Note: Descriptions are shown in the official language in which they were submitted.
WO 90/14g93 P(~/AU90/00227
The present invention relates to a method and apparatus for
the fab~ication of 3 dimensional blan*~ for ~he pac:kaging of ar~cles and
is par'dcularly, although not ~xclusively, directed to a method and
apparatus for fabnca~on of 3 dimensional blanl~ for ~he mould;ng of foil
enca~ed ar~des.
In the prior art hollow chocolate eggs, rabbits and o~her
novellies are n~de us~g 3 dimensional foil blanks. These bl~s are cut
into sheets when fo~med and contain a plurali~r of moulds. l~ese
moulds are usually located transverse to the lon~tudinal direc~on of the
conveying direction and m~y contain two rows of moulds. The shaped
blanks form one h~lf of a mould for producing the hollow novel~des.
Each mould i~ formed by a pressing opera'don where a condnuous leng~
of foil passes through male and female dies. The shape of the dies is
impressed into the foil to achieve each. ~dimension~l mould shape.
Once pressed the dies are opened and the foil advanced to shape the
next mould. The foil is then cut to size e.g~ 5 moulds per sheet. Each
sheet is placed in a spinning frame mated with a corresponding sheet
ant chocolate inserted. When spun the chocolate inside the c~opera~ng
moulds will form a hollow ar~cle encased in foil~
The problems ~nth the prior art are numerous. As a single
press operation is used only one ~ype of shaped mould can be fabricated
in a production run. If the foil tears the production line is halted with
significant down time and wastage of the foil. As 'che foil is prep~ted
t~ c;an be an expensive e3cerc~se. The stamping procedure is very slow
and prone to pinholing of the ~ormed bl~
Alignment of the prep~ted foil with the shape fo~g
moulds is not ex~ct with this proce~s and can result in slight drif~ng of
the patterns.
It is an object of th~ present i:nYention to alleviate the
abovementioned problems to produce a more cons~stent blank.
A fur~er object of l~e present invention is to provide an
increase in the speed of produc~on of the blanlcs over the prior art.
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A still h~rth~ objeet of the invention is to provide a method
and machine for forming mul~ple blanks at a pre~sing station.
With these objects in new the present invention ~ one aspect
provides a method for producing 3 dimensional bl~cs containing a
5 plurality of moulds 1mpressed Ul a sheet material, ~d methad in~uding
the steps of:-
(i) clamping said ~heet;
(ii) fo~r~ing a first plurali~y of mould impressions ill said
~lamped 3heet at a ~ t 5tation to subdivide said
sheet;
(iii3 moYirlg ~aid subdivided sheet to a second station;
~iv) clamping said stlbdivided sheet at said second sta~on;
(v) fo~g at least one set of final mould impressions
coinci&g with said first plurality of mould
impre~sions.
I~ a ~er a~pe~ of the invention ~ere ;8 provided an
apparatus for producing 3 dimensional blarlks cont~g a plurality of
moulds impres~ed in a sheet material, said apparatus ~c~luding a
plurali~r of sequentialI~r arran~ed sta~on~ for form:ing said moulds; a first
s~ation includin~ ~heet clarnping means and means for subdividin~ said
sheet into a plurality of f~st :mould impressions, a second stativn
including sheet ~lamping mean~ and a pair of c~operating
complementary dies for forming final mould impressions coinciding with
said plurality of first mould impressiorls.
- 25 - The above and other objects, features and advantages of the
present inven~on will become apparent ~om the eIlSDg detailed
description of preferTed em~odiments the~eof, which is to be considered
in conjunction wi~ the accomparlying drawings, in which:-
Fig. 1 is a side view of a first embodiment of ma~hine for the
fabrica'don of 3 dimension~l blanks made in accordance with the
inven~on;
Fig. 2 i~ a plan ~riew of the ~chine ~hown in Fig. 1 w~th the
stations removed f~om the ma~hine;
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wo go/14993 Pcr/Au9o/oo227
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- Fig. 3 is a cross-sectional view along and in the direction of
arrows ~3 of Fig. 1 of a first station for subdividing a sheet with a first
set of mould impressions;
Fig. 4 is a simil~r view to that of Fig. 3 ~howing the station
in its closed position;
Fig. 5 is a cross-3ectional view along and irl the direction of
arrows 5-5 of Fig. 4;
Fig. 6 is a perspective view of the blank as formed at the first
station;
Fig. 7 is a cros~sec~onal view along and in the directisn of
arrows 7-7 of Fig. 1 of a second staffon for further subdividing a sheet
with a second set o mould impressions;
Fig. 8 is a cross-sec~onal view along and in the direction of
arrows ~8 of Fig. 7 of the second station;
Fig. 9 is a ~oss~ectional ~2W along and in ~e direction of
arTows 9-9 Fig. 8 of ~e second station;
Fig. 10 is a perspective vi~ of the blanlc as formed at the
second station;
Fig. 11 s a cross-sectional view along and in the di~ection of . .
