Note: Descriptions are shown in the official language in which they were submitted.
~31~6~
7435-88
TITLE: METHOD FOR PROD~CING A FOIL-CONTAINE~, APPARATUS
FOR THE IMPLEMENTATION OF THE SAID METHOD, AND A
FOIL-CONTAINER PRODUCED ACCORDING TO THE SAID_METHOD
SPECIFICATION
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The invention relates to a method for producing
foil-containers in the form of bottles filled with freely
flowing substances, and having bases upon which they are
adapted to stand, by:
(a) deep-drawing at least a part of each foil-container
from a piece of flat deformable foil having a base-part
running substantially at right angles to the plane of
the foil, with a neck-section remote from the base-part,
and with edge-areas projecting outside the base at the
periphery of the container-part;
(b) by folding the foil-material about a line located
~: substantially at the edge-like transition between the
base-part and the plane of the foil;
(c) by connecting the pieces of foil lying on each side
of the fold-line and one upon the other in the
edge-areas after having been folded around, from the
bases to at least approximately the upper ends of the
half-sectionsJ by means of a first connecting process;
(d~ by filling each container through the half-section;
; (e) by closing each container, characterized in that:
A method of this:kind, and a foil-contain~er :
: produced thereby, are known from German AS 55 802. With the
~: 30 known method it is, however, initially possible only to use a
: sequence of st~eps to produce an empty foil-contalner, the
peripheral~ flange of which is sealed all around. In order ~o
fill the ~nown container, the neck of the bottle must be cut
: off andJ after it has been filled, a closure must be fitted
; ~3;5: t:o, or inser~ted~into, the neck. However, not only does this
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7435-88 -2-
mean that a liquid-tight closure can be obtained only at
considerable expense and by using additional parts but~ if
the sealing edge is cut off just above the end of the neck,
this produces only a narrow gap, through which it is almost
impossible to fill the container. Because of the sealing
edges at the side of the neck, it is also impossible to fit a
sealed closure thereto. It is also difficult to cut off the
closing wall of the neck because it is impossible to provide
any abutment in the neck of the bottle for the cutting
operation. Any damage to the top end of the neck also makes
it impossible to fit a sealed closure and there exist, in the
vicinity of the seals, at diametrically opposite locations on
the neck, so-called capillary gaps which cannot be closed
with an insert, or at least not without additional sealing
means. None of these measures can be used in conjunction
with a continuous or quasi-continuous process.
In the prior art also mentioned in German AS 10 55
802, namely in the case of foil-containers consisting of two
halves with a peripheral seal, it is also known to form, on
the neck o~ the bottle, a tubular part having an aid to
opening and to carry out the filling of the container in the
inverted position through the base. To this end a filling
duct is formed, during the deep-drawing process, on each of
;~ the two base-parts and extending to the edge of the
respective piece of foil. Containers are formed
- progressively by congruent and mirror-image placing of two
pieces of foil one upon the other, the filling duct running
from the base being approximately cylindrical and being open
towards the top. By means of a first sealing process, sealed
edge-areas are produced between the said filling ducts.
After this process of filling through the base, the filling
ducts are closed by a second sealing process whereby the
- 35 semicylindrically deformed material in each half of the
filling duct is returned to the extended position, i.e. must
be upset (?) onto the periphery. Because of the initially
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uneven surfaces, the necessary heating process is difficult
to control. Apart from this, however, the sealing seam under
the base of the bottle, occurring with this known process,
makes it impossible for the bottle to stand upon its base.
Such a container is already described in German AS 10 55 802
as disadvantageous.
It is therefore the purpose of the invention to
provide a method of the type described at the beginning
hereof, whereby a filled and reliably closed upstanding foil-
container can be produced and will require no additional
closure-parts.
According to the invention, this purpose is
accomplished in that:
(f) during the deep-drawing process, there is formed, on
each neck-section, a tubular part directed away from the
base which is directed to the nearest foil-edge and ends
at a distance "A' therefrom, and which subsequently
ensures a sealed connection between the foil-parts lying
upon the other end of the tubular part and initially
un-connected;
(g) the foil-parts lying one upon the other are joined
together in the edge-area, with the exception of a
filler opening 5 at the tubular ends;
(h) each foil-container is filled through the tubular
part;
(i) the foil-parts lying one upon the other at the
tubular end in the vicinity of the filler opening are
sealed together by a second connecting process and,
fi nal ly,
(j) the filled and sealed foil-containers are separated
individually or into groups.
