Method for manufacturing a container, related shape for manufacturing such a container, machine for implementing such a method, and container

Abstract

A method for manufacturing a container (1), such as a disposable cup, from a sheet (20) of a flexible material, the method comprising the following steps: - a step of cutting out a planar related shape (21) for said container (1) from said sheet (20), - a step of shaping the planar related shape (21), the method being characterized in that the cutting-out step comprises the formation, at what is referred to as an upper edge (24), of at least one tab (7) of material connecting a lid, and of at least one turn-over rim strip (29), and in that it also comprises a step of rolling the turn-over rim strip (29) in order to form a turned-over rim (6), leaving the tab (7) of material intact.

Description

DESCRIPTION Title: Method for manufacturing a container, related form for manufacturing such a container, machine for implementing such a method and container FIELD OF THE INVENTION

[0001] The present invention relates to the field of containers intended to receive a product, in particular a food liquid such as a drink, and more particularly to so-called disposable containers.

[0002] More specifically, the invention relates to a so-called disposable container comprising a lid, which can be found anywhere. TECHNOLOGICAL BACKGROUND

[0003] A known type of container is commonly called a "cup": it is a container intended primarily to hold a beverage, generally hot like coffee, but which can be suitable for holding any other liquid or solid products, particularly small ones, in the form of granules for example. A cup typically comprises a base and a side wall, which define a filling volume. It can be made of plastic. For ecological reasons, it is increasingly made of paper or cardboard, and is obtained from folding and gluing a sheet so as to form the side wall of a substantially cylindrical shape, the base being attached and glued to the side wall.

[0004] Disposable cups can also be found more generally in any type of business or at events such as concerts or festivals.

[0005] Such a container is generally intended for temporary use, for the time it takes to consume the product it contains, and then to be disposed of as waste. It is therefore known to be made from inexpensive and biodegradable materials, such as paper or cardboard. Such a container is found in particular for vending machines, such as coffee machines, or for takeaway sales. Its diversity of use, its availability and its low cost make it a very common object throughout the world.

[0006] A lid may advantageously be associated with the container, in order to close the filling volume; the risks of splashing and spilling are reduced, and, in the case of hot drinks in particular, heat loss is reduced. In the case of a container intended for drinks, the lid may be provided with openings for drinking the contents and / or for inserting a straw. The lid is generally attached to the edge of the opening of the container.

[0007] One problem is that the lid, in order to fit and stay on the container, must have dimensions that are adapted to the container. However, it is desirable to have containers of different dimensions, in order to adapt to the volume or quantity of product desired by the consumer: this is commonly referred to as container size. Thus, it is necessary to have as many lids of different dimensions as container sizes available. Managing lids in addition to container sizes involves additional costs.

[0008] The lid must also be rigid enough to provide a good fit on the container. It is generally made of plastic, which can be an environmental issue. It can also be made of paper / cardboard with a large amount of material or a special treatment to give it sufficient rigidity. In both cases, the manufacturing costs of the lid are significant.

[0009] Furthermore, the consumer may want to remove the lid from the container, either temporarily or permanently, which may cause inconvenience to the consumer, especially when moving. In addition, the lid removed from the container constitutes additional waste, which may be mistreated as such by the consumer.

[0010] Document US6601728 describes a solution in which the lid is manufactured and attached with a sleeve to be placed around the container, especially when the contents are hot to prevent the consumer from burning themselves. However, such a solution is partial. Indeed, the sleeve and the lid are made of polystyrene, which poses environmental problems. In addition, the sleeve and the lid are attached to the container, not solving the size management problem. In addition, the sleeve can be separated from the container by the consumer. Finally, the lid implies the presence of the sleeve, which is not necessary depending on the contents of the container and / or the consumer's need.

[0011] Document WO2010 / 144810 proposes forming a container from a sheet cut according to a particular geometry and then rolled, so that the container can be folded so as to provide a closure of the filling volume. A spout shape is also provided, to be able to drink or pour a liquid contained in the container thus closed. However, such a container offers an unconventional shape, which does not attract consumers. In addition, the originality of the cut geometry implies reviewing the manufacturing chain of known containers, which increases manufacturing costs. Finally, opening the container involves an unfolding step, which can be tedious or even dangerous for the consumer in the case of hot liquid in the container: unfolding must be carried out with care to avoid splashing the consumer or tearing the container, making it unusable.

[0012] GB2420265 proposes molding a single-piece container with a lid from paper pulp. However, the manufacturing costs of a container using this technique are high. For example, processing paper pulp involves using large quantities of heated water and additives. Energy consumption is therefore high. The leak-tightness of such a container is limited. In addition, once the material is wet, it becomes softer, making it difficult to properly hold a lid on it. Finally, the molding technique requires molds of different dimensions to meet size requirements.

