U.S. patent application number 16/315252 was filed with the patent office on 2019-05-30 for thermoforming machine and method.
The applicant listed for this patent is KIEFEL GmbH. Invention is credited to Thomas Halletz, Erwin Wabnig.
Application Number | 20190160725 16/315252 |
Document ID | / |
Family ID | 57391724 |
Filed Date | 2019-05-30 |
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United States Patent
Application |
20190160725 |
Kind Code |
A1 |
Halletz; Thomas ; et
al. |
May 30, 2019 |
THERMOFORMING MACHINE AND METHOD
Abstract
A thermoforming device is described. It relates to a mold
assembly including a first and second mold, and to a mold that can
be used in a thermoforming device. It also relates to a method for
thermoforming a product. The thermoforming device is characterized
in that the thermoforming device comprises a second pre-stretcher,
in addition to a first pre-stretcher and a calibration element (19,
20), and that the second pre-stretcher is at least partially and
moveably arranged in a second mold body (12, 43). A movement
relative to the second mold body (12, 43) and towards the same
forming cavity of the first pre-stretcher, the second
pre-stretcher, and the calibration element (19, 20), can be
individually controlled, arid the second pre-stretcher at least
partially surrounds the first pre-stretcher and the calibration
element (19, 20).
Inventors: |
Halletz; Thomas; (Waging am
See, DE) ; Wabnig; Erwin; (Siegsdorf, DE) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
KIEFEL GmbH |
Freilassing |
|
DE |
|
|
Family ID: |
57391724 |
Appl. No.: |
16/315252 |
Filed: |
July 5, 2017 |
PCT Filed: |
July 5, 2017 |
PCT NO: |
PCT/EP2017/000789 |
371 Date: |
January 4, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15594097 |
May 12, 2017 |
9840036 |
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16315252 |
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15594172 |
May 12, 2017 |
9931782 |
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15594097 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B29C 51/087 20130101;
B29C 51/428 20130101; B29L 2031/7132 20130101; B29C 51/261
20130101; B29C 51/04 20130101; B29C 51/38 20130101; B29C 51/264
20130101; B29C 51/10 20130101; B29C 51/20 20130101; B29C 51/18
20130101; B29K 2105/256 20130101 |
International
Class: |
B29C 51/04 20060101
B29C051/04; B29C 51/20 20060101 B29C051/20; B29C 51/10 20060101
B29C051/10; B29C 51/26 20060101 B29C051/26; B29C 51/18 20060101
B29C051/18; B29C 51/38 20060101 B29C051/38 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 5, 2016 |
NL |
2017101 |
Oct 20, 2016 |
DE |
10 2016 012 487.3 |
Nov 14, 2016 |
EP |
16 002 415.4 |
Claims
1. A thermoforming device, comprising: a first mold comprising a
first mold body and a forming cavity arranged in said first mold
body; a second mold comprising a second mold body, a first
pre-stretcher, and a calibration element, wherein the first
pre-stretcher and the calibration element are at least partially
and moveably arranged in the second mold body; wherein the first
and second mold can be moved relative to each other for clamping a
plastic foil there between; wherein the calibration element is
configured to locally clamp the plastic foil in between the
calibration element and a wall and/or bottom of the forming cavity;
wherein the thermoforming device further comprises a second
pre-stretcher that is at least partially and moveably arranged in
the second mold body, and wherein a movement relative to the second
mold body and towards the same forming cavity of at least one of
the first pre-stretcher, the second pre-stretcher, and the
calibration element, can be individually controlled, and wherein
the second pre-stretcher at least partially surrounds the first
pre-stretcher and the calibration element.
2. The thermoforming device according to claim 1, wherein at least
two of the first pre-stretcher, the second pre-stretcher, and the
calibration element, can be individually controlled.
3. The thermoforming device according to claim 1, wherein each of
the first pre-stretcher, the second pre-stretcher, and the
calibration element, can be individually controlled.
4. The thermoforming device according to claim 1, wherein the
calibration element is arranged at least partially around the first
pre-stretcher.
5. The thermoforming device according to claim 4, wherein the
second pre-stretcher and the calibration element are essentially
hollow structures, wherein the calibration element is at least
partially arranged inside the second pre-stretcher, and wherein the
first pre-stretcher is at least partially arranged inside the
calibration element.
6. The thermoforming device according to claim 5, wherein the first
pre-stretcher is configured to move relative to the second
pre-stretcher or relative to the calibration element, and wherein
the calibration element is configured to move relative to the
second pre-stretcher.
7. The thermoforming device according to claim 4, wherein the
second pre-stretcher and the first pre-stretcher are essentially
hollow structures, wherein the first pre-stretcher is at least
partially arranged inside the second pre-stretcher, and wherein the
calibration element is at least partially arranged in the first
pre-stretcher.
8. The thermoforming device according to claim 5, wherein the
calibration element is configured to move relative to the second
pre-stretcher or relative to the first pre-stretcher, and wherein
the first pre-stretcher is configured to move relative to the
second pre-stretcher.
9. The thermoforming device according to claim 5, wherein the first
pre-stretcher, the second pre-stretcher, and the calibration
element are coaxially arranged.
10. The thermoforming device according to claim 1, wherein at least
one of the first pre-stretcher, the second pre-stretcher, and the
calibration element is shaped as a sleeve, a jacket, or a bush,
preferably having a square, rectangular, or circular cross
section.
