WO2004113073A1 - Procede et appareil pour produire un film a bulles a partir d'un extrudat tubulaire - Google Patents

Procede et appareil pour produire un film a bulles a partir d'un extrudat tubulaire Download PDF

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Publication number
WO2004113073A1
WO2004113073A1 PCT/IT2003/000386 IT0300386W WO2004113073A1 WO 2004113073 A1 WO2004113073 A1 WO 2004113073A1 IT 0300386 W IT0300386 W IT 0300386W WO 2004113073 A1 WO2004113073 A1 WO 2004113073A1
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WIPO (PCT)
Prior art keywords
film
bubble
rolls
welding
nip
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
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PCT/IT2003/000386
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English (en)
Inventor
Bruno Attucci
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Individual
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Individual
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Priority to PCT/IT2003/000386 priority Critical patent/WO2004113073A1/fr
Priority to AU2003244087A priority patent/AU2003244087A1/en
Publication of WO2004113073A1 publication Critical patent/WO2004113073A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0013—Extrusion moulding in several steps, i.e. components merging outside the die
    • B29C48/0014—Extrusion moulding in several steps, i.e. components merging outside the die producing flat articles having components brought in contact outside the extrusion die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
    • B29C51/18—Thermoforming apparatus
    • B29C51/20—Thermoforming apparatus having movable moulds or mould parts
    • B29C51/22—Thermoforming apparatus having movable moulds or mould parts rotatable about an axis
    • B29C51/225—Thermoforming apparatus having movable moulds or mould parts rotatable about an axis mounted on a vacuum drum
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/20—Layered products comprising a layer of metal comprising aluminium or copper
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/28—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding involving assembly of non-flat intermediate products which are flattened at a later step, e.g. tubes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/12—Deep-drawing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D81/00—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents
    • B65D81/02—Containers, packaging elements, or packages, for contents presenting particular transport or storage problems, or adapted to be used for non-packaging purposes after removal of contents specially adapted to protect contents from mechanical damage
    • B65D81/03—Wrappers or envelopes with shock-absorbing properties, e.g. bubble films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/001—Shaping in several steps
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C2791/00—Shaping characteristics in general
    • B29C2791/004—Shaping under special conditions
    • B29C2791/007—Using fluid under pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0017—Combinations of extrusion moulding with other shaping operations combined with blow-moulding or thermoforming
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0018—Combinations of extrusion moulding with other shaping operations combined with shaping by orienting, stretching or shrinking, e.g. film blowing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/001—Combinations of extrusion moulding with other shaping operations
    • B29C48/0019—Combinations of extrusion moulding with other shaping operations combined with shaping by flattening, folding or bending
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B29C48/10—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels flexible, e.g. blown foils
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/712—Containers; Packaging elements or accessories, Packages
    • B29L2031/7138—Shock absorbing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2323/00—Polyalkenes
    • B32B2323/10—Polypropylene
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00—Packaging equipment or accessories not otherwise provided for
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00—Packaging equipment or accessories not otherwise provided for
    • B32B2553/02—Shock absorbing
    • B32B2553/026—Bubble films
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
    • B32B37/15—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state
    • B32B37/153—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with at least one layer being manufactured and immediately laminated before reaching its stable state, e.g. in which a layer is extruded and laminated while in semi-molten state at least one layer is extruded and immediately laminated while in semi-molten state

