Package body top part forming apparatus

Abstract

An apparatus for forming the three-dimensional top portion of a package body is configured. The apparatus comprises a three-dimensional anvil (21'). The anvil (21') is configured to receive a sleeve (11) of base material, and the front sleeve portion (11') of the sleeve (11) is positioned to surround at least a portion of the anvil (21'). The apparatus also comprises a sonotrode (25) that defines a three-dimensional cavity configured to receive the anvil (21') and the front sleeve portion (11') on the anvil (21'). The sonotrode (25) is configured to apply mechanical vibration to the front sleeve portion (11') on the anvil (21') via the three-dimensional cavity, causing permanent deformation of the front sleeve portion (11') to form the three-dimensional top portion.

Description

Technical Field

[0001] The present disclosure relates to the manufacture of food packages, particularly to the technology for forming the shape of the top portion of the package body of the package.

Background Art

[0002] In the food industry, it is common to package food in a packaging material made from a paper-based laminate having a core layer of paper or cardboard and one or more barrier layers such as plastic.

[0003] One common form of packaging is to form a tubular blank ("sleeve") from the above-mentioned paper-based laminate material and seal one end thereof with a top portion made of a plastic material to form a bottle-shaped package body. Usually, this top portion is formed directly by injection molding at the end of the sleeve. The top portion has a neck portion that defines a pouring spout, and this pouring spout is sealed by a cap and / or a foil. The cap and / or the foil are provided by injection molding or in a separate attachment process. Thereafter, the container body is conveyed to a subsequent filling station where a liquid product is filled from the open end on the opposite side of the container body. After filling, the open end of the container body is folded and sealed to form the final package. An example of this manufacturing technology is shown in the specification of International Patent Application Publication No. WO2007 / 106006.

[0004] A modification is shown in the specification of International Patent Application Publication No. WO2010 / 085182, where after one end of the sleeve is formed as a shoulder portion, a top portion that defines a neck portion is injection molded on the shoulder portion. The shoulder portion is produced by folding the packaging material into the sleeve along a crease line to form radial pleats. During injection molding, the upper end portions of the radial pleats are covered with an injection plastic material to fix the creases and prevent the formation of gaps inside the package. The related solution was first described in International Patent Application Publication No. WO2004 / 041663.

[0005] In another modification described in German patent application DE102005048821, a pre-molded pyramidal plastic top is attached to four folding flaps at one end of a sleeve. The flaps are molded to fit the pyramidal top and are attached to the flaps by horizontal joints along each side of the pyramidal top. [Overview of the project] [Problems that the invention aims to solve]

[0006] In the food packaging sector, there is a common demand for bottle-shaped packaging suitable for mass production. Therefore, robust technology is required to manufacture bottle-shaped packaging with high processing capacity and low defect rates.

[0007] Furthermore, it is generally desirable to improve the recyclability of packaging by reducing the amount of different materials used in the packaging.

[0008] The objective is to overcome, at least in part, one or more limitations of the prior art.

[0009] One of its objectives is to provide a simple and efficient technology for manufacturing bottle-shaped packaging bodies for food packaging. [Means for solving the problem]

[0010] At least one of these objectives, and any further objectives that may become apparent from the following description, are at least partially achieved by the apparatus and sonotrode described in the independent claim, the embodiments thereof as defined by the dependent claims.

[0011] The first aspect is an apparatus for forming the top portion of a three-dimensional package. The apparatus comprises a three-dimensional anvil, which is configured to receive a substrate sleeve, with the front sleeve portion of the sleeve positioned to surround at least a portion of the anvil. Furthermore, the apparatus comprises a sonotrode defining a three-dimensional cavity configured to receive the anvil and the front sleeve portion on the anvil, the sonotrode being configured to apply mechanical vibration to the front sleeve portion on the anvil via the three-dimensional cavity, thereby causing permanent deformation of the front sleeve portion and forming the three-dimensional top portion shape.

[0012] The second embodiment is a sonotrode used in the apparatus of the first embodiment. A third aspect is an anvil used in the apparatus of the first aspect.

[0013] A fourth embodiment is a sonotrode having a cavity defined by a three-dimensional cavity wall and configured to receive a three-dimensional anvil, the sonotrode being configured to apply mechanical vibrations to the three-dimensional anvil through the three-dimensional cavity wall.

[0014] Embodiments of the apparatus according to the first embodiment are described below. These embodiments are also applicable to the second to fourth embodiments.

[0015] When the front sleeve portion is housed within the three-dimensional cavity, the longitudinal central axis of the three-dimensional cavity can be aligned with the longitudinal central axis of the anvil.

[0016] The three-dimensional cavity can be configured to fit snugly into the front sleeve portion on the anvil.

[0017] The device may be configured to compress the substrate of the front sleeve portion by pressing the anvil and sonotrode toward each other with a predetermined force during the application of mechanical vibration.

[0018] The device may be configured to compress the substrate by at least 10%, preferably at least 50%, by applying a predetermined force during the application of mechanical vibration.

[0019] The three-dimensional cavity may extend in the depth direction into the sonotrode from the entrance opening and is defined by cavity walls that surround the three-dimensional cavity in the circumferential direction.

[0020] The anvil has a three-dimensional surface portion formed to fit the three-dimensional wall portion of the cavity wall, the three-dimensional wall portion being circumferential in the circumferential direction, and defining a strip-shaped contact surface for engaging with the three-dimensional surface portion of the anvil via a front sleeve portion.

[0021] The three-dimensional surface of the anvil may be formed so as to be locally parallel to the three-dimensional wall of the cavity when the anvil is housed in the three-dimensional cavity.

[0022] At least one of the anvil or cavity wall may have a surface structure configured to locally change the engagement force applied to the front sleeve portion from the anvil and cavity wall.

[0023] The surface structure may be arranged to extend in alignment with the deformation zone of the front sleeve portion, and the deformation zone may be arranged to cause local deformation of the front sleeve portion when the front sleeve portion is housed in a three-dimensional cavity.

[0024] The surface structure may be elongated and extend in the depth direction when the anvil is housed in a three-dimensional cavity.

[0025] At least a portion of the deformation zone may be configured to form multiple overlapping layers of the substrate when the front sleeve portion is housed in the three-dimensional cavity.

[0026] The surface structure may include, at least in some deformation zones, elongated depressions configured to accommodate multiple overlapping layers in each deformation zone.

[0027] At least one of the deformation zones may be configured to form an elongated joint between adjacent edges of the base material when the front sleeve portion is received in the three-dimensional cavity.

[0028] The surface structure may include an elongated depression configured to receive the elongated joint when the front sleeve portion is received in the three-dimensional cavity.

[0029] The cavity wall may include a wall portion defining a shoulder portion configured to deform at least a part of the front sleeve portion toward the shoulder portion of the package body.

[0030] The sonotrode may be configured such that the radial thickness of the material around the three-dimensional cavity increases along the depth direction at least in a part of the wall portion defining the shoulder portion.

[0031] The cross-section of the three-dimensional cavity orthogonal to the depth direction may be non-circular, with radial protrusions distributed around the entrance opening, and may be arranged at the position of the maximum radial distance from the center line of the three-dimensional cavity.

[0032] The front end portion of the anvil may include a mounting structure for a neck element including a tubular portion defining an access opening in the package body, and this mounting structure may be arranged to position the neck element at least partially within the front sleeve portion when the front sleeve portion is placed on the anvil.

[0033] The cavity wall may include a neck-defining wall portion configured to engage the front sleeve portion with a flange on the neck element when the front sleeve portion is received within the three-dimensional cavity.

[0034] The cavity wall further includes a bottom wall portion adjacent to the neck-defining wall portion, the bottom wall portion being configured to receive the tubular portion of the neck element when the front sleeve portion is housed in the three-dimensional cavity.

[0035] The bottom wall portion may be configured to be positioned at a distance from the tubular portion of the neck element when the front sleeve portion is housed within the three-dimensional cavity.

[0036] The entrance opening may be defined by a tapered wall formed at an angle within the three-dimensional cavity, thereby allowing the front sleeve portion to be received within the three-dimensional cavity.

[0037] The sonotrode may be positioned so that the three-dimensional cavity faces upward relative to gravity.

[0038] The sonotrode has a first end face, a second end face, and a circumferential outer surface extending between the first and second end faces, with the three-dimensional cavity formed on the first end face.

[0039] The circumferential outer surface may have a convex shape between the first end face and the second end face.

[0040] The second end face may be configured to be mechanically attached to the generating unit to receive mechanical vibrations.

[0041] The device may include a generating unit configured to generate mechanical vibrations and transmit them to a sonotrode.