In this connection it is essential that the tubular
part shall not extend to the respective foil-edge but shall
terminate at a distance "A" therefrom~ a distance that may
amount to between 5 and 20 mm. This ensures that there will
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7435-88 -4-
be flat foil-parts above the end of the tubular part which
can be joined together, after filling, by a second connecting
process, with no need for the tubular part to be squeezed and
for the material to be upset. The hot sealing of foil-parts
lying flat one upon the other raises less problems in a
continuous manufacturing process than reforming open filing
ducts as far as the edge, especially since the said ducts are
larger in diameter.
With the method according to the invention it is
possible to fill and close securely a foil-container adapted
to stand upon its base, in an uninterrupted sequence of steps
and from a single piece of foil, with no need for separate
and additional closure-parts or means for connecting these
parts to the container.
This is a particularly advantageous way of
packaging so-called test-samples which are very often
mass-produced in large numbers and are distributed for
publicity purposes. A special effort is made in this
connection to make the miniatures as alike as possible to the
original package, so that they are associated in the mind of
the public. Above all, it must be possible to produce these
miniatures in the largest possible numbers at the lowest
possible costs. ?
The terms "deepdrawing" is intended to mean any
method for producing permanent deformation of a single- or
multi-layer foil whereby a depression is produced in the flat
foil which can subsequently be filled with a freely flowing
medium (liquid, paste, powder). The deep-drawing process may
be used with or without heat. Other foils, for example those
consisting of an aluminum-laminate may be cold-shaped
accordingly.
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7435-88 -5-
Suitable foils are so-called monofoils. Laminated
foils are particularly advantageous. The overall thickness
of the foil may scart at about 0.1 mm, most of the wall-
thickness serving to provided mechanical s~rength. This part
of the laminate is preferably made of polyvinyl-chloride,
polystyrene, aluminum~foil, polypropylene and polyester~ For
vapour- and gas-barriers it is preferable to use a laminate
consisting of aluminum-foil, polyvinyl-dichloride,
polyacrylonitrile~ polyethtylene, polypropylenem polyester or
polyamide. This list of materials, however, is given merely
by way of example and is no way restrictive. A vapour-and
gas-barrier also serves as an aroma-barrier, a property which
is important in the case of perfumes.
The so-called "neck-section" need not differ in
cross-section from the main part of the container. In this
case, the upper part of the container is regarded as the
neck-section. In order to promote similarity with a "real
bottle", it is preferable for the neck section to be visibly
smaller than the remainder of the container.
In this connection it is possible, with consider-
able advantage, to join to~ether the flat foil-parts
lying one upon the other only from the base to about the
upper end of the neck-section, leaving the flat foil-parts
above the neck section unconnected; then to spread the foil-
parts in the vicinity of the tubular end and to fill the
container through this spread. The spread is then released
and the foil-parts are finally sealed together, by the second
connecting process, from above the tubular end a~ least as
far as the connected area of the first connecting process.
In a quite particularly advantageous manner, how-
ever, the method may be carried out continuously with the
sequence of steps set forth in claim 3. A continuous method
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7435/88 -6-
is also to be understood as one in which either the foil
moves stepwise in relation to stationary work-stations or the
said work-stations move, together with the foil, over a
limited step-length, i.e. it is all a matter of relative
motion. The deep-drawing process, sealing processes, filling
processes and stamping processes are all carried out during
the pauses. With certain tool-designs, however, it is also
possible to keep the foil and the tools moving together
continuously, for example if the tools are designed in the
Form of drums. However, a stepwise process may also be
called "quasi-continuous". It is desirable for several, for
example four, foil containers to be deep-drawn, hot-sealed,
filled and stamped out simultaneously. Such a continuously
processed length of foil is also known as a "repeat-length".