Definitions

  • the present invention relates to a process and apparatus for producing plastic bubble sheet, and to the sheet produced by the said process.
  • Plastic bubble sheets generally used in packaging and insulation, are known. These bubble sheets comprise at least two layers or films of plastic, at least one of which is formed into bubbles and welded to the other, at least in the areas around the said bubbles.
  • two continuous webs of plastic film are preheated to a sufficient temperature to allow them to be deformed and welded; at least one of the webs is shaped into bubbles by passing it around a roll with a shaped surface connected to a vacuum system; and finally the two webs are joined together on a calender, incorporating ambient air in the airtight bubbles which they form.
  • Patent application PCT/IT02/00455 discloses a bubble sheet with the bubbles filled with carbon dioxide, and a process for producing it, in an airtight chamber in which a carbon dioxide atmosphere is created.
  • the prior art also includes apparatuses for the continuous extrusion of a tubular plastic film; the film is extruded by a circular extrusion head and is then used for tubular articles which are welded or cut into sheets or wound up.
  • One object of this invention is to produce bubble film more simply and quickly than conventional systems do. Another object is to produce bubble film, especially film in which the bubbles are filled with carbon dioxide or other gas without necessitating the use of an airtight chamber.
  • a continuous tube of plastic film is extruded through a circular extrusion head, the tube is adjusted to a temperature that will allow it to be vacuum-deformed and welded, and the tube is passed through a nip between two rolls, of which at least one is a vacuum-forming roll for bubble film.
  • the invention achieves the objectives stated above, in particular: it allows rapid production of bubble film, with the bubbles filled with air or other gas, such as carbon dioxide; it reduces investment costs and management costs for the production apparatus; it is easy to use; and it uses less energy than current processes.
  • the new apparatus according to the invention can be completely automated with the help of, for example, sensors inside the extruded and inflated tube. Furthermore, existing extrusion apparatuses can be adapted to carry out the method of the invention.
  • the product can be produced with a slight pressure of gas inside the bubbles. This improves its properties for use as packaging, or for other uses, and makes its shape more stable when the material is cooled.
  • Fig. 1 shows a perspective view of a piece of bubble film which it is wished to produce with the invention
  • Fig. 2 shows, on a reduced scale, the central parts of an apparatus for the extrusion forming of a tubular plastic film;
  • Figs. 3, 4 and 5 show diagram matically, in an end view, a side view and a perspective view, respectively, the ringed detail marked III in Figure 2;
  • Fig. 3a shows the shapes A, B, C assumed in cross section by the tubular film in the planes indicated at A-A, B-B, C-C in Fig. 4;
  • Fig. 6 is an interrupted section through a variant of the bubble sheet
  • Fig. 7 is a view similar to Figure 3 but shows a system of rolls for producing the bubble film seen in Fig. 6;
  • Fig. 8 is a section through a bubble film, in another variant;
  • Fig. 9 is a diagrammatic drawing of an apparatus for producing the bubble film of Fig. 8;
  • Figs. 10, 11 and 12 show an arrangement of an apparatus in vertical section, in a reduced plan view, and with diagrams of the relative positions of forming and/or welding rolls;
  • Fig. 13 is a section showing bubble articles capable of being produced by the apparatus seen in Figs. 10 to 12;
  • Figs. 14 and 15 show another arrangement for an apparatus and articles which it can produce; Figs. 16; 17 and 18; 19 show other diagrams for production apparatuses; and
  • Figs. 20, 21 and 22 show in simplified form a machine for producing the article seen in Fig. 6 and another similar article.
  • a sheet of bubble material is indicated as a whole by the reference 10 and comprises an essentially flat first layer or film
  • FIG. 2 to 5 An apparatus for producing the bubble sheet 10 is illustrated in Figures 2 to 5, and indicated as a whole by the reference 20.
  • the apparatus comprises an extruder 22, known per se, with an extrusion head 24 with an annular exit slot for the plasticized material - known per se -and it also comprises a nozzle in the center, that is inside the annular slot, for blowing air at slightly above atmospheric pressure to dilate the extruded tubular material which is still sufficiently hot.
  • This type of extruder is generally used to extrude plastic film in the form of a tube T, whose walls are kept apart by the in -blown air.
  • a so-called funnel indicated by reference 26, also known per se, which comprises a V-shaped structure 28 which converges with distance from the extrusion head 24, i.e. it converges upwards in the example seen in Figure 1.
  • the structure 28 may take any form, such as (Figs. 3 and 4) having two flat frames 29 carrying two series of idle rollers 30 with transverse axes relative to the axis of the extruded tube T, that is their axes are essentially horizontal in the example seen in Figures 2 to 4.
  • the job of the funnel is to impart gradually (Fig.
  • two rolls are mounted downstream of the funnel 26 with their axes transverse with respect to the formed tube. They are similar to conventional rolls and work together, but at least one of them is a forming roll 34 and the other may simply be a welding roll 32. Both rolls 32, 34 may be of a type known per se.