[0013] Document US 2015 / 210443 proposes a container, a method of using the container and a method of manufacturing the container. The container described in this document consists of a body of circular section and a lid which is folded down onto the body to which it is attached. When the lid is folded down, the body of the container is necessarily deformed: the fold line at the junction between the lid and the body imposes a straight line on the section. In order to remedy this, two vertical cuts are made on the body, in the extension of the lid. However, these cutting lines are detrimental to the leaktightness of the container. In addition, the lid is locked onto the body using a groove made inside the container on the body, and into which the edge of the lid is inserted.Therefore, whether to open or close the container with the lid, the body and / or the lid must be deformed by handling by the consumer. Such deformation is delicate, especially in the case where the container contains a liquid: it risks spilling. This deformation can even be dangerous in the case of a hot liquid that could burn the consumer handling the lid. Thus, such a container cannot in practice be used to contain a liquid.

[0014] US 2006 / 169759 proposes disposable containers, in particular for liquids, powders and other flowable materials. A container body is provided with an integrated lid, similar to that proposed in US 2015 / 210443 presented above, but in which the lid is permanently sealed to the body, so that only an operation involving a high risk of damaging the body and / or the lid, in particular by tearing them, can allow the lid to be removed. Reattaching the lid to close the container is then impossible.

[0015] The invention thus aims in particular to address the aforementioned drawbacks. SUMMARY OF THE INVENTION

[0016] Thus, according to a first aspect, the invention relates to a method for manufacturing a container, such as a disposable cup, a fast food container such as a bucket and a container for salads, or other food products, from a sheet of a flexible material. The material is for example typically paper or cardboard. The container comprises a side wall obtained by shaping said sheet. Said side wall defines an opening of the container and is provided with a rim. The container further comprises a lid intended to close said opening, a hem extending strictly over a portion of the rim, leaving a portion of the rim without a hem, and at least one tab of material connecting the lid to the portion of the rim without a hem. The tab is distinct from the lid and the side wall.The side wall, the tongue and the cover form a single unit, that is to say they are made in one piece. The process then includes the following steps: - A step of cutting out on said sheet a planar related shape of said container, the planar related shape of said container comprising at least one body portion intended to form at least the side wall of the container, and at least one lid portion, intended to form at least the lid of the container, - A step of shaping the container from the related plane shape.

[0017] The cutting step more particularly comprises the formation on a so-called upper edge of the body portion of at least one tab of material connecting the body portion to the lid portion, and at least one hemmed strip. In addition, the method comprises a step of rolling the hemmed strip in order to form the hem on the edge of the side wall of the container, the tab being excluded from the rolling step, leaving the tab of material intact, i.e. it is not affected by the rolling step. The tab, which is distinct from the side wall and the lid, i.e. it is not confused with the side wall and the lid, can advantageously form a hinge connection, guaranteeing a satisfactory level of sealing.

[0018] The process thus allows the container and its lid to be manufactured jointly. The resulting container is then always equipped with its lid attached to it. Manufacturing and storage costs are reduced compared to the prior art. Since the lid is attached to the rest of the container, it will be discarded with the rest of the container, facilitating waste management.

[0019] Depending on different aspects, it is possible to provide one and / or the other of the characteristics below taken alone or in combination.

[0020] The method may include a step of embossing the lid portion to form a collar on the lid. Said collar is intended to engage with the hem of the side wall. The lid can thus be held on the rest of the container to close the opening, preventing it from lifting unexpectedly.

[0021] According to one embodiment, the body section of the planar related shape of the container may comprise a bottom section. The shaping step may then comprise an operation of closing the container by folding down the bottom section. Manufacturing costs are again reduced.

[0022] According to one embodiment, the method may further comprise perforating the cover, to form an opening for a straw-like device.

[0023] According to one embodiment, the sheet material comprises paper and / or cardboard, which is a biodegradable material.

[0024] According to one embodiment, the method may comprise a printing step before the shaping step, in which an ink-like substance is deposited on the surface of at least one side of the planar shape. The printing may be carried out before or after the cutting step, on the sheet or on the planar shape, in order to produce any kind of image on all or part of the surface of at least one side of the sheet or of the planar shape. The printing may concern, for example, messages and / or images and / or graphics and / or patterns, intended for the consumer, in particular for informational and / or advertising purposes.The printing can be controlled on a single side of the sheet or flat shape, in particular the side intended to form the outer face of the container, so that the side intended to form the inner face, intended to potentially be in contact with a food product, can remain free of any ink-type substance, and thus meet high health requirements.

[0025] According to one embodiment, after the rolling step or during the rolling step, the method may comprise a folding operation between the tab and the portion without a hem, at a folding angle less than or equal to 180°. The semi-circular folding may preferably be carried out for an angle greater than or equal to 90°. The semi-circular folding may be carried out during or just after the step of rolling the hem, and follows at least in part the curvature of the hem in order to limit the risks of leakage, for example when a liquid is introduced into the container 1, at the level of the tab.

