TECHNICAL FIELD
[0001] The present invention relates to a folding unit for a packaging assembly configured
to form, seal and fold a plurality of packages containing a pourable product, in particular
a pourable food product.
[0002] The present invention also relates to a packaging assembly configured to form, seal
and fold a plurality of packages containing a pourable product, in particular a pourable
food product, and comprising a folding unit.
BACKGROUND ART
[0003] As it is generally known, many pourable food products, such as fruit juice, UHT (ultra-high
temperature-treated) milk, wine, tomato sauce, etc., are sold in packages made of
sterilized packaging material.
[0004] A typical example is the parallelepiped-shaped package for pourable food products
known as Tetra Brik Aseptic (registered trademark), which is made by folding and sealing
a laminated web of packaging material.
[0005] In particular, the packaging material has a multilayer structure, known and not described
in detail.
[0006] The packages are normally produced on fully automatic packaging assemblies, in which
a continuous tube is formed from the web of packaging material.
[0007] Typically, the known packaging assemblies comprise a forming unit, a folding unit
and an outfeed device.
[0008] In particular, the web of packaging material is folded and sealed longitudinally
to form the tube, and then the tube is fed to the forming unit along a vertical direction.
[0009] In order to complete the forming operations, the tube is filled from above with the
pourable food product by means of a pipe and is formed, sealed and subsequently cut
along equally spaced transversal cross sections.
[0010] Pillow packs are obtained thereby, which have a longitudinal sealing band, a top
transversal sealing band and a bottom transversal sealing band.
[0011] More specifically, each pillow pack usually comprises a prismatic main portion, which
has a longitudinal axis, a top end portion and a bottom end portion opposite to one
another. In detail, the top end portion and the bottom end portion define respective
transitions from the main portion towards the top sealing band and the bottom sealing
band, respectively.
[0012] Each pillow pack further comprises an elongated rectangular top end fin, arranged
at the top end portion, and an elongated rectangular bottom end fin, arranged at the
bottom end portion. In detail, the top end fin and the bottom end fin protrude orthogonally
from the respective top end portion or bottom end portion.
[0013] Each pillow pack also comprises two pairs of substantially triangular flaps projecting
from opposite sides of the respective top end portion or bottom end portion.
[0014] After being formed, sealed and cut, the pillow packs are typically fed to the folding
unit, which is configured to perform one or more folding operations on the pillow
packs, so as to obtain respective finished packages.
[0015] Typically, the folding unit comprises an endless conveyor configured to advance the
pillow packs and then the folded packages along an endless folding path defined by
the endless conveyor.
[0016] In detail, the folding path comprises an input station, at which the folding unit
receives a plurality of formed and sealed semi-finished pillow packs from the forming
unit, and an output station, at which the fully-folded and finished packages are fed
to the outfeed device.
[0017] In greater detail, the folding path generally comprises a top straight branch, a
bottom straight branch and two curved branches, which are opposite to one another
and connect, on respective opposite sides, the top straight branch and the bottom
straight branch.
[0018] In particular, the input station is arranged at the curved branch adjacent to the
forming unit, hereafter first curved branch, and the output station is arranged at
the bottom straight branch, downstream of the curved branch opposite to the first
curved branch, hereafter second curved branch.
[0019] Typically, the folding units of the known type further comprise a plurality of folding
devices movably coupled to the endless conveyor so as to cyclically move, in use,
along the folding path.
[0020] In detail, each folding device is configured to receive one pillow pack at a time
at the input station, to carry such pillow pack along the folding path, from the input
station to the output station, and to interact with such pillow pack to perform one
or more relative folding operations thereon, thereby obtaining a respective finished
package.
[0021] In greater detail, while each pillow pack is carried along the folding path:
- the top end portion and the bottom end portion of such pillow pack are pressed towards
each other, so as to form a top end and a bottom end of the package opposite to each
other;
- the top end fin and the bottom end fin are folded onto the top end and the bottom
end of the package, respectively; and
- the triangular flaps of the top end portion are folded outwards onto the respective
lateral walls of the main portion and the triangular flaps of the bottom end portion
are folded inwards onto the respective bottom end.
[0022] A folding device adapted to be implemented in the above-mentioned folding unit is
known from
EP-B-2586719, and substantially comprises:
- a plate adapted to receive and support one single pillow pack to be folded at a time;
- a paddle, which projects perpendicularly from the plate and is adapted to cooperate
in contact with one lateral wall of the main portion of such pillow pack, so as to
push this latter along the folding path; and
- a pair of shells which are integrally movable along the folding path, are also movable
towards each other relatively to the paddle and transversally to the folding path,
and are configured to fold the triangular flaps of the top end portion onto the lateral
walls.
