Manufacturing process for the manufacture of food containers made from cardboard material

Abstract

The manufacturing process for the manufacture of food containers made from cardboard material comprises at least the following phases: supply of at least one sheet element (4) made at least partly from cardboard material; application of at least one waterproofing agent (5) and of at least one bonding agent (6) on at least one area of the sheet element (4); forming the sheet element (4) to obtain at least one container (1) provided with at least one bottom wall (2) and with at least one side wall (3); wherein, prior to the forming phase, at least one phase of identification on the bottom wall (2) and on the side wall (3) of at least a first working portion (7), intended to receive the waterproofing agent (5), and of at least a second working portion (8), intended to receive the bonding agent (6), the forming phase being adapted to arrange the second working portions (8) of the bottom wall (2) and of the side wall (3) mating each other and adjacent to the respective first working portions (7).

Description

[0001] MANUFACTURING PROCESS FOR THE MANUFACTURE OF FOOD CONTAINERS MADE FROM CARDBOARD MATERIAL

[0002] Technical Field

[0003] The present invention relates to a manufacturing process for the manufacture of food containers made from cardboard material.

[0004] Background Art

[0005] To date, it is becoming increasingly common to use containers made from cardboard material for the storage, transportation and possible consumption of some special food products.

[0006] Examples in this regard include cardboard cups for ice cream, cardboard tumblers for beverages and cardboard boxes for hamburgers.

[0007] Generally, the aforementioned food containers consist of a bottom wall and a side wall, both made from cardboard material and mutually associated to define a food containment compartment.

[0008] Preferably, the inner surface of the container, both at the bottom wall and at the side wall, is coated with a waterproofing material that prevents the liquid fraction of food from being absorbed by the cardboard material.

[0009] This prevents the container from flaking to the point of splitting, resulting in the spillage of the food product and / or its contamination with external agents.

[0010] The bottom wall and side wall are assembled and / or deformed in order to define the container and are held in the predetermined position through the use of bonding substances and / or sealing.

[0011] However, food containers made from known types of cardboard material do have some drawbacks, which are mainly related to the fact that the bottom wall and the side wall can disconnect very easily and / or to the fact that the side wall can open at their joining edges, if any.

[0012] This drawback is mainly related to the fact that the waterproofing layer overlaps, at least partly, the bonding substance with which it may interact, thus reducing the sealing strength thereof.

[0013] This can result in spillage from the container of the food product stored therein or can cause the container itself to split. It is clear that the containers made from known types of cardboard materials are not always suitable for containing food products because they may spill or expose them to external agents.

[0014] This aspect often makes the containers of known type unsuitable for guaranteeing compliance with the mandatory requirements in terms of hygiene and / or proper food storage.

[0015] The drawbacks just described are amplified when silica-based waterproofing substances are used, the latter being generally preferred because they have a superior waterproofing capacity to waterproofing agents (coatings) of a different nature.

[0016] Description of the Invention

[0017] The main aim of the present invention is to devise a manufacturing process for the manufacture of food containers made from cardboard material which allows improving the sealing of the containers themselves.

[0018] Within the scope of this aim, the object of the present invention is to devise a manufacturing process for the manufacture of food containers made from cardboard material which allows limiting the spillage of food products from the containers and incidents of splitting the containers themselves.

[0019] Another object of the present invention is to devise a manufacturing process for the manufacture of food containers made from cardboard material which allows meeting the cogent requirements in terms of hygiene and proper food storage.

[0020] Another object of the present invention is to devise a manufacturing process for the manufacture of food containers made from cardboard material which allows the aforementioned drawbacks of the prior art to be overcome within the framework of a simple, rational, easy and effective to use as well as affordable solution.

[0021] The aforementioned objects are achieved by this manufacturing process for the manufacture of food containers made from cardboard material having the characteristics of claim 1.