[0026] According to a second aspect, the invention relates to a planar related shape obtained by implementing the cutting step of the manufacturing method presented above. Such a planar related shape makes it possible to quickly and easily obtain lower cost the container equipped with its lid. It can also be stored easily, with limited space, before undergoing the shaping step. In addition, the planar related shape thus obtained by the cutting step can make it possible to easily add a printing step on the planar shape, on at least one side of said shape, in order for example to obtain a finished container entirely printed on both the side wall and its lid.

[0027] According to a third aspect, the invention relates to a machine for implementing the method presented above. The machine comprises at least: - A cutting station comprising a device for cutting the related plane shape; - A shaping station to form the side wall of the container; - A rolling station for rolling the hem strip to form a hem on the side wall while leaving the material tab intact.

[0028] Such a machine allows the entire container manufacturing process, including the lid, to be combined into a single machine. It can be installed in a limited space, thus reducing floor space requirements.

[0029] According to one embodiment, the machine may further comprise a station for embossing the cover portion in order to form a collar intended to engage with the hem of the side wall.

[0030] According to a third aspect, the invention relates to a container, such as a disposable cup, made from a sheet of flexible material. The container comprises a side wall obtained by shaping said sheet, said side wall defining an opening of the container provided with a rim. The container further comprises a lid intended to close said opening. The container comprises a hem which extends strictly over a portion of the rim, leaving a portion of the rim without a hem, and it comprises a tab of material connecting the lid to the portion of the rim without a hem. The tab is distinct from the side wall and the lid, that is to say it is not confused with the side wall and the lid. Finally, the side wall, the lid and the tab form a single-piece assembly, that is to say they are made in one piece.

[0031] Such a container can be obtained in particular by implementing the manufacturing process presented above.

[0032] According to one embodiment, the container may further comprise a bottom that is one-piece with the rest of the container. BRIEF DESCRIPTION OF THE DRAWINGS

[0034] Embodiments of the invention will be described below with reference to the drawings, briefly described below:

[0035] [Fig. 1] represents a three-dimensional view of an example of a container according to one embodiment

[0036] [Fig. 2] represents a view of a detail of the container of figure 1 at the level of a tab.

[0037] [Fig. 3] shows a sheet of flexible material on which the contours of a shape to be cut to form a container are drawn, in accordance with one embodiment of the invention

[0038] [Fig. 4] schematically shows a manufacturing machine according to an embodiment in accordance with the invention.

[0039] In the drawings, like references designate like or similar objects. DETAILED DESCRIPTION

[0040] The invention relates to a container 1, a method for manufacturing such a container and a machine for implementing the method. Such a container 1 may be located, for example, near coffee machines in public places or businesses, inside automatic beverage dispensers, in places where beverages are sold, in particular those called "cafés" ("coffee shops" in English) or in any takeaway catering location. The container 1 may be any type of container for which the presence of a lid is relevant, for example containers for fast food such as buckets ("buckets" in English) and containers for salads or other food products. The container 1 is particularly intended to contain a liquid or non-liquid, hot or cold food product.

[0041] Figure 1 shows an exemplary embodiment of a container 1 according to the invention. Without this being limiting, the container 1 presented in the following example is of the disposable cup type. As will be explained later, the container 1 is obtained by shaping a flat shape from a cut sheet. It is therefore distinguished in particular from containers obtained by molding techniques.

[0042] The container 1 comprises a cylindrical side wall 2, with a substantially circular base according to the example presented, but not necessarily. The container 1 further comprises a bottom (not visible) and a lid 3 intended to close an opening 4 of the container 1, on the side opposite that of the bottom. The opening 4 gives access to an internal volume of the container 1 defined by the side wall 2 and the bottom. The shape and dimensions of the lid 3 are adapted to those of the opening 4. side wall 2 and the cover 3 form a single-piece assembly, that is to say that they are made from one piece, and manufactured as a single assembly of related material, without any subsequent assembly operation. Preferably, but not necessarily, the bottom may also be a single piece with the rest of the container 1.

[0043] The side wall 2 comprises, around the opening 4, a rim 5 provided with a hem 6. The hem 6 makes it possible, in particular, to drink a liquid from the internal volume of the container, by bringing the hem 6 directly to the mouth of a consumer, preventing drops from running down the side wall 2. As will be seen later, the hem 6 is formed by a winding of material, preferably facing the outside of the container 1.

