Device and method for bonding a plastic inlay to a blank to form a tray and tray therewith

Abstract

Device and method for bonding a plastic inlay to a blank to form a tray and tray therewith Device (10) for bonding a plastic inlay (102) to form a tray (100), - wherein the device (10) comprises a plate element (13) with a cavity (11) for receiving the blank (101), which comprises a surrounding wall, - wherein the device (10) further comprises means (20, 21, 22, 23) for applying a pressure difference between the side of the blank (101) facing the wall and the side of the plastic inlay (102) facing the interior of the tray (100) to be formed, - and wherein at least one outer recess (17) and / or at least one indent is provided in the plate element (13) in such a way that, by applying a pressure difference between the side of the blank (101) facing the wall and the side of the plastic inlay (102) facing the interior of the tray (100) to be formed, a form-fit connection can be produced between the blank (101) and the plastic inlay (102), in which the plastic inlay (102) engages piece- wise behind the blank (101).

Description

[0001] Device and method for bonding a plastic inlay to a blank to form a tray and tray therewith

[0002] The invention relates to a device and a method for bonding a plastic inlay to a blank to form a tray. Furthermore, the invention relates to a tray which is obtainable by the method for bonding the plastic inlay.

[0003] The manufacture and use of tray-shaped containers, such as packaging trays, for transport and storage, in particular for the transport and storage of foodstuffs, is known. The containers are usually formed from a carrier, for example a carrier material made of paper, cardboard or corrugated cardboard, and a plastic film, for example a film made of polyethylene (PE) or polypropylene (PP). The main task of the film is to maintain a suitable atmosphere for the product inside the packaging, in particular to prevent oxygen from entering. The use of plastic materials to line the carriers consisting of fibre materials also protects them against the ingress of moisture, for example moisture from the foodstuff contained in the container.

[0004] One known method of lining and joining the carrier and plastic film is to shrink the film onto the carrier material or to bond it to the carrier using adhesive. However, these methods have the disadvantage that separating the carrier material and plastic film is only possible with a great deal of effort, which is why consumers regularly refrain from separating the material and dispose of the containers without separating them. In addition, adhesives regularly remain on the carrier material and / or the plastic film. As a result, it is often impossible for consumers to separate the materials by type.

[0005] An object of the present invention is therefore to provide a device, a method and a tray obtainable by the method, which avoids the above-mentioned drawbacks and in particular enables an improvement in terms of recyclability.

[0006] The problem of the present invention is solved by a device according to claim 1, a method according to claim 11 and a tray according to claim 15. The invention is based on the idea of creating a, preferably exclusively, form-fit connection between the blank and the plastic inlay, which provides sufficient stability for the use of the tray, but allows easy separation of the blank from the plastic inlay in order to improve recyclability. In particular, the connection between the blank and the plastic inlay should be made without chemical bonding in order to enable easier separation after use.

[0007] The device for bonding a plastic inlay to a blank to form a tray has a plate element with a cavity for receiving the blank. The cavity is surrounded by a plate element surface. In addition, the cavity has a surrounding wall with a collar section adjoining the wall. The blank to be used with the device is adapted to the shape of the cavity and can have one or more recesses and / or a collar, whereby the collar can rest on the collar section at least piecewise.

[0008] Furthermore, the surrounding wall of the cavity is preferably formed by a base wall and a side wall. However, the wall of the cavity can also have a rounded, for example hemispherical shape. An exact separation or the exact determination of the transition between the base wall and the side wall is then not clearly possible, which is why only a surrounding wall is referred to below. Depending on the design of the cavity or the shape of the wall, the tray produced with the aid of the device can have a piecewise rounded shape or a polygonal shape.

[0009] Preferably, the device also has means for applying a pressure difference between the side of the blank facing the wall and the side of the plastic inlay facing the interior of the tray to be formed. In particular, these means can have a suction and / or compressed air connection or channels, recesses, grooves or the like in the wall. The device can also have a pump to generate an overpressure or a vacuum. Alternatively, the device can be connected to such a pump.

[0010] The blank to be used with the device can be a monolithic (one-piece) blank. Alternatively, the blank can be formed from several partial blanks that are, for example, glued together or interlocked. The blank can also be formed from several partial blanks that are only connected with the aid of the plastic inlay. For example, a partial blank can be placed on the base wall of the surrounding wall and a partial blank on the collar section of the plate element, whereby the partial blanks are held together by the plastic inlay as described below. When the term "blank" is used below, it always refers to the entirety of the blank, which may comprise several partial blanks as mentioned above.

[0011] The blank can be made of a fibre-based material such as paper, cardboard or corrugated cardboard. Preferably, the blank is made of corrugated cardboard with an E-flute. Alternatively, corrugated cardboard with F-flute or cardboard can also be used. In addition, the material of the blank is preferably different from that of the plastic inlay.

[0012] The plastic inlay is bonded to the blank with the aid of the device. The plastic inlay is preferably made of a material that is more dimensionally stable than PE or PP. Preferably, the plastic inlay consists of mono plastics that do not have to be separated from each other for recycling. Suitable mono plastics are, for example, polyethylene terephthalate (PET) or polypropylene (PP).