arrows 11-11 of Fig. 2 s)f a third sta'don;
Fig. 12 is a similar ~iew to that of Pig. 11 showing ~e third
sta'don ~ its ~losed position;
Fig. 13 i~ a cros~sec~onal view along and in the direction of
arrows 13^13 of Fig. 12 of the third sh'don;
Fig. 14 ~s a cro~e~onal view along and in the direction of
arrows 1~14 of Fig. 2 of a fo~ station;
Fig. 15 is a cross-sec'don~l view along and in ~e direction of
arrows 1~15 of Fig. 2 of a fifth station;
Fig. 16 is a view similar to Fig. 3 showing an alternative
embo&ent for the opera'don of ~e various stations shown in Figs. 1
to 15;
Pig, 17 is a simil~ view to ~at of Fig. 6 showing a variation
of the mould shape; and
WO 90/14993 P~l'/AU90/00227
4 Z~5~3~35
Fig. 18 is the final bl~c fabricated by the machine shown ln
Figs 1 to 16 using the blank in Fig. 17.
Turning to E~igs. 1 to 15 there is shown a machine 20 for
form~ng ~dimer sional b1anlcs from a sheet material. ~e machine
5 ~ncludes two of~set endless chain conveyors :22,. 24 which are driven by
sprockets 26 through motors (not shown~. The conveyors are controlled
by a controller (not showrl~ to move the chains in an intermittent
manner through the various statio~s to be des~ibed. A pl~Lrality of
trays 28 are pivotally att~ched at diagonal corners 30, 32 to conveyors 22,
10 24 to provide horizontal movement of trays 28. I~e offset nature of
conveyors 22, 24 will always maintain trays 28 in the horizontal
disposi~don. In the embodiment il~ustrated each tray 28 is subdivided
into two smaller ~ays 34, 36 to pronde a dual in-~ine fabrica'don
machine. I~ ear that a s~n~le tray or multiple tr~y ~y5~em can be
15 used depending on req~ements. Each tray 3~, 36 is basically formed
as a peripheral reetangular ~ame of L~haped Cro5~YeCtion. A lower
ledge 38 (Fig. 3) supports a template 40 to ~o~m the base of trays 34, 36.
The machine 20 requires sheets 42 of material for placing in
trays 34, 36. These sheets ~re usually formed ~om a preprinted.
.. .. ...
20 aluminium foil. Such foils ca~ include other material or be incorporated
in a l~minate. Pref~ed m~terial~ to be used incllude alwninium foil
wit~ a food ~rade v~sh and a three lay~ l~minate comprising an
outer layer of polypropylene, a nuddle l~yer of aluminium foil and an
inner layer of polyethylene. T~e sheets 42 can be provided ~ a stack
25 (not shown) or can be cut by the machine. ~ the embodiment
illustrated a roll 4~ of sheet material is run over rollers 46 to stra~ghten
the material and ~ then cut to length by a cutter 48. The cut sheets 42
are placed in trays 34, 36 for mould impressing.
The sheets are ~en transported sequen~lly through the
30 machine ~rough SL'C s~ations 50, 52, 54, 56 58 and ~0.
5ta~on 50 prondes an iniffal subdivision o~ sheet ~ into
preliminary moulds a~ shown in Fig. 6. Fig. 6 shows that sheet 42 has
been formed into three langitudin21 moulds 6~ r sta'don 50. It is to be
WO 90/14993 ~'Cr/~U~O/~)0227
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noted that the n~nber of moulcls ean vary depending on requirements.
Station 50 includes an outer support frame 64 f~om which depends a
stationary box frame 66 having a divid~ 68 intermediate its length.
Secured to divider 68 is a ~iasing means 70, preferably pneumatically
5 controlled or spring tensioned, with a piston rod 72 passing ~rough an
aperture in divider 68. In an especially preferred embodiment biasing
means 70 is an air spring. Piston rod 72 is attached to a plate member
74 ha~g two long~tudin~l parallel depending dividers 76; 78. Each
divider 76, 78 t~tes in a roller ~0. Dividers 76, 78 form a telescopic
10 rela~onship ~vith box ~ame 66. C:en~ally locatecl along plate member 74
is a pair of parallel flarlges 82 which cons~ain a longitudinal cl~mphg
member 84. Clamping member is spring loaded by spr~ngs 86 and
terminates with a bumper 88.