[0042] The generating unit may be configured to generate mechanical vibrations at a frequency determined based on the distance between the first end face and the second end face.

[0043] The circumferential outer surface of the sonotrode can be formed such that, when the front sleeve portion is housed in the three-dimensional cavity, mechanical vibrations cause the cavity walls to vibrate locally and are substantially perpendicular to the front sleeve portion on the anvil.

[0044] The sonotrode may define at least one channel extending from a first opening at the bottom of the three-dimensional cavity to a second opening on the circumferential outer surface.

[0045] At least one channel may be configured to extend away from the first end face.

[0046] The apparatus may include a deformation unit configured to engage with the front sleeve on the anvil to cause preliminary deformation of the front sleeve before the front sleeve is housed in the three-dimensional cavity.

[0047] The deformation unit may include an engagement element for engaging with a corresponding deformation zone of the front sleeve portion, the corresponding deformation zone being positioned to facilitate local deformation of the front sleeve portion when the front sleeve portion is housed in a three-dimensional cavity.

[0048] The engaging elements may be configured to be biased toward their respective deformation zones.

[0049] The deformation unit may be operable to slide its engaging elements to engage with their respective deformation zones.

[0050] The deformation unit may be configured to engage its engaging elements in synchronous manner with each deformation zone.

[0051] The deformation unit may be positioned in front of the three-dimensional cavity and configured to engage with the front sleeve as the front sleeve moves relative to the three-dimensional cavity.

[0052] The deformation unit may be positioned at a distance from the sonotrode and may be configured to be operationally independent of the sonotrode. The apparatus further includes a transport device for moving an elongated holder with a sleeve from the deformation unit to the sonotrode.

[0053] The base material of the front sleeve may be a plastic material configured to soften due to mechanical vibrations applied by a sonotrode and then solidify when the mechanical vibrations cease, thereby enabling permanent deformation of the front sleeve.

[0054] The base material may include a sheet, and a plastic material is provided on at least one side of the sheet.

[0055] The base material may be compressible.

[0056] A three-dimensional cavity can form a blind hole within the sonotrode.

[0057] Sonotrode may also be made of solid block material.

[0058] The anvil may be detachably incorporated into an elongated holder for receiving the substrate sleeve.

[0059] The device may further include a moving device connected to a sonotrode and capable of operating to move the sonotrode linearly relative to the anvil.

[0060] Further purposes, features, embodiments, aspects, and advantages will become apparent from the following detailed description and attached schematic diagrams. [Brief explanation of the drawing]

[0061] [Figure 1A] This is a schematic diagram showing an example of a manufacturing process using a first-type blank embodiment. [Figure 1B] This is a plan view of a substitute blank used in the manufacturing process. [Figure 1C] This is a plan view of a substitute blank used in the manufacturing process. [Figure 1D] This is a side view of a neck element used in the manufacturing process. [Figure 2A]This is a plan view showing an example of a first-type blank. [Figure 2B] This is a perspective view of a sleeve having a deformed front sleeve portion. [Figure 2C] This is a perspective view of the package body manufactured through the manufacturing process. [Figure 2D] Figure 2C is a cross-sectional view of the package body. [Figure 2E] This is a magnified view of a portion of Figure 2D. [Figure 2F] This is a cross-sectional view of the blank material. [Figure 3] This is a schematic diagram of an exemplary station for manufacturing the package body (see Figure 2C) according to an embodiment. [Figure 4A] Figure 3 is a cross-sectional view showing an example of a top molding station in operation within the station. [Figure 4B] This is a perspective view showing an example of an anvil used in a top molding station. [Figure 4C] This is a cross-sectional view of the blank material placed on the anvil. [Figure 4D] This is a cross-sectional view of the blank material placed on the anvil. [Figure 4E] Figure 4B shows the side view, cross-sectional view, and bottom plan view of the anvil. [Figure 4F] Figure 4B shows the side view, cross-sectional view, and bottom plan view of the anvil. [Figure 4G] Figure 4B shows the side view, cross-sectional view, and bottom plan view of the anvil. [Figure 5A] This is a perspective view showing an example of a sonotrode used in a top molding station. [Figure 5B] This is a perspective view showing an example of a sonotrode used in a top molding station. [Figure 5C] This is a floor plan of Sonotoroad. [Figure 5D] This is a side view of Sonotoro. [Figure 5E] Figure 5C is a cross-sectional view of the sonotrode. [Figure 5F]This is a side view of the sonotrode, rotated 45° around its longitudinal axis relative to Figure 5D. [Figure 5G] Figure 5F is a cross-sectional view of Sonotoroad. [Figure 6] Figure 4B shows a cross-sectional view of the anvil, which includes a sleeve and neck element, in relation to the deformation unit. [Figure 7A] This diagram shows an example of a sonotrode's vibration cycle. [Figure 7B] Figure 7A is a schematic diagram of the periphery of the cavity within the sonotrode at different stages in the vibration cycle. [Figure 8] This is a schematic diagram of another station for manufacturing the package body according to the embodiment. [Modes for carrying out the invention]

[0062] The embodiments will be described in more detail below with reference to the attached drawings. The drawings show some (but not all) of the embodiments. In fact, the subject matter of this disclosure can be embodied in various forms and should not be limited to the embodiments described herein. Rather, these embodiments are provided to satisfy the legal requirements to which this disclosure applies.

[0063] To the extent possible, the advantages, features, functions, apparatus, and / or modes of operation of any embodiment described and / or assumed herein may be included in any other embodiment described and / or assumed herein, and vice versa. Furthermore, to the extent possible, terms expressed in the singular form herein shall be construed to include the plural form and / or vice versa unless expressly otherwise specified. Thus, the terms “a” and / or “an” shall be construed to mean “at least one” or “one or more.” However, the expressions “one or more” or “at least one” may also be used herein. The terms “multiple,” “plural,” and “plurality” mean the provision of two or more elements. The term “and / or” encompasses any combination that includes one or more of the related enumerated elements. Terms such as “first,” “second,” etc., may be used herein to describe various elements, but these elements should not be limited by these terms. These terms are used simply to distinguish one element from another.

[0064] Well-known functions or configurations may not be described in detail for the sake of brevity and / or clarity. Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as those commonly understood by those skilled in the art to which this disclosure pertains.

[0065] The same reference numeral indicates the same component throughout the entire system.

[0066] This disclosure relates to a technology for manufacturing food packaging. This technology uses welding to form a three-dimensional (3D) top shape of the package. This welding involves transmitting mechanical vibrations to the packaging material to form welds or fused joints between different parts of the packaging material. The welds are generated by heating due to friction caused by the mechanical vibrations. The mechanical vibrations are, for example, in the ultrasonic range of 15 to 40 kHz, and are so-called ultrasonic welding. The mechanical vibrations are transmitted to the packaging material by a so-called sonotrode (also called a horn). The packaging material is sandwiched between the sonotrode and an anvil (also called a nest) under pressure. The anvil does not actively vibrate. Conventionally, the sonotrode and anvil are configured to be in linear contact, resulting in one-dimensional welding. This disclosure is based on the fundamental insight that at least a portion of the top region can be formed by simultaneously performing three-dimensional welding. Specifically, a sonotrode having a three-dimensional surface is used, which is configured to transmit mechanical vibrations to the packaging material when pressed against an anvil shaped to match the three-dimensional surface shape of the sonotrode. This three-dimensional welding can form welded portions of any three-dimensional shape and size. In this specification, a 3D surface includes one or more curved or non-planar surface portions in a three-dimensional Euclidean coordinate system. For example, in bottle-shaped packaging, the top region may have a dome shape, which is a three-dimensional object. This novel three-dimensional welding (3DW) technology allows the top region (or a portion thereof) to be formed in a single welding process, achieving high processing capacity and reliability in production. The packaging material is made of paper or cardboard and is coated with a thermoplastic material that is melted during the welding process and then solidified. Three-dimensional welding makes it possible to manufacture at least a portion of the top structure from the packaging material that forms the packaging body. This reduces the amount of plastic material used in the packaging body compared to when the top structure is manufactured entirely from plastic material by injection molding or other methods.