[0013] The plastic inlay can be provided as a film, which is then deep drawn. Preferably, the plastic inlay has a material thickness of between approx. 70 pm and approx. 200 pm mm before deep drawing. Higher material thicknesses are suitable for deeper moulds so that the plastic inlay still has sufficient material thickness after deep drawing.

[0014] The plastic inlay to be used is formed, for example, by a web-shaped material section, whereby the corresponding material section can be separated from the rest of the material web after bonding. The plastic inlay can be heated before it is bonded to the blank. Furthermore, the plastic inlay can be deep-drawn into the cavity of the device using known deep-drawing processes. For example, the plastic inlay can be deep-drawn using a vacuum deep-drawing process or with the aid of a punch, whereby the plastic inlay lines the blank or reinforces the blank.

[0015] The collar section of the panel element has a support surface and a side surface. The support surface forms a raised surface compared to a surrounding plate element surface for supporting a collar of the blank. If the blank has a collar, the collar can rest on the collar section of the plate element when the blank has been inserted into the cavity. The collar section is located outside the cavity and is formed, for example, by an area of the plate element that adjoins the wall of the cavity.

[0016] Furthermore, the device is configured to deform an area of the plastic inlay that protrudes outwards over the collar section in the direction of the side surface of the collar section with the aid of a vacuum. For example, after a blank has been inserted into the cavity, it can be covered by a plastic inlay, with the plastic inlay projecting outwards over the collar section. In other words, a plastic inlay can be placed over the cavity so that the plastic inlay covers the cavity and protrudes away from the cavity over the collar section. Similarly, the collar of the blank can also project outwards over the collar section, at least piecewise, with the plastic inlay projecting outwards over the collar of the blank and consequently also over the collar section, at least piecewise. A vacuum then deforms or sucks or pulls the outwardly projecting area of the plastic inlay at least piecewise towards the side surface of the collar section, so that the plastic inlay encloses or grips the collar of the blank piecewise and, in particular, mechanically binds the plastic inlay to the blank.

[0017] With the device can thus be formed a tray in which the plastic inlay surrounds or encloses a collar of a blank, at least piecewise, so that the plastic inlay is bonded to the blank without additional aids, such as adhesive, and is held purely mechanically. The plastic inlay is not only arranged on one side of the blank, in particular the inside of the blank. It is also possible with the aid of the device to join partial blanks of a blank by means of the plastic inlay to form a tray. At the same time, the structure of the tray formed with the aid of the device makes it easy to separate the plastic inlay from the blank, whereby pressing the tray together is sufficient to release the gripping or enclosure and separate the plastic inlay from the blank.

[0018] Furthermore, the wall of the recess of the device according to one aspect of the invention has at least one indent as an alternative or supplement to the aforementioned option for gripping or enclosing the collar of the blank. The indent can, for example, be formed by a hemispherical or polygonal recess in the wall of the cavity. Such a indent can be formed, for example, on a side wall or the base wall of the wall. By introducing a vacuum into the at least one indent, the plastic inlay can be deformed piecewise in or through the slot in the blank in the direction of the wall of the cavity with the aid of the vacuum. In other words, the indent can thus be used to deform the plastic inlay with the aid of vacuum piecewise from an inside of the blank into or through the slot in the blank towards an outside of the blank. The vacuum can, for example, be introduced into the indent along a surface of the wall or through a fluid channel arranged in the wall.

[0019] The slot can be a cut-out or a blank recess, i.e. embossing, which allows the plastic inlay to be bonded accordingly. The blank recess differs from the cut-out in that the blank recess does not completely penetrate the blank after the tray has been formed. This means that the plastic inlay does not have to be visible from the outside in the area of the embossing or blank recess.

[0020] In addition, the indent formed in the wall of the cavity can be larger than the corresponding slot in the blank. The slot or the blank can also have a indent. For example, the blank can have a smaller slot on the inner side, which is surrounded by a larger slot on the outer side of the blank.

[0021] Consequently, as already described above, the device makes it possible to bond the plastic inlay to the blank by deformation, even if the blank does not have a collar. In addition, the device makes it possible to bond the plastic inlay both to the collar and to the slot in the blank.

[0022] Once the tray has been manufactured, it can be filled with food, for example, and sealed using a sealing film. Depending on the choice of material for the blank and the plastic inlay and depending on the type, number and size of the connections between the blank and the plastic inlay, the mechanical force that the tray can withstand can be determined. For example, if the filling weight of the tray is greater, more connections can be provided between the blank and the plastic inlay so that the sealed tray remains stable when the tray is turned upside down and a load is applied to the sealing film. For example, a tray designed for a higher filling weight can have a completely surrounding collar, which is completely surrounded by the plastic inlay, whereas a tray designed for a lower filling weight is only surrounded piecewise to ensure sufficient stability. According to one aspect of the present invention, the device according to the previous description is configured to connect the blank and the plastic inlay exclusively in a formfit manner. This means that the plastic inlay is held exclusively mechanically on the blank, whereby the form fit can only be released by deformation of the packaging, which releases the form fit between the blank and the plastic inlay. The advantage of this is that the blank and plastic inlay can be completely separated by type.

