifications are possible without departing from the scope of the invention, as defined in the appended claims. For example, the apparatus can be modified to include an arrangement for humidifying and / or heating the packaging material 14. This can include an apparatus for applying steam and / or humidified hot air to the packaging material. In one embodiment, at least a portion of the package-forming section can be housed within a chamber, and the apparatus can include a system for injecting steam and / or humidified hot air into the chamber. Alternatively, a pre-treatment chamber for humidifying the packaging material is provided upstream of the package-forming section 26 through which the packaging material is conveyed. In another possible arrangement, the apparatus can include one or more nozzles for directing steam and / or humidified hot air toward the packaging material 14.

Claims

1. Apparatus for continuously producing tubular packages from an initially flat continuous length of packaging material, each package enclosing one of a series of articles which, in use, are conveyed through the apparatus in a machine direction, the machine direction being the direction in which the packaging material moves through the apparatus, the apparatus comprising: a) a packaging material dispenser arranged to dispense a continuous strip of packaging material and convey said packaging material in said machine direction; b) arrangements for scoring, debossing, and / or pre-creasing said packaging material; c) a forming section through which the packaging material is conveyed in the machine direction, the forming section configured to fold the packaging material from an initial flat configuration into a tubular package structure, the forming section including a progressive folding region having a plurality of discrete elongated external guide surfaces extending in the machine direction, the elongated external guide surfaces being spaced apart from one another and configured to contact an outer surface of the packaging material to progressively fold the packaging material about a longitudinal axis extending in the machine direction as the packaging material passes through the progressive folding region; An apparatus comprising:

2. An apparatus as described in claim 1, wherein, when considered from the upstream end to the downstream end, at least some of the elongated external guide surfaces can be angled laterally inward and perpendicular to the machine direction.

3. The apparatus described in claim 2, wherein the apparatus comprises one or more guide members that define the elongated external guide surface.

4. The device described in claim 3, wherein at least one of the guide members includes a cylindrical rod.

5. An apparatus as described in claim 3 or claim 4, wherein at least some of the guide members are supported at at least one end by a plate having an opening through which the packaging material and the items to be packaged pass.

6. An apparatus as described in any one of claims 3 to 5, wherein the elongated external guide member is configured to define a cage or funnel through which the packaging material passes during use.

7. An apparatus as described in any one of claims 1 to 6, wherein the apparatus conveys a series of articles to be packaged in the machine direction, and further comprises an article conveying arrangement for successively positioning each article proximate to the packaging material in a position such that, during use, inserted articles are conveyed between the elongated external guide surfaces through at least a portion of the progressive folding area, and the packaging material is positioned between the article and the elongated external guide surfaces.

8. An apparatus as described in any one of claims 1 to 7, wherein the forming section comprises at least one package former, the at least one package former defining a package material folding channel through which the package material is conveyed, the folding channel of the at least one package former being shaped to fold the package material about the longitudinal axis as the package material passes through the folding channel towards the folding channel during use.

9. The apparatus described in Claim 8, wherein the at least one package former is positioned upstream of the progressive folding region in the machine direction and is configured to fold side regions of the packaging material from the plane of the initial flat packaging material.

10. An apparatus as described in any one of claims 1 to 9, wherein the apparatus is configured to package block-shaped articles having opposing first and second major surfaces and opposing sides, and the progressive folding area comprises at least one first elongated external guide surface configured to hold the packaging material proximate to a first major surface of an article being transported through the progressive folding area, and a pair of second elongated external guide surfaces, each second elongated external guide surface configured to hold a portion of the packaging material proximate to a respective side of the article.

11. The apparatus described in Claim 10, wherein the progressive folding area further comprises a pair of third elongated external guide surfaces, each third elongated external guide surface configured to progressively fold a respective side area of ​​the packaging material adjacent to the second major surface of the item as the packaging material and item move longitudinally from the upstream end to the downstream end of the progressive folding area.

12. An apparatus as described in claim 10 or claim 11, wherein the apparatus is configured to produce a package in which outer lateral edge regions of the packaging material are sealed together to form a vertical fin seal, and the apparatus includes a guide arrangement at the downstream end of the progressive folding region for holding the outer lateral edge regions of the packaging material in close proximity.

13. An apparatus described in any one of claims 1 to 12, wherein the progressive folding region extends in the machine direction over a length of 1 m or more, or over a length of 1.5 m or more, or over a length of 2 m or more.

14. An apparatus as described in any one of claims 1 to 13, wherein the apparatus is configured so that at least a portion of the packaging material progresses through the entire forming section in a constant plane parallel to the longitudinal axis.

15. An apparatus described in any one of claims 1 to 14, wherein the packaging material is a semi-rigid packaging material.

16. A method for producing a series of tubular packages from an initially flat continuous length of packaging material, each package enclosing one of a series of articles conveyed in a machine direction, the machine direction being the direction in which the packaging material moves during production, the method comprising: a) dispensing a continuous strip of packaging material and conveying said packaging material in said machine direction; b) scoring, debossing, and / or pre-creasing said packaging material; c) folding the packaging material into a tubular structure by passing the packaging material in a machine direction through a forming section, the forming section configured to fold the packaging material from its initial flat configuration into a tubular package structure, at least a portion of the forming section comprising a plurality of discrete elongated external guide surfaces extending in the machine direction, the elongated external guide surfaces being spaced apart from one another and configured to contact an outer surface of the packaging material, thereby progressively folding the packaging material about a longitudinal axis extending in the machine direction as the packaging material passes between the elongated external guide surfaces; A method comprising:

17. The method of claim 16, wherein the packaging material is a semi-rigid packaging material.

18. The method of claim 16 or claim 17, wherein the packaging material comprises any one or more selected from the group including paperboard, carton board, cardboard, or semi-rigid plastic.

19. A method as described in any one of claims 16 to 18, comprising transporting the item through a progressive folding area with the packaging material positioned between the item to be packaged and the elongated external guide surface.

20. A method as described in any one of claims 16 to 19, wherein the method includes maintaining at least a portion of the packaging material in a constant plane as the packaging material passes through the forming section.

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