[0067] Figure 1A shows an overview of the operating steps for manufacturing a packaging body according to an embodiment, from left to right. The illustrated procedure begins with a sheet or blank 10 (also referred to as the base material) of packaging material. The sheet 10 is rectangular and has opposing edges 110, which are connected by side edges 111. In the illustrated example, one edge 110 of the sheet 10 has a predetermined deformation zone 10' that allows for controlled, defined deformation of the base material during the manufacturing of the packaging body. In some embodiments, each deformation zone 10' encompasses one or more fold lines or creasing lines. The folds act as hinges for bending the base material and may be formed as depressions within the base material. If the depressions are formed on one side of the sheet, bending on that side is facilitated. The folds are positioned so that the base material folds over itself during 3D welding (operating step S3). In some embodiments, the deformation zones 10' are omitted. In operation step S1, the sheet 10 is formed into a sleeve or collar 11 by overlapping and joining the edges at the side edges 111, for example, by adhesive or welding. The overlapping edges form a longitudinal seam (not shown) that extends along the sleeve 11. The sleeve 11 is a cylindrical body having any cross-section, whether circular or non-circular. The sleeve 11 has a front portion 11' ("front sleeve portion") which is molded into the top shape during the manufacture of the package body 13. If a deformation zone 10' exists, it is located in the front sleeve portion 11'. The remaining portion of the sleeve 11 forms the body 11'' which extends from the front sleeve portion 11' to the opposite end of the sleeve 11. In operation step S2, the front sleeve portion 11' undergoes pre-deformation or "pre-forming" to become a deformed sleeve 12. Pre-forming is optional and is performed to impart a shape to the front sleeve portion 11' that is suitable for the subsequent operation step S3. As shown in the figure, pre-forming typically changes the shape of the front sleeve portion 11' from a cylinder to a frustocone. Pre-forming can improve the ability to produce a top section with a uniform shape in operation step S3, potentially contributing to a reduction in the defect rate. Pre-forming also ensures uniform attachment of the neck element (described later) to the top section in operation step S3.Pre-forming can be performed by mechanically engaging a deformation unit (not shown) with the front sleeve portion 11' and bending the base material. For example, pre-forming may include bending the base material along a fold line. In operation step S3, the deformed sleeve 12 is subjected to the aforementioned 3D welding process to manufacture a package body 13 having a top portion 13' having a desired 3D shape. As will be described later, in operation step S3, the base material self-folds when the front sleeve portion 11' is deformed into the desired shape, and the overlapping portions are fused together by 3D welding to fix the shape of the front sleeve portion 11', thereby forming the top portion 13'.

[0068] As shown in Figure 1A, a pre-fabricated neck element 14 is supplied to the operation step S3 and incorporated into the top portion 13' by 3D welding. The neck element 14 defines an access opening 14a for the consumer to access the food. The neck element 14 may include a cap or foil to seal the access opening 14a. Alternatively, a cap or foil covering the access opening 14a may be attached in a subsequent operation step (not shown). The package body 13 is then transported to a filling station (not shown), where the food is filled through the upward opening of the package body 13. The upward opening is then sealed by a method well known to those skilled in the art.

[0069] Figure 1D shows an example of a neck element 14. The neck 14 has a tubular portion 14'' that defines an access opening 14a. The tubular portion 14'' may be provided with external threads (not shown) for engagement with a cap. As previously stated, the cap may or may not be included in the neck element 14. The neck element 14 further includes a circumferential flange 14' projecting from the tubular portion 14''. The flange 14' defines a mounting surface that is joined to the base material of the package body 13 during or after 3D welding.

[0070] Many deformations are possible. If pre-forming is omitted, 3D welding is performed directly on the sleeve 11. The pre-formed neck element 14 does not need to be attached by 3D welding; it may be attached to the package body 13 in a separate process after 3D welding. Alternatively, the neck element may be formed and attached by injection molding after 3D welding.

[0071] Furthermore, the deformation zone 10' does not need to include a fold line. Figure 1B shows a sheet 10 having notched deformation zones 10'. Each notch 10' is defined by the boundary edge of the base material. Each notch 10' is shaped such that its boundary edges align and contact each other and fuse together by 3D welding when the front sleeve portion 11' is deformed in operation step S3. To ensure a strong and durable seal between the boundary edges, strands 10'' of thermoplastic material can be provided on at least a portion of the boundary edge around each notch 10'. The boundary edges are preferably curved (non-straight) to ensure a durable seal and prevent wrinkle formation. As shown, in some embodiments, the boundary edges are convex.

[0072] Figure 1C shows a sheet having a notched deformation zone 10' covered with a film or web of thermoplastic material. This film arrangement may alleviate the need for precise alignment between the notch boundary edges during 3D welding. This is because, as the front sleeve portion 11' deforms in operation step S3, the film folds over the substrate, covering a larger surface area than the strand 10'' in Figure 1B. Thus, the deformation zone 10' in Figure 1C allows the substrates to overlap as the notch 10' closes due to deformation in operation step S3.

[0073] The deformation zone 10' may also be composed of any combination of deformations shown in Figure 1A-1C, such as fold lines and notches.

[0074] Figure 2A shows a detailed example of sheet 10, which comprises deformation zones 10' formed by crease lines that promote a predetermined bending pattern of the base material in each deformation zone 10'. Each deformation zone 10' includes a first set of crease lines 10a that promotes bending in one direction and a second set of crease lines 10b that promotes bending in the opposite direction. Specifically, when sheet 10 is formed into sleeve 11, the first set of crease lines 10a promotes the formation of an outer crease protruding from the inside of sleeve 11, and the second set of crease lines 10b promotes the formation of an inner crease protruding in the inside of sleeve 11. The crease lines 10a and 10b may be straight lines as shown. The first and second sets of crease lines 10a and 10b are arranged to define a triangle (e.g., an isosceles triangle), the base of which is located at the edge 110, i.e., the front edge of the front sleeve portion 11'. The triangles in each deformation zone 10' are aligned with each other, with one triangle positioned within the other. In the illustrated example, the fold line 10a is positioned around the fold line 10b, but the reverse arrangement is also possible. In a modified example, the vertices of the triangle are removed to form a truncated triangle, which is thought to reduce the occurrence of wrinkles at the top. Such a truncated triangle is included in the deformable sleeve 12 shown in Figure 2B. As shown, the fold line 10a forms an outward fold in the front sleeve portion 11', and the fold line 10b forms an inward fold. Figure 2C shows the package body 13 manufactured from the deformable sleeve 12 of Figure 2B. The body 11'' is not affected by 3D welding, but the front sleeve portion 11' is molded into a top portion 13' with a substantially smooth outer surface. The base material folds and fuses itself along the fold lines within the deformable zone 10'. The dashed lines within each deformable zone 10' in Figure 2C indicate the position where the inward fold (fold line 10B) forms a joint 1' inside the package body 13. By welding overlapping substrates within the deformation zone 10', a strong and durable molding of the top portion 13' is achieved. Furthermore, the deformation zone 10' is flattened on both the outer and inner sides of the top portion 13 of the package body. The flat inner surface can improve food safety and facilitate sterilization as needed.Figure 2C also shows that 3D welding typically deforms the front sleeve portion 11' which is outside the deformation zone 10'. In the illustrated example, a panel 13'' that slightly protrudes from the side of the top portion 13' is formed. The deformation zone 10' differs from the rest of the front sleeve portion 11' in that it is formed to accommodate the excess material that becomes present when the front sleeve portion 11' is deformed into a dome shape. In the example of Figure 1B-1C, the excess material is at least partially cut off. In the example of Figure 2A, the excess material is instead folded in a controlled manner.

[0075] Figure 2D is a cross-sectional view of the package body 13 in Figure 2C in the 2D direction, and Figure 2E is an enlarged view of area 2E in Figure 2D. As shown, a dome-shaped top portion 13' is formed and extends from the body 11'' to the neck portion NP of the package body 13. The neck portion NP is formed by a neck element 14. The top portion 13' consists of a strip-shaped shoulder portion SP adjacent to the body 11'' and a mounting portion AP at the distal end of the top portion 13'. The mounting portion AP is attached to the flange 14' of the neck element 14. In the illustrated embodiment, the cap''' engages with the tubular portion 14 of the neck element 14, and the access opening 14a defined by the tubular portion 14'' is sealed by the internal thread of the cap 14''' engaging with the external thread of the tubular portion 14''. As is well known to those skilled in the art, the neck element 14 also includes a tamper-evident element 14'''' which breaks when the cap 14''' is removed from the tubular portion 14''.

[0076] Figure 2F is a cross-sectional view of the base material 1 in sheet 10. The base material 1 is malleable and can be reshaped by applying force. In some embodiments, the base material 1 is compressible. This improves the performance of 3D welding. In the illustrated example, the base material has a thickness T0 and consists of a core 1A and plastic material covering surfaces 1B provided on both sides of the core 1A. The covering surfaces 1B can be made of any plastic material or combination of plastic materials that softens due to mechanical vibrations applied during 3D welding and then solidifies when the mechanical vibrations cease. For example, the covering layer 1B may be made of a thermoplastic material. Depending on the bending pattern in the deformation zone 10', it may be sufficient to provide the covering layer 1B on only one side of the core 1A. It is also conceivable that one covering layer 1B is optimized for 3D welding and the other covering layer 1B is optimized for another purpose, such as barrier properties. In some embodiments, the core 1A is a fibrous material, such as one or more layers of paper or cardboard, or includes them. Other materials or combinations of materials, including plastic materials, may define or constitute part of core 1A. If core 1A is composed of plastic materials, the coating layer 1B may be omitted.