[0023] According to a further embodiment, the device can be configured to deform the plastic inlay in such a way that the plastic inlay piecewise engages behind the blank at the collar and / or at the recess. An engagement behind is to be understood in such a way that the plastic inlay with a first area of the plastic inlay forms piecewise a surface contact with an inner side of the blank or an upper side of the collar, wherein the plastic inlay grips through the slot or around the collar, so that a second area of the plastic inlay is arranged piecewise opposite the first area, and wherein the blank is arranged piecewise between the two areas of the plastic inlay. For example, a first area of the plastic inlay can form a surface contact with the inner side of the blank or the upper side of the collar, whereby the second, oppositely arranged area is arranged on a side of the blank which forms an underside of the collar, an outer side of the blank or a indent of the blank. Engaging the blank behind the collar and / or the slot thus allows a form-fit connection between the plastic inlay and the blank.

[0024] According to one embodiment, the side surface of the collar portion and / or the at least one indent in the wall of the cavity of the device may comprise at least one vacuum opening. The vacuum opening may be any opening or inlet which allows the introduction of the vacuum into the indent and / or to the side surface of the collar section, so that the plastic inlay can be deformed according to the preceding description. For example, the number, size, shape and / or spacing of the vacuum openings can be used to determine the degree and / or type of deformation of the plastic inlay. The device can also have several indents, whereby the degree and type of deformation of the plastic inlay can be determined via the number, size, shape and / or spacing of the indents. Preferably, the air between the plastic inlay and the blank is evacuated with the aid of the applied vacuum to such an extent that the plastic inlay comes to rest against the side surface of the collar section and / or the recess, in the event that the slot is a cut-out. In accordance with the previous embodiments, the device can also have several vacuum openings. According to one embodiment, the side surface of the collar section has, for example, 20 vacuum openings, which are arranged on the side surface of a surrounding collar section.

[0025] According to one aspect of the invention, the collar portion of the plate element can be surrounded, at least in certain areas, by an outer recess, in particular a channel-shaped recess. Furthermore, according to one embodiment of the device, the collar portion of the plate element can be completely surrounded by the outer recess. Furthermore, a wall of the outer recess can be formed on one side by the side surface of the collar section. In other words, the side surface of the collar section protrudes into the outer recess instead of the outer recess being formed at a distance from the collar section, for example. The at least one vacuum opening can be arranged at least piecewise within the outer recess. For example, the vacuum opening can be arranged on the side surface of the collar section, wherein a part of the vacuum opening is arranged in an area of the side surface of the collar section that is located above the outer recess, and another part of the vacuum opening can be arranged in an area of the side surface of the collar section that is located inside the outer recess. It is also possible that the device or the side surface of the collar section has several vacuum openings, some of which are arranged inside the outer recess and others outside, for example on the side surface of the collar section above, the outer recess. Irrespective of the specific arrangement of the vacuum openings, the use of an outer recess and a vacuum opening arranged piecewise therein enables the plate element of the device to be constructed as flat and material-saving as possible.

[0026] According to a further embodiment, the device can have at least one through opening. In particular, a through opening is understood to be an opening that penetrates the wall of the cavity of the plate element of the device. The at least one through opening can be arranged in the wall of the cavity of the device and can be connected to a vacuum source. Consequently, the at least one through-opening can be set up to introduce a vacuum into the cavity, for example to fix the blank or to deep-draw the plastic inlay. The at least one through-opening can be arranged on a base wall of the wall of the cavity. In addition, several through openings can be arranged on the base wall. According to one embodiment, for example, a plurality of through openings can be arranged at a distance from one another and distributed around an outer perimeter of the base wall. However, as described below, the vacuum introduced via the through-openings can be distributed via fluid passages, such as channels or ducts, so that the vacuum introduced into the through- opening can be used for the deformation of the plastic inlay according to the invention. In addition to the aforementioned effects, the introduction of the vacuum via the recess and the subsequent distribution via fluid passages enables a simple design of the device with only one vacuum source.

[0027] Accordingly, according to a further embodiment, the device can have at least one fluid passage. A fluid passage is understood to be a channel, a groove or a passageway, wherein the fluid passage is arranged to conduct a fluid from one location to another. The at least one fluid passage can be arranged in the wall of the cavity. The at least one fluid passage can connect the at least one vacuum opening of the collar section to the cavity of the device and / or be designed in the form of a indent in the wall of the cavity, at least piece- wise open towards the cavity. For example, the fluid passage can be arranged in the wall in the form of a channel. Preferably, the fluid passage can be arranged in the form of a channel in a side wall of the wall of the cavity. When a blank is inserted into the cavity and rests against the wall, the at least one fluid passage extends, for example, in the form of a channel on an outer side of the blank. In this way, the fluid passage allows fluid to flow past the blank from an area of the cavity on the collar section side to an area of the cavity on the base wall side. The fluid passage can also be used to form beads in the plastic inlay by deforming the plastic inlay into the grooves of the wall by evacuating the air. The formation of beads can give the plastic inlay additional stability.

[0028] According to a further embodiment, the device can have at least one indent in the form of an inner recess, wherein the at least one inner recess is arranged in a transition region between the wall of the cavity and the collar section. Preferably, the inner recess is formed in a transition region between the side wall of the cavity and the collar section. The formation of the inner recess in this transition area results in the inner recess being arranged both partially in the wall and partially in the collar section. Furthermore, the at least one inner recess can be designed to be at least partially open at the top and can be configured to accommodate a projection of the blank. This means that the inner recess is open in the removal direction of the tray so that, for example, a projection of the blank, e.g. a stacking nose, can be inserted into the inner recess from above when the blank is inserted. This allows the blank to be held in position even before a vacuum is applied.