  • the surface of the forming roll is formed into cavities corresponding in form and dimensions to the form of the bubbles to be produced in the finished sheet, and the cavities are connected to a vacuum apparatus.
  • the welding roll preferably has an essentially smooth cylindrical surface.
  • the number 33 denotes the nip formed between the rolls 32 and 34.
  • the extrusion head 24 extrudes a continuous tube T of plastic film.
  • Air or other air-like substance preferably carbon dioxide CO 2
  • the tube cools as it moves towards the funnel 26. Sometimes the gas is even circulated through the tube, being injected and extracted, to cool the material of the tube T more rapidly.
  • the tube is then conveyed into the funnel structure 26, which gradually flattens it (see cross sections A, B and C in Fig. 3a), defining two opposite walls which are brought towards each other.
  • the two walls of film are brought together - at a temperature suitable for deformation and welding, depending on the material in question - and are passed through the nip 33 between the rolls 32 and 34, at least one of the walls being deformed, so that the said rolls weld the two walls together between themselves at least in the spaces between the bubbles or at least around the bubbles.
  • the air or other gas held inside the film tube at a slight pressure remains trapped inside the bubbles.
  • the continuous bubble sheet 10 emerges from the pair of rolls 32 and 34 and is sent for cutting or rew inding or other processing.
  • the carbon dioxide is preferably contained in bottles in liquid form, and its absorption of heat on passing into the gaseous state can be exploited to lower the temperature of the tube T to an appropriate level for deformation and welding. This lowering of the temperature can however also be achieved in other ways accessible to those skilled in the art, as already hinted at above and also, for example, by circulating air around the outside of the tube T.
  • a bubble sheet F is formed with two films 11 and 12. It is also possible to form bubble sheets with more than two films.
  • a bubble sheet 50 as illustrated in Figure 6 can be produced, according to the invention, by a system of rolls 60 as illustrated in Figure 7, mounted downstream of the extrusion head.
  • the sheet 50 comprises three layers of plastic film 51 , 52, 54 welded together to form bubbles 53 between layers 51 and 52, and spaces 55 enclosed between the bubbles, between layers 52 and 54.
  • the bubbles 53 may be filled with air at atmospheric pressure or at a slightly higher pressure, or with gas, such as carbon dioxide, at a slight pressure.
  • the spaces 55 may be filled with air at atmospheric pressure or with gas, such as carbon dioxide, at a slight pressure.
  • the system of rolls 60 (Fig. 7) comprises a forming roll 62 and a welding roll 64 similar to the rolls 32 and 34, respectively, described in relation to the first embodiment; while a roll 65 and a roll 66, both welding and both known per se, are provided in series.
  • the tube T is shown being fed from above into the nip 63 between the forming and welding rolls, but it could of course be fed from underneath as in the apparatus shown in Fig. 2.
  • the intermediate bubble sheet emerging from the rolls 62, 64 is fed into the nip 67 between the welding rolls 65, 66, together with a web N of smooth plastic film, preferably at a temperature sufficient for welding, which will form the film 54.
  • the bubble sheet 50 seen in Fig. 6 is the bubble sheet 50 seen in Fig. 6 in continuous form.
  • the nip 67 between the rolls 65 and 66 is located in an airtight chamber 68 in which air or C0 2 or other gas is maintained at pressure.
  • a bubble sheet 70 as illustrated in Figure 8 can be produced, according to the invention, by a system of rolls 80 (81 to 86) as illustrated in Figure 9, mounted downstream of extrusion heads E1 and E2.
  • the film comprises four layers of plastic film 71 , 72, 74, 75 welded to each other to form bubbles 73 between layers 71 and 72, and bubbles 76 between layers 73 and 74, in addition to spaces 77 enclosed between the bubbles and situated between layers 72 and 75.
  • the bubbles 73 and/or 76 can be filled with air at atmospheric pressure or at a slightly higher pressure, or with gas, such as carbon dioxide, at a slight pressure.
  • the spaces 77 may themselves be filled with air at atmospheric pressure or with gas, such as carbon dioxide, at a slight pressure.
  • the system 80 shown in Fig. 9 comprises a first extruder E1 and a second extruder E2, the respective extrusion heads of which produce a first tubular film T1 and a second tubular film T2, respectively.
  • the tubular film T1 is flattened, shaped into bubbles and welded as stated above in respect of the first embodiment, between the rolls 81 and 82, generating a bubble sheet F1 , which comprises the layers 71, 72.
  • the second tubular film T2 is flattened, shaped into bubbles and welded as stated above in respect of the first embodiment, between the rolls 83 and 84, to form a bubble sheet F2 comprising the layers 74, 75.
  • the bubble sheets F1 , F2 are joined together via the bubble parts 73, 75, head to head, and welded by the rolls 85, 86 to give the sheet 70.
  • the bubbles 73 and/or 76 may be filled with compressed air, or with C0 2 or other gas by injecting compressed gas through the center of the extrusion head of the extruder E1 , and likewise of the extruder E2, respectively.