[0044] The container 1 then comprises a tab 7 of material connecting the side wall 2 to the lid 3. The tab 7 is flexible, that is to say that it can be deformed without breaking under normal conditions of use, described below. The tab 7 is shaped and sized in particular according to the shape and dimensions of the container 1. In particular, the tab 7 is sufficiently wide (that is to say of dimension along two free edges) to ensure a robust connection between the lid 3 and the side wall 2, while being sufficiently narrow so as not to cause deformation of the side wall 2 and / or the lid. Indeed, for example, in the case where the section of the container 1 is circular, the tab 7 is sized so as not to visibly deform said circular section.The tab 7 must also be sufficiently long (i.e. of dimension in the direction between the side wall 2 and the lid 3) to allow the lid 3 to be placed along the side wall 2 in a manner suitable for the consumer to access the interior of the container 1 while limiting the inconvenience. The tab 7 must however be short enough so that the lid 3 remains in a limited region around the rest of the container 1. The hem 6 is formed strictly on a portion of the rim 5, that is to say that the hem 6 does not extend over the entire rim 5. In other words, at least one portion, which is called in the following portion 8 without hem, of the rim 5 is devoid of hem 6. More precisely, a tab 7 connects on the one hand the portion 8 without hem of the rim 5 of the side wall 4 and on the other hand the lid 3. The tab 7 is made in one piece with the side wall 2 and with the lid 3, ensuring the connection.In other words, the side wall 2, the tab 7 and the lid 3 form a single-piece assembly. The hem 6 is separate from the lid 3, i.e. it is not directly connected to it. The tab 7 of the container 1 is separate from both the side wall 2 and the lid 3. In other words, the lid 3 is not directly connected to the side wall 2, the tab 7 providing the connection between the side wall 2 and the lid 3. In other words, a. removing tab 7 would allow obtaining the complete side wall 2 and the complete cover 3.

[0045] According to one embodiment, the cover 3 comprises a collar 9 extending substantially at 90° from a main portion 10 of the cover. The collar 9 preferably extends continuously over the entire periphery of the cover 3. Said collar 9 is complementary to the hem 6 so that when the cover 3 closes the opening 4, the collar 9 is engaged with the hem 6, ensuring sufficient retention of the cover 3 on the side wall 2 to prevent the cover 3 from being lifted easily, for example under the effect of its own weight and / or wind. The complementarity between the collar 9 of the cover 3 and the hem 6 of the side wall 2 is obtained by cooperation of shapes for example. The tab 7 can then extend in the extension of the collar 9 of the cover 3, up to the portion 8 without hem of the edge 5 of the side wall 2, to achieve the connection.

[0046] The cover 3 may also, according to one embodiment, comprise a device for drinking a liquid contained in the volume of the container 1 without removing the cover. Such a device may be a hole, for example in the form of a spout, or a window 11 with shutters for inserting a straw.

[0047] The cover 3 is sufficiently rigid to provide closure by cooperation with the hem 6. According to one embodiment, the cover 3 comprises so-called stiffening shapes, i.e. shapes intended to increase the rigidity of the cover 3. For example, as illustrated in FIG. 1 and FIG. 2, hollows 12 may be regularly printed on the collar 9, and a step 13 extending substantially circularly may be formed on the main portion 10 of the cover 3.

[0048] The tab 7 of material is manually deformable by a consumer, and preferably elastically, so as to form a hinge.

[0049] According to one embodiment, the deformation of the tab 7 can be guided by folding lines. Folding deformation by curvature at an angle is designated. In the example of Figures 1 and 2, the tab 7 comprises three folding lines represented by broken lines: a first line 14a at the junction with the portion 8 without hem 6 of the rim 5, a second line 14b at the junction with the cover 3, and finally a third line 14c located between the two previous lines 14a, 14b, for example halfway. Guiding the deformation of the tab 7 along the lines 14a, 14b and 14c facilitates the positioning of the cover 3 on the side wall 2.

[0050] The folded tab 7 may protrude outside the container 1 when the lid 3 closes the opening 4, or protrude towards the inside of the container 1. preferably, however, the folded tab 7 projects outwards from the container 1, so that the tab 7 is not in contact with the product in the container 1 when the lid 3 is put in place. Thus, the risk of the tab 7 degrading, for example by dissolving, upon contact with the food product in the container 1 is limited or even avoided.

[0051] The tab 7 thus allows the lid 3 to be placed on the side wall 2 to close the opening 4 and removed to open the opening 4, preferably repeatedly while the product is being consumed, without degrading the quality of the closure. More precisely, by separating the lid 3 from the side wall 2 by means of the tab 7, neither the side wall 2 nor the lid 3 are folded, ensuring a tight closure. Indeed, when the lid 3 is placed on the side wall 2, the collar 9 of the lid 3 engages with the hem 6 of the side wall 2. The unhemmed portion 8 of the side wall is covered by the collar 9, and the outwardly projecting tab 7 fills the space between the unhemmed portion 8 and the collar 9. Optionally, the main portion 10 of the cover 3 may come to bear on the edge of the side wall 2 at the level of the unhemmed portion 8.A high level of sealing for a disposable container, particularly for a container intended to contain a liquid, is thus achieved.

[0052] In the container 1 according to the invention, the lid 3 is attached to the rest of the container 1 by the tab 7 acting as a hinge. There is therefore no separate management between containers and lids, ensuring that each container 1 offered to a consumer has an associated lid.