[0029] In one embodiment, the inner recess can also have at least one vacuum opening. Depending on the choice of blank, the plastic inlay can be moulded into the inner recess through a slot in the blank. Due to the arrangement of the inner recess described above, it is also possible that when using a blank with a collar, the plastic inlay can be moulded piecewise under the collar, whereby a form fit can be created between the blank and the plastic inlay.

[0030] According to a further aspect, the device may additionally comprise at least one of the following devices: a fixing device which is designed to fix the plastic inlay piecewise to the plate element; a cutting device which is designed to separate the plastic inlay from a material web, the cutting device having in particular a separating tool which is designed to be inserted into the outer recess; an overpressure device which is designed to provide an overpressure, whereby the overpressure applies at least piecewise a force to the plastic inlay which counteracts the vacuum.

[0031] A fixing device can be used to fix the plastic inlay to a plate element surface of the plate element, for example to hold it down. The fixing device favours the evacuation of air underneath the plastic inlay. For example, the cavity of the plate element can be completely surrounded by the fixing device, whereby the plastic inlay is held down on the plate element surface and forms a space that is subsequently evacuated by air. However, the plastic inlay can alternatively also be fixed to the plate element surface with the aid of vacuum outside the cavity. It is also possible that, due to the size and weight of the plastic inlay, no fixation with the aid of a fixing device is required at all and sufficient deformation of the plastic inlay is made possible solely by the application of a vacuum. Furthermore, the device can have a cutting device that is used to cut off excess material from the plastic inlay after the plastic inlay has been bonded to the blanks. In particular, the cutting device can have a separation tool for this purpose, which can be inserted into the outer recess. Accordingly, once the plastic inlay has been moulded, the separation tool can be inserted into the outer recess from above and cut off excess material of the plastic inlay from the tray.

[0032] In addition, the device can comprise an overpressure device which, for example, applies an overpressure, such as compressed air, to a side of the plastic inlay that is opposite the side of the plastic inlay to which the vacuum is applied. In this way, a force counteracting the vacuum can be applied to the plastic inlay at least piecewise and, in particular, support the deformation of the plastic inlay according to the invention.

[0033] Furthermore, the problem is solved by a method for bonding a plastic inlay to a blank to form a tray using the bonding device according to the aspects of the previous description. The method comprises the following steps:

[0034] - providing a blank, for example a blank made of a fibre-based material, and a plastic inlay, for example made of PET;

[0035] - inserting the blank into the device, for example into the cavity of the plate element of the device, whereby the collar of the blank protrudes piecewise outwards over the collar section and / or the blank has a slot; covering the recess of the plate element with the plastic inlay; deforming the plastic inlay with the aid of the vacuum, whereby the plastic inlay is deformed piecewise in the direction of the side surface of the collar section and / or piecewise in or through the recess in the blank;

[0036] - removing the tray comprising the blank with the bonded plastic inlay.

[0037] Firstly, a blank and a plastic inlay are provided in accordance with the aspects of the previous description.

[0038] The blank is then inserted into the device. Since only a partial blank in the form of a collar can be provided, which can be placed on the support surface of the collar section, insertion into the cavity is not absolutely necessary. However, the blank can also be inserted into the cavity of the device, whereby "insertion" does not necessarily mean complete insertion of the blank. This means that the blank does not have to sink completely into the cavity of the device. For example, when inserting the blank into the cavity of the plate element, a partial blank, for example a collar, could also come to rest on the collar section or the support surface of the collar section, whereby, for example, a further partial blank can be arranged in the cavity of the plate element, for example on the base wall.

[0039] Furthermore, the cavity of the plate element is covered with the plastic inlay. In particular, the plastic inlay can cover the cavity completely. For example, the plastic inlay can be moved over the cavity as part of a material web so that the cavity is covered. Depending on whether the blank has a collar, the plastic inlay lies at least partially on the support surface of the collar section or on an upper side of the collar of the blank. Furthermore, depending on the deformation of the plastic inlay described below and the design of the blank, the plastic inlay can protrude outwards at least piecewise over the collar section of the plate element and the collar of the blank.

[0040] As soon as this relative arrangement of device, blank and plastic inlay has taken place, the plastic inlay can be moulded in accordance with the invention with the aid of the vacuum. In the process, the plastic inlay is deformed piecewise in the direction of the side surface of the collar section and / or piecewise in or through the recess in the blank. For the deformation, a vacuum can be applied to the vacuum openings so that the plastic inlay is deformed in the corresponding direction.

[0041] As soon as the moulding process is complete and the plastic inlay has been bonded to the blank, the tray is formed. The film is then cut from the film web and the tray with the plastic inlay bonded to the blank can be removed.

[0042] However, this of course does not exclude the possibility of carrying out one or more further process steps between the individual steps, in preparation for the individual steps or before removal. According to one aspect, and as previously described in relation to the device, the plastic inlay is attached to the blank exclusively in a form-fit manner by the deformation.