[0022] Brief Description of the Drawings

[0023] Other characteristics and advantages of the present invention will become more apparent from the description of a preferred, but not exclusive, embodiment of a manufacturing process for the manufacture of food containers made from cardboard material, illustrated by way of an indicative, yet non-limiting example, in the accompanying tables of drawings in which:

[0024] Figure 1 is a schematized view of the phase of supplying a sheet element of the process according to the invention;

[0025] Figure 2 is a schematized view of the phase of identifying the working portions of the process according to the invention;

[0026] Figure 3 is a schematized view of the phase of applying a waterproofing agent and a bonding agent of the process according to the invention;

[0027] Figures 4, 5 and 6 are schematic views of the forming phase of the process according to the invention.

[0028] Embodiments of the Invention

[0029] With particular reference to these figures, reference numeral 1 globally denotes a food container made from cardboard material which can be made by means of the process according to the invention.

[0030] The container 1 is provided with at least one bottom wall 2 and with at least one side wall 3.

[0031] With reference to the particular embodiment shown in the figures, the process is implemented to make a container 1 of the type of a tumbler made from cardboard material.

[0032] In detail, the container 1 has a substantially cylindrical conformation and has an open top in order to allow beverages to be placed within the container 1 itself.

[0033] With reference to this particular embodiment, the bottom wall 2 has a substantially circular conformation and the side wall 3 has a substantially rectangular conformation and is closed back on itself to define the side surface of the container 1.

[0034] However, there are alternative embodiments of the process which is implemented to manufacture a different container 1 and, for example, of the type of an ice cream cup or a hamburger box.

[0035] The process according to the invention comprises at least the following phases: supply of at least one sheet element 4 made at least partly from cardboard material; application of at least one waterproofing agent 5 and of at least one bonding agent 6 on at least one area of the sheet element 4; forming of the sheet element 4 to obtain at least one container 1 provided with at least one bottom wall 2 and with at least one side wall 3.

[0036] The process according to the invention comprises, prior to the forming phase, at least one phase of identification on the bottom wall 2 and on the side wall 3 of at least a first working portion 7 intended to receive the waterproofing agent 5 and of at least a second working portion 8 intended to receive the bonding agent 6.

[0037] Still according to the invention, the forming phase is adapted to arrange the second working portions 8 of the bottom wall 2 and of the side wall 3 mating each other and adjacent to the respective first working portions 7.

[0038] The first working portion 7 and the second working portion 8, defined at the bottom wall 2 and the side wall 3, are separate from each other and bounded by sharp, well-defined contours.

[0039] In detail, each of the first working portions 7 is arranged contiguous to a respective second working portion 8 but without overlapping the latter.

[0040] In other words, the application of the waterproofing agent 5 and of the bonding agent 6 on the sheet element 4 is performed by register, that is, without overlapping the waterproofing agent 5 and the bonding agent 6.

[0041] This allows improving the sealing of the bonding agent 6, thus allowing for obtaining a container 1 wherein the bottom wall 2 and the side wall 3 are stably coupled.

[0042] It is thus possible to limit the occurrence of spillage of food product from the container 1 and / or the opening of the container 1 itself.

[0043] According to the preferred embodiment shown in the figures, the forming phase comprises at least one step of cutting the sheet element 4, to obtain the bottom wall 2 and the side wall 3, and at least one step of assembling the bottom wall 2 with the side wall 3 to define the container 1.

[0044] The cutting step and the assembly step are shown in schematic form in Figure 4 and Figures 5 and 6, respectively.

[0045] According to the above possible embodiment of the process according to the invention, and as visible in Figure 2, the bottom wall 2 and the side wall 3 are first identified and bounded on the sheet element 4.

[0046] As also visible in Figure 2, the respective first working portions 7 and the respective second working portions 8 are identified on the bottom wall 2 and on the side wall 3.

[0047] Next, and as schematically visible from Figure 3, the waterproofing agent 5 is applied onto the first working portions 7 while the bonding agent 6 is applied onto the second working portions 8.

[0048] At this point, the sheet element 4 is cut so as to obtain the bottom wall 2 and the side wall 3, and the bottom wall 2 and the side wall 3 are coupled and fastened together so as to define the container 1.

[0049] Preferably, the assembly step comprises at least a first sub-step of fastening at least a first outer edge 9 of the side wall 3 to at least a second outer edge 10 of the side wall 3 and at least a second sub-step of fastening at least a third outer edge 11 of the side wall 3, located between the first outer edge 9 and the second outer edge 10, to a perimeter edge 12 of the bottom wall 2.