The movable part of statisn 50 comprises a base member 90
15 on which are mountecl male moulds 92. T~e moulcls 92 are separated
by gaps 94 which gap~ are aligned with di~iders 76, 78. Base member
90 is attached to a r~proca~ng piston 96. Mould~ 92 can, ~n use,
protrude through ap~tures 98 of te~plate 40.
~ operahon, ~e ini~ position is sh~wn in Fig, 3~ Moulds
20 92 are moved upwardly by piston g6 throu~h template ~0 to contact
sheet 42. Fur~er upward m~vement of pi~ton 96 raise3 sheet 42 as
moulds ~2 protrude through the te~pL~te un~l template 40 rests on base
member 90. Sheet 42 will contact bumper 88 tc7 clamp sheet ~ to the
central mould. As ~lamping member 84 is spnng loaded a con~nuous
25 clamping pressure will be maintained preventing any slippage of sheet
42. Further movement results in di~iders 76, 78 ent~g gaps 94 to
draw sheet 42 i~wardly between the gaps and form the central mould.
Rollers 80 will assist in preven~ng any nipping or tearing of sheet 42.
Sheet 42 will be simultaneously drawn over the outennost moulds 92.
30 Rollers 80 wDl abut template ~0 and form a flattened area which
subdivides the moulds ormed in t~e sheet. Fur~er upward msvement
of piston 96 forces the free ends of box ~ame 66 to contact te~plate 40
to finali~e the moulding of sheet 42. I~is posi~on is shown in Fig. 4.
wo 90/ 1 4g93 rcl /A U~0/00227
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Fig. 4 shows that ~le moulds 92 have impressed into sheet ~2 the
mould shapes shown in Fig. 6. It will be noted that the height of the
moulds 62 formed in sheet 42 can be vaned by chan~g the thickness
of templ~te 40. The fo~ on of moulds 62 is from the ce:ntre and
outwardly therefrom m opposing direc~ons. This results ~n less s~ess
being applied to sheet 42 and a uni~o~m movement of the sheet over
moulds 92. C)nce moulds 62 have been formed the procedure is
reversed. Tray 28 is then moved to .~tation 520
Station 52 is very simil~r to ~ta'don 50 and s~ integers
have been referenced with the same re~erence nu~nerals anc~ an "A"
suffix. The differences are tha~ male moulds 92 have been subdivided
transversely to ~rm S~teen (15) male moulds 92A i.e. a grid of 5 x 3.
Again it must be emphasized ~at the grid can be increased or decreased
depending on requirements. From Figs. 7 and 8 it is shown that
dividers 76A, 78A are transverse to the dire ~ on of dividers 76, 78 of
station 50. To provlde ~he Dncrease in subcUv~on, ~urther din ders 100,
102 depend fro m plate m e m ber 104. Plate m ernber 104 is supported by
trvo biashng m ealls 106, 108 s~oL~ar to b ~ g m eauns 70 of sta~on S0.
Fig. 8 clearly sho ws ~he telescopic ruature of the dividers 76A, 78A, 100,
102 ~ th box fra m e 66A. As wi~h stabion 50 ~he ~ er di~iders 100, 102
terrnunate wl~h ro~ers 110. Wrng~ets 112 aIe atta~hed to the free ends of
box fraIne 66A aund d~vider~ 76A, 78A, 1 W, 102 amd are a~ned ~nth the
ng~budin~l gaps formed betwee~ mould~ 62 sho~m Dn Fig. 6. llhe
winglets will assist in location and guida~ce o~ the dinders in further
subdivision of sheet 42.
Operation of station 52 is idenl:ical- to that de~cribed in
relation to station 50. Again, the ~elescopic na~ure of ~he dinders allows
for a smooth sequen~al subdivision of moulds 62 into the moulds 114 as
shown in Fig. 10. The moulds 114 are formed from the centre and
outwardly ~ere~om in opposing directions.
The furthe~ subdivided ~heet ~ is passed through to station
54. Stativn 54 is very ~imilar to st~ion~ 50 and 52 arld similar reference
numerals have been used ~or ~imilar inte~ with the sufflx "B/'. The
WO 90/149~3 pc~-r/A U9~/00227
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differences between station 52 and station 54 are that male moulds 92B
are shaped with almost ~e final desired shape. Div~ders 76A, 78A, 100
and 102 have ~een replaced by the feD~le moulds 115 and clamping
member 8BA has been replaced by a female mould 118. Additional
5 female moulds 120 are also secured to the inner waLls of box frame 66B.
