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DESCRIPTION

Field of the invention

The present invention relates to an apparatus for forming containers which are filled with a liquid and sealed, from a sheet of packaging material unwound from a reel.

In particular, the apparatus described is of the type comprising a forming and filling unit, for I) folding the sheet in the form of tube around a main axis, II) sealing along this axis the sheet folded to form a tube, III) filling the tube with a liquid, IV) forming on the tube, in succession, sealing bands which are transverse to the main axis and define on the tube single semifinished containers which are sealed and filled with the liquid, the forming and filling unit comprising a cutting device designed to separate the single semi-finished containers from the tube along cutting lines formed on the transverse sealing bands.

In the solutions of the prior art, the cutting device comprises a cutting blade which is driven with an alternating translation movement in a plane orthogonal to the aforementioned main axis. The system for driving the cutting blade is of the hydraulic type, owing to the forces which the cutting blade must exert in order to penetrate the packaging material along the transverse sealing bands.

In the present description and the claims attached thereto, some terms and expressions are considered to have, unless explicitly indicated otherwise, the meaning given in the definitions below.

In particular, the term “parallel” is understood as meaning a substantial parallel arrangement between two elements, comprising both the real case where these elements are arranged relative to each other so as to form a zero angle, and more frequent cases where the two elements are arranged relative to each other so as to form an angle which is not zero, but is in any case negligible or not significant for the purposes of operation according to the present invention.

The Applicant has noted that, during the operation of the solutions of the prior art, the apparatus and the containers made by it are subject to soiling due to a plurality of contaminating agents. As a result, long machine downtimes and therefore long interruptions in production are necessary in order to carry out the appropriate cleaning cycles for restoring the initial working conditions, in particular in plants which are subject to severe hygiene and sterility constraints.

The Applicant has also noted that these undesirable consequences are often due to the working liquid used in the hydraulic system(s) designed to operate one or more devices of the apparatus, since these systems may be affected by malfunctioning or breakages resulting in the loss of said liquid.

Furthermore, the Applicant has noted that these hydraulic systems require complex structures for managing the working liquid, these complicating significantly the configuration of the apparatus according to the prior art.

In view of the above, the Applicant initially thought to replace the aforementioned hydraulic systems with alternative systems.

However, the Applicant established that this solution had different drawbacks which prevented the effective implementation thereof. In particular, with regard to the aforementioned cutting device, the Applicant ascertained that a high penetrating power of the cutting blade was not always guaranteed, thereby negatively affecting the correct execution of the cut and the high production volumes required by the industry which uses such apparatus.

In this respect, the Applicant therefore realized that it is possible to use a mechanical system in order to drive the cutting device, but that it is necessary to provide this system with a configuration which enables a high penetrating power of the cutting blade to be obtained. Moreover, the Applicant understood that such a drive system must in any case have a simple structure in order to ensure a high degree of reliability and facilitate the associated maintenance and/or repair operations.

The Applicant has therefore found that a cutting device which comprises at least one cutting blade rotatable about an axis of rotation can be mechanically driven and is able to overcome the mechanical resistance of the sheet, penetrating it easily and gradually along given cutting lines so as to separate the single containers. In this way, the use of oils or similar working liquids is avoided, along with the risk of corresponding soiling of the production line and the containers produced by it, while ensuring a correct execution of the cut, and at the same time the high production volumes required by the industry in the sector are maintained.

Therefore, according to a first aspect, the present invention relates to an apparatus for forming containers which are filled with a liquid and sealed, in particular from a sheet of packaging material unwound from a reel.

Preferably, the apparatus comprises a forming and filling unit, in particular for folding the sheet around a main axis so as to obtain a tube, and/or sealing along this axis the sheet folded to form a tube, and/or filling the tube with a liquid, and/or forming on the tube sealing bands which are transverse to the main axis and define on the tube single semi-finished containers, which are sealed and filled with the liquid. Preferably, the transverse sealing bands are formed in succession.

Preferably, the forming and filling unit comprises a cutting device designed to separate the single semi-finished containers from the tube, along the cutting lines formed on the transverse sealing bands.

Preferably, the cutting device comprises at least one cutting blade which is rotatable about an axis of rotation parallel to the main axis.