[0053] The conventional general shape of the container 1 allows it to be stacked with other containers to reduce bulk, in a manner similar to that done for containers of the prior art. In addition, the container 1 retains a conventional general shape, known and appreciated by consumers, so that the use of the container 1 is done with complete confidence.

[0054] As will be explained later, the side wall 2 and / or the lid 3 may comprise messages and / or images and / or graphics and / or patterns printed using an ink-like substance. Preferably, the printing is carried out on the side of the side wall 2 and / or the lid 3 intended to face outwards, for the benefit of the consumer.

[0055] A method of manufacturing such a container 1 will now be described.

[0056] The method comprises a prior step of providing a sheet 20 of a flexible material. By flexible is meant here the ability of the sheet to be deformed during the manufacturing process without tearing. Preferably, the sheet 20 is further made of biodegradable material. By biodegradable is meant here the ability of the material to be decomposed by living organisms for the most part, or even all of it. This is for example a sheet 20 of paper and / or cardboard, similar to the sheets already used to make containers. Paper or cardboard here refers to any material obtained in a thin sheet from plant fibers. The sheet 20 may optionally be covered with a thin film in order to provide waterproof properties in particular, in a known manner. It may be for example plastic such as polyethylene or PLA (Polylactic Acid). The film may be made of biodegradable material, but not necessarily. The sheet 20 may be homogeneous, or include areas with different properties.

[0057] The method comprises, following the step of providing the sheet 20, a step of cutting out from said sheet 20 a planar shape 21 of the container 1. The planar shape 21 of the container 1 comprises at least one body portion 22a, intended to form at least the side wall 2 of the container, and at least one lid portion 22b, intended to form the lid 3 of the container 1. The planar shape 21 is connected, that is to say that it defines a continuous surface defined by a single external boundary, without discontinuity of the external boundary. In other words, there is a surface continuity between the different elements of the planar shape 21.

[0058] More specifically, the body portion 22a comprises a side wall section 23, intended to form the side wall 2 of the container. The side wall section 23 may typically be a quadrilateral, for example of a substantially trapezoidal shape, comprising two substantially parallel edges 24, 25 called upper edge 24 and lower edge 25 in the following for the sake of clarity. According to the example presented here, the side wall section 23 being of trapezoidal shape, the longest edge 24 is said to be upper, the other shorter edge 25 is said to be lower, and the two inclined edges 26 are said to be lateral edges 26.

[0059] According to one embodiment, the body portion 22a may comprise a bottom section 27, intended to form the bottom of the container 1, connected to the side wall section 23 either directly or by a strip 28 of material connected to the side wall section 23 and the bottom section 27.

[0060] According to the invention, the cutting step comprises the formation on the upper edge 24 of the body portion 22a of at least one strip of material, corresponding to the tongue 7 of material of the container, connecting the body portion 22a to the lid portion 22b and at least one hemmed strip 29, intended to form the hem 6 of the container 1. The hemmed strip 29 is distinct from the tongue 7 of material in that the hemmed strip 29 is not connected directly to the lid portion 22b. In other words, the connectivity between the lid portion 22b and the body portion 22a passes exclusively through the tongue 7 of material. In other words, the The hemmed strip 29 and the tab 7 are separated by at least one cutting line which extends at least partly in the direction of formation of the hem 6, substantially perpendicular to the upper edge 24. The dimension in the direction perpendicular to the upper edge 14 of such a cutting line is preferably strictly equal to the dimension in this same direction of the hemmed strip 29. The tab 7 is distinct from the body portion 22a and the lid portion 22b, that is to say that it does not merge with the body portion 22a and the lid portion 22b.

[0061] According to the example illustrated in Figure 3, the hemmed strip 29 comprises two sections on either side of the tab 7. More specifically, two notches 30 are cut from the upper edge 24, over a determined distance which corresponds to the length of the tab 7 of material, and to the distance over which the hemmed strip 29 is wound to form the hem 6, as will be seen later. Alternatively, the hemmed strip 29 may be distinguished from the tab 7 by a single notch, for example when the tab 7 is formed near a lateral edge 26 of the side wall section 23. In a way, the tab 7 may be considered to originate from an upper strip extending along the upper edge 25, in which both the hemmed strip 29 and the tab 7 are formed.

[0062] The method further comprises a shaping step, in which the side wall 2 of the container 1 is formed by joining the two side edges 26 of the side wall section 23 of the planar shape 21.