[0043] In addition, according to one aspect, when the blank is inserted, the collar of the blank can rest at least piecewise on a support surface of the collar section and protrude outwards over the collar section. The blank or the collar thus overlaps the collar section and protrudes over the collar section in a direction pointing away from the cavity of the plate element. A plastic inlay projecting beyond the collar section or the collar can be moulded with the aid of the vacuum so that the plastic inlay engages behind the collar and thus, as described above, at least piecewise surrounds or encloses the collar or the blank.

[0044] In addition, when the blank is inserted, the slot in the blank can cover a indent in the wall of the cavity in the plate element, at least piecewise. For example, the blank can have a small circular slot which, when the blank has been inserted into the cavity of the plate element, is arranged in front of a larger, circular indent in the wall of the plate element, so that the indent is partially covered by the slot. With the aid of the vacuum, the plastic inlay can then be deformed in or through the slot piecewise in the direction of the wall of the cavity and engage piecewise behind the blank. For example, the plastic inlay can be moulded piecewise on an outer side or in a indent of the blank.

[0045] Furthermore, as described above, it is not excluded that the method comprises one or more further steps between the individual steps, in preparation for the individual steps or prior to removal. According to one aspect of the invention, the method may comprise, as a further step, fixing the plastic inlay to the plate element by means of a fixing device. For example, once the plastic inlay has covered the cavity, it can be fixed by the fixing device and held down on the plate element surface. In particular, the fixing device can be used to create a space underneath the plastic inlay that can be evacuated with the aid of vacuum, i.e. from which the air can be extracted. In addition, vacuum can be introduced into the cavity and the plastic inlay can be deep-drawn. Similarly, the vacuum introduced into the recess can be channelled to the side surface of the collar section via corresponding fluid passages and deform the plastic inlay in the direction of the side surface. In addition, the plastic inlay can be cut to size by a cutting device in a further process step. In particular, the cutting device can have a separating tool for this purpose. For example, the separating tool can separate the plastic inlay from a material web after moulding. For this purpose, the separating tool can, for example, penetrate into a recess in the device which surrounds the collar section of the device in some areas.

[0046] In addition, the plastic inlay can be heated in a further process step. For example, the plastic inlay can be heated prior to being provided and / or prior to moulding, whereby the plastic inlay can be moulded with a lower vacuum, for example.

[0047] Furthermore, in a further process step, an overpressure can be applied, which, as described above, supports the deformation of the plastic inlay by the vacuum. For example, compressed air can act on the plastic inlay to support the deformation of the plastic inlay.

[0048] Depending on whether the plastic inlay is heated in a process step or, for example, the device is used at a corresponding ambient temperature, the plastic inlay can be cooled following the moulding process. The cooling of the plastic inlay can then favour material hardening of the plastic inlay.

[0049] Furthermore, the tray can be filled in a further process step, in particular with food, and / or sealed, for example by applying a sealing film.

[0050] In addition, the problem of the invention is solved by a tray which is obtainable by the method described above and a plastic inlay attached to the blank.

[0051] The invention is explained in more detail below with reference to embodiments and drawings. All the features described and / or illustrated, either individually or in any combination, form the object of the invention, irrespective of their summary in the claims or their relation to each other.

[0052] It shows schematically: Fig. 1 a perspective view of a device according to the invention;

[0053] Fig. 2 a perspective wireframe representation of the device according to the invention;

[0054] Fig. 3 a perspective view of a cross-section through a device according to the invention;

[0055] Fig. 4a a perspective view of a longitudinal section through a device according to the invention with a tray;

[0056] Fig. 5 a detailed view of section A of figure 4;

[0057] Fig. 6 a modified detail view according to Figure 5 with a separating tool;

[0058] Fig. 7A an exemplary sectional view of a collar section of a device accor ing to the invention including a fixing device, before a plastic inlay has been engaged behind it;

[0059] Fig. 7B an exemplary sectional view of a collar section according to Figure7A, after the engagement behind the plastic inlay has been completed;

[0060] Fig. 8 a perspective view of a device according to the invention with a further embodiment of a tray, which is also shown in Figure 10;

[0061] Fig. 9 an illustration of a cut-out of the tray shown in Figure 8;

[0062] Fig. 10 a perspective view of the tray shown in Figure 8;

[0063] Fig. I l a perspective view of a further embodiment of a tray;

[0064] Fig. 12 a top view of the tray according to Figure 11;

[0065] Fig. 13 a perspective view of an alternative embodiment of a tray with a circular slot; and

[0066] Fig. 14 a detail sectional view of the slot shown in Figure 13.

[0067] Although various variants and embodiments of the device or tray according to the invention are shown below, identical elements are provided with identical reference signs in the various embodiments. For example, the reference sign 100 is always assigned to a tray, irrespective of which embodiment of a blank 101 was used to manufacture the tray 100.

[0068] Figure 1 shows a perspective view of an embodiment of a device 10 having a cavity 11 which is embedded in a panel element surface 12 of a panel element 13, which is shown in Figure 2. The device 10 is designed to form the tray 100 from the blank 101 and a plastic inlay 102, the plastic inlay 102 being bonded to the blank 101.

[0069] In the present case, the cavity 11 has a surrounding wall, which is formed by a base wall 14 and a circumferential side wall 15 adjoining it. Adjacent to the surrounding wall or, more precisely, adjacent to the side wall 15 is a collar section 16, which is surrounded by an outer recess 17, whereby the outer recess 17 in the present case completely surrounds the collar section 16.