  • the spaces 77 may be filled with compressed air or gas - such as carbon dioxide - by enclosing at least rolls 85 and 86 in an airtight chamber 88 containing an atmosphere of the gas under the desired conditions.
  • Figs. 10 to 13 show a version with an extruder 101 , which may be single, double or triple, as in Fig. 11 where there are three extruders 101 A, 101B, 101C.
  • the extrusion head 103 outputs the tubular film Tb (with one or two or three layers) which travels to the pair of rolls 105 and 107, one of which may be a forming roll and the other simply a welding roll, or both may be forming rolls, with versions as indicated in Fig. 12; the pair 105A, 107A is designed to form a tube of morphology A as seen in Fig. 14; the pair 105B is designed to form a tube of morphology B as seen in Fig. 14; and the pair 105C, 107C is designed to form a tube of morphology C, as seen in Fig. 14.
  • auxiliary rolls 123 and 125 are also next to each other to weld together the tubes coming from the pairs of rolls 115, 117 and 119, 121 of the two systems 111 and 112.
  • the rolls 123 and/or 125 and/or the rolls 117 and 119 may be suitably heated to give a degree of plasticity to the two tubes arriving from the two systems 111 and 113, so that these two tubes can be welded as indicated in one or other of combinations D, E, F, G, H illustrated in Fig. 15, depending on the relative positions of the bubbles formed by the pairs of rolls 115, 117 and 119, 121.
  • Fig. 16 shows an alternative form to that seen in Fig. 14, with two extrusion heads 211 and 213 and a single shaft with two opposed screws and a single motor.
  • Figs. 17 and 18 show another alternative, with a single extruder 400 feeding both extrusion heads 400A and 400B .
  • Fig. 19 shows a system 500 with extruder 501 and extruder head 503 at the top, for forming a bubble Tg which extends downwards and through the pair of forming and/or welding rolls 505, 507, which may be operating in a similar way to that illustrated in either of the previous examples.
  • a welding arrangement as indicated in Figs. 20 and 21 is envisaged.
  • the tube 51 , 52, 53 of Fig. 6 formed by the forming cylinders 662, 664 (similar to 62, 64 in Fig. 7), in which the two films 51 , 52 are cut along the edges, is passed around a roll 666 next to a roll 668 having annular projections 668A to make the edge welds 57. These projections and/or the roll 666 will be heated to weld the two films 51 and 52 together. If the tube seen in Fig.
  • this film 54 is fed in by a roll 670, passes between the rolls 666 and 668 and is welded at 57 together with the films 51 and 52 by the annular projections 668A.
  • the product shown in Fig. 6 and produced in this way may also be given another film 700 fed in by a roll 672 and welded, again at the edges, by the annular projections 668A, to produce the product shown in Fig. 22.
  • FIG. 800 Some of the figures illustrating the tubes extruded by the annular extrusion heads and closed by the forming and/or welding rolls show the presence of a rod 800 rising from the surface of the extrusion head inside the annular extrusion nozzle forming the bubble, where there are also holes for supplying the gas (air or C0 2 or the like) into the bubble and for optional circulation of gas to heat or cool the material of the developing bubbles.
  • This rod 800 can be adjusted for length and it supports at its end a unit 802 which may contain various instruments, specifically temperature and pressure sensors and the like.
  • Plastics suitable for the process are all the plastics that can be extruded with bubble apparatuses and that are biodegradable, coextrudates, metallocenes.
  • the material of this flat film may be a material such as paper, board, aluminum film or the like, made heat-weldable or may be a resin - such as polyester, polypropylene or other resins - having very different properties from those of the bubble-shaped film.
  • Alternatives to the embodiments of the invention illustrated and described are possible. It is intended that alternatives accessible to those skilled in the art with ordinary experience be understood to come within the scope of the present invention.
  • a product of the type seen in Fig. 22 may have sheets 51 and 52 welded to form the bubbles, and sheets 54 and 700 welded only along the longitudinal edges such as 57; the two films 54 and 700 will be welded to the films 51 and 52 in the process of forming a product.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Extrusion Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un procédé pour une production continue d'une feuille à bulles constituée d'une matière plastique. Ce procédé comprend les étapes consistant à extruder un film tubulaire continu (T) constitué de matière plastique, à partir de l'ajutage annulaire d'une tête d'extrusion, ajuster la température du film à une valeur appropriée à sa déformation et à son soudage, donner au film une forme essentiellement aplatie présentant deux couches opposées ou deux parois opposées du tube essentiellement adjacentes et passer le film aplati dans l'écart situé entre une paire de rouleaux (32, 34), au moins l'un de ces rouleaux étant un rouleau de formation pouvant former des bulles, et souder ensemble les parois opposées du film aplati, de sorte à former des bulles entre les deux couches du tube soudées ensemble.
PCT/IT2003/000386 2003-06-23 2003-06-23 Procede et appareil pour produire un film a bulles a partir d'un extrudat tubulaire Ceased WO2004113073A1 (fr)