[0077] Figure 3 is a side view of a station or machine 2 for manufacturing a package body 13 according to a non-limiting example. The station 2 comprises an indexing device 300, a neck loading device 301, a sleeve loading device 302, a top forming device 303, and an unloading device 304. The neck loading device 200 is configured to receive a neck element 14 as shown by arrow A1 and place it on the indexing device 300. The sleeve loading device 302 is configured to receive a supplied sleeve 11 as shown by arrow A2 and place it on the indexing device 300. The top forming device 303 is configured to reform the sleeve 11 and attach the neck element 14 to form the package body 13. The unloading device 304 is configured to remove the package body 13 from the indexing device 300 and supply it to a downstream process (indicated by arrow A4).

[0078] The loading device 301, the discharge device 302, and the discharge device 304 can be configured in various ways to perform their respective functions and will not be described in detail. Non-limiting examples are described in International Patent Application Publication WO2007 / 106006.

[0079] The indexing device 300 includes an elongated holder or arm 21 attached to or combined with a rotatable member 22 (also called a wheel or mandrel wheel). Each arm 21 is equipped with an internal tool 21' corresponding to the anvil described above. In some embodiments, the anvil 21' is detachably attached to the arm 21 to facilitate replacement of the anvil 21'. The anvil 21' wears out and may need to be replaced. In addition, an anvil 21' with a different 3D shape and a corresponding sonotrode 25 may be provided to manufacture package bodies 13 with different top section 13 shapes.

[0080] The elongated arms 21 project radially from the wheel 22 and are arranged at equal intervals around the wheel. In the example with four arms 21 shown, each arm is positioned perpendicular to the adjacent arm. A drive unit 23 is connected to the wheel 22 and operates to rotate the wheel 22 in the direction indicated by arrow A0. The drive unit 23 may be an electric motor capable of precise angular positioning, such as a servo motor or a stepping motor. The drive unit 23 operates to intermittently rotate or index the wheel 22, and thus the arms 21, to four different angular positions. The drive unit 23 stops at each angular position. These positions are indicated by Roman numerals within dashed circles in Figure 3. Position I is the first loading position, where the anvil 21' is aligned with the neck loading device 301. Position II is the second loading position, where the anvil 21' is aligned with the sleeve loading device 302. Position III is the processing position, where the anvil 21' is aligned with the top forming device 303. Position IV is the discharge position, where the anvil 21' is aligned with the discharge device 304.

[0081] The configuration, which provides an anvil 21' on each of the four arms 21, enables high processing capacity for station 2. Specifically, the following four operations can be performed simultaneously: device 301 places the neck element 14 onto the anvil 21', device 302 places the sleeve 11 onto the anvil 21', device 303 processes the sleeve 11 on the anvil 21', and device 304 discharges the package body 13 from the anvil 21'.

[0082] The arm 21 extends from the wheel 22 into a common plane, which forms the rotation plane of the arm 21. Depending on the implementation, the rotation plane may be vertical or horizontal.

[0083] In a modified example not shown, the neck mounting device 301 is instead configured to position the neck element 14 on the anvil 21' while the anvil 21' moves between position IV and position I, or between position I and position II. In yet another modified example, the neck mounting station 301 is omitted, and the neck is attached to the package body 13 downstream of the discharge device 304, or formed in any other way.

[0084] The top molding apparatus 303 includes an outer tool 25 that is movable relative to the anvil 21' in position III. The outer tool 25 is the sonotrode described above. In the illustrated example, the sonotrode 25 is linearly movable between a resting position and an operating position, as indicated by the double-ended arrows A3. In the resting position, the sonotrode 25 is positioned at a distance from the anvil 21'. In the operating position, the sonotrode 25 is positioned to surround the anvil 21'. The top molding apparatus 303 includes an actuator or moving device 26 connected to the sonotrode 25 and operable to grant its movement between the resting position and the operating position. As shown by the dashed line, the sonotrode 25 has a cavity 25' for receiving the anvil 21'. Since the anvil 21' has a neck portion 14 and a sleeve portion 11, the sonotrode 25 surrounds both the neck portion 14 and the front sleeve portion 11' (Figures 1A and 2B). The sleeve 11 is sized such that when the arm 21 is in position III, the inside of the sleeve 11 at least partially contacts the arm 21, thereby preventing the sleeve 11 from falling off the arm 21. The cavity 25' defines the aforementioned 3D surface. In the operating position, the sonotrode 25 is operable to reshape the front sleeve portion 11' onto the top portion 13' of the package body 13, while simultaneously joining the neck element 14 to the front sleeve portion 11'.

[0085] The top molding apparatus 303 further includes a supply device 27A that generates a supply signal at a predetermined frequency, and a conversion unit 27B configured to convert the supply signal into mechanical vibrations. The supply device 27A and the conversion unit 27B together constitute a generating unit that generates mechanical vibrations and transmits them to the sonotrode 25. The sonotrode 25 is mechanically attached to the conversion unit 27B and receives the mechanical vibrations. The conversion unit 27B has a conventional configuration and includes a transducer that converts the supply signal into mechanical vibrations. The mechanical vibrations are generated by one or more piezoelectric crystals in the transducer. As is well known in the art, the conversion unit 27B may include a booster or amplitude coupler configured to define the amplitude of the mechanical vibrations transmitted to the sonotrode by amplifying or attenuating the amplitude of the mechanical vibrations generated by the transducer.

[0086] In the illustrated example, the deformation unit 28 is positioned in front of the cavity 25'. The deformation unit 28 is configured to perform the preliminary deformation ("preforming") of the front sleeve portion 11' described above. The deformation unit 28 is movably positioned with the sonotrode 25 so as the sonotrode 25 moves toward and contacts the anvil 21', it contacts the front sleeve portion 11' to perform preforming. As shown in the illustration, the deformation unit 28 may be attached to the sonotrode 25. Alternatively, the deformation unit 28 may be isolated from mechanical vibrations by being attached to a separate holder (not shown) which moves in conjunction with the sonotrode 25, for example, by an actuator 26 or another actuator (not shown).

[0087] The top molding apparatus 303 shown in Figure 3 is an example of an apparatus for molding the three-dimensional (3D) top portion 13' of the package body 13. This apparatus includes an anvil 21' having a 3D shape. The anvil 21' is configured to receive the sleeve 11 of the base material 1, and the front sleeve portion 11' is positioned to surround at least a portion of the anvil 21'. The apparatus further includes a sonotrode 25, which defines a 3D cavity 25' and is configured to receive the anvil 21' and the front sleeve portion 11' positioned on the anvil 21'. The sonotrode is configured to apply mechanical vibration to the front sleeve portion 11' on the anvil 21' via the 3D cavity 25', causing permanent deformation of the front sleeve portion 11', thereby forming the 3D top portion 13'.

[0088] As shown in Figure 3, the sonotrode 25 may be positioned so that the cavity 25' faces upward relative to gravity. This can reduce the risk of fine powder, which may be generated during the operation of the top molding unit 303, spreading throughout the station 2. In addition, the upward-facing cavity 25' facilitates the controlled removal of any liquid or fine powder that may enter or form inside the cavity 25' during the operation of the top molding unit 303. Controlled removal of fine powder is important in ensuring consistent quality of the manufactured package body 13.

[0089] As shown in Figure 3, in some embodiments, the cavity 25' forms a blind hole in the sonotrode 25. The axial extension of this blind hole is limited by its bottom surface. The blind hole shape of the cavity 25' allows the sonotrode 25 between the cavity 25' and the conversion unit 27B to be made of solid material, which is thought to improve the proper transmission of mechanical vibrations to the wall surface of the cavity 25'.

[0090] Station 2 does not necessarily have to be configured to rotate each arm 21 between devices 301 and 304; for example, it may be configured to move the arm 21 between devices 301 and 304 along a straight path.

[0091] The station 2 may be designed to fix the sonotrode 25 and move the anvil 21', to which the sleeve 11 is attached, between a standby position separated from the sonotrode 25 and an operating position engaged with the sonotrode 25.