[0050] The first sub-step of fastening and the second sub-step of fastening are implemented by means of the bonding agent 6.

[0051] The first sub-step of fastening and the second sub-step of fastening are shown, in schematic form, in Figure 5 and Figure 6.

[0052] Still with reference to the preferred embodiment shown in the figures, the second working portion 8 of the bottom wall 2 is identified at the perimeter edge 12 and the second working portion 8 of the side wall 3 is identified at the outer edges 9, 10, 11.

[0053] Preferably, the first sub-step of fastening is carried out by positioning the second working portion 8 defined at the first outer edge 9 substantially mating the second working portion 8 defined at the second outer edge 10.

[0054] According to an alternative embodiment of the process according to the invention, not shown in the figures, the forming phase is carried out by means of thermoforming of the sheet element 4.

[0055] In actual facts, according to such possible embodiment, the sheet element 4 is deformed through the application of heat so as to define the bottom wall 2 and the side wall 3.

[0056] In such possible embodiment, the step of cutting the sheet element 4 and the step of assembling the bottom wall 2 with the side wall 3 are not provided.

[0057] For example, the process according to this particular embodiment is implemented when the container 1 to be obtained is of the type of a tray.

[0058] Advantageously, the phase of identification of the first working portions 7 and of the second working portions 8 comprises at least one step of making at least one mold adapted to delimit the first working portions 7 and the second working portions 8 on the bottom wall 2 and on the side wall 3.

[0059] The mold made is adapted to sharply delimit the first working portions 7 from the second working portions 8.

[0060] Preferably, the step of making the mold is carried out by means of at least one of a flexographic printer, a gravure printer or an offset printer.

[0061] In detail, the mold may be made in different ways which, e.g., may vary depending on the type of cardboard material that forms the sheet element 4 and / or depending on the nature and type of the container 1 to be made.

[0062] According to one possible embodiment of the process according to the invention, the waterproofing agent 5 is silica-based.

[0063] This special technical expedient makes it possible to obtain a container 1 provided with a high degree of waterproofing.

[0064] The use of this special waterproofing agent 5 is made possible by the particular maimer in which the waterproofing agent 5 and the bonding agent 6 are planned to be applied, that is, without overlapping them.

[0065] Alternative ways of carrying out the process cannot however be ruled out wherein the waterproofing agent 5 may be of a different type and, for example, may consist of a dispersion of waterproofing products of type known to the technician in the field, such as, e.g., polyethylene, polylactic acid, paints.

[0066] Advantageously, the bonding agent 6 is selected from the list comprising: acrylic- based heat seal lacquer, vinyl-based heat seal lacquer.

[0067] In the event of the bonding agent 6 being of the type of an acrylic-based heat seal lacquer, it is possible to waterproof the second working portions 8 onto which it is applied.

[0068] In other words, the bonding agent 6 is adapted to assist and operate in conjunction with the waterproofing agent 5 in defining a barrier to the food product spillage from the container 1.

[0069] The use of a bonding agent 6 of the type of a vinyl-based heat seal lacquer is particularly advantageous in the event of the container 1 being intended to contain food products at temperatures below 40°C.

[0070] Usefully, the process comprises at least one phase of activation of the bonding agent 6 carried out by means of at least one of heating the bonding agent 6 or ultrasonic treatment of the bonding agent 6.

[0071] In the event of the bonding agent 6 being activated by heating, it is preferable to use heat-radiating devices or heat-elevating devices by mechanical action (friction).

[0072] However, it is appropriate to specify that the bonding agent 6 used may be a conventional type of glue that, upon exposure to air, dries allowing the portions involved to be attached.

[0073] Usefully, the process comprises, prior to the phase of application of the waterproofing agent 5 and of the bonding agent 6, at least one phase of making at least one application medium adapted to promote the spread of at least one of either the waterproofing agent 5 or the bonding agent 6 on at least one of either the bottom wall 2 or the side wall 3.

[0074] The application medium is adapted to allow a predetermined amount of the waterproofing agent 5 and / or of the bonding agent 6 to be applied onto the respective working portions 7, 8.