[0070] The collar section 16 has a support surface 18 and a side surface 19. The side surface 19 is provided with a plurality of vacuum openings 20, which can introduce a vacuum into the outer recess 17 in order to deform the plastic inlay 102 according to the invention.

[0071] Furthermore, the device 10 or the base wall 14 has several through openings 21 which are designed to introduce a vacuum into the cavity 11. In addition, the side wall 15 is provided with several fluid passages 22, which in the present case are piecewise designed in the form of indents. In addition, the fluid passages 22 form a fluid connection between the cavity 11 and the vacuum openings 20 of the side surface 19 of the collar section 16, as can be seen in Figure 2 or in Figures 3 and 4. Consequently, by introducing a vacuum into the through openings 21, a suction effect can occur at the vacuum openings 20 arranged on the side surface 19 of the collar section 16, whereby the plastic inlay 102 can be deformed in the direction of the side surface 19. However, the fluid passage 22 can also be formed as a completely closed channel arranged in the wall, which only has an opening into the cavity 11, whereby a fluid connection can be created between the vacuum openings 21 of the side surface 19 of the collar section 16 and the cavity 11. Similarly, the fluid passage 22 can also conduct a vacuum to the vacuum openings 21 completely independently of the cavity.

[0072] Furthermore, four inner recesses 23 are shown in Figure 1, which are arranged in a transition area between the side wall 15 and the collar section 16. The inner recesses 23 are designed in the form of indents in the wall of the cavity 11. In addition, the inner recesses 23 are open at the top, i.e. open in the direction of removal of the tray 100. The vacuum openings 20, 21, the fluid passage 22 and / or the recesses 23 can thus form means for applying a pressure difference between the side of the blank 101 facing the wall and the side of the plastic inlay 102 facing the interior of the tray 100 to be formed.

[0073] The inner recesses 23 are designed to accommodate a projection 103, for example a stacking nose, of the blank 101. This allows the blank 101 to be fixed in place during, before and after the plastic inlay 102 is bonded. The plastic inlay 102 can be made of PET or PP and have a thickness of 70 pm to 200 pm. A corresponding blank 101 with a projection 103 is shown in Figure 13.

[0074] In addition, Figure 4 shows a blank 101 inserted into the cavity 11 of the device 10 with a bonded plastic inlay 102, whereby the plastic inlay 102 and the blank 101 together form a tray 100. The connection of the plastic inlay 102 in the area of the collar section 16 is illustrated in the detailed view A in Figure 5.

[0075] The blank 101 shown in Figure 5 has a collar 104, the underside 105 of which rests on the support surface 18 of the collar section 16. A first region of the plastic inlay 102 is arranged on an upper side 106 of the collar 104. In some areas, a second region of the plastic inlay 102 is arranged on the side of the underside 105 of the collar 104 and opposite the first region, wherein the collar 104 of the blank 101 is arranged between the two regions of the plastic inlay 102. The plastic inlay 102 thus engages behind the collar 104.

[0076] In addition, the plastic inlay 102 is in surface contact with an inner side 107 of the blank 101, with the outer side 108 of the blank 101 resting on the side wall 15 of the recess 11. The introduction of a vacuum via the fluid passages 22 or the vacuum openings 20 enables the collar 104 of the blank 101 to be sucked onto the support surface 18 of the collar section 16 and the plastic inlay 102 to be sucked onto the side surface 19 of the collar section 16 in the region of the outer recess 17, with the plastic inlay 102 engaging behind the collar 104.

[0077] Furthermore, the blank 101 has slots 109, which are better seen in Figure 4 or the trays 100 of Figures 11 and 13. The recesses 109 are arranged in the corner regions of the tray 100, so that with the aid of vacuum introduced into the inner recesses 23 via vacuum openings 20, as shown for example in Figure 1, the plastic inlay 102 can be deformed through the slots 109 into the inner recesses 23. In Figure 13, the upper slots 109, which are arranged closer to the collar 104, are cut-outs, whereas the lower slots 109, which are arranged closer to the tray base, are blank recesses.

[0078] A plastic inlay 102 moulded into the slots 109 is shown, for example, in Figure 11, wherein the plastic inlay 102 is bonded to the blank 101 both by gripping behind the collar 104 and by gripping behind in the corner regions through the slots 109 near the collar 104 and through the slots 109 near the base of the tray. The plastic inlay 102 completely lines the blank 101 on the inner side 107 and protects it from moisture, for example.

[0079] A top view of the tray 100 from Figure 11 is shown in Figure 12.

[0080] Once the plastic inlay 102 has been moulded, the plastic inlay 102 can be separated from the remaining material web using a separating tool 24, as shown in Figure 6. For this purpose, the separating tool 24 of a cutting device can engage in the outer recess 17 and cut through the plastic inlay 102.

[0081] However, as shown in Figures 7A and 7B, an outer recess 17 is not necessarily required to deform the collar 104 according to the invention and to bond the plastic inlay 102 to the blank 101. A vacuum opening 20, which is not shown, can be used to generate a vacuum which deforms the plastic inlay 102 in the direction of the side surface 19 of the collar 16. The deformation is exemplified by an arrow in Figure 7B.