[0063] Following the shaping step, the method then comprises a rolling step in which the hemmed strip 29 is rolled through an angle greater than or equal to 360°, so as to form the hem 6, while leaving the tab 7 of material intact, i.e. the tab 7 is excluded from the rolling step. Simultaneously with or just after the rolling step, at least one folding step may be carried out at the junction between the tab 7 and the portion 8 of the side wall 2 without a hem. The folding of the tab 7 at the junction with the side wall 2 is carried out for example by means of a semi-circular convex fold towards the outside of the container 1, while taking care not to cause additional folding at undesired locations, in particular on the tab 7.When the tab 7 is folded semicircularly, it partly follows the rolling angle of the hem 6 from the edge 5, so as to limit the risk of leakage when the container 1 is used, without however being rolled: the tab 7 forms an arc. By semicircular folding, we mean here a folding of the tab 7 at an angle less than or equal to 180°. Preferably, the semicircular folding angle is greater than or equal to 90°. This semicircular folding helps to ensure the flexibility of the tab 7 when repeatedly opening and closing the container. cover 3, as well as maintaining a sufficient level of sealing at the junction between the tab 7 and the upper edge 24 of the body 2. This folding operation results in particular in forming the first folding line 14a mentioned above.

[0064] An example of implementation of the method for manufacturing the container 1 in a machine 100 for manufacturing the container 1 will now be described.

[0065] The method may comprise an initial step of providing a sheet of a flexible and biodegradable material. This is for example a sheet of paper optionally coated with a material giving it desired properties, such as water resistance. The sheet may be provided in the form of a roll wound around a core, ready to be installed on an unwinding device. When patterns on the container 1 are provided, the sheet in the roll may be unwound into a continuous ribbon in a dedicated system for transferring the patterns onto the form 21, for example a printer.

[0066] The method then comprises a cutting step, in which the planar related shape 21 of the container 1 is cut out. For example, the foil strip is transferred, preferably continuously, into a rotary cutting machine in order to obtain a plurality of planar related shapes 21. The dimensions of the cut planar related shape 21 can be adjusted according to the volume targeted for the container 1. This adjustment then concerns both the body portion 22a and the lid portion 22b, so that the lid 9 is automatically adapted to the dimensions of the side wall 2 of the container 1.

[0067] The related planar shape 21 may be stored in this way, with a plurality of others, the planar shape 21 facilitating stacking with a small footprint. For example, a plurality of related planar shapes 21 are stacked in a determined number to form a package. Each package is preferably stored in such a way as to guarantee hygiene and cleanliness conditions compatible with food use, that is to say a use in which the container 1 is intended to contain a food product. Alternatively, the packages are directly transferred to the next station, without storage, to be stacked at the entrance of the next station and processed quickly.

[0068] A step of marking the folds 14a, 14b and 14c can be carried out at the same time as the cutting step, or immediately before or immediately after.

[0069] The method then comprises a step of shaping the container 1 from the planar related shape 21 in a shaping station 101. More specifically, planar related shapes 21, for example in the form of a stack, are brought to the inlet of the shaping station 101. Preferably, the shaping station 101 comprises means for ensuring conditions hygiene and cleanliness compatible with food use, and each flat shape 21 is gripped by a clamp or an arm provided with suction cups to be placed in the shaping station 101. The shaping step may first comprise a volume formation operation during which, on a related flat shape 21, the side wall 2 of the container 1 is formed by joining the two side edges 26 of the side wall section 23, typically by overlapping one side edge 26 over the other side edge 26 and fixing them for example by ultrasonic welding, by gluing, heat sealing or any other technique ensuring a watertight fixing. The shaping step may also comprise a bottom closing operation, in which the bottom of the container 1 is fixed to the side wall 2.For this purpose, the bottom may have been cut out beforehand, independently of the planar shape 21, then brought back into the shaping station 101 to be fixed to the side wall. According to the embodiment in which the planar related shape 21 comprises a bottom section 27, the latter can then be folded down so as to close one side of the side wall 2, in the shaping station 101. The bottom is then fixed in a sealed manner to the side wall 2 by any known technique. For example, the shaping station 101 comprises a tool for positioning the bottom and sealing it, for example by a heat sealing technique, on the side wall 2.

[0070] The method further comprises a rolling step for forming the hem 6 in a rolling station 102. For example, the container 1 being formed is transferred from the shaping station 101 to the rolling station 103 automatically, by a gripper carousel type device or an endless belt conveyor. The rolling station 102 comprises, for example, a rolling tool, hot or cold, which folds the hemmed strip 29 at an angle greater than or equal to 360°, without however applying this folding angle to the material tab 7, nor to the lid portion 22b, which remain intact, i.e. not affected by the rolling. In other words, the tab 7, as well as the portion 22b of the cover, are excluded from the rolling step. According to the example described, at this stage, the tab 7 and the section 22b of the cover have not undergone any transformation with respect to their shape on the planar related shape 21.The tab 7 is then folded according to the semi-circular folding described above by a dedicated tool. Alternatively, the tab 7 can be folded during the rolling step according to the semi-circular folding described above. For this purpose, the rolling tool can be modified so as to roll the hemmed strip 29 through 360° and form the hem 6 while folding the tab 7 through 180° or less at the junction with the side wall 2. Thus, although the folding of the tab 7 can be carried out simultaneously with the rolling of the hem, these are two different operations.