[0023] In detail, the plate is adapted to cooperate in contact with the top end portion
of the pillow pack.
[0024] In light of the above, the pillow pack is carried along the first curved branch and
the subsequent straight branch in an upside-down position, while being transformed
into a folded finished package. Then, the package is turned by 180° along the second
curved branch, so that the package is fed to the outfeed device, along the bottom
straight branch, in a right-side-up position.
[0025] In the configuration described in
EP-B-2586719, the shells are movable towards each other between:
- a fully closed position, in which the shells exert a pressure onto the relative pillow
pack, so as to perform the folding operations thereon; and
- an open position, in which the shells are detached from the relative pillow pack or
the relative finished package.
[0026] Furthermore, the shells may be also arranged in a closed position, in which the shells
grip the relative finished package without exerting any pressure thereon.
[0027] In this last configuration, the shells are configured to surround the package, after
the relative folding operations have been completed thereon, so as to carry the package
to the output station.
[0028] The folding units of the above-described type usually operate at high speed, that
is to say, the folding devices cyclically move along the folding path at high speed.
[0029] Consequently, the packages are advanced from the input station to the output station
at high speed.
[0030] This may cause the packages to slide out from their nominal positions, i.e. from
the respective seats defined between each pair of shells and the relative paddle due
to the centrifugal force that may arise and act on such packages, in particular when
the packages are advanced along the second curved branch of the folding path.
[0031] This can lead to mispositioning of the packages, which could compromise their discharge
to the outfeed device, thereby causing production jamming.
DISCLOSURE OF INVENTION
[0032] It is therefore an object of the present invention to provide a folding unit, which
is designed to overcome the above-mentioned drawback in a straightforward and low-cost
manner.
[0033] This object is achieved by a folding unit as claimed in claim 1.
[0034] It is a further object of the present invention to provide a packaging assembly,
which is designed to overcome the above-mentioned drawback in a straightforward and
low-cost manner.
[0035] This object is achieved by a packaging assembly as claimed in claim 8.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] A non-limiting embodiment of the present invention will be described by way of example
with reference to the accompanying drawings, in which:
Figure 1 is a top perspective view, with parts removed for clarity, of a folding unit
according to the present invention;
Figure 2 is a schematic side view, with parts removed for clarity, of the folding
unit of Figure 1;
Figures 3A and 3B are two front views, with parts removed for clarity, of a folding
device of the folding unit of Figure 1 in two different operating conditions;
Figure 4 is a perspective view of a pillow pack the folding unit of Figure 1 is fed
with.
BEST MODE FOR CARRYING OUT THE INVENTION
[0037] With reference to Figure 1, number 1 indicates as a whole a folding unit for a packaging
assembly (known per se and not shown) configured to form, seal and fold a plurality
of pillow packs 3 containing a pourable product, in particular a pourable food product
such as fruit juice, milk, wine, tomato sauce, etc.
[0038] In particular, pillow packs 3 may be obtained from a tube, which is formed in a known
manner upstream of folding unit 1 by longitudinally folding and sealing a web (not
shown) of packaging material.
[0039] After being formed, the tube is filled with the pourable food product and is fed
to a forming unit (not shown) of the packaging assembly. In the forming unit, the
tube is sealed and cut along equally spaced cross-sections to form the plurality of
semi-finished pillow packs 3, which have a longitudinal sealing band, a top transversal
sealing band and bottom transversal sealing band.
[0040] More specifically, as shown in particular in Figure 4, each pillow pack 3 comprises
a prismatic main portion 4, having a longitudinal axis A and being defined by four
lateral walls 4a (only two visible in Figure 4) and two shaped walls 4b (only one
visible in Figure 4). Each pillow pack 3 further comprises a top end portion 5 and
a bottom end portion 6, axially opposite to one another. In detail, axis A extends
between top end portion 5 and bottom end portion 6, and top end portion 5 and bottom
end portion 6 define respective transitions from main portion 4 towards the top sealing
band and the bottom sealing band.
[0041] Each pillow pack 3 also comprises an elongated rectangular bottom end fin 7, protruding
from bottom end portion 6, and an elongated rectangular top end fin 8, protruding
from top end portion 5.
[0042] In detail, top end fin 8 and bottom end fin 7 protrude axially from the respective
top end portion 5 or bottom end portion 6, and define the top sealing band and the
bottom sealing band of pillow pack 3, respectively.