The heat-treatment station is of particular
significance to the process. As will described in greater
detail hereinafter, with the details of the apparatus, while
the foil is being folded from the flat position to a vertical
position, the two edges of the foil travel over a longer
distance than the middle thereof. The foil-parts lying on
each side of the centreline "M" are twisted at this time to a
certain extent, an operation which causes stresses in the
~ 25 relatively stiff foil. By heating the foil to a material-
; specific temperature definitely below the deep-drawing
plasticizing temperature9 it is possible to make the foil so
supple that it willingly follows the folding operation. This
is particularly important in connection with the fold-line
located in the middle of the foil, since the foil in this
very small area has to be bent through 180.
It is therefore particularly desirable for the foil
in the heating station to pass under a heater-element which
heats the middle of the foil from above, and for the foil
~; 3~ also to be passed over a hot-edge which contacts the foil
from below in the vicinity of the fold-line. The said
heater-element and hot-edge are preferably heated to
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7435/88 -7-
material-specific temperatures which, depending upon the type
of foil used, may vary between 80 and 140C.
The invention also relates to an apparatus for
producing deep-drawn foil containers having bases upon which
they are adapted to stand.
In order to accomplish this purpose9 an apparatus
of this kind is characterized according to the invention in
that, in a deep-drawing tool having a flat surfaces serving
to support the foil, at least one mould-cavity per container
is arranged, the said cavity comprising mould-surfaces
merging with each other in order to produce a base-part
running at right angles to the tool-surface, a
container-wall, a neck-section and a tubular part extending
therefrom, the axis of which runs in the tool-surface
determining the edge-area of the foil-surface.
An apparatus for continuous production and filling
of deep-drawn containers with a deep-drawing tool of this
kind is characterized in a particularly advantageous manner
by the features set forth in the characterizing part of claim
7.
Further advantageous configurations of the method
and apparatus may be gathered from the remaining sub-claims.
An example of embodiment of the object according to
the invention is explained hereinafter in greater detail in
conjunction with the drawing attached hereto, wherein:
Fig.1 is an overall view of an apparatus for the
continuous production of foil-containers;
Fig.2 is a perspective view of a deep-drawing station
showing a foil with deep-drawn container-parts
emerging therefrom;
Fig.3 is a plan view of a deep-drawing tool accommodated
- ~ in a deep-drawing station;
Fig.4 is a cross~section through the deep-drawing tool
; according to Fig.3 in the vicinity of the
longitudinal axis of two container-halves;
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Fig,5 is a perspective representation of the proceedings
in the heating station as far as the entry into
the first sealing station,
Fig.6 is a perspective representation of the proceedings
in the filling station between the first and
second sealing stations;
Fig.7 is a perspective representation of the filled
foil-laminate emerging from the second sealing
station;
Fig.8 is a front elevation of a stamped-out foil
container:
Fig.9 is a side elevation of the foil-container accord-
ing to Fig.8; and
Fig.10 is a front elevation of four connected foil-
containers according to Fig.8.
According to Fig.l, the apparatus comprises a
supply-station 1 having a roll 2 of foil, two conveyors 3,3a
in the form of "stepping mechanisms" with reciprocating
grippers, not shown, for stepwise feeding the foil 5 taken
from the roll, a deep-drawing station 4 preceded by a heating
~ device 14, a heating station 6 for the purpose of folding up
-~` 25 the foil-parts on each side of a centreline, a first sealing
station 7, a filling station 8, a second sealing station 9 to
which there also pertains a cooling station 9a, a first
stamping station 10 used to produce weakening zones
(embossings, stamping in linear or split form) for the
`~ 30 purpose of forming an opening aid, and a second stamping
station 11 which is used to separate the foil-containers from
the laminate still connected together. The essential
stations are described h~ereinafter in greater detail in
;~ conjunction with Figs,2 to 7.~ The final stamping station is
~35 followed by~a collecting bin.
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7435/88 9
Located in the deep-drawing station shown in Fi~.2,
in a heat-insulated housing 12, is a deep-drawing tool 27
which will be explained in greater detail in conjunction with
Figs,3 and 4. Associated with this tool is a heating device
14, shown only in broken lines, which is used to plasticize
foil 5 prior to deep-drawing. The details of the deep~
drawing process are state of the art and need not therefore
be gone into here in greater detail.