[0092] Figure 4A is a cross-sectional view illustrating the sonotrode 25 engaged with the anvil 21'. The anvil 21' and sonotrode 25 may be included in the station 2 of Figure 3. Both the anvil 21' and sonotrode 25 may be made of metal. The anvil 21' is attached to the arm 21. The sleeve 11 is slid onto the anvil 21' by, for example, the sleeve loading device 302 shown in Figure 3, before the anvil 21' is housed in the cavity 25'. Furthermore, the neck element 14 is attached to the anvil 21' by, for example, the neck loading device 301 shown in Figure 3, and housed in the cavity 25'. The anvil 21' and sonotrode 25 are pressed against each other and engaged by a force F, as indicated by the opposing block arrows. At this time, at least a portion of the front sleeve portion 11' is engaged between the anvil 21' and the sonotrode 25. The force F is applied during the welding process and optionally before the welding process. The force F is adjusted to deform the front sleeve portion 11' into a predetermined top shape. The force F may be adjusted to compress the base material by at least 10%, for example, at least 50%, compared to the base material thickness T0 (see Figure 2F) in an unloaded state. In other embodiments, the compression ratio may be at least 20%, 30%, 40%, 60%, or 70%. In some embodiments, the force F is at least 500N, for example, at least 1000N.

[0093] The anvil 21' and the cavity have surface portions having complementary 3D shapes. The anvil 21' is molded to fit into the cavity 25' of the sonotrode 25, and the front sleeve portion 11' positioned on the anvil 21' is tightly fitted into the cavity 25'. In this specification, “tightly fitted” means that, at least when a force F is applied, the front sleeve portion 11' is in contact with both the anvil 21' and the cavity wall 250 around its entire circumference.

[0094] Anvil 21' is shown in a perspective view in Figure 4B and in a side view in Figure 4E. Figure 4F is a cross-sectional view of anvil 21' in direction 4F of Figure 4E. Figure 4G is a plan view of the protruding end (free end) of anvil 21'. The sonotrode 25 is shown in perspective views from two different angles in Figures 5A and 5B. Figure 5C is a plan view from above of the entrance opening 250' of the cavity 25' of the sonotrode 25. Figures 5D and 5F show the sonotrode 25 from different side views, with the sonotrode rotated 45° around its longitudinal central axis from Figure 5D to Figure 5F. Figure 5E is a cross-sectional view in direction 5E of Figure 5D. Figure 5G is a cross-sectional view in direction 5G of Figure 5F.

[0095] The anvil 21' has a vertical central axis or centerline CS1, as shown in Figure 4F, and the cavity 25' has a vertical central axis or centerline CS2', as shown in Figures 5E and 5G. These central axes CS1 and CS2' are aligned to coincide when the anvil 21', i.e., the front sleeve portion 11', is housed in the cavity 25'.

[0096] In the illustrated example, the cavity 25' within the sonotrode 25 is defined by a peripheral cavity wall 250 and a bottom wall 250b (Figures 5E, 5G). The cavity wall 250 surrounds and restricts the cavity 25' in the circumferential direction, and the cavity 25' has an axial extension in the depth direction DD from the inlet opening 250' to the bottom wall 250b (Figures 4A, 5E, 5G). The cavity wall 250 includes a 3D wall portion 250a (Figures 4A, 5E, 5G) configured to engage with the 3D surface portion 211 of the anvil 21' via the front sleeve portion 11'. The 3D wall portion 250a and the 3D surface portion 211 have shapes that conform to each other in order to achieve a tight fit with the aforementioned front sleeve portion 11'. Therefore, as shown in Figure 4A, the 3D wall portion 250a defines a strip-shaped contact surface for engaging with the 3D surface portion 211 of the anvil 21' via the front sleeve portion 11'. This contact surface is strip-shaped in that it extends circumferentially over the entire circumference of the cavity 25' and extends in the depth direction DD.

[0097] In some embodiments, in order to achieve a tight fit, the 3D surface portion 211 and the 3D wall portion 250a are formed to be locally parallel when the anvil 21' is housed in the cavity 25'. In this context, "locally parallel" means that the tangent plane of the surface portion 211 at a corresponding position on the surface portion 211 and the tangent plane of the wall portion 250a at a corresponding position on the wall portion 250a are approximately parallel, for example, within a range of ±10° or ±5°.

[0098] Comparing Figure 2C and Figure 4B, it can be seen that the 3D surface portion 211 of the anvil 21' is formed to provide the 3D shape of the top portion 13' including the protruding panel 13''. Similarly, as shown in Figures 5E and 5G, the cavity wall 250 within the cavity 25' of the sonotrode 25 is formed to provide the 3D shape of the top portion 13' including the protruding panel 13''.

[0099] The free end of the anvil 21' is provided with a mounting structure 212 for receiving the neck element 14. In the illustrated example, the mounting structure 212 is defined for conformal engagement with the neck element 14, thereby holding the neck element 14 at the free end of the anvil 21' during its movement from the neck loading device 301 to the top forming device 303 (Figure 3). As shown in Figures 4A-4B, the anvil 21' is detachably mounted to the arm 21 using a bolt 220 and a washer 221. At the end opposite the mounting structure 212, the anvil 21' is provided with a fitting hole 214 (Figure 4F) configured to receive an axially projecting arm member 21a (Figure 4A). The anvil 21' defines a through hole 213, which is positioned to fit with an internally threaded mounting hole in the projecting arm element 21a and engage with the external thread of the bolt 220.

[0100] In the example in Figure 4B, the anvil 21' further comprises a surface structure 210, which is configured to locally vary the engagement force between the anvil 21' and the cavity wall 250 and the front sleeve portion 11'. This means that the engagement force is varied compared to an alternative situation where the surface structure 210 is omitted. In the illustrated example, each surface structure 210 is a limited area on the 3D surface portion 211 of the anvil 21'. In some embodiments, when the sleeve 11 is pressed into engagement with the cavity wall 250, the surface structure 210 coincides with or is positioned along the deformation zone 10' on the front sleeve portion 11'. In some embodiments, the surface structure 210 may be designed to locally increase the engagement force to enhance friction and heat generation due to mechanical vibration. In other embodiments, the surface structure 210 may be designed to achieve an engagement force approximately equivalent to that achieved by the other parts of the 3D surface portion 211.

[0101] In some embodiments, as shown in Figure 4A, the surface structure 210 is formed to be elongated, and the anvil 21' housed in the cavity 25' is configured to extend in the depth direction DD of the cavity 25'. Such an elongated surface structure 210 is suitable when the deformation zone 10' also extends in the depth direction DD, as exemplified by the deformation zone 10' shown in Figures 1A-1C and 2A-2C.

[0102] Figure 4C shows an example of a cross-section along direction 4 of the anvil 21' in Figure 4B. Furthermore, the base material 1 is shown superimposed with a dashed line to indicate that the surface structure 210 coincides with the deformation zone as the front sleeve portion 11' is pressed between the anvil 21' and the cavity wall 250. In this example, two separate edges of the base material 1 are joined at an open joint 1'. Such a joint 1' may be formed using a sheet 10 with a notch, for example, as shown in Figure 1B or Figure 1C. It is understood that the joint 1' has an elongated range along the depth direction DD of the cavity 25'. In the illustrated example, the surface structure 210 is raised, thereby forming projections or ridges positioned to support the base material 1 at the joint 1'. The projections 210 locally increase the engagement force between the anvil 21' and the cavity wall 250, thereby locally increasing the effect of mechanical vibration. Such a localized increase may be beneficial in ensuring that the joint 1' is properly and permanently welded by the heat from the mechanical vibration. The height T2 of the projection 210 relative to the surrounding surface is dimensionally set in relation to the thickness T0 of the substrate 1 in order to achieve appropriate local heating. In some embodiments, the ratio of T2:T0 is greater than 0.1 to 0.3 and less than 0.7 to 0.9.

[0103] Figure 4D is another illustrative diagram of a cross-section along direction 4 of the anvil 21' in Figure 4B. Here, the substrate 1 is folded into multiple overlapping layers in the deformation zone, and the inner layers constitute an open joint 1' where different parts of the base substrate are joined. This joint 1' is permanently welded by heat from mechanical vibration. In Figure 4D, three layers are stacked on top of each other. Such a stacked structure is formed by the deformation zone shown, for example, in Figures 2A-2B. In the illustrated example, the surface structure 210 defines a recess or tray and is positioned to receive the stacked structure of the substrate 1 and the joint 1'. The depth T2 of the recess 210 can be dimensioned to obtain a desired engagement force between the anvil 21' and the cavity wall 250. If the recess 210 is absent, the engagement force may be excessive as a result of the stacked layers. In some embodiments, the depth T2 is equal to or less than the difference between the height T1 of the stacked layers and the thickness T0 of the substrate. As a result, the engagement force on the substrate within the laminated layers is approximately equal to or greater than the engagement force on the substrate around the recess 210. In some embodiments, T2 = T1 - T0·(1+α), where α is greater than 0.1 to 0.3 and less than 0.7 to 0.9.