As ean be seen in Fig. 11 the mQulds 116, 118 and 120 are solid and
telescopic in nature and operated in a similar m~nner as ~e dividers in
station 50, 52. Fig 14 shows the completion of the formation of the
almost completed mould shapes. Sheet ~ then moves to sta~on 56.
Station 56 impre~se~ the final mould shapes into sheet ~.
Si~r reference mlmeTals have been used for similar integer3 with a
SllffK of "C'~. As this is the final shaping process fem~le moulds 116,
118 and 120 are replaced by a heated female r~ould 122. Mo~d 122 is
secured to dinder 68C by an insulation heat bar~ 124. With ~he applied
pressure and heat a s'dff~g of the sheet will occlLr. If the sheet i8 the
laminate of polypropylenelaluminium foiVpolye~hylene the hea'dng will
soften the polyethylene to form a series of moulds in ~heet ~2.
Station 58 is optional and is a cufflng sta~don. Blades 126 are
located in a bl~ 128 and co operate with a spling loaded pressure pad
130. Blades 126 can be in any desired formation for completel~ severing
sheet 42 into indivi~ual moulds. l~e sheet 42 need no~ be severed as
it can be used direc~y in a spinning ~ame.
Ihe finished sheet is finally ~ansported to statiora 60 (Fig. 1)
where a suction l~ng mechar~m 132 removes the formed ~heet 42 ~om
~ays 28 and places ~hem on a nested stack 134.
The inven'don has many advantages ove~ the pnor art. As
a plurality of mnulds can be pressed simultaneously the moulds can be
different. l~e speed of operation is significan'dy increased and four-fdd
increases in production can be ~xpected. The smoo~ movement of the
sheet over the male moulds decreases the rejection rate of moulded
sheets and reduces the down'dme during production runs. ~rom the
foregoing it will be understood that the shaped-foil blanks formed by the
method and apparatus of the u~ven'don are especially suitable for the
wo go/14993 PCT/AU90/l)OZ~7
2~5~3~5
production of foil-encased hollow arti~les suc~ as hollow c~ocolate eggs
or hollow chocolate rabbits or oth~ such hollow chocolate novelffes.
However, it i~ also to be understood ~at said shaped-foil b~s are
suitable for the packa~ing of a wide range of other products such as
5 confec~onery for hum~n consump'don; ice cream; food industty goods;
cosmetics and toiletries; pet products, such a~ confectionery not for
hlLman consumption; garderL product~; sporting goods; hobbies;
automotive products; ~ashion gift products; hardware products; toys;
ag~icultural products; convenience pa~; promotional produ~ such as
10 for pop concert~, ~por~ng events, and the like; souvenirs; and trzvel
goods.
~ the first em~odiment, sta'dons 50, 52, 54, 56 have movable
pistons 96, 96A, 96B, 96C for con~olling the mould fo~g operations.
Fig. 16 illustrates a second embodimen~ wh~e box frame 130 reciprocates
15 vertically throug~ a pi3ton~ylinder arrange~ent 132. Fig. 16 shows the
equivalent of station 50 of the first embodiment. The opera~on of the
embodiment shown in Pig. 16 is fairl~ similar to ~at previously
described and will not be furth~ described.
Reference to Figs. 17 and 18 show variation~ of moulds that
20 can be produced by the present ~nvention. The blan~ 134 shown in Fig.
17 can be obtained by omitting station 50 and replacing male moulds 92A
of station 52 wi~ male moulds similar to tho~e at ~ ion 50 but ha~nng
longitudinal direction~ transverse to ~ose shown at station 50. At
stations 54, 56 the m~le rnoulds 92B, 92C will have the shapes shown in
25 blank 136 of Fig. 18. Station 56 may also be omitted if ~e desired
stiffen~ng of the final moulded sheet is not required.
It is W~ved that the invention and many of its attendant
advantages will be understood from the fore~oing de~cription and it will
be apparent ~at various changes may be made in the foxm, construction
30 and arrangement of the parts and that change~ may be made in the
form, construc~ons and arrangement of the method and apparatus
described without depar~ng from the sp~rit and scope o~ the invention
or sscrificing all of its material ~tv~ntsges, ffle hrms hereinbefore
WO 90/14993 P~/AU90/00227
g X~,'5f~3~S
described beLng merely prefe~ed embodimer~ eof.
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