11. The thermoforming device according to claim 1, further
comprising a heating element configured for heating the calibration
element relative to the second mold body.
12. The thermoforming device according to claim 1, wherein at least
one of a stroke length, a stroke duration, a stroke speed, and a
stroke starting time for the first pre-stretcher, the second
pre-stretcher, and/or the calibration element can be individually
controlled.
13. The thermoforming device according to claim 1, wherein at least
one of a starting time of clamping the plastic foil in between the
calibration element and said wall and/or bottom of the forming
cavity, a clamping duration, and a clamping strength, can be
individually controlled.
14. The thermoforming device according to claim 1, further
comprising a forming air unit for generating an overpressure on a
first side of the plastic foil that is clamped in between the first
and second molds to urge the plastic foil to move towards the wall
and/or bottom of the forming cavity, said first side being directed
away from the forming cavity.
15. The thermoforming device according to claim 14, wherein the
second mold comprises one or more second channels, and wherein the
forming air unit is configured to generate said overpressure by
applying pressurized gaseous medium through the one or more second
channels to said first side of the clamped plastic foil.
16. The thermoforming device according to claim 14, wherein the
first mold comprises one or more first channels, and wherein the
forming air unit is configured to generate said overpressure by
evacuating a space in the forming cavity between the clamped
plastic foil and the wall and/or bottom of the forming cavity
through the one or more first channels.
17. The thermoforming device according to claim 14, wherein the
thermoforming device is configured, for the purpose of forming a
product out of the plastic foil clamped by the first and second
molds, to generate said overpressure only after at least partially
completing the stretching of the plastic foil using the first and
second pre-stretchers.
18. The thermoforming device according to claim 14, wherein the
thermoforming device is configured, for the purpose of forming a
product out of the clamped plastic foil, to cause the clamping of
the plastic foil by the calibration element only after having
started the application of the overpressure by the forming air
unit.
19. The thermoforming device according to claim 1, comprising: a
first actuator for moving the first pre-stretcher relative to the
second mold body, a second actuator for moving the second
pre-stretcher relative to the second mold body, and/or a third
actuator for moving the calibration element relative to the second
mold body, the thermoforming device further comprising a control
system for controlling the first, second, and/or third
actuator.
20. The thermoforming device according to claim 19, wherein the
first actuator, the second actuator, and/or the third actuator
comprises a respective pneumatic or hydraulic cylinder, for moving
the first pre-stretcher, the second pre-stretcher, and the
calibration element, respectively.
21. The thermoforming device according to claim 19, wherein at
least one of the first actuator, the second actuator, and the third
actuator comprises an electric motor for moving the first
pre-stretcher, the second pre-stretcher, and the calibration
element, respectively.
22. The thermoforming device according to claim 1, wherein the
first and second pre-stretcher each comprise a respective plastic
foil contacting part that is made of a different material than a
remainder of the pre-stretcher.
23. The thermoforming device according to claim 22, wherein the
respective plastic foil contacting part is releaseably connected to
the remainder of the pre-stretcher.
24. The thermoforming device according to claim 1, wherein the
calibration element comprises a plastic foil contacting part that
is thermally isolated from a remainder of the calibration
element.
25. The thermoforming device according to claim 11, wherein the
heating element is configured to heat the plastic foil contacting
part relative to said remainder of the calibration element.
26. The thermoforming device according to claim 1, wherein an
outward stroke of at least one of the first pre-stretcher, the
second pre-stretcher, and the calibration element is limited by a
mechanical stop that is formed by or is coupled to the second mold
body.
27. The thermoforming device according to claim 26, wherein the
mechanical stop defines a stop position for the at least one of the
first pre-stretcher, the second pre-stretcher, and the calibration
element, wherein the stop position is adjustable by increasing or
decreasing the effective thickness of the mechanical stop.
28. The thermoforming device according to claim 1, wherein the
first mold comprises a plurality of forming cavities, and wherein
the second mold comprises, for each forming cavity, a respective
first pre-stretcher, a respective second pre-stretcher, and a
respective calibration element.
29. A method for thermoforming a product using the thermoforming
device of claim 1, comprising the steps of: clamping a heated
plastic foil in between the first and second mold; individually
stretching the plastic foil in a direction towards a wall and/or
bottom of a forming cavity in the first mold using the first and
second pre-stretcher; generating an overpressure on a side of the
clamped plastic foil directed away from the forming cavity to urge
the plastic foil to move towards the wall and/or bottom of the
forming cavity; locally clamping the heated plastic foil between
the calibration element and a wall and/or bottom of the forming
cavity after having started the application of the
overpressure.
30. The method for thermoforming a product according to claim 29,
further comprising allowing the shaped plastic foil to cool down
while keeping it locally clamped using the calibration element.