[0071] The method then comprises an embossing step in an embossing station 103, during which the lid portion 22b is shaped to form the lid 3 provided with the collar 9. If necessary, the window 11 and the stiffening shapes 12, 13 are also formed during the embossing step. Preferably, the embossing step consists of a single operation of applying an imprint to the lid portion 22b.

[0072] During the embossing step, the tab 7 can be folded at a location adapted to the size and shape of the container 1, so that the lid 3 can be placed in the closed position on the body 2, for example substantially halfway between the lid 3 and the body 2. This additional folding of the tab 7, which has been previously folded at the junction with the body 2 by the semi-circular folding step presented above, also contributes to the flexibility of the tab 7 and limits the risks of it tearing during the repeated opening and closing of the lid 3.

[0073] The embossing step may be performed hot, cold, wet, dry or under pressure. The embossing step may also include forming the folds 14a, 14b and 14c on the tab 7 of material, if they have not already been formed during a previous marking step. Alternatively, the folds 14a, 14b and 14c are not formed during the manufacturing process, and may be applied manually when the cover 3 is applied to the side wall 2 to close the opening 4 for the first time.

[0074] According to one embodiment, before the shaping step, the method may comprise a printing step in which an ink-type substance is deposited on all or part of the surface of at least one side of either the sheet before the cutting step, or of the planar shape 21. Thus, the ink deposition may concern both the lid 3 and the side wall 2 of the container 1, making it possible to provide continuity of the printing. This printing step may be fully integrated into the manufacturing method, before the shaping step. Preferably, the printing step is implemented immediately after the cutting step, so that the container, once formed, does not need to be subsequently treated for the affixing of messages, patterns, images, graphics, etc. The printing may extend over the side wall 2, the tab 7 and the lid 3 continuously, for increased aesthetics.The printing step can be carried out by any technique, the sheet 20 or the flat form 21 facilitating its implementation. The printing step can be controlled on only one side of the sheet 20 of the flat form 21, leaving the other side free of any ink-like substance. When the container 1 is formed, the printed side is preferably the one facing outwards, for the purpose. of the consumer, the side facing inwards intended in particular to be in contact with food products, remaining definitely free of any ink, thus meeting high health requirements.

[0075] The container 1 thus formed is then scanned to detect defects, then transferred to an output station 104, in which the container 1 is ejected from the machine 1 to be stacked with the other containers 1 thus formed. For example, the output station 104 is connected to a chute-type system, in which the container 1 falls under the effect of gravity into stacking tubes in a packaging area. The packaging area may be part of the machine 100, or be directly juxtaposed therewith. Once a stack has reached a determined number of containers 1, it may be wrapped for example by a plastic film or a paper or cardboard packaging, then be stored for delivery to the places where the containers are used.

[0076] The environment of the machine 100, from the shaping station 101 to the packaging area, can be controlled, for example using an air filtering system, so as to maintain a clean atmosphere, free from germs potentially harmful to health and guaranteeing a container 1 suitable for containing a food product that can be consumed by the user. In particular, the transfer between the output station 104 and the packaging area is carried out so that the containers follow a short path, limiting the risks of contamination, and preferably under a controlled atmosphere.

[0077] According to one embodiment, between the shaping station 101, the rolling station 102, the embossing station 103 and the output station 104, the machine 100 comprises automatic transfer means. For example, the machine 1 comprises at least one carousel 105 provided with at least one gripping device 106 making it possible to grip each planar related shape 21 one by one. The rotation of the carousel 105 makes it possible to move the container 1 being formed from station to station. Preferably, the carousel 105 comprises a plurality of gripping devices 106 making it possible to simultaneously implement each of the stations 101, 102, 103 and 104.

[0078] The use of a 105 carousel makes it possible to reduce the footprint of the machine, and allows several 105 carousels to be stacked vertically to increase manufacturing rates.

[0079] Any other arrangement of the machine 100 is however possible, for example a linear arrangement.

[0080] The order of the steps in the process described above may vary. In fact, the order of succession of the steps can be adapted to follow the manufacturing processes of already known containers and thus limit adaptations to existing tools.

[0081] In particular, the installation of the bottom and its fixing can be carried out at any time during the process, for example during the shaping step or the rolling step. For this purpose, a bottom closing operation is implemented, in which the bottom of the container 1 is fixed to the side wall 2. For this purpose, the bottom may have been cut beforehand, independently of the shape 21, then brought back into the shaping station 101 or the rolling station 103 to be fixed to the side wall. According to the embodiment in which the planar related shape 21 comprises a bottom section 27, the latter can then be folded down so as to close one side of the side wall 2, in the shaping station 101. The bottom is then fixed in a sealed manner to the side wall 2 by any known technique.For example, the shaping station 101 or the rolling station 103 comprises a tool for positioning the base and sealing it, for example by a hot sealing technique, on the side wall 2.