[0082] During moulding, as shown here, a fixing device 25 can be used to hold the plastic inlay 102 down on the plate element surface 12. However, a mechanical fixing device 25 is not absolutely necessary, as previously described.

[0083] Figure 8 shows the device 10 with an alternative tray 100, which is formed from a blank 101 with two separate partial blanks, which are shown in Figure 9, and a plastic inlay 102 connecting the partial blanks. In Figure 8, the partial blanks from Figure 9 and the plastic inlay 102 are arranged in the cavity 11 of the plate element 13 and form the tray 100. The removed, finished tray 100 is shown in Figure 10.

[0084] The lower partial blank of the blank 101 has slots 109 through which the plastic inlay 102 has been moulded. In addition, the plastic inlay 102 engages behind the collar 104. Due to the connections of the plastic inlay 102 to the blank 101, a tray 100 can be produced with a low material input of the blank 101.

[0085] Furthermore, the plastic inlay 102 has beads 110 which reinforce the plastic inlay 102. The beads 110 can be formed, for example, by fluid passages 22 open in the direction of the cavity 11, which are arranged in the wall of the cavity 11, whereby vacuum can be introduced into the fluid passages 22.

[0086] Although square slots 109 are used to connect the plastic inlay 102 in the trays 100 and blanks 101 shown in Figures 8 to 12, the slots 109 can also have other shapes, in particular round, square or mixed shapes. Figure 13 shows a blank 101 with a circular (round) slots 109.

[0087] The indents in the wall of the cavity 11 can also have different shapes corresponding to the shape of the slots 109 of the blank 101. For example, a indent can have a circular, angular or otherwise shaped contour, whereby a vacuum introduced into the indent deforms the plastic inlay 102 in the direction of the wall.

[0088] The circular slots 109 shown in Figure 13 is shown in detail in section in Figure 14. The bold line in Figure 14 indicates the plastic inlay 102, which lies against the inner side 107 of the blank 102 and extends into the slots 109 from the inner side 107 of the blank 101 to the outer side 108 of the blank 101, where it engages behind a indent 111 in the outer side 108. The blank 101 is arranged between the plastic inlay 102 on the inner side 107 and the plastic inlay 102 in the area of the indent 111. The plastic inlay 102 is thus moulded here into the slot 109.

[0089] Alternatively, however, the outer side 108 could also have no indent 111, so that the plastic inlay 102 engages behind the outer side 108. The plastic inlay 102 would then also rest on the inner side 107 and extend through the slot 109, with the blank 101 being arranged between the plastic inlay 102 on the inner side 107 and the plastic inlay 102 in the area of the outer side 108.

[0090] To summarise, a device 10 according to the invention can therefore be used to bond a plastic inlay 102 to a blank 101. For this purpose, the blank 101 is inserted into the cavity 11 of the device 10 and covered by the plastic inlay 102. By applying vacuum, the plastic inlay 102 can then engage behind the blank 101 and thus be bonded to the blank 101. The purely mechanical connection of plastic inlay 102 and blank 101 allows the tray 100 produced with the aid of device 10 to be easily recycled.

[0091] The wall of the cavity 11 can provide indents for the connection of the plastic inlay 102 to the blank 101 in order to deform the plastic inlay 102 in or through the slot 109 and / or to engage behind the collar 104 of the blank 101. Consequently, it is possible to attach the plastic inlay 102 to the blank 101 purely mechanically without the use of aids such as adhesives.

[0092] List of reference symbols

[0093] 10 Device 100 Tray

[0094] 11 Cavity 101 Blank

[0095] 12 Plate element surface 102 Plastic inlay

[0096] 13 Plate element 103 Projection

[0097] 14 Base wall 104 Collar

[0098] 15 Side wall 105 Underside (of the collar)

[0099] 16 Collar section 106 Upper side (of the collar)

[0100] 17 Outer recess 107 Inner side

[0101] 18 Support surface 108 Outer side

[0102] 19 Side surface 109 Slot

[0103] 20 Vacuum opening 110 Bead

[0104] 21 Through opening 111 Indent (of the blank)

[0105] 22 Fluid passage

[0106] 23 Inner recess

[0107] 24 Separating tool

[0108] 25 Fixing device

Claims

CLAIMS1. Device (10) for bonding a plastic inlay (102), in particular a plastic inlay made of mono-PET or mono-PP, to a blank (101), in particular a blank made of a fibre-based material, to form a tray (100),- wherein the device (10) comprises a plate element (13) with a cavity (11) for receiving the blank (101), which comprises a surrounding wall,- wherein the device (10) further comprises means (20, 21, 22, 23) for applying a pressure difference between the side of the blank (101) facing the wall and the side of the plastic inlay (102) facing the interior of the tray (100) to be formed,- and wherein at least one outer recess (17) and / or at least one indent is provided in the plate element (13) in such a way that, by applying a pressure difference between the side of the blank (101) facing the wall and the side of the plastic inlay (102) facing the interior of the tray (100) to be formed, a form-fit connection can be produced between the blank (101) and the plastic inlay (102), in which the plastic inlay (102) engages piece- wise behind the blank (101).