31. A thermoforming machine, comprising a plastic foil providing
station, a transport means for the plastic foil, and a
thermoforming device, preferable a thermoforming device according
to claim 1, the thermoforming device comprising: a first mold
comprising a first mold body and a forming cavity arranged in said
first mold body; a second mold comprising a second mold body, a
first pre-stretcher, and a calibration element, wherein the first
pre-stretcher and the calibration element are at least partially
and moveably arranged in the second mold body; wherein the
thermoforming machine comprises a central processing unit and an
actor, for moving the first pre-stretcher and the calibration
element in the second mold body; wherein the first and second mold
can be moved relative to each other for clamping a plastic foil
there between; wherein the thermoforming machine is arranged--with
its central processing unit and at least one actor, especially a
motor--for moving the first and second mold relative to each other;
wherein the calibration element is configured to locally clamp the
plastic foil in between the calibration element and a wall and/or
bottom of the forming cavity; wherein the thermoforming machine
might be arranged--with its central processing unit and at least
one actor, especially a motor--for making the calibration element
clamp the plastic foil; characterized in that the thermoforming
device further comprises a second pre-stretcher that is at least
partially and moveably arranged in the second mold body, wherein a
movement relative to the second mold body and towards the same
forming cavity of at least one of the first pre-stretcher, the
second pre-stretcher, and the calibration element, can be
individually controlled by the central processing unit, the central
processing unit being connected to an actor for the second
pre-stretcher, wherein the actor for the second pre-stretcher might
preferably be mounted on the first pre-stretcher, so that the actor
moves the second pre-stretcher by making a relative stroke versus
the first pre-stretcher, wherein the second pre-stretcher at least
partially surrounds the first pre-stretcher and the calibration
element.
32. A thermoforming machine, especially a thermoforming machine
according to claim 31, comprising: a thermoforming device; a
plastic foil providing station; a transport device configured for
delivering the plastic foil from the station to the thermoforming
device; a central processing unit; at least one actuator disposed
in communication with the central processing unit and with the
thermoforming device; wherein the thermoforming device comprises: a
first mold comprising a first mold body and a forming cavity
arranged in said first mold body; a second mold comprising a second
mold body, a calibration element, a first pre-stretcher, and a
second pre-stretcher moveably disposed in the second mold body;
wherein the first pre-stretcher and the calibration element are
moveably arranged at least partially within the second mold body;
wherein the at least one actuator is configured to move the first
pre-stretcher and the calibration element in the second mold body;
wherein the central processing unit and the at least one actuator
are configured to move the first and second mold relative to each
other in order to clamp the plastic foil there between; wherein the
calibration element is configured to locally clamp the plastic foil
in between the calibration element and a wall of the forming
cavity; wherein the central processing unit and the at least one
actuator are configured to move the calibration element to said
locally clamped the plastic foil; wherein the central processing
unit is configured to individually control a movement of at least
one of the first pre-stretcher, the second pre-stretcher, and the
calibration element relative to the second mold body and toward the
forming cavity; wherein the at least one actuator is configured to
move the second pre-stretcher and is mounted on the first
pre-stretcher such that the actuator is configured to move the
second pre-stretcher by making a relative stroke versus the first
pre-stretcher, and wherein the second pre-stretcher at least
partially surrounds the first pre-stretcher and the calibration
element
33. The thermoforming machine according to claim 31, wherein at
least two of the first pre-stretcher, the second pre-stretcher, and
the calibration element are configured to be individually
controlled.
34. The thermoforming machine according to claim 31, wherein each
of the first pre-stretcher, the second pre-stretcher, and the
calibration element are configured to be individually
controlled.
35. The thermoforming machine according to claim 31, wherein the
calibration element at least partially surrounds the first
pre-stretcher.
36. The thermoforming machine according to claim 35, wherein the
second pre-stretcher and the calibration element are essentially
hollow structures, wherein the calibration element is at least
partially arranged inside the second pre-stretcher, and wherein the
first pre-stretcher is at least partially arranged inside the
calibration element.
37. The thermoforming machine according to claim 31, wherein the
second pre-stretcher and the first pre-stretcher are essentially
hollow structures, wherein the first pre-stretcher is at least
partially arranged inside the second pre-stretcher, and wherein the
calibration element is at least partially arranged inside the first
pre-stretcher.
38. The thermoforming machine according to claim 31, wherein the
first pre-stretcher, the second pre-stretcher, and the calibration
element are coaxially arranged.
39. The thermoforming machine according to claim 31, wherein at
least one of the first pre-stretcher, the second pre-stretcher, and
the calibration element is shaped as a sleeve, a jacket, or a bush,
having a square, rectangular, or circular cross section.
40. The thermoforming machine according to claim 31, further
comprising a heating element configured for heating the calibration
element relative to the second mold body.
41. The thermoforming machine according to claim 31, further
comprising a forming air unit for generating an overpressure on a
first side of the plastic foil that is clamped in between the first
and second molds to urge the plastic foil to move towards the wall
and/or bottom of the forming cavity, said first side being directed
away from the forming cavity.
42. The thermoforming machine according to claim 41, wherein the
second mold comprises one or more second channels, and wherein the
forming air unit is configured to generate said overpressure by
applying pressurized gaseous medium through the one or more second
channels to said first side of the clamped plastic foil.
43. The thermoforming machine according to claim 31, wherein the
first mold comprises one or more first channels, and wherein the
forming air unit is configured to generate said overpressure by
evacuating a space in the forming cavity between the clamped
plastic foil and the wall and/or bottom of the forming cavity
through the one or more first channels.
44. The thermoforming machine according to claim 31, wherein the
thermoforming device is configured, for the purpose of forming a
product out of the plastic foil clamped by the first and second
molds, to generate said overpressure only after at least partially
completing the stretching of the plastic foil using the first and
second pre-stretchers.