[0082] Similarly, the embossing step can be carried out at any time during the process. However, the step of cutting out the shape 21 remains a necessary preliminary step to the shaping, rolling and embossing steps. In addition, the volume formation operation is preferably carried out before the rolling and embossing steps.

[0083] The method thus described thus makes it possible to manufacture a complete container with a lid, that is to say that the method makes it possible to jointly manufacture the volume intended to contain a product and the lid associated with this volume. The manufacturing costs are thus greatly reduced. In particular, the time to manufacture a container 1 comprising the lid 3 is reduced compared to the time required to manufacture a container on the one hand and the adapted lid on the other hand. In addition, instead of having two separate manufacturing locations or machines, one for the container and one for the lid, a single machine 100 to implement the method according to the invention is sufficient. Thus, the footprint of the machine is reduced, and the number of people required to operate the single machine 100 is also reduced. Maintenance costs are also reduced.

[0084] Furthermore, since each container 1 already has a lid, the problems of managing the size of the lids in relation to the size of the containers are eliminated.

[0085] The use of biodegradable material helps to limit the environmental impact.

Claims

CLAIMS

1. A method of manufacturing a container (1), such as a disposable cup, from a sheet (20) of a flexible material, the container (1) comprising a side wall (2) obtained by shaping said sheet (20), said side wall (2) defining an opening (4) of the container (1) and being provided with a rim (5), the container (1) comprising a lid (3) intended to close said opening (4), a hem (6) extending strictly over a portion of the rim (5), leaving a portion (8) of the rim without a hem (6), and at least one tab (7) of material connecting the lid (3) to the portion (8) without a hem (6) of the rim (5), the tab (7) being distinct from the lid (3) and the side wall (2), and container (1) in which the side wall (2), the tab (7) and the lid (3) form a whole monobloc, the method comprising the following steps: - A step of cutting out on said sheet (20) a planar related shape (21) of said container (1), the planar related shape (21) of said container (1) comprising at least one body portion (22a) intended to form at least the side wall (2) of the container (1), and at least one lid portion (22b), intended to form at least the lid (3) of the container (1), - A step of shaping the container (1) from the related planar shape (21), The method being characterized in that the cutting step comprises the formation on a so-called upper edge (24) of the body portion of at least one tab (7) of material connecting the body portion (22a) to the lid portion (22b), and at least one hemmed strip (29), And in that it further comprises a step of rolling the hemmed strip (29) in order to form the hem (6) on the edge (5) of the side wall (2) of the container (1), the tab (7) being excluded from the rolling step.

2. Method according to claim 1, comprising a step of embossing the portion (22b) of cover in order to form a collar (9) on the cover (3), said collar (9) being intended to engage with the hem (6) of the side wall (2).

3. A method according to claim 1 or claim 2, wherein the body section (22a) of the planar related shape (21) of the container (1) comprises a bottom section (27), and wherein the shaping step includes an operation of closing the container (1) by folding down the bottom section (27).

4. Method according to any one of the preceding claims, comprising, after the cutting step, a step of printing on all or part of at least one side of the planar related shape (21).

5. Method according to any one of the preceding claims, further comprising, after the rolling step or simultaneously with the rolling step, a folding step between the tab (7) and the portion (8) without a hem, according to a folding angle less than or equal to 180°.

6. A method according to any preceding claim, comprising perforating the lid (3), to form an opening (11) for a straw-like device.

7. A method according to any preceding claim, wherein the material of the sheet (20) comprises paper and / or cardboard.

8. Planar related shape (21) obtained by implementing the cutting step of the manufacturing method according to any one of the preceding claims.

9. Machine (100) for implementing the method according to any one of the preceding claims, comprising at least: - A cutting station comprising a device for cutting the planar related shape (21); - A shaping station (101) for forming the side wall (2) of the container (1); - A rolling station (102) for rolling the hemmed strip (29) so as to form a hem (6) on the side wall (2) while leaving the tab (7) of material intact.

10. Machine (100) according to the preceding claim, further comprising a station (103) for embossing the portion (22b) of the cover in order to form a collar (9) intended to engage with the hem (6) of the side wall (2).

11. Container (1), such as a disposable cup, made from a sheet (20) of a flexible material, comprising a side wall (2) obtained by shaping said sheet (20), said side wall (2) defining a opening (4) of the container (1) provided with a rim (5), and the container (1) comprising a cover (3) intended to close said opening (4), the container (1) being characterized in that it comprises a hem (6) extending strictly over a portion of the rim (5), leaving a portion (8) of the rim without a hem (6), in that it comprises a tab (7) of material connecting the cover (3) to the portion (8) without hem (6) of the edge (5), the tab (7) being separate from the cover (3) and the side wall (2), and in that the side wall (2), the tab (7) and the cover (3) form a single-piece assembly.

12. Container (1) according to the preceding claim, further comprising a base which is one-piece with the rest of the container (1).

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