[0075] The application medium is also adapted to promote the spread and application of the waterproofing agent 5 and / or of the bonding agent 6 exclusively on the respective working portions 7, 8.

[0076] The application medium is, e,g„ of the type of an anilox polymer medium or of a painting slab.

[0077] Usefully, the process comprises at least one printing phase of at least one of either the bottom wall 2 or the side wall 3.

[0078] The printing phase is implemented only when needed in order to make at least one print on at least one area of the bottom wall 2 and / or of the side wall 3 to make a decoration and / or to make some business-like information visible.

[0079] Advantageously, the process comprises at least one die-cutting phase of at least one of either the bottom wall 2 or the side wall 3.

[0080] It has in practice been ascertained that the described invention achieves the intended objects, and in particular, it is pointed out that the fact of applying the waterproofing agent and the bonding agent by register, i.e., without overlapping them, makes it possible to obtain a more stable sealing of the portions composing the container, thus improving the sealing of the container itself.

[0081] It is possible to state that the process according to the invention makes it possible to limit the spillage of food products from the containers and the episodes of splitting the containers themselves.

[0082] Again, the process according to the invention makes it possible to manufacture food containers made from cardboard material that are capable of meeting the cogent requirements in terms of hygiene and proper food storage.

Claims

CLAIMS1) Manufacturing process for the manufacture of food containers made from cardboard material, comprising at least the following phases: supply of at least one sheet element (4) made at least partly from cardboard material; application of at least one waterproofing agent (5) and of at least one bonding agent (6) on at least one area of said sheet element (4); forming of said sheet element (4) to obtain at least one container (1) provided with at least one bottom wall (2) and with at least one side wall (3); characterized by the fact that it comprises, prior to said forming phase, at least one phase of identification on said bottom wall (2) and on said side wall (3) of at least a first working portion (7), intended to receive said waterproofing agent (5), and of at least a second working portion (8), intended to receive said bonding agent (6), said forming phase being adapted to arrange said second working portions (8) of said bottom wall (2) and of said side wall (3) mating each other and adjacent to said respective first working portions (7).2) Process according to claim 1, characterized by the fact that said forming phase comprises at least one step of cutting said sheet element (4), to obtain said bottom wall (2) and said side wall (3), and at least one step of assembling said bottom wall (2) with said side wall (3) to define said container (1).3) Process according to one or more of the preceding claims, characterized by the fact that said step of assembling comprises at least a first sub-step of fastening at least a first outer edge (9) of said side wall (3) to at least a second outer edge (10) of said side wall (3) and at least a second sub-step of fastening at least a third outer edge (11) of said side wall (3), located between said first outer edge (9) and said second outer edge (10), to a perimeter edge (12) of said bottom wall (2), said first sub-step of fastening and said second sub-step of fastening being implemented by means of said bonding agent (6).4) Process according to one or more of the preceding claims, characterized by the fact that said first sub-step of fastening is carried out by positioning said second working portion (8) defined where said first outer edge (9) is locatedsubstantially mating said second working portion (8) defined where said second outer edge (10) is located.5) Process according to claim 1, characterized by the fact that said forming phase is carried out by means of thermoforming said sheet element (4).6) Process according to one or more of the preceding claims, characterized by the fact that said phase of identification of said first working portions (7) and of said second working portions (8) comprises at least one step of making at least one mold adapted to delimit said first working portions (7) and said second working portions (8) on said bottom wall (2) and on said side wall (3).7) Process according to one or more of the preceding claims, characterized by the fact that said step of making said mold is carried out by means of at least one of a flexographic printer, a gravure printer or an offset printer.8) Process according to one or more of the preceding claims, characterized by the fact that said waterproofing agent (5) is silica-based.9) Process according to one or more of the preceding claims, characterized by the fact that said bonding agent (6) is selected from the list comprising: acrylic - based heat seal lacquer, vinyl-based heat seal lacquer.10) Process according to one or more of the preceding claims, characterized by the fact that it comprises at least one phase of activation of said bonding agent (6) carried out by means of at least one of either heating said bonding agent (6) or ultrasonic treatment of said bonding agent (6).

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