45. The thermoforming machine according to claim 31, wherein the
thermoforming device is configured, for the purpose of forming a
product out of the clamped plastic foil, to cause the clamping of
the plastic foil by the calibration element only after having
started the application of the overpressure by the forming air
unit.
46. The thermoforming machine according to claim 31, wherein the at
least one actuator comprises: a first actuator for moving the first
pre-stretcher relative to the second mold body, a second actuator
for moving the second pre-stretcher relative to the second mold
body, and/or a third actuator for moving the calibration element
relative to the second mold body, and wherein the central
processing unit is configured for controlling the first, second,
and/or third actuator.
47. The thermoforming machine according to claim 31, wherein the
first and second pre-stretcher each comprise a respective plastic
foil contacting part that is made of a different material than a
remainder of the pre-stretcher.
48. The thermoforming machine according to claim 47, wherein the
respective plastic foil contacting part is releaseably connected to
the remainder of the pre-stretcher.
49. The thermoforming machine according to claim 31, wherein the
heating element is configured to heat the plastic foil contacting
part relative to said remainder of the calibration element.
50. The thermoforming machine according to claim 31, wherein an
outward stroke of at least one of the first pre-stretcher, the
second pre-stretcher, and the calibration element is limited by a
mechanical stop that is formed by or is coupled to the second mold
body.
Description
TECHNICAL FIELD
[0001] The present invention relates to a thermoforming device. It
further relates to a mold assembly and mold that can be used in a
thermoforming device. It also relates to a method for thermoforming
a product, and to a thermoforming machine.
BACKGROUND
[0002] Thermoforming is a known technique by which a heated plastic
foil can be shaped using a mold assembly. Generally, the mold
assembly comprises two molds that can be moved relative to each
other for clamping the heated plastic foil. At least one of these
molds is provided with one or more forming cavities. The other mold
is provided, for each forming cavity, with a pre-stretcher that can
be moved into the forming cavity thereby stretching the plastic
foil. Thereafter, an overpressure will be generated on one side of
the plastic foil to force the plastic foil against the wall of the
forming cavity. There, the plastic foil cools down and the shape of
the product is defined.
[0003] For some applications, wall thickness of the final product,
both in terms of size and variation among different products, is an
important parameter. For instance, the thermoformed product may be
required to cooperate with another product or device, wherein the
latter product or device imposes size restraints on the
thermoformed product. Typically, the size restraints only apply to
certain parts of the product. As an example, a particular region of
the bottom wall of the product may need to have a thickness within
a predefined range.
[0004] DE 10 2007 023 301 A1 presents a solution to address this
problem. In this known system, an upper mold of the mold assembly
of the thermoforming apparatus is provided with a calibration
element in the form of a pen that is either fixedly attached to the
upper mold or it is moveably attached thereto. In this known
system, the pen is partially arranged in the pre-stretcher. During
operation, the pen is moved downward to engage the plastic foil
before pre-stretching the plastic foil using the pre-stretcher. By
clamping the plastic foil in between the pen and a wall of the
forming cavity, it becomes possible to accurately define the wall
thickness of the product at the position where the plastic foil is
clamped.
[0005] Further prior art is known from EP 1 842 651 A, EP 0 734 838
A, US 2005/196567 A, U.S. Pat. No. 3,964,856, US 2008/044603 A, EP
1 854 614 A, DE 10 2007 037 748 A, and EP 2 682 250 A.
[0006] There is a continuing demand for increasing the throughput
of thermoforming apparatuses while at the same time allowing
smaller variations in product geometry. The applicant has found
that although the abovementioned known system provides a solution
for products having a particular geometry, it may still show wall
thickness variations for some product geometries that may be
unacceptable for some applications.
[0007] It is an object of the present invention to provide an
alternative or improved technology.
SUMMARY
[0008] According to the invention, this object has been achieved
using a thermoforming device that comprises a first mold comprising
a first mold body and a forming cavity arranged in the first mold
body, and a second mold comprising a second mold body, a first
pre-stretcher, and a calibration element, wherein the first
pre-stretcher and the calibration element are at least partially
and moveably arranged in the second mold body. According to the
invention, the first and second mold can be moved relative to each
other for clamping a plastic foil there between, and the
calibration element is configured to locally clamp the plastic foil
in between the calibration element and a wall and/or bottom of the
forming cavity.
[0009] The invention is characterized in that the thermoforming
device further comprises a second pre-stretcher that is at least
partially and moveably arranged in the second mold body, and
wherein a movement relative to the second mold body and towards the
same forming cavity of at least one of the first pre-stretcher, the
second pre-stretcher, and the calibration element, can be
individually controlled, and wherein the second pre-stretcher at
least partially surrounds the first pre-stretcher and the
calibration element.
[0010] Preferably at least two, and more preferably each of the
first pre-stretcher, the second pre-stretcher, and the calibration
element can be individually controlled. In case one or more of the
first pre-stretcher, the second pre-stretcher, and the calibration
element cannot be individually controlled, the movement of that
component or those components will depend on the movement of one or
more of the controllable components. For instance, the controllable
component may be driven by an actuator. When this component is
driven, the movement thereof may cause the movement of another
non-controllable component by means of a mechanical coupling.