[0043] More precisely, top end fin 8 and bottom end fin 7 extend along a direction orthogonal
to axis A.
[0044] In addition, each pillow pack 3 comprises two pairs of substantially triangular flaps
9, which project from opposite sides of top end portion 5 and bottom end portion 6,
respectively.
[0045] After being formed, sealed and cut, pillow packs 3 are fed to folding unit 1, which
is configured to perform one or more folding operations on pillow packs 3, so as to
transform pillow packs 3 into corresponding fully-folded finished packages 2.
[0046] As visible in Figure 1, folding unit 1 comprises an endless conveyor 10 configured
to advance semi-finished pillow packs 3 and finished packages 2 along an endless folding
path P defined by endless conveyor 10.
[0047] In particular, folding path P comprises an input station I, at which folding unit
1 receives the plurality of pillow packs 3 from the forming unit, and an output station
0, at which the fully-folded and finished packages 2 exit from folding unit 1 to be
fed to an outfeed device (not shown) and subsequently exit from the packaging assembly.
[0048] According to this non-limiting preferred embodiment shown, folding path P has a substantially
oval-shaped profile and comprises a first curved branch P1, a top straight branch
P2, a second curved branch P3 and a bottom straight branch P4.
[0049] In detail, first curved branch P1 and second curved branch P3 are opposite to one
another and connect, on respective opposite sides, top straight branch P2 and bottom
straight branch P4.
[0050] In greater detail, top straight branch P2 extends from first curved branch P1; second
curved branch P3 extends from top straight branch P2; and bottom straight branch P4
extends from second curved branch P3 and is connected to first curved branch P1.
[0051] In particular, input station I is arranged at first curved branch P1, i.e. the one
adjacent to the forming unit, and output station 0 is arranged at bottom straight
branch P4, i.e. the one adjacent to the outfeed device.
[0052] In light of the above, pillow packs 3 and packages 2 are advanced, from input station
I, first along first curved branch P1, then along top straight branch P2, subsequently
along second curved branch P3 and eventually along bottom straight branch P4, along
which packages 2 reach output station O.
[0053] In particular, pillow packs 3 and packages 2 are advanced from input station I to
output station 0 with their respective axes A orthogonal to folding path P.
[0054] As visible in Figures 1 and 2, folding unit 1 further comprises a plurality of moving
units, in particular folding devices 11 (only five shown in Figure 1) movably coupled
to conveyor 10 so as to cyclically move along folding path P.
[0055] More specifically, each folding device 11 is adapted to move along folding path P
and has a receiving element 17a for supporting one single pillow pack 3 and/or package
2 at a time, from input station I to output station O.
[0056] According to this non-limiting preferred embodiment, folding devices 11 form an endless
transport element, in the example shown a chain 14 (Figure 2), formed by a plurality
of consecutive links, each one defined by a single folding device 11.
[0057] In detail, chain 14 is looped about a pair of driving members, preferably a pair
of coaxial sprockets 15, and about a cam (not shown).
[0058] In greater detail, chain 14 is driven by sprockets 15, so that the consecutive folding
devices 11 can be moved on conveyor 10 and along folding path P.
[0059] Hence, chain 14 is configured to carry pillow packs 3 and packages 2 along folding
path P, from input station I to output station O.
[0060] Since all folding devices 11 are identical to one another, only one single folding
device 11 according to one non-limiting preferred embodiment of the present invention
will be described in the following, for the sake of brevity.
[0061] However, all the features disclosed hereinafter for such folding device 11 are applicable
to each folding device 11 of folding unit 1.
[0062] As shown in Figures 1 and 3A-3B, folding device 11 comprise:
- at least one moving member, preferably a plate 17, defining receiving element 17a
and configured for carrying one single pillow pack 3 and/or package 2 at a time, from
input station I to output station 0, and movably carried by folding device 11;
- a paddle 18, which projects orthogonally from plate 17 and is adapted to cooperate
in contact with one lateral wall 4a of main portion 4 of pillow pack 3 and/or package
2, so as to push pillow pack 3 and/or package 2 along folding path P; and
- a pair of shells 19, which are arranged on opposite sides of plate 17, are movable
along folding path P integrally with paddle 18, are also movable towards one another
along a direction C orthogonal to folding path P and said axis A, and are configured
to fold triangular flaps 9 of top end portion 5 onto lateral walls 4a.
[0063] It is specified that, throughout the folding operations, top end portion 5 of pillow
pack 3 is transformed into a top end 50 of package 2, and bottom end portion 6 of
pillow pack 3 is transformed into a bottom end 60 of package 2.