Priority Applications (2)

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PCT/IT2003/000386 WO2004113073A1 (fr) 2003-06-23 2003-06-23 Procede et appareil pour produire un film a bulles a partir d'un extrudat tubulaire
AU2003244087A AU2003244087A1 (en) 2003-06-23 2003-06-23 Process and apparatus for producing bubble film from tubular extrudate

Applications Claiming Priority (1)

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PCT/IT2003/000386 WO2004113073A1 (fr) 2003-06-23 2003-06-23 Procede et appareil pour produire un film a bulles a partir d'un extrudat tubulaire

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Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2907189A1 (fr) * 2006-10-16 2008-04-18 Saint Gobain Isover Sa Isolant mince pour isolation thermique
GB2507325A (en) * 2012-10-26 2014-04-30 Euroform Products Ltd Composite insulation including gas filled pockets
WO2016198355A1 (fr) * 2015-06-11 2016-12-15 Colines S.P.A. Feuille ou panneau sandwich en nid d'abeille à base de polypropylène comprenant plusieurs films centraux thermoformés
WO2016198354A1 (fr) * 2015-06-11 2016-12-15 Colines S.P.A. Feuille ou panneau sandwich en nid d'abeille à base de prolypropylène comprenant un film central thermoformé
WO2017146577A1 (fr) * 2016-02-25 2017-08-31 Generation Of Change B.V. Feuille de rembourrage pliable et biodégradable
CN107187073A (zh) * 2017-07-21 2017-09-22 成泰昌包装制品(深圳)有限公司 一种三层结构包装袋的覆合设备及其覆合方法
NL2017518B1 (en) * 2016-09-23 2018-04-04 Generation Of Change B V Foldable and Biodegradable Cushioning Sheet
CN110588156A (zh) * 2019-10-10 2019-12-20 枣庄正奇包装科技有限公司 一种无介质印刷气泡膜生产设备
CN113085148A (zh) * 2021-05-06 2021-07-09 曹桂芬 气泡袋及其制备工艺与应用
CN116021738A (zh) * 2022-12-14 2023-04-28 浙江鹏远新材料科技集团股份有限公司 一种固碳相变气泡膜生产设备及工艺
CN117532989A (zh) * 2023-10-20 2024-02-09 南安市万航包装科技有限公司 抗压复合包装材料及其制备方法
US12595111B2 (en) 2024-06-03 2026-04-07 Pratt Corrugated Holdings, Inc. Modular shipping assembly with insulator wrap and inner insulator boxes