Foil-parts 5a and 5b of equal width are formed in
foil 5 on each side of an imaginary centreline "~" which
coincides with the subsequent fold-line. These areas are
defined outwardly by edges 5c and 5d running parallel with
centreline"M".
Container-parts 15 and 16 are formed in foil 5,
each in so-called "blocks of four" arranged in pairs and in
mirror-symmetry with each other, each consisting of a base-
part 17,18, a container-wall 19,20, a neck-section 21,22, and
a tubular part 23,24. Base-parts 17,18 are arranged at the
smallest possible distance apart, and parallel with each
other on each side of centreline"M" which runs in parallel
with the direction of travel indicated by arrow 25. Tubular
parts 23,24 do not reach edges 5c, and 5d but terminate at a
distance "A" in front of them. It will be seen that the
longitudinal axes of the container-parts, and especially of
the tubular parts, run at right angles to the edges of the
foils and to the direction of travel, and that the parts
within the foil pertaining to one container are at the same
distance from each other9 as determined by the configuration
of the deep-drawing tool on the one hand and by the step-
length predetermined by the conveyor, on the other hand.
Foil 5 7eaves housing 12 through an opening 26.
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7435-88 -10-
Figs.3 and 4 show details of deep-drawing tool ~7.
Arranged in a steel plate 28, running from a flat tool-
surface 29 which is also the supporting surface for foil 5,are two mould-cavities F15,5F15 per container exhibiting
mould-surfaces merging into each other. Mould-surfaces F17
and F18 are substantially at right angles to tool-surface 29
and serve to produce base-parts 17 and 18. Located there-
between is a thin-walled web 30, the upper edge of which is
rounded off. Mould-surfaces F19 and F20 are substantially
cylindrical and serve to produce container-walls 19 and 20.
Mould-surface F21 and F22 are also cylindrical and serve to
produce neck-sections 21 and 22. Mould-surface F23 and F24
are again cylindical and serve to produce tubular parts 23
and 24. Located between individual mould-surfaces, for the
purpose of bridging differences in diameter, are other mould-
surfaces not defined herein which may be regarded as roughly
- semicircular. It will be seen that the axes of mould-
cavities 15 and 16 are located in the sur~ace of the tool and
run at right angles to the direction of travel of foil 5,
also indicated here with an arrow 31. The width of the foil
is substantially equal to that of tool-surface 29, as seen at
right angles to the direction of travel. This ensures that
distance "A" is maintained (Fig.2). When the foil is placed
upon tool-surface 299 centreline "M" coincides with axis of
symmetry S-S thereof.
Fig.5 shows details of heating station 6, although
path "L", followed by the foil in the direction of travel is
shown somewhat abbreviated for the sake of clarity. The
foil-sections in Figs.2 and 5 must be regarded as directly
connected together. Located in the central area of the foil
are two heating devices 33 and 34 by means of which foil-
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7435/88
parts 5a and 5b, located on each side of centreline "M" are
heated. Starting from the horizontally extended position (at
the left of Fig.5), they are gradually folded up, about
centreline "M", until they contact each other in a vertical
plane ~at the right of Fig.5). For the sake of clarity only
a few of container-parts 15 and 16 are shown.
It will be seen that edges 5c and 5d travel over a
longer distance than centreline "M". This is attributable to
twisting of foil-parts 5a and 5b - also shown graphically.
Heating devices 33,34 are provided in order to overcome the
bulkiness oF the foil.
First heating device 33 along the path of the foil
is in the form of a heater-element arranged above foil 5.
Lower side 35 of the said element, facing the foil, is
defined by surfaces 35a and 35b which are in mirror-symmetry
and are arranged in a V in relation to each other. It will
be seen that the angle of the V decreases continuously from
inlet-side "El' to outlet-side "A" in accordance with the
fold-angle between the foil-parts, and that the crest-line of
surfaces 35a and 35b runs directly above the fold-line of the
foil-parts. The underside of the heater-element is at all
`~ 25 points at the shortest possible distance from the foil moving
past. It will be seen from Fig.6 that the so-called fold-
angle at the left-hand edge of the figure amounts to 180
but is 0 at the right-hand edge.