[0011] The applicant has found that by using two or more
individually controllable pre-stretchers in combination with a
calibration element, it becomes possible to better control the wall
thickness of the thermoformed product, in particular at positions
where the calibration element engages the plastic foil. Control of
wall thickness is further improved because the second pre-stretcher
at least partially surrounds the first pre-stretcher and the
calibration element. This allows proper control of the outer
regions of the product.
In one embodiment of the thermoforming machine, the first
pre-stretcher is configured to move relative to the second
pre-stretcher or relative to the calibration element, and the
calibration element is configured to move relative to the second
pre-stretcher. In another embodiment of the thermoforming device,
the calibration element is configured to move relative to the
second pre-stretcher or relative to the first pre-stretcher, and
the first pre-stretcher is configured to move relative to the
second pre-stretcher.
[0012] The first and second pre-stretchers are each configured to
stretch the heated plastic foil that is clamped between the first
and second molds in a direction towards a wall and/or bottom of the
forming cavity.
[0013] The calibration element can be arranged at least partially
around the first pre-stretcher. In an embodiment, the second
pre-stretcher completely surrounds the calibration element, and the
calibration element completely surrounds the first pre-stretcher.
In this case, a bottom edge of the calibration element may have a
ring shape, wherein other shapes are not excluded.
[0014] It should be noted that the second pre-stretcher need not
fully surround the calibration element over the full length of the
second pre-stretcher or calibration element. The same holds for the
first pre-stretcher and the calibration element.
[0015] The second pre-stretcher and the calibration element may be
essentially hollow structures, wherein the calibration element is
at least partially arranged inside the second pre-stretcher, and
wherein the first pre-stretcher is at least partially arranged
inside the calibration element. In this case, the first
pre-stretcher can be configured to move relative to the second
pre-stretcher or relative to the calibration element, and the
calibration element can be configured to move relative to the
second pre-stretcher.
[0016] Alternatively, the second pre-stretcher and the first
pre-stretcher can be essentially hollow structures, wherein the
first pre-stretcher is at least partially arranged inside the
second pre-stretcher, and wherein the calibration element is at
least partially arranged in the first pre-stretcher. In this case,
the calibration element can be configured to move relative to the
second pre-stretcher or relative to the first pre-stretcher, and
the first pre-stretcher can be configured to move relative to the
second pre-stretcher.
[0017] The first and second pre-stretchers and the calibration
element can be elongated in a direction perpendicular to the second
and first mold bodies. The longitudinal axis of the first and
second pre-stretchers and of the calibration element can be
arranged in parallel. Additionally or alternatively, the first
pre-stretcher, the second pre-stretcher, and the calibration
element are coaxially arranged.
[0018] At least one of the first pre-stretcher, the second
pre-stretcher, and the calibration element can be shaped as a
sleeve, a jacket, or a bush, preferably having a square,
rectangular, or circular cross section. Because the calibration
element cooperates with a segment of the wall and/or bottom of the
forming cavity, it is advantageous if the shape of the lower edge
of the calibration element is complementary to the shape of the
aforementioned segment. As an example, both the segment and the
lower edge of the calibration element may be essentially flat.
[0019] The thermoforming device may further comprise a heating
element configured for heating the calibration element relative to
the second mold body. Heating the calibration element prevents
early solidification of heated plastic foil when engaged by the
calibration element. By controlling the amount of heating, the
cooling down process of the plastic foil at the position of the
calibration element can be controlled in correspondence of the
cooling down process in other parts of the plastic foil.
[0020] In an embodiment, only a lower part of the calibration
element is heated. This part can be thermally isolated from a
remainder of the calibration element by a thermal isolator.
[0021] At least one of a stroke length, a stroke duration, a stroke
speed, and a stroke starting time for the first pre-stretcher, the
second pre-stretcher, and/or the calibration element can be
individually controlled. Here, a stroke length can be defined as
the maximum distance that the relevant component moves during the
thermoforming process. Alternatively, the stroke length can be
defined as the penetration depth of the relevant component in the
forming cavity. The stroke duration can be defined as the time that
the relevant component is held at its lowest position inside the
forming cavity. The stroke speed can be defined as the maximum
speed of the relevant component during the movement of the
component towards the forming cavity or the time that is required
for performing the stroke motion.
[0022] As the first pre-stretcher, the second pre-stretcher, and
the calibration element can be controlled individually, for
instance meaning that the movement of one component can be
controlled separate from the controlling of the movement of another
component, it is advantageous if the starting time of such motion
can be set independently. This allows an order to be set for the
thermoforming process. For example, it can be decided to first
clamp the plastic foil using the calibration element and to then
pre-stretch the foil. In this case, the calibration element also
provides a stretching effect. Alternatively, it can be decided to
first pre-stretch the plastic foil and to clamp the plastic foil
using the calibration element only after the pre-stretching is
partially or fully completed.
[0023] With respect to the calibration element, it is preferred if
at least one of a starting time of clamping the plastic foil in
between the calibration element and the wall and/or bottom of the
forming cavity, a clamping duration, and a clamping strength, can
be independently controlled. The clamping strength generally refers
to the force exerted by the calibration element in a direction
towards the relevant part of the wall and/or bottom of the forming
cavity.
[0024] The thermoforming device may further comprise a forming air
unit for generating an overpressure on a first side of the plastic
foil that is clamped in between the first and second molds to urge
the plastic foil to move towards the wall and/or bottom of the
forming cavity. Here, the first side is directed away from the
forming cavity.