Owing to these characteristics, the cutting device is able to operate in a more precise and reliable maimer without using oils or similar working liquids, and any malfunctioning of the said device does not result in soiling of the production line or the containers produced.

It is also evident that the apparatus according to the present invention provides cutting means which have a simpler structure with fewer maintenance requirements.

According to a second aspect, the present invention relates to a process for forming containers which are filled with a liquid and sealed, from a sheet of packaging material unwound from a reel. Preferably the process comprises the steps of: folding the sheet around a main axis so as to obtain a tube, and/or sealing along this axis the sheet folded to form a tube, and/or filling the tube with a liquid, and/or forming on the tube, preferably in succession, sealing bands which are transverse to the main axis and define on the tube single semi-finished containers, which are sealed and filled with the liquid, from the tube.

Preferably, the step of separating the single semi-finished containers from the tube includes driving at least one cutting blade of a cutting device, with a movement of rotation about an axis of rotation parallel to the main axis, in particular so as to separate by means of cutting the single semifinished containers from the tube, along the cutting lines formed on the transverse sealing bands.

By driving the cutting blade with a rotational movement it is possible to make use of a lever effect in order to provide the cutting blade with a high penetrating power, without having to use hydraulic actuators for performing the movement of the cutting blade. The absence of hydraulic means avoids the risk of contamination by oils or other working fluids and moreover facilitates the setting-up and maintenance of the apparatus.

According to one or more of the aforementioned aspects, the present invention may comprise one or more of the following characteristics:

In one or more embodiments, the cutting device comprises a follower element. Preferably, the follower element is intended to cooperate with a cam. In an equally preferred maimer the follower element is connected to the cutting blade so to operate it during a cutting stroke according to a movement of rotation about the axis of rotation.

Advantageously, the use of a cam system for driving the cutting blade results in more precise and reliable operation.

In one or more embodiments, the cutting blade comprises an elongated body having a first end and a second end opposite to one another. Preferably, the elongated body also has a cutting edge formed on an intermediate portion of the body between the first and second ends. Preferably, the axis of rotation is positioned at the first or second end of the cutting blade.

In one or more embodiments, the cutting device comprises a drive chain for transmitting the motion from the follower element to the cutting blade. Preferably the drive chain is configured to act on the second or first end of the cutting blade so as to drive the cutting blade according to the movement of rotation.

In one or more embodiments, the drive chain comprises a transmission element which acts on the second or first end of the cutting blade, preferably with a pushing or pulling action along a direction which is contained in a plane orthogonal to the axis of rotation of the cutting blade, preferably transverse to a longitudinal axis of the cutting blade.

In one or more embodiments, the forming and filling unit comprises at least one pair of arms arranged opposite to one another. Preferably the arms can be operated cyclically, in particular according to an alternating motion along the main axis, in a working stroke, from an upper position to a lower position, and a return stroke, from the lower position to the upper position. Preferably, in the lower position the arms are kept in a closed position for forming, in succession, the transverse sealing bands. In an equally preferred manner in the upper position the arms are kept in an open condition.

Preferably, the cutting device is mounted on an end of one of the two arms.

In one or more embodiments, driving the cutting blade includes driving the at least one cutting blade during a cutting stroke according to a movement of rotation about the axis of rotation, preferably by means of a system for transmission of motion, in particular of the cam type.

The use of a cam system for driving the cutting blade advantageously results in more precise and reliable operation.

In one or more embodiments, the cutting blade comprises an elongated body having a first end and a second end opposite to one another. Preferably, the elongated body has a cutting edge, preferably formed on an intermediate portion of the body between the first and second ends. Preferably, the axis of rotation is positioned at the first or second end of the cutting blade. Preferably, driving the cutting blade includes acting on the second or first end of the cutting blade with a pushing or pulling action along a direction which is contained in a plane orthogonal to the axis of rotation of the cutting blade. Preferably, the direction of the pushing or pulling action is transverse to a longitudinal axis of the cutting blade.

In one or more embodiments, the operation of forming, in succession, the transverse sealing bands includes cyclically operating at least one pair of arms which are arranged opposite to one another and can be cyclically operated according to an alternating movement along the main axis, in a working stroke from an upper position into a lower position, in which the arms are preferably kept in a closed condition, for forming, in particular in succession, the transverse sealing bands, and a return stroke, from the lower position to the upper position, in which the arms are preferably kept in an open condition. Preferably, the cutting device is mounted on the end of one of the two arms.