Heating device 33 consists of a block of light `-
alloy designed as indicated hereinbefore and accommodating a
heating resistor, not shown. The leads thereto run in
~ supports 37 and by means of which the said heating device may
; be adjusted vertically.
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743~-88 -12-
Heating device 33 is followed by a second heating
device 34 in the form of a hot-edge arranged below fold-line
36 and centreline "M" and running in parallel with the
fold-line. This hot-edge has a heat-transfer-plate 38
clamped into a heater-element 39 which also contains a
heating resistor, not shown. While the apparatus is in
operation, linear upper edge 38a of heat-transfer-plate 38 is
in contact with the underside of fold-line 36. While the
apparatus is stationary, heating device 34 may be lowered by
means of its supports 40 which are connected to hydraulic
drives 41, in order to avoid overheating the foil. As a
rule, the hot-edge has a higher surface-temperature than
heating device 33 but the latter may also be arranged to be
raised.
Heating devices 33 and 34 are shown shortened in
the direction of travel of the foil. It is to be understood,
however, that the length of the heating devices, in the
direction o~ travel of the foil, corresponds at least to the
total length of simultaneously deep-drawn container-parts
15,16. Since four parts of container-parts are produced
simultaneously, the length of the heating devices must be at
least equal to the distance between the axes of the first and
fourth pair of mould-cavities, the so-called "repeat-
length".
Located at the end of the heating station is guide-
means 63 having two guide-walls 63a, 63b bent outwardly and
forwardly in mirror-symmetry with the now vertical path of
the foil, between which the upward-folding process is
completed.
~ Upon completion of the upward-folding process,
`I foil-parts 5a, 5b, lying flatly one upon the other except ~or
the container parts, are passed to first sealing station 7
consisting of two sealing jaws 42,43 adapted to move a~ right
angles to the axes of the containers.
The effects of first sealing station 7
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7~35/88 -13-
appear in Fig.6 to the right of the station. Foil-parts 5a,
5b are sealed together in the edge-areas of deep-drawn
container-parts 15,16 lying in mirror-image one upon the
other, from base 17,18 to the upper end of neck-section 21,
22, as indicated by the diagonally cross-hatched areas. The
sealing does not, however, extend to the overlying area of
tubular parts 23,24 nor to the upper edges of the foil;
instead, this sealing zone ends at an upper boundary-line 44
located at the transition between relevant neck-section 21
and tubular 23. Hence the shape of the heated parts of
sealing jaws 42,43.
First sealing station 7 follows filling station 8
on inlet-side "E" of which is arranged the start of a spread-
ing device 45 located in the path of the now existing
foil-lamination on sides 45a and 45b of which upper edges 5c
and 5d of foil 5 move past as upper tubular ends 23a are
spread apart. The said spreading device is of wedge-shaped
design at inlet side "E" and outlet-side "A" and has
substantially the shape of the hull of a ship, i.e. the ends
are Y-shaped. Filling station 8 comprises a total of four
tubular filler-necks 46, the distance between them
corresponding to the distance between the tubular parts in
the foil-laminate. These filler-necks are connected by
lines, not shown, and a metering device, to a storage-tank
also not shown. ey means of a timing control, care is taken
to ensure that the filler-necks can be introduced into the
tubular parts when the foil-laminate has come to a halt.
During this time, four pairs of container-parts 15,16 are
deep-drawn in station 4, are provided with suitable first
sealing zones in the first sealing station, and are finally
sealed in second sealing station 9 which will be dealt with
further hereinafter.
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In order to make it possible for filler-necks 46 to
move in the direction of double arrow 47, a recess 4~,
running from top to bottom, is arranged in spreading device
45 along the longitudinal axis thereof running in the direc-
tion of travel of the foil-laminate, through which recess the
said filler-necks are adapted to pass. Two supports 49 are
used to adjust the height of spreading device 45. After the
filling operation, foil-edges 5c,5d close up again as a
result of their inherent resiliency and move between sealing
jaws 50,51 of second sealing station 9, which are mounted in
such a manner as to move at right angles to the foil in the
direction of the two double arrows, as in the case of jaws
42,43 of first sealing station 7.