[0104] The anvil 21' may have a surface structure specifically for the longitudinal joint of the sleeve 11. This surface structure may be a projection or a recess, depending on the embodiment. An example of such a surface structure is shown by reference numeral 210' in Figure 4E.

[0105] The surface structures 210, 210' on the anvil 21' can be complemented or replaced by similar surface structures on the cavity walls 250 within the sonotrode 25. However, at present, it is considered beneficial to provide the surface structures 210 only on the anvil 21'. If the surface structures are provided as recesses or protrusions on the cavity walls 250 of the sonotrode 25, they may be observed on the outside of the top portion 13' of the package body 13 on which the corresponding surface structures are formed. This is undesirable from an aesthetic standpoint. Also, it is generally desirable for the top portion 13' to have a smooth outer surface to reduce the accumulation of dust and dirt. A smooth outer surface of the top portion 13' can be achieved by providing a smooth 3D wall portion 250a within the cavity 25'. Furthermore, providing surface structures on the cavity walls 250 of the sonotrode 25 may affect the vibration pattern of the sonotrode 25. Therefore, providing surface structures 210 and 210' on the cavity wall 250 may make the design of the sonotrode 25 more difficult. On the other hand, the anvil 21' does not transmit mechanical vibrations and does not affect the vibration pattern of the sonotrode, allowing for greater design freedom or modification in relation to existing sonotrode.

[0106] Referring to the example in Figures 5A-5G, the sonotrode 25 extends between a first end face 253' and a second end face 253''. The first end face 253' has an inlet opening 250' into the 3D cavity 25', which extends in the depth direction DD from the first end face 253' toward the second end face 253''. Thus, the depth direction DD aligns with the axial centerline CS2 of the sonotrode 25, and the end faces 253' and 253'' are spaced apart axially by a distance D3 (Figure 5D). The second end face 253'' is configured for mounting to a conversion unit (27B in Figure 3). In the illustrated example, the second end face 253'' is flat and is configured to be bolted to the conversion unit using a threaded mounting hole 255 that extends axially toward the cavity 25'. It is understood that the sonotrode 25 is configured to receive mechanical vibrations through the second end face 253''.

[0107] The circumferential outer surface 251 extends between the end faces 253' and 253''. In the illustrated example, the outer surface 251 is formed in a generally convex shape in the axial direction. Therefore, the distance between the outer surface 251 and the axial centerline is minimized in the region adjacent to the end faces 253' and 253''. The shape of the outer surface 251 is determined by the need for solid material around the cavity 25' in order to achieve an appropriate vibration pattern for the sonotrode 25 and to bring about the intended permanent deformation of the front sleeve portion 11', as will be explained later with reference to Figures 7A to 7B.

[0108] The cavity 25' is positioned in the center of the first end face 253'. This ensures that the axial centerline CS2' of the cavity 25' coincides with the axial centerline CS2 of the sonotrode 25 (Figures 5E, 5G). As previously described, the cavity 25' is defined by a peripheral cavity wall 250 and a bottom wall 250b, the peripheral cavity wall 250 extending in the depth direction DD from the inlet opening 253' to the bottom wall 250b. Depending on the function, the cavity wall 250 may be divided into different peripheral wall portions as shown in Figures 5E and 5G. The inlet wall portion EW ("inlet wall") is positioned to extend into the cavity 25' from the inlet opening 250' along the depth direction DD by an axial distance W1. The inlet wall EW has a shape that receives and guides the front sleeve portion 11' into the cavity 25'. In the illustrated example, the inlet wall EW forms a tapered surface. This tapering surface is inclined inward into the cavity 25' toward the centerline CS2' of the cavity 25'. The cavity wall 250 further includes a shoulder-defining wall SW ("shoulder wall") configured to form the shoulder portion SP (see Figure 2E) of the package body 13 by the deformation of the front sleeve portion 11'. The shoulder wall SW may be adjacent to the inlet wall EW as shown, or an intermediate wall may be provided between the inlet wall EW and the shoulder wall SW. The shoulder wall SW has a range W2 extending in the depth direction DD. The shoulder wall SW is part of the strip-shaped contact surface 250a. The cavity wall 250 further includes a neck-defining wall NW ("neck wall"). This neck wall is configured to guide the front sleeve portion 11' on the anvil 21' into engagement with the flange 14' on the neck element 14 when the front sleeve portion 11' on the anvil 21' is pressed into the cavity 25'. The neck wall NW is adjacent to the shoulder wall SW and extends over a distance W3 in the depth direction DD. It is understood that the neck wall NW is also part of the band-shaped contact surface 250a. In the illustrated example, the neck wall NW forms a tapered surface inclined toward the centerline CS2' of the cavity 25'. The cavity wall 250 also includes a bottom wall BW ("circumferential bottom wall") adjacent to the neck wall NW and configured to receive the tubular portion 14'' of the neck element 14 when the anvil 21' is inserted into the cavity 25'.In the examples of Figures 5E and 5G, the circumferential bottom wall BW has a range W4 extending in the depth direction DD. The circumferential bottom wall BW may be positioned to maintain a gap between the tubular portion 14'' of the neck element 14 when the anvil 21' is inserted into the cavity 25'. This prevents the tubular portion 14'' from being damaged by mechanical vibration. Furthermore, this gap prevents the neck element 14 from becoming stuck in the cavity 25'' as a result of welding. However, in some embodiments, the circumferential bottom wall BW may have a surface portion that contacts the tubular portion 14'' to achieve intentional pattern formation or reshaping. The circumferential bottom wall BW is joined to the bottom wall 250b of the cavity 25'. The bottom walls BW, 250b together define the bottom cavity and are positioned to accommodate the neck element 14 when the anvil 21' is pressed into the cavity 25'.

[0109] As described above, the neck element 14 may be attached to or formed in a separate process after deformation and welding within the sonotrode 25. In such an embodiment, the neck wall NW and circumferential bottom wall BW can be omitted from the cavity wall 250, and the shoulder wall SW can be configured to deform at least a portion of the front sleeve portion 11' into the top portion 13'. It is also conceivable to omit the inlet wall EW from the cavity wall 250.

[0110] In the illustrated example, the sonotrode 25 comprises a plurality of channels 252 extending from an inner opening 252' at the bottom of the cavity 25' to an outer opening 252'' on the outer surface 251. The channels 252 are positioned to remove any fine powder or liquid that may accumulate in the bottom portion of the cavity 25' during operation of the sonotrode 25. For example, fine powder may be generated by deformation of the front sleeve portion 11'. In some embodiments, the outer opening 252'' is connected to a pressure control system (not shown). This system is operable to generate a suction force within the channels 252 to draw fine powder and / or liquid away from the cavity 25'. This suction is generated when the anvil 21' is inserted into the cavity 25' and / or when the anvil 21' is separated from the cavity 25'. As shown in Figures 5E and 5G, the channels 252 are inclined and extend away from the first end face 253'. This ensures that the discharge of fine powder and / or liquid is at least partially driven by gravity. A pressure control system is optional but can also be used to generate overpressure within the channel 252 to assist the top section 13' in moving out of the cavity 25' after the welding operation. Any number of channels 252 can be provided. A symmetrical arrangement of the channels 252 with respect to the cavity 25', as shown in the figure, can improve the removal of fine powder and / or fluid. The inner opening 252' of each channel 252 may be formed in the circumferential bottom wall BW and / or bottom wall 250b.

[0111] In the illustrated example, the sonotrode 25 has a plurality of shallow recesses 256 formed on its outer surface 251, each recess having a corresponding blind hole 256' (Figure 5A). The recesses 256 and blind holes 256' are independent of the operation of the sonotrode 25. The blind holes 256' are used for mounting the sonotrode 25 to a jig during manufacturing, and the recesses 256 are provided to secure space for tools.