[0064] The package 2, therefore, extends along longitudinal axis A. In particular, longitudinal
axis A extends from top end 50 to bottom end 60. Longitudinal axis A is arranged transversal
to folding path P.
[0065] In detail, plate 17 is adapted to cooperate in contact with top end 50. Hence, pillow
pack 3/package 2 is carried by folding device 11 with top end portion 5/top end 50
facing plate 17.
[0066] In light of the above, pillow pack 3 is carried, from input station I, along first
curved branch P1 and the subsequent top straight branch P2 of folding path P in an
upside-down position. Along first curved branch P1 and top straight branch P2, such
pillow pack 3 is transformed into a package 2. Then, package 2 is turned by 180° along
second curved branch P3, and eventually is fed to the outfeed device at output station
O in an upright position.
[0067] After package 2 exits from folding unit 1, folding device 11 advances along bottom
straight branch P4 until it reaches again first curved branch P1 and input station
I.
[0068] As visible in Figure 1, paddle 18 mirrors the shape of lateral wall 4a it cooperates
in contact with.
[0069] Similarly, as visible in Figures 3A-3B, shells 19 define respective surfaces 21,
which are adapted to cooperate in contact with lateral walls 4a and shaped walls 4b
of pillow pack 3.
[0070] In detail, surfaces 21 face one another and mirror lateral walls 4a of main portion
4, so as to control the final shape of pillow pack 3 to be folded.
[0071] In greater detail, surfaces 21 are configured to cooperate with triangular flaps
9 of top portion 5 so as to fold them outwards onto corresponding lateral walls 4a
of main portion 4.
[0072] As shown in Figure 1, each shell 19 is connected to conveyor 10 of folding unit 1
by means of a relative arm 22 extending along direction C.
[0073] In detail, arms 22 define corresponding slides 23 (Figures 3A and 3B) extending along
direction C and configured to engage respective guides 24 integrally carried by folding
device 11 on opposite sides of paddle 18.
[0074] In greater detail, each arm 22 carries, on its end opposite to relative shell 19,
a roller 25 configured to engage a relative endless cam 26 (Figure 1).
[0075] More precisely, folding unit 1 comprises two cams 26 arranged at opposite lateral
sides of conveyor 10 and extending along a direction parallel to part of folding path
P. In particular, cams 26 are configured to control, together with rollers 25, a movement
of arms 22 transversal to folding path P and, hence, the movement of shells 19 towards
one another along direction C between:
- an open position, in which shells 19 are detached from pillow pack 3 or package 2;
- a fully closed position, in which shells 19 exert a pressure onto pillow pack 3, so
as to perform the folding operations thereon (as disclosed in EP-B-2586719 and not described in detail); and
- a closed position, in which shells 19 grip package 2 without exerting any pressure
thereon.
[0076] In detail, shells 19 are arranged in the open position at input station I and move
from the open position towards the fully closed position when folding device 11 is
advancing along the top straight branch P2 of folding path P.
[0077] In greater detail, shells 19 move back from the fully closed position towards the
open position when folding device 11 is advancing along the bottom straight branch
P4 of folding path P.
[0078] In particular, each shell 19 moves between the fully closed position and the open
position when the respective roller 25 engages corresponding operative portions of
cam 26, converging to or diverging from folding path P.
[0079] According to a manner known and described in
EP-B-2586719, in order to complete the folding operations on pillow pack 3, top end portion 5
and bottom end portion 6 are pressed towards each other, so as to form top end 50
and bottom end 60.
[0080] Furthermore, top end fin 8 is folded onto top end 50, bottom end fin 7 is folded
onto bottom end 60, triangular flaps 9 of bottom end portion 6 are folded inwards
onto bottom end 60 and triangular flaps 9 of top portion 5 are folded outwards onto
corresponding lateral walls 4a of main portion 4.
[0081] After the folding operations are completed, package 2 is carried by folding device
11 along the remaining portion of top straight branch P2, along second curved branch
P3 and along bottom straight branch P4, until package 2 reaches output station O.
[0082] This advancement of folding device 11 and, therefore, of package 2 along folding
path P occurs at high speed.
[0083] Advantageously, folding device 11 comprises a pair of retaining members, preferably
a pair of retaining fingers 27 configured to cooperate with package 2 and defining
an abutment for bottom end 60, so as to prevent a displacement of package 2 away from
receiving element 17a and transversally, in particular orthogonally, to folding path
P.