Preferably, the operation of separating the single semi-finished containers from the tube includes driving the cutting blade according to its movement of rotation, preferably at the end of the working stroke of the arms, when the latter are in the lower position or in any case close to it.

Further characteristic features and advantages of the present invention will become clear from the following description below, with reference to the attached drawings, provided purely by way of a non-limiting example, in which:

- Figure 1 shows in schematic form an example of the apparatus described here;

- Figure 2 shows a preferred embodiment of the cutting means of the apparatus described here, in the condition installed in the said apparatus;

- Figure 3 shows the cutting means of Figure 2 separated from the other parts of the apparatus.

The description below shows various specific details aimed at providing a fuller understanding of the embodiments. The embodiments may be realized without one or more of the specific details, or using other methods, components or materials, etc. In other cases, known structures, materials or operations are not shown or described in detail so that various aspects of the embodiment may be clearly understood.

The references used here are used solely for convenience and therefore do not define the scope of protection or the range of the embodiments.

As already mentioned above, the apparatus described here has the function of forming containers which are filled with a liquid and sealed, from a sheet of packaging material unwound from a reel.

With reference to Figure 1, the apparatus comprises a forming and filling unit 100 for:

- folding a sheet 220 of packaging material around a main axis I;

- sealing along the main axis I the sheet 200 folded to form a tube;

- filling the tube 202, formed by the sheet 200, with a liquid;

- forming on the tube 202, in succession, sealing bands 204 which are transverse to the main axis I and define on the tube 202 single semi- finished containers 206, which are sealed and filled with the liquid;

- separating by means of cutting the single semi-finished containers 206 from the tube 202 along the cutting lines 208 formed on the transverse sealing bands 204.

In a manner known per se, the cutting lines 208 may be formed on the sealing bands 204 or, in alternative embodiments, in an adjacent position situated between two sealing bands formed close together, each for closing a respective semi-finished container.

During operation, the sheet 200 is fed according to a feeding movement along the reference axis I.

In a manner known per se, the forming and filling unit 100 comprises at least one, usually two, pairs of arms 102 which are arranged opposite to one another, with respect to the main axis I, and which are movable relative to each other between an open condition and a closed condition. In particular, the arms 102 are arranged opposite to one another in relation to the tube 102, or, in other words, the tube 202 is located between the two arms 102 of a pair. Moreover, the arms 102 are operated according to an alternating translation movement along the main axis I, in a working stroke from an upper position to a lower position, in the mutually closed condition, and a return stroke, from the lower position to the upper position, in the mutually open condition.

In a manner known per se, the ends 102A of the arms 102 are configured to flatten the tube 102, in the closed condition of the arms 102, until the inner walls of the tube are brought into contact with each other.

Furthermore, again in a manner known per se, the end 102A of one of the arms 102 of the single pair is provided with a welding device 106 for forming the transverse sealing bands 204. Again in a maimer known per se, the ends 102 A of the arms 102 are provided with shells 104 configured to define a given containing volume, in the mutually closed condition of the arms 102.

Finally, again in a manner known per se, a cutting device 20 is mounted on the end 102 A of one of the arms 102 of the single pair, said cutting device being designed to form the cutting lines 208, which separate the single semi-finished containers 206 from the tube 202.

During operation, the tube 202, which is closed longitudinally and filled with the liquid to be packaged, is fed to the upper position of the working stroke of the arms 102. Incidentally, it should be noted that the means for folding the sheet of packaging material 200 and welding it in the longitudinal direction may be of the known type and therefore are not described here in order to avoid complicating the present description.

In their upper position, the arms 102 are closed together and at the same time the welding device 106 is activated. The shells 104 limit the expansion of the tube 202 which occurs as a result of the flattening action exerted on it

During the working stroke from the upper position to the lower position, the welding device 106 forms the transverse sealing bands 204. Once the lower position is reached, or in the vicinity thereof, the cutting device 20 is activated so as to separate the single semi-finished containers 206 from the overlying tube 202.