[0112] In the examples shown in Figures 5A-5G, identical projections 254, made of the same solid material, are symmetrically arranged around the inlet opening 250'. The projections 254 protrude radially from the centerline CS2' of the cavity 25' and also extend in the depth direction DD along the cavity 25'. The amount of material in each projection 254 increases monotonically toward the inlet opening 250', as shown, for example, in the perspective view of Figure 5A. The projections 254 are provided to achieve controlled vibration of the cavity wall 250 near the inlet opening 250' when the cavity 25' has a non-circular shape with a cross-section perpendicular to the depth direction DD. The cavities 25' shown in Figures 5A-5G have a non-circular cross-section, as can be seen from the shape of the inlet opening 250' in Figure 5C. Here, the inlet opening 250' has the shape of a square with rounded corners, forming approximately an octagon with opposing parallel sides. The minimum and maximum distances D1 and D2 of the cavity 25' with respect to the centerline CS2' are indicated by double arrows in Figure 5C. Through considerable experimentation, it was found that when the material thickness around the inlet opening 250' is uniform, the mechanical vibrations transmitted to the cavity wall 250 near the inlet opening 250' differ depending on the distance from the centerline CS2'. Therefore, the projection 254 is positioned to add mass at the maximum radial distance D2 from the centerline CS2', thereby altering the amplitude of the mechanical vibrations of the cavity wall 250 at least at and near these positions.

[0113] Figure 6 shows a cross-section of the sleeve 11 positioned on the arm 21. The front sleeve portion 11' is positioned to surround the anvil 21'. The neck element 14 is detachably attached to the mounting structure 212 by a snap-fit ​​between the tubular portion 14'' and the mounting structure 212. In the illustrated example, the neck element 14 is provided with an integrated cap (see 14''' in Figure 2E). A portion of the mounting structure 212 protrudes beyond the front edge of the front sleeve portion 11'. The flange 14' of the neck element 14 is positioned within the front sleeve portion 11' by the mounting structure 212. As a result, when the front sleeve portion 11' is deformed by the engagement of the anvil 21' with the cavity wall 250, the outermost edge of the front sleeve portion 11' comes into contact with the flange 14' (see mounting portion AP in Figure 2E).

[0114] Figure 6 shows a cross-sectional view of an example of a deformation unit 28 for pre-forming the deformation zone 10' on the front sleeve portion 11'. The illustrated deformation unit 28 is configured to be positioned in front of the sonotrode 25, for example, as shown in Figure 3. For this purpose, the deformation unit 28 is formed in an annular shape so that the anvil 21' can pass through the deformation unit 28. The deformation unit 280 comprises a hollow, collar-shaped base element 280. Legs 281 extend from the base element 280 and are connected to engaging elements 282. Each engaging element 282 is positioned to engage the base material of the front sleeve portion 11' at its respective contact surface 282' in each deformation zone 10' as the anvil 21' is inserted into the deformation unit 28. In the illustrated example, the contact surface 282' is flat and inclined, gradually guiding the front sleeve portion 11' toward the anvil 21' as the anvil 21' slides into the deformation unit 28. The engaging element 282 can, for example, cause bending of the substrate around one or more fold lines. In some embodiments, the engaging element 282 is positioned to be biased toward the front sleeve portion 11', ensuring a clear engagement force between the engaging element 282 on the anvil 21' and the front sleeve portion 11'. In some embodiments, the leg portion 281 is configured to bend radially, allowing the engaging element 282 to slide along the anvil 21' toward the arm 21. This reduces the risk of damage to the sleeve 11. In some embodiments, the deformation unit 28 is a passive component, and when the anvil 21' slides into the deformation unit 28, the engaging element 282 is positioned to essentially engage with and deform the front sleeve portion 11'. The example in Figure 5 is a passive component. In other embodiments (not shown), the deformation unit 28 is an active component, and when the anvil 21' slides into the deformation unit 28, an actuator moves the engaging element 282 to actively engage with the front sleeve portion 11'. For example, the engaging element 282 is configured in a tongue shape and retracts when the anvil 21' is inserted into the deformation unit 280, and is then pushed into the engagement position with the front sleeve portion 11'.

[0115] It has been found to be beneficial to configure the deformation unit 28 so that the engaging elements 282 engage with the front sleeve portion 11' in a synchronous manner. This means that the engaging elements 282 engage with the front sleeve portion 11' almost simultaneously, whether by actuator or passively. This ensures that the engaging force acts uniformly, allowing for controlled preforming of the front sleeve portion 11'. Furthermore, controlled preforming is possible by arranging the engaging elements 282 in opposing pairs so that they engage with the front sleeve portion 11' from radially opposite directions. For similar reasons, it is also beneficial to arrange the deformation zones 10' to form opposing pairs on the front sleeve portion 11', as shown in Figure 2B, for example.

[0116] The Sonotrode 25 is designed to achieve a desired vibration pattern for the cavity wall 250 with respect to both the local direction and local amplitude of the mechanical vibration. It is generally desirable that the mechanical vibration moves the cavity wall 250 nearly perpendicular to its local extent. This means that the cavity wall 250 vibrates locally nearly perpendicular to the front sleeve portion 11' on the anvil 21', at least between the shoulder wall SW and the neck wall NW (see Figures 5E and 5G). In this context, "essentially perpendicular" means that the local direction of the vibration deviates from 90° by an angle of less than β, where β is ±5°, ±10°, or ±15° depending on the implementation. Non-perpendicular vibration can cause significant local wear of the substrate, leading to the formation of excessive fine powder and potentially impairing the usability of the package body. It is also generally desirable that the amplitude of the mechanical vibration is clearly defined across the cavity wall 250, at least between the shoulder wall SW and the neck wall NW. Different amplitudes result in different heating, ultimately affecting the welding performance. In some embodiments, the sonotrode 25 is configured so that the amplitude of mechanical vibration is constant within the shoulder wall SW. In this context, "constant amplitude" may mean that the amplitude deviates by less than 5%, 10%, or 15% across the entire shoulder wall SW. Also, by analogy with a tuning fork, it may be desirable to ensure that the sonotrode vibrates at a single frequency, thereby avoiding the presence of parasitic or alternative frequencies that consume power.

[0117] The vibration pattern of Sonotrode 25 may be evaluated by simulation using a mathematical model of Sonotrode 25. This mathematical model may be based, for example, on finite element analysis (FEA), which is commonly used in vibration analysis.

[0118] Figure 7A shows the estimated vibration pattern of the sonotrode 25 shown in Figures 5A-5G, generated by a dedicated simulation program. The sonotrode 25 is shown in cross-sectional views at six consecutive stages (indicated by reference numbers 71-76) during the vibration period. As can be seen from the figure, the sonotrode changes its shape significantly during the vibration period. Similarly, the shape of the cavity 25' also changes significantly in both the axial and radial directions. The shape of the cavity 25' (and the sonotrode 25) is substantially identical between stages 72 and 76, and between stages 73 and 75. The sonotrode 25 in Figure 7A is designed so that the cavity wall 250 vibrates almost perpendicular to its local extent. This is schematically shown in Figure 7B, where the periphery line PL of the cavity 25' at different stages 71-76 in Figure 7A is plotted. As indicated by the double-ended arrows MV, the periphery line PL moves locally almost vertically during the vibration period. It should be understood that this vibration pattern is primarily related to the portion of the cavity wall 250 that contacts the front sleeve portion 11' on the anvil 21', i.e., the aforementioned contact surface 250a. In other parts of the cavity 25', it is possible to control the amplitude of the vibration pattern to prevent unintended contact with the front sleeve portion 11' or the neck element 14.

[0119] The applicant has identified several design features of the sonotrode 25 that are adjustable to achieve an appropriate vibration pattern.

[0120] The first design feature is the axial length of the sonotrode 25. This axial length is the distance D3 between the end faces 253' and 253'', as shown in Figure 5D. It has been found that this distance D3 can be matched to the frequency of the supply signal supplied from the supply unit 27A to the conversion unit 27B, i.e., the target frequency of mechanical vibration in the sonotrode 25. This reduces the risk of vibration occurring at parasitic frequencies in addition to the intended frequency, improving the efficiency and durability of the sonotrode 25. Therefore, for a given sonotrode, the supply unit 27A is configured to tune to the sonotrode and generate a supply signal with a frequency given by the sonotrode's distance D3. Similarly, the conversion unit 27B is adapted to this frequency.

[0121] The second design feature is the shape or contour of the outer surface 251 of the sonotrode 25. The shape of the outer surface 251 has been found to affect the amplitude and / or direction of the mechanical vibration of the cavity wall 250. The applicant has found that in some embodiments, a suitable vibration pattern can be obtained when the outer surface 251 is formed to be generally convex with respect to the axial direction of the sonotrode 25 (for example, as shown in Figures 5A-5G). For comparison, it has been found that if the outer surface 251 is cylindrical, the vibration pattern of the cavity wall 250 is unacceptable, at least when the cavity 25' is dome-shaped.

[0122] A third design feature is the radial thickness of the material around the strip-shaped contact surface 250a. It has been found that an appropriate vibration pattern can be obtained when the radial thickness increases along the depth direction DD of the cavity 25' over the entire or a corresponding portion of the strip-shaped contact surface 250a. This is shown in Figures 5E and 5G, where the radial thickness is indicated by thick double-ended arrows. In the illustrated example, the strip-shaped contact surface 250a includes a shoulder wall SW and a neck wall NW. As mentioned above, the neck wall NW can be omitted in some embodiments.