[0084] In particular, retaining members 27 are configured to prevent the displacement of
package 2 away from receiving element 17a, orthogonally to folding path P and along
axis A.
[0085] More precisely, bottom end 60 is configured to abut against retaining members 27
at least when package 2 is advanced along second curved branch P3. Hence, retaining
members 27 are configured to prevent the displacement of package 2 away from a center
of curvature K of second curved branch P3.
[0086] In detail, as folding device 11 advances at high speed along second curved branch
P3, a centrifugal force may arise and may be exerted on package 2, causing package
2 to move away from center of curvature K, i.e. to slide along axis A, and orthogonally
to both direction C and folding path P.
[0087] As visible in Figures 1 and 3A-3B, each retaining finger 27 is carried by one respective
shell 19.
[0088] In particular, each retaining finger 27 is mounted on a top portion of the respective
shell 19 and protrudes from such shell 19 along direction C and towards package 2.
[0089] More precisely, each retaining finger 27 protrudes from an edge of the top portion
of the respective shell 19.
[0090] In detail, retaining fingers 27 are movable along direction C at least between:
- a first position, in which retaining fingers 27 are detached from package 2 (Figure
3A); and
- a second position, in which retaining fingers 27 cooperate with package 2 and define
the abutment for bottom end 60 (Figure 3B).
[0091] In light of the above, retaining fingers 27 are in the second position when shells
19 are in the fully closed position or in the closed position.
[0092] In particular, retaining fingers 27 are carried (moved) to the second position when
shells 19 are controlled (moved) to the fully closed position or to the closed position.
[0093] Conversely, retaining fingers 27 are in the first position, when shells 19 are in
the open position.
[0094] Hence, retaining fingers 27 are configured to cooperate with package 2 and to define
an abutment for bottom end 60 when shells 19 are in the closed position or in the
fully closed position.
[0095] The operation of folding unit 1 is described hereinafter with reference to a single
folding device 11 advancing on conveyor 10 and starting from a condition in which
folding device 11 is advancing along first curved branch P1 and is receiving one respective
pillow pack 3 at input station I.
[0096] More precisely, plate 17 receives and supports one pillow pack 3 and paddle 18 pushes
the lateral wall 4a of pillow pack 3 along folding path P. The movement of folding
device 11 along folding path P is controlled, as described above, by sprockets 15.
[0097] In this condition, shells 19 are in the open position.
[0098] As folding device 11 advances along top straight branch P2 of folding path P, rollers
25 start to engage the operative portion of cam 26 arranged at top straight branch
P2.
[0099] At the same time, arms 22 are controlled to move along direction C, thereby causing
the sliding of slides 23 through guides 24. In this way, shells 19 move, due to the
interaction between rollers 25 and cams 26, from the open position towards the fully
closed position.
[0100] Accordingly, retaining fingers 27 are carried by shells 19 from the second position
towards the first position.
[0101] At this point, pillow pack 3 is folded and transformed into package 2, and folding
device 11 starts to advance along second curved branch P3. Shells 19 move from the
fully closed position to the closed position.
[0102] As package 2 advances along second curved branch P3, bottom end 60 abuts against
retaining fingers 27 due to the centrifugal force acting on package 2.
[0103] Therefore, any movement of package 2 away from plate 17 (receiving element 17a) and
along axis A, caused by the centrifugal force, is prevented by retaining fingers 27,
as bottom end 60 of package 2 abuts thereon.
[0104] Along second curved branch P3, package 2 is turned by 180°, from an upside-down position
to an upright position.
[0105] Eventually, folding device 11 advances along bottom straight branch P4, where shells
19 move back to the open position, and package 2 is discharged to the outfeed device
at output station O.
[0106] Then, folding device 11 moves again along first curved branch P1, and is ready to
pick another pillow pack 3 at input station I.
[0107] The operation is repeated cyclically for each pillow pack 3 to be folded and for
each folding device 11 that may be present in folding unit 1.
[0108] The advantages of folding unit 1 according to the present invention will be clear
from the foregoing description.
[0109] In particular, retaining fingers 27 prevent package 2 from sliding out from its nominal
positions inside the respective receiving element 17a defined by the relative folding
device 11, especially when such package 2 is advanced along second curved branch P3
of folding path P.
[0110] In this way, any mispositioning of packages 2 is prevented, thereby avoiding any
production jamming.
[0111] Clearly, changes may be made to folding unit 1 as described herein without, however,
departing from the scope of protection as defined in the accompanying claims.
[0112] In particular, according to a possible variant not shown, folding device 11 may comprise
only one single retaining finger 27.