[0025] An overpressure situation is generated when a higher
pressure exists on the aforementioned side of the clamped plastic
foil than on the other side of the plastic foil. For example, the
second mold may comprise one or more second channels, wherein the
forming air unit is configured to generate the overpressure by
applying pressurized gaseous medium through the one or more second
channels to the first side of the clamped plastic foil.
Additionally or alternatively, the first mold may comprise one or
more first channels, wherein the forming air unit is configured to
generate the overpressure by evacuating a space in the forming
cavity between the clamped plastic foil and the wall and/or bottom
of the forming cavity through the one or more first channels.
[0026] The thermoforming device may be configured, for the purpose
of forming a product out of the plastic foil clamped by the first
and second molds, to generate the overpressure only after at least
partially completing the stretching of the plastic foil using the
first and second pre-stretchers. Additionally or alternatively, the
thermoforming device may be configured, for the purpose of forming
a product out of the clamped plastic foil, to cause the clamping of
the plastic foil by the calibration element only after having
started the application of the overpressure by the forming air
unit.
[0027] The thermoforming device may comprise a first actuator for
moving the first pre-stretcher relative to the second mold body, a
second actuator for moving the second pre-stretcher relative to the
second mold body, and/or a third actuator for moving the
calibration element relative to the second mold body. The
thermoforming device may further comprise a control system for
controlling the first, second, and/or third actuator. As an
example, the first actuator, the second actuator, and/or the third
actuator may comprise a respective pneumatic or hydraulic cylinder,
for moving the first pre-stretcher, the second pre-stretcher, and
the calibration element, respectively. Alternatively, at least one
of the first actuator, the second actuator, and the third actuator
may comprise an electric motor for moving the first pre-stretcher,
the second pre-stretcher, and the calibration element,
respectively.
[0028] The first and second pre-stretcher may each comprise a
respective plastic foil contacting part that is made of a different
material than a remainder of the pre-stretcher. The plastic foil
contacting part may for instance be made of a material having a
relatively low thermal conductivity to prevent or limit the cooling
of the plastic foil by the pre-stretchers. The respective plastic
foil contacting part may be releaseably connected to the remainder
of the pre-stretcher.
[0029] Similarly, the calibration element may comprise a plastic
foil contacting part that is thermally isolated from a remainder of
the calibration element. As stated before, the heating element may
be configured to heat the plastic foil contacting part relative to
said remainder of the calibration element. Moreover, the heating
element may be controlled by the aforementioned control system.
[0030] The thermoforming device may comprise a mechanical stop that
limits an outward stroke of at least one of the first
pre-stretcher, the second pre-stretcher, and the calibration
element. The mechanical stop can be formed by or can be coupled to
the second mold body. The mechanical stop may define a stop
position for the at least one of the first pre-stretcher, the
second pre-stretcher, and the calibration element, wherein the stop
position is adjustable by increasing or decreasing the effective
thickness of the mechanical stop.
[0031] Generally, the first mold may comprise a plurality of
forming cavities. In this case, the second mold may comprise, for
each forming cavity, a respective first pre-stretcher, a respective
second pre-stretcher, and a respective calibration element. The
control system may be configured to control the first
pre-stretchers, the second pre-stretchers, and the calibration
element as a respective single unit. This can be achieved by
simultaneously controlling the actuators of such unit such that,
for example, every first pre-stretcher performs the same
motion.
[0032] In other embodiments, a single first, second, or third
actuator may be used to actuate several first pre-stretchers,
second pre-stretchers, or calibration elements, respectively.
[0033] According to a second aspect, the present invention provides
a mold assembly for thermoforming a product comprising the first
and second mold as defined above.
[0034] According to a third aspect, the present invention provides
a mold for thermoforming a product comprising the second mold as
defined above.
[0035] According to a fourth aspect, the present invention provides
a method for thermoforming a product using the thermoforming device
as described above, comprising the steps of:
[0036] clamping a heated plastic foil in between the first and
second mold;
[0037] individually stretching the plastic foil in a direction
towards a wall and/or bottom of a forming cavity in the first mold
using the first and second pre-stretcher;
[0038] generating an overpressure on a side of the clamped plastic
foil directed away from the forming cavity to urge the plastic foil
to move towards the wall and/or bottom of the forming cavity; and
locally clamping the heated plastic foil between the calibration
element and a wall and/or bottom of the forming cavity after having
started the application of the overpressure.
[0039] The method preferably further comprises the step of allowing
the shaped plastic foil to cool down while keeping it locally
clamped using the calibration element.
[0040] According to further aspects of the invention, the object is
reached by providing a thermoforming machine with the features as
claimed in any of the independent claim 31 or 32, wherein further
optional features will be understood from the invention's
embodiments description or from the dependent claims 33-50.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] Next, the present invention will be described in more detail
referring to the appended drawings, wherein:
[0042] FIG. 1 schematically illustrates an embodiment of the
present invention;
[0043] FIG. 2 illustrates a cross section of a mold assembly
according to the present invention;
[0044] FIG. 3A, 3B present different detailed views of the assembly
of FIG. 2;
[0045] FIG. 4 schematically illustrates an embodiment of the
thermoforming machine; and
[0046] FIG. 5 shows a schematic representation of an enlarged
partial view of FIG. 2.