According to an important characteristic feature of the apparatus described here, the cutting device 20 comprises a cutting blade 21 which is rotatable about an axis of rotation R parallel to the main axis I.

With reference to Figures 2 and 3, the cutting blade is mounted on the end 102 A of one of the two arms 102. In one or more preferred embodiments, such as that shown, the cutting blade 21 comprises an elongated body, having opposite ends 21 A, 2 IB, and a cutting edge 21C formed on a portion comprised between the two ends 21 A, 2 IB.

In one or more preferred embodiments, such as that shown, the axis of rotation R is positioned at one of the two ends, in the example shown, the end 21 A.

In one or more preferred embodiments, such as that shown, the cutting device 20 is designed so that the cutting stroke of the blade 21 is performed by a cam which extends in a plane parallel to the main axis I and which makes use of the movement of the arms 102 along the same axis.

In particular, in one or more preferred embodiments, such as the one shown, the cutting device 20 comprises a shaft 22 rotatable about an axis of rotation II orthogonal to the main axis I. A first end 22 A of the shaft 22 has, rotatably connected thereto, a lever 23 which, in turn, has mounted on its distal end a roller 24 designed to engage with the cam for performing the cutting stroke (not shown). The opposite end 22B of the shaft 22 has, rotatably connected thereto, a further lever 25 which, in turn, is connected to a further lever 26 rotatable about an axis of rotation 12 parallel to the main axis I, by means of a linkage 27.

A further lever 28 is mounted rotatably about the axis of rotation 12, integrally with the lever 26, and is connected to the end 2 IB of the cutting blade 21 by means of a second linkage 29.

In view of that stated above, it will be clear to the person skilled in the art how the transmission of the motion via the kinematic chain described above causes the rotation of the cutting blade 101 about the axis of rotation R, owing to a rotation of the lever 23 about the axis of rotation II, induced by the action of the aforementioned cam on the roller 24.

As an alternative to the system described it is in any case possible to use systems for transmission of the motion which are of another type or are arranged in different configurations, depending on the requirements of the specific applications.

Owing to the particular system for driving the cutting blade 21 it is possible to make use of a lever effect in order to provide the cutting blade with a high power for penetrating the tube 202, without having to use hydraulic actuators in order to perform the movement of the cutting blade. The absence of hydraulic means avoids the risk of contamination by oils or other working fluids and moreover facilitates the setting-up and maintenance of the apparatus. On the other hand, the cam system used by the cutting device 20 ensures operation which is more precise - also from the point of view of synchronization of the device with the other parts of the apparatus - and more reliable.

In an alternative embodiment (not shown), the driving of the cutting blade 21 may be performed by means of an electric motor configured to perform rotation of the shaft 22 about the axis of rotation II (see Figure 3), instead of the aforementioned cam system.

In a further embodiment of the apparatus described here (also not shown), the cutting device 20 may comprise a second cutting blade which is preferably fixed and is mounted on the arm 102 opposite to the arm on which the cutting blade 21 is mounted. This second blade operates as a counter element against which the sealing band 204 is pressed by the blade 21 and against which the blade 21 is gradually brought into contact during execution of the cut. Obviously, without altering the principle of the invention, the embodiments and the constructional details may vary, even greatly, with respect to that illustrated here purely by way of a non-limiting example, without thereby departing from the scope of the invention, as defined in the accompanying claims.

In particular, the cutting device described here may also be used in an apparatus of a type different from that to which reference was made above. For example, the cutting device described here - as illustrated in the above description and the claims below - may also be used in an apparatus where the single semi-finished containers are first made, again from the sheet unwound from a reel, and only subsequently, the single semi-finished containers are filled with the liquid to be packaged and, finally, completely closed. Apparatus of this type are also widely known in the art.

Therefore, the solution described here may apply, more generally, to an apparatus for forming containers which are filled with a liquid and sealed, from a sheet of packaging material unwound from a reel, wherein the apparatus comprises a forming and filling unit for forming, from the sheet unwound from a reel, semi-finished containers which are then separated from the sheet by means of cutting, and for filling the semi-finished containers with the liquid, wherein the forming and filling unit comprises a cutting device designed to separate the single semi-finished containers from the sheet unwound from a reel.