The action of sealing jaws 50,51 may be gathered
from Fig.7. Foil-parts 5a,5b are sealed together in the
hitherto un-connected edge areas of the foil-container, as
far as previously described boundary lines ~4 (Fig.6), as
indicated in Fig.7 by cross-hatched areas with parallel
edges. The foil-container is now sealed on all sides without
the need for squeezing together tubular parts 23~24, as may
; easily be gathered from Fig.7. From the shape of the cross-
hatched areas with parallel edges in Fig.7 comes the design
of the heated zones of sealing jaws 50,51 which are shown in
Fig.7 as separate or slightly overlapping zones. It is
highly desirable, however, to design the effective sealing
surfaces of second sealing station 9 in such a manner that
the sealing zones produced by them at the foil-lamina~e
completely cover the sealing zones produced by the first
sealing station so that it cannot be seen from the first
container that the sealing was carried out in separate
operations. This increases safety.
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7435-88 -lS-
Also of special importance is the cooling of all
sealing zones in cooling station 9a. To this end, the said
station is equipped with cooling jaws whose cooling surfaces,
acting on the foil, are of such a configuration as regards
shape, size and position in relation to the foil-laminate,
that the total area of all simultaneously cooled sealing
zones is rapidly and effectively cooled. The sealing
surfaces of the sealing tools, and the cooling surfaces of
the cooling jaws, are thus substantially congruent - if they
were to be projected one upon the other. For this reason,
the heat introduced during the sealing process is rapidly
removed again from the foil-laminate with the containers
which have been ~illed in the meanwhile and the rigidity of
the foil is restored. This is of particularly advantage
during further handling of the group.
Fig.8 shows a section of laminated foil consisting
of foil-parts 5a,5b, separated from adjacent foil-containers
54 by two broken lines 55. A twist-off is first produced in
first stamping station 10 by producing, on each side of
tubular part 23, weakening lines 58,59 which are directed
towards the said tubular par~, are in alignment with each
other, but do not extend as far as the tubular part.
~` 25 Thereafter, in second stamping station 11, foil-
container 54 is separated from foil-laminate 5a,5b by cutting
into weakening iines 58,59 along a trace 56 which comprises
two indentations in the vicinity of the said weakening
lines. Broken line 60 below fold-line 36 indicates the
course of flanged edges would take in the edge-areas of foil-
` container 54 if the latter were made of two separate pieces
of foil and were filled through the base, for example.
During the manufacturing process, foil-containers 54 may also
be provided with labels 61.
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Fig.10 shows that several such foil-containers 54
may also remain joined together in the form of a packet.
Additional weakening lines 62 are provided between connected
edge-areas (the cross-hatched areas), along which individual
holders may be separated, for example broken off~ without the
aid of tools. It will be seen that base-parts 17,18 lie in a
common plane which also contains fold-line 36. However, it
is not necessary for all containers to be of the same shape
and size, or to have the same content. Instead it is quite
possible to join containers of different sizes together and
to fill them with difference substances, subsequently
identifying them with labels.
As may be gathered more particularly from Fig.9,
foil-container 54 is mirror-symmetrical as regards its
parting plane E-E. As regards parting plane E-E defined by
its edge-areas, the foil-containers according to the inven-
tion may be either asymmmetrical or symmetrical. An
asymmetrical example of embodiment consists, for example, of
a deep-drawn container-part and a flat container-part which
serves merely as a closure`. Also conceivable, of course, are
` intermediate forms in which the two container-parts are drawn
to different depths or even have different geometrical
`:
shapes.
It is also possible to have the contain~r-parts
staggered in relation to each other in the parting plane, in -
order to produce a container of particularly striking appear-
ance.
Finally, it is also conceivable to make one of the
container-parts convex instead of concave, so that a space
having a sickle-shaped cross-section is formed between the
two parts9 thus accommodating a particularly small amount of
~` 35 the product over a large surface. This is quite sufficient
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7435/88 -17-
for packaging samples or publicity material.
In the interests of clarity, vertical guides for
the foil or laminate, i.e~ so-called support-plates, and
horizontal guides, i.e. so-called lateral walls, are not
shown, with the exception of guide-means 63. It is to be
understood, however, that such guide-means are provided
wherever the foil or laminate is in need of guidance or
support, for example on both sides of filling station 8 and
below spreading device 45.
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:
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:
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