DETAILED DESCRIPTION
[0047] FIG. 1 illustrates an embodiment of the present invention.
This embodiment comprises a control system 1 that is configured to
control a first actuator 2, a second actuator 3, a third actuator
4, and a mold actuator 5, which actuators are configured to actuate
the first pre-stretcher, the second pre-stretcher, the calibration
element, and the first and/or second mold, respectively. Control
system 1 can further be configured to control heating element 7 in
dependence of a temperature sensed by temperature sensor 6.
[0048] In one mode of operation, control system 1 may control mold
actuator 5 to cause the first mold and the second mold to move
relative to each other for the purpose of clamping a heated plastic
foil there between. Next, control system 1 may control second
actuator 3 to cause the second pre-stretcher to move downward
towards to the forming cavity, thereby performing a primary
stretching of the plastic foil. Depending on the configuration of
the calibration element and the first pre-stretcher, the
calibration element and the first pre-stretcher may remain
stationary with respect to the second pre-stretcher during the
motion of the latter.
[0049] As a next step, control system 1 may control first actuator
2 to cause the first pre-stretcher to move downward towards to the
forming cavity, thereby performing a secondary stretching of the
plastic foil. Here, the secondary stretching may be performed
simultaneous with or after the primary stretching.
[0050] Once the primary and secondary stretching are completed, or
substantially completed, control system 1 may control third
actuator 4 to cause the calibration element to move downward
towards to the forming cavity for the purpose of locally clamping
the pre-stretched plastic foil against a wall and/or bottom of the
forming cavity. During and/or before this clamping, the temperature
of the calibration element may be controlled using heating element
7 that is controlled by control system 1 preferably in dependence
of a temperature sensed by temperature sensor 6.
[0051] It is noted that the present invention is not limited to the
order of the steps mentioned above.
[0052] FIG. 2 illustrates a cross section of an embodiment of a
mold assembly according to the invention. FIGS. 3A and 3B present
detailed views of this assembly.
[0053] Now referring to FIG. 2, second pre-stretcher 10 is coupled
to a mechanical drive. This drive comprises an at least partially
hollow pen 11 that is capable of moving up and down relative to
second mold body 12. Second pre-stretcher 10 comprises a first part
13 and a foil engaging part 14, wherein foil engaging part 14 can
be fixedly or releasably connected to first part 13.
[0054] Second mold body 12 defines a mechanical stop 15 that
defines a maximum position of second pre-stretcher 10, although the
mechanical drive may be configured such that second pre-stretcher
10 stops its downward movement before it engages mechanical stop
15.
[0055] First part 13 of second pre-stretcher 10 comprises a bore in
which on the top side thereof a guiding element 16, in the form of
a piston, is arranged, which guiding element 16 is provided with a
sealing ring 17. Guiding element 16 is provided with a through hole
in which a rod 18 corresponding to first pre-stretcher 19 is
moveably arranged.
[0056] Calibration element 20 is moveably arranged inside the bore
of second pre-stretcher 10. Calibration element 20 comprises a foil
engaging part 21 which is thermally isolated, using a thermal
isolator 22, from a second part 23. Here, parts 21 and 23 are
fixedly connected to each other via isolator 22. At a top side,
second part 23 is provided with a sealing ring 24. Moreover, second
part 23 is fixedly arranged with respect to guiding element 16.
[0057] Second part 23 is able to move up and down in the space
defined by an inside wall of first part 13. A mechanical stop 25 is
fixedly arranged with respect to first part 13 to limit the upward
motion of second part 23 and a further mechanical stop 26 is formed
by first part 13.
[0058] First pre-stretcher 19 comprises a foil engaging part 29,
rod 18, and a cylinder 30 that is moveably arranged inside a
chamber 31 inside a part 32 that is fixedly coupled to first part
13. Cylinder 30 comprises a sealing ring 34. Part 32 is fixedly
connected to a mechanical stop 35 that provided a first limit to
the upward motion of first pre-stretcher 19. Similarly, a
mechanical stop 36 is formed by part 32. Moreover, cylinder 30 is
connected to a rod 37 that is provided with a T-like element 38 at
its top. Here, rod 37 is guided through an opening in mechanical
stop 39, which stop 39 is attached stationary relative to second
mold body 12. Hence, the downward motion of pre-stretcher 19 is
limited due to cylinder 30 engaging stop 36 or due to T-like
element 38 engaging stop 39.
[0059] At a bottom side, second mold body 12 is provided with a
cutting plate 40 that is configured to cooperate with a cutting
nipple 41 that is arranged in a top plate 42 of first mold body
43.
[0060] Inside cutting nipple 41, a forming cavity is formed using a
forming jacket 44 and a forming bottom 45.
[0061] The space defined by the inside wall of first part 13 is
divided in two chambers 27, 28. To move second part 23 downward,
pressurized air can be applied in between guiding element 16 and
part 32. At the same time, pressurized air can be applied in
between second part 23 and mechanical stop 25. To enable a downward
motion of second part 23, chambers 27, 28 are vented through
conduits (not shown)
[0062] To move second part 23 upward, pressurized air is applied to
chamber 27 in between mechanical stop 25 and guiding element 16. At
the same time, the space in between guiding element 16 and part 32
is vented, preferably using the conduits (not shown) through which
the pressurized gas was transported for the downward motion. The
same holds for the space in between second part 23 and mechanical
stop 25, and chamber 28.