[0123] A fourth design feature is that the sonotrode 25 is constructed as a solid or one-piece material block. For example, the sonotrode 25 can be manufactured by casting and subsequently subjected to machining processes such as grinding, milling, boring, and reaming as needed. Alternatively, the sonotrode 25 can be manufactured solely by machining. Since this solid or one-piece material block has no joints or welds, the transmission of mechanical vibrations from the end face 253'' to the cavity wall 250 is clearly defined.

[0124] A fifth design feature is the local addition of material to the periphery of the inlet opening 250', as exemplified by the radial projection 254. As mentioned above, such local addition of material is beneficial to the vibration pattern when the cavity 25' has a non-circular cross-section with respect to the depth direction DD.

[0125] Figure 8 shows an alternative configuration of Station 2 in Figure 3. Figure 8 illustrates Station 2 during manufacturing. Similar to Figure 3, Station 2 comprises an indexing device 300, a neck loading device 301, a sleeve loading device 302, a top forming device 303, and an ejection device 304. Furthermore, Station 2 is provided with an independent pre-forming station 303', which is functionally located between the sleeve loading device 302 and the top forming device 303. The indexing device 300 has six elongated holders or arms 21, with an anvil 21' at the outer end of each arm. The arms 21 are equiangled on the wheel 22. The indexing device 300 indexes to six different angular positions I to VI during one rotation. Devices 301, 302, 303, and 304 may be identical to the corresponding devices in Figure 3, except that device 303 does not have a deformation unit 28. In the illustrated example, the neck mounting device 301 is configured to position the neck element 14 on the anvil 21' while the anvil 21' moves between positions I and II. Thus, in position II, the neck element 14' is mounted on the anvil 21'. In another embodiment (not shown), the device 301 can be positioned in position I or position II to mount the neck element 14 on the anvil 21'. In position III, the sleeve 11 slides onto the arm 21, and its front sleeve portion is properly aligned with the anvil 21'. In position IV, the pre-forming device 303' is activated, and the front sleeve portion is pre-deformed ("pre-forming") using the deformation unit 28. The deformation unit 28 may be configured in accordance with the deformation unit 28 in Figure 6. In the example in Figure 8, the deformation unit 28 is linearly movable between a resting position and an operating position, as indicated by the double-ended arrows A3'. In the resting position, the deformation unit 28 is positioned at a distance from the anvil 21'. In the operating position, the deformation unit 28 is positioned to surround the front sleeve portion on the anvil 21'. The pre-molding device 303' is connected to the deformation unit 28 and includes an actuator or moving device 26' that can be operated to give it movement between its stationary position and operating position. As described above, the deformation unit 28 can be a passive or active component.In the case of active components, the actuator 26' is also operable to actively engage the deformation unit 28 with the front sleeve portion. At position V, the top molding device 303 operates to reshape the front sleeve portion to the top shape of the package body 13 and at the same time attach the neck element 14 to the front sleeve portion. At position VI, the ejection device 304 operates to remove the package body 13 from the arm 21.

[0126] Figure 8 shows an example of an embodiment in which the deformation unit 28 is operationally independent and spaced apart from the sonotrode 25, and the sleeve 11 is pre-formed in the deformation unit 28 and then moved from the deformation unit 28 to the sonotrode 25 by a transport device. In the embodiment of Figure 8, the transport device is composed of a combination of wheels 22 and a drive unit 23, but other methods for transporting the sleeve are also possible.

[0127] The combination of the sonotrode 25, the 3D cavity 25', and the corresponding 3D anvil 21' has been developed and tested for shaping the top portion of a package body, but can be used to form sheet material into a three-dimensional surface of any kind of product (including non-food packaging), whether or not it is formed into a sleeve. Accordingly, this disclosure provides a sonotrode 25 comprising a cavity 25' defined in general by a three-dimensional cavity wall 250 and configured to receive a three-dimensional anvil 21'. The sonotrode 25 applies mechanical vibration to the 3D anvil 21' through the three-dimensional cavity wall 250, thereby transmitting the mechanical vibration to the sheet material positioned between the three-dimensional anvil 21' and the three-dimensional cavity wall 250.

Claims

1. An apparatus for forming the top portion (13') of the three-dimensional shape of the package body (13), wherein the apparatus is An anvil (21') having a three-dimensional shape, wherein the anvil (21') is configured to receive a sleeve (11) of a base material (1), and the front sleeve portion (11') of the sleeve (11) is arranged to surround at least a part of the anvil (21'), A sonotrode (25) comprising a three-dimensional cavity (25') configured to receive the anvil (21') and the front sleeve portion (11') on the anvil (21'), wherein the sonotrode (25) applies mechanical vibration to the front sleeve portion (11') on the anvil (21') via the three-dimensional cavity (25'), causing permanent deformation of the front sleeve portion (11') to form the three-dimensional top portion (13'), and the sonotrode (25), Equipped with, Device.

2. When the front sleeve portion (11') is housed in the three-dimensional cavity (25'), the longitudinal central axis (CS2') of the three-dimensional cavity (25') aligns with the longitudinal central axis (CS1) of the anvil (21'). The apparatus according to claim 1.

3. The anvil (21') and the sonotrode (25) are pressed together with a predetermined force (F) while mechanical vibration is applied, thereby compressing the base material (1) of the front sleeve portion (11'). The apparatus according to claim 1 or 2.

4. The three-dimensional cavity (25') extends in the depth direction (DD) into the sonotrode (25) from the inlet opening (250') and is defined by a cavity wall (250) that surrounds the three-dimensional cavity (25') in the circumferential direction. The apparatus according to any one of claims 1 to 3.

5. The anvil comprises a three-dimensional surface portion (211) formed to fit the three-dimensional wall portion (250a) of the cavity wall, the three-dimensional wall portion (250a) being circumferentially circular in the circumferential direction, and defining a strip-shaped contact surface for engaging with the three-dimensional surface portion (211) of the anvil (21') via the front sleeve portion (11'). The apparatus according to claim 4.

6. At least one of the anvil (21') or the cavity wall (250) is provided with a surface structure (210) configured to locally change the contact force applied from the anvil (21') and the cavity wall (250) to the front sleeve portion (11'), The apparatus according to claim 4 or 5.

7. At least a portion of the deformation zone (10') is configured to form multiple overlapping layers of the base material (1) when the front sleeve portion (11') is housed in the three-dimensional cavity (25'). The apparatus according to claim 6.

8. The surface structure (210) includes elongated recesses configured to accommodate multiple overlapping layers of each deformation zone (10') in at least some of the deformation zones. The apparatus according to claim 7.

9. The cavity wall (250) includes a wall portion (SW) that defines the shoulder portion, and the wall portion is configured to deform at least a part of the front sleeve portion (11') into the shoulder portion (SP) of the package body (13). The apparatus according to any one of claims 4 to 8.

10. The front end of the anvil (21') is provided with a mounting structure (212) for a neck element (14) having a tubular portion (14'') that defines an access opening to the package body (13), and the mounting structure (212) is configured to position the neck element (14) at least partially within the front sleeve portion (11') when the front sleeve portion (11') is placed on the anvil (21'). The apparatus according to any one of claims 4 to 9.

11. The sonotrode (25) comprises first and second end faces (253', 253'') and a circumferential outer surface (251) extending between the first and second end faces (253', 253''), and the three-dimensional cavity (25') is formed on the first end face (253'). The apparatus according to any one of claims 4 to 10.

12. The device comprises a deformation unit (28), the deformation unit is configured to engage the front sleeve portion (11') with the anvil (21') and pre-deform the front sleeve portion (11') before the front sleeve portion (11') is housed in the three-dimensional cavity (25'), The apparatus according to any one of claims 1 to 11.

13. The base material (1) of the front sleeve portion (11') includes a plastic material (1B) configured to be softened by mechanical vibration applied by the sonotrode (25) and then solidified after the mechanical vibration is removed, thereby achieving permanent deformation of the front sleeve portion (11'). The apparatus according to any one of claims 1 to 12.

14. The anvil (21') is removably housed in an elongated holder (21) that receives the sleeve (11) of the base material. The apparatus according to any one of claims 1 to 13.

15. A sonotrode comprising a cavity (25'), wherein the cavity is defined by a three-dimensional cavity wall (250) and configured to receive a three-dimensional anvil (21'), and the sonotrode (25) is configured to apply mechanical vibrations to the three-dimensional anvil (21') through the three-dimensional cavity wall (250). Sonotoro.

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