2. Device according to claim 1, characterised in that the cavity (11) of the plate element (13) has the surrounding wall with a collar section (16) adjoining the wall, wherein the collar section (16) of the plate element (13) has a support surface (18) and a side surface (19), wherein the support surface (18) forms a surface which is raised relative to a surrounding plate element surface (12) for bearing a collar (104) of the blank (101), and wherein the device (10) is arranged to deform a region of the plastic inlay (102) projecting outwards over the collar section (16) with the aid of a pressure difference piece- wise in the direction of the side surface (19) of the collar portion (16), and / or in that the wall of the cavity (11) of the device (10) comprises at least one indent, and wherein the device (10) is arranged to introduce a vacuum into the at least one indent in order to deform the plastic inlay (102) piecewise in the direction of the wall of the cavity (10) in or through a slot (109) in the blank (101) with the aid of the vacuum.

3. Device (10) according to claim 2, characterised in that the device (10) is arranged to deform the plastic inlay (102) in such a way that the plastic inlay (102) engagespiecewise behind the blank (101) at the collar (104) and / or at the slot (109).

4. Device (10) according to any of the preceding claims, characterised in that the side surface (19) of the collar section (16) and / or the at least one indent has at least one vacuum opening (20).

5. Device (10) according to any of the preceding claims, characterised in that the collar section (16) of the plate element (13) is surrounded at least partially by the outer recess (17), in particular a channel-shaped recess, and wherein the at least one vacuum opening (20) is arranged partially within the outer recess (17).

6. Device (10) according to any of the preceding claims, characterised in that the device (10) has at least one through-opening (21), wherein the at least one through-opening (21) is arranged in the wall of the cavity (11) of the device (10), and wherein the through-opening (21) is arranged to introduce a vacuum into the cavity (11).

7. Device (10) according to one of the previous claims, characterised in that the device has at least one fluid passage (22), wherein the at least one fluid passage (22) connects the at least one vacuum opening (20) of the collar section (16) to the cavity (11) of the device (10) and / or is formed in the wall of the cavity (11) in the form of a indent at least partially open towards the cavity (10).

8. Device (10) according to any of the preceding claims, characterised in that the device (10) has at least one indent in the form of an inner recess (23), wherein the at least one inner recess (23) is arranged in a transition region between the wall of the cavity (11) and the collar portion (16), and wherein the at least one inner recess (23) is configured to be at least partially open at the top and is arranged to receive a projection (103) of the blank (101).

9. Device (10) according to claim 8, characterised in that the inner recess (23) has at least one vacuum opening (20).

10. Device (10) according to any of the preceding claims, characterised in that the device (10) additionally comprises at least one of the following devices: a fixing device (25) which is configured to fix the plastic inlay (102) piecewise on the plate element (13); a cutting device which is configured to separate the plastic inlay (102) from a material web, wherein the cutting device has in particular a separating tool (24) which is configured to be inserted into the outer recess (17); an overpressure device which is configured to provide an overpressure, wherein the overpressure applies a force to the plastic inlay (102) which counteracts at least piecewise the vacuum.

11. Method for form-fit bonding of a plastic inlay (102) on a blank (101) to form a tray (100) using a device (10) for bonding, in particular according to any of the preceding claims, wherein the method comprises the following steps:• providing the blank (101), for example a blank made of a fibre-based material, and the plastic inlay (102), for example the plastic inlay made of PET;• inserting the blank (101) into the device (10), for example into a cavity (11) of a plate element (13) of the device (10), wherein the collar (104) of the blank (101) protrudes outwards piecewise over the collar section (16) and / or the blank (101) has a recess (109);• covering the cavity (11) of the plate element (13) with the plastic inlay (102);• deforming the plastic inlay (102) with the aid of a vacuum, wherein the plastic inlay (102) is deformed piecewise in the direction of the side surface (19) of the collar section (16) and / or piecewise in or through the slot (109) in the blank (101);• removing the tray (100) comprising the blank (101) with the plastic inlay (102) bonded in a form-fit manner.

12. Method according to claim 11, characterised in that the plastic inlay (102) is bonded to the blank (101) exclusively in a form-fitting manner by deforming.

13. Method according to claim 11 or 12, characterised in that- when the blank (101) is inserted, a collar (104) of the blank (101) rests at leastpiecewise on a support surface (18) of the collar section (16) and projects outwards over the collar section (16), and wherein the plastic inlay (102) is deformed with the aid of the vacuum and engages behind the collar (104), and / or that- when the blank (101) is inserted, the slot (109) of the blank (101) covers at least piecewise a indent in the wall of the cavity (11) of the plate element (13), and wherein the plastic inlay (102) is deformed piecewise in the direction of the wall of the cavity (11) with the aid of the vacuum in or through the slot (109) and engages piecewise behind the blank (101).

14. Method according to any one of claims 11 to 13, characterised in that the method additionally comprises one or more of the following steps:- fixing the plastic inlay (102) on the plate element (13) by means of a fixing device; cutting the plastic inlay (102) by a cutting device, in particular a separating tool (24) of the cutting device;- heating the plastic inlay (102), in particular before the plastic inlay (102) is provided and / or before it is deformed; applying an overpressure to support the deformation of the plastic inlay (102) by the vacuum; cooling the plastic inlay (102); filling the tray (100); sealing the tray (100), in particular by applying a sealing film.

15. Tray (100) obtainable by a method according to any one of claims 11 to 15, wherein the plastic inlay (102) is preferably exclusively form-fittingly connected to the blank (101).

Images