[0063] FIG. 2 illustrates a situation wherein first pre-stretcher
19 is at its most downward position relative to second
pre-stretcher 10 and wherein calibration element 20 is at its most
upward position relative to second pre-stretcher 10.
[0064] Although the present invention is not limited to a
particular order of controlling pre-stretchers 10, 19 and
calibration element 20, an exemplary mode of operation will be
described next.
[0065] As a starting position, first pre-stretcher 19 will be in
its most upward position, in which cylinder 30 lies against stop
35. Moreover, calibration element 19 will also be in its most
upward position, in which the top of part 23 lies against stop 25.
Moreover, second pre-stretcher 10 will be in its most upward
position.
[0066] As a first step, first and second molds will be brought
together for clamping a plastic foil in between them. More in
particular, a plastic foil will be clamped in between a
down-holding element 46, which is received in a bore of cutting
plate 40, and cutting nipple 41.
[0067] As a second step, the mechanical drive will be actuated for
moving pen 11 downward. This will cause foil engaging part 14 of
second pre-stretcher 10 to engage the clamped plastic foil, thereby
pre-stretching the latter. During this primary pre-stretching,
first pre-stretcher 19 and calibration element 20 do not move
relative to second pre-stretcher 10.
[0068] As a next step, pressurized air will be supplied to chamber
31 via channels (not shown) to press cylinder 30 downward, thereby
causing a secondary pre-stretching to occur as foil engaging part
29 engages the clamped plastic foil. During this motion,
calibration element 20 does not move relative to second
pre-stretcher 10.
[0069] Next, pressurized forming air will be supplied from inside
the second mold to engage the plastic foil from an upper side
thereof. This will cause the plastic foil to be pressed against the
inside walls of forming jacket 44 and forming bottom 45.
[0070] As a next step, pressurized air will be supplied to cause a
downward motion of second part 23 as described above, thereby
causing a local clamping of the pre-stretched plastic foil in
between foil engaging part 21 and forming bottom 45.
[0071] The shaped product will now be allowed to cool down,
preferably while keeping it clamped using calibration element
20.
[0072] As a next step, the forming air will be vented and
pressurized air will be supplied to chamber 27 to move calibration
element 20 back to its initial position relative to second
pre-stretcher 10. Additionally, pressurized air will be supplied to
chamber 36 on another side of cylinder 30 to move first
pre-stretcher 19 upward to its initial position relative to second
pre-stretcher 10. In addition, second pre-stretcher 10 will be
moved upward by driving pen 11.
[0073] In this embodiment, calibration element 20 is moved using a
double-acting configuration, wherein pressurized air is supplied to
move calibration element 20 up and down. Alternatively, a
single-acting configuration can be used wherein calibration element
20 is pre-biased to move in a given direction, and wherein
pressurized air can be used to cause calibration element 20 to move
in the other direction.
[0074] The first and second molds may make a slight movement
towards each other such that cutting plate 46 and cutting nipple 41
may pass each other thereby cutting through the plastic foil in
between them. In this manner, the formed product can be separated
from the remainder of the plastic foil.
[0075] Next, the second and first molds may move away from each
other. As a last step, the forming bottom 45 can be moved upward
for pushing out the formed product.
[0076] It should be noted that a mold assembly may comprise a
plurality of forming cavities as illustrated in FIG. 2. For each
cavity, a first pre-stretcher 19, a calibration element 20, and a
second pre-stretcher 10 can be arranged.
[0077] Although the present invention has been described using a
detailed embodiment thereof, the skilled person readily understands
that the present invention is not limited thereto but that various
modifications can be made without departing from the scope of the
invention which is defined by the appended claims.
[0078] For example, the order of movement of the first and second
pre-stretchers, and of the calibration element, can be varied as
well as the moment in time when the forming air is applied. The
forming air may for instance be applied only after the calibration
element has started to clamp the plastic foil. By using the mold
assembly of the present invention a great variety of thermoforming
processes can therefore be realized.
FIG. 4 schematically illustrates an exemplary embodiment of a
thermoforming machine 200. As shown in FIG. 4, the thermoforming
machine 200 comprises a thermoforming device 201, a plastic foil
providing station 202, a transport device 203, and a central
processing unit 204. The plastic foil providing station 202 could
be any suitable storage or distribution device that is configured
to operate with the transport device 203 to deliver the plastic
foil from the station to the transforming device 201. In one
embodiment, the plastic foil providing station 202 is a storage
rack and the transport device 203 is a conveyer belt. The transport
device 203, more generally, is any suitable mechanism or
arrangement which is configured to deliver the plastic foil to the
thermoforming device 201. As mentioned, the transport device 203
may comprise a conveyor belt arrangement. In other embodiments, the
transport device 203 may comprise a vehicle, a transfer arm, and/or
a robotic apparatus. FIG. 5 shows a schematic representation of an
enlarged partial view of FIG. 2. Therein, the second actuator 3,
which is configured to move the second pre-stretcher 10, is mounted
on the first pre-stretcher 19 such that the actuator 3 is arranged
to move the second pre-stretcher 10 by making a relative stroke
versus the first pre-stretcher 19. That is, the second actuator 3
bears against the first pre-stretcher 19 in order to move the
second pre-stretcher 10.
* * * * *