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US3142599A (en) * 1959-11-27 1964-07-28 Sealed Air Corp Method for making laminated cushioning material
US3575757A (en) * 1967-12-08 1971-04-20 Reinforced Air Corp Process for making inflated articles
US3660189A (en) * 1969-04-28 1972-05-02 Constantine T Troy Closed cell structure and methods and apparatus for its manufacture
US4417936A (en) * 1981-10-19 1983-11-29 Gafcel Industries, Inc. Plastic web with multiplicity of gas filled bubbles, containing printing thereon and method of making same

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Publication number Priority date Publication date Assignee Title
US3142599A (en) * 1959-11-27 1964-07-28 Sealed Air Corp Method for making laminated cushioning material
US3575757A (en) * 1967-12-08 1971-04-20 Reinforced Air Corp Process for making inflated articles
US3660189A (en) * 1969-04-28 1972-05-02 Constantine T Troy Closed cell structure and methods and apparatus for its manufacture
US4417936A (en) * 1981-10-19 1983-11-29 Gafcel Industries, Inc. Plastic web with multiplicity of gas filled bubbles, containing printing thereon and method of making same

Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2907189A1 (fr) * 2006-10-16 2008-04-18 Saint Gobain Isover Sa Isolant mince pour isolation thermique
WO2008047027A1 (fr) * 2006-10-16 2008-04-24 Saint-Gobain Isover Isolant mince pour isolation thermique
GB2507325A (en) * 2012-10-26 2014-04-30 Euroform Products Ltd Composite insulation including gas filled pockets
EA034090B1 (ru) * 2015-06-11 2019-12-26 Колинес С.п.А. Многослойное сотовое полотно или панель на основе полипропилена, содержащее центральную термоформованную пленку
WO2016198354A1 (fr) * 2015-06-11 2016-12-15 Colines S.P.A. Feuille ou panneau sandwich en nid d'abeille à base de prolypropylène comprenant un film central thermoformé
WO2016198355A1 (fr) * 2015-06-11 2016-12-15 Colines S.P.A. Feuille ou panneau sandwich en nid d'abeille à base de polypropylène comprenant plusieurs films centraux thermoformés
US11084246B2 (en) 2015-06-11 2021-08-10 Colines S.P.A. Honeycomb sandwich sheet or panel, based on polypropylene, with a number of central thermoformed films
US10654243B2 (en) 2015-06-11 2020-05-19 Colines S.P.A. Honeycomb sandwich sheet or panel, based on polypropylene, with a central thermoformed film
EA038351B1 (ru) * 2015-06-11 2021-08-12 Колинес С.п.А. Ячеистый слоистый лист или панель на основе полипропилена с центральными термоформованными пленками
WO2017146577A1 (fr) * 2016-02-25 2017-08-31 Generation Of Change B.V. Feuille de rembourrage pliable et biodégradable
US10625918B2 (en) 2016-02-25 2020-04-21 Generation Of Change B.V. Foldable and biodegradable cushioning sheet
NL2017518B1 (en) * 2016-09-23 2018-04-04 Generation Of Change B V Foldable and Biodegradable Cushioning Sheet
CN107187073A (zh) * 2017-07-21 2017-09-22 成泰昌包装制品(深圳)有限公司 一种三层结构包装袋的覆合设备及其覆合方法
CN110588156A (zh) * 2019-10-10 2019-12-20 枣庄正奇包装科技有限公司 一种无介质印刷气泡膜生产设备
CN113085148A (zh) * 2021-05-06 2021-07-09 曹桂芬 气泡袋及其制备工艺与应用
CN116021738A (zh) * 2022-12-14 2023-04-28 浙江鹏远新材料科技集团股份有限公司 一种固碳相变气泡膜生产设备及工艺
CN117532989A (zh) * 2023-10-20 2024-02-09 南安市万航包装科技有限公司 抗压复合包装材料及其制备方法
CN117532989B (zh) * 2023-10-20 2026-01-23 南安市万航包装科技有限公司 抗压复合包装材料及其制备方法
US12595111B2 (en) 2024-06-03 2026-04-07 Pratt Corrugated Holdings, Inc. Modular shipping assembly with insulator wrap and inner insulator boxes

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