The present invention relates to an induction sealing device for heat sealing packaging material for producing sealed packages of pourable food products.
As is known, many food products, such as fruit juice, pasteurized or UHT (ultra-high-temperature treated) milk, wine, tomato sauce, etc., are sold in packages made of sterilized packaging material.
A typical example of this type of package is the parallelepiped-shaped package for liquid or pourable food products known as Tetra Brik Aseptic (registered trademark), which is made by folding and sealing laminated strip packaging material.
The packaging material has a multilayer structure substantially comprising a base layer for stiffness and strength, which may be defined by a layer of fibrous material, e.g. paper, or mineral-filled polypropylene material; and a number of layers of heat-seal plastic material, e.g. polyethylene film, covering both sides of the base layer.
In the case of aseptic packages for long-storage products, such as UHT milk, the packaging material also comprises a layer of gas- and light-barrier material, e.g. aluminium foil or ethyl vinyl alcohol (EVOH) film, which is superimposed on a layer of heat-seal plastic material, and is in turn covered with another layer of heat-seal plastic material forming the inner face of the package eventually contacting the food product.
As is known, packages of this sort are produced on fully automatic packaging machines, on which the tube is formed continuously from the web-fed packaging material. More specifically, the web of packaging material is unwound off a reel and fed through a station for applying a sealing strip of heat-seal plastic material, and through an aseptic chamber on the packaging machine, where it is sterilized, e.g. by applying a sterilizing agent such as hydrogen peroxide, which is subsequently evaporated by heating, and/or by subjecting the packaging material to radiation of appropriate wavelength and intensity.
The web of packaging material is then fed through a number of forming assemblies which interact with the packaging material to fold it gradually from strip form in a tube shape.
More specifically, a first portion of the sealing strip is applied to a first longitudinal edge of the packaging material, on the face of the material eventually forming the inside of the packages; and a second portion of the sealing strip projects from the first longitudinal edge.
The forming assemblies are arranged in succession, and comprise respective roller folding members defining a number of compulsory packaging material passages varying gradually in section from a C shape to a substantially circular shape.
On interacting with the folding members, the second longitudinal edge is laid on the outside of the first longitudinal edge with respect to the axis of the tube being formed. More specifically, the sealing strip is located entirely inside the tube, and the face of the second longitudinal edge facing the axis of the tube is superimposed partly on the second portion of the sealing strip, and partly on the face of the first longitudinal edge located on the opposite side to the first portion of the sealing strip.
Packaging machines of the above type are known in which the first and second longitudinal edge are heat sealed to form a longitudinal seal along the tube, which is then filled with the sterilized or pasteurized food product, and is sealed and cut along equally spaced cross sections to form pillow packs, which are then folded mechanically to form respective parallelepiped-shaped packages.
More specifically, the heat-seal operation comprises a first heating step to heat the second longitudinal edge without the sealing strip; and a second pressure step to compress the sealing strip and the longitudinal edges.
The first heating step melts the polyethylene layer of the second longitudinal edge, which transmits heat by conduction to the first longitudinal edge and the sealing strip, so as to melt the polyethylene layer of the first longitudinal edge and the heat-seal material of the sealing strip.
At the second pressure step, the tube is fed between a number of first rollers outside the tube, and at least one second roller inside the tube.
More specifically, the first rollers define a compulsory circular passage for the tube of packaging material, and have respective axes in a plane transversal to the path of the tube.
In the case of barrier material comprising a sheet of electrically conductive material, e.g. aluminum, the longitudinal seal may be formed by induction heat-sealing.
More specifically, the packaging machine comprises a sealing device which is wholly arranged outside the tube.
The sealing device substantially comprises one or more inductive elements electrically fed by a high-frequency alternate current generator.
In use, the alternate current flowing inside the inductive elements generates an alternate magnetic field flux which extends substantially transversal to the feeding direction of the tube.
This alternate magnetic field flux generates eddy currents in the aluminium layer to melt the heat-seal plastic material locally.
Sealing device is mounted above and is connected with the first rollers.
Though efficient, sealing device of the above type leave room for improvement.
EP-A-387512 discloses a heating induction sealing device.
A need is felt within the industry to improve uniformity of the heating and, therefore, of the longitudinal sealing, especially at the start-up of the packaging machine and/or when the longitudinal seal is performed in a region of the packaging material at which a new reel has been joined to an existing one.
In particular, the known inductive elements comprise a first and second leg within which alternate current flows in opposite directions.
The first leg is arranged in front of the sealing area defined by the overlapping regions of the first and second longitudinal edges and of the sealing strip whereas the second leg is spaced from such a sealing area.
Accordingly, only the first leg induces eddy currents within the sealing area whereas the second portion induces eddy current in a region of the packaging material which is spaced and far from the overlapping edges.
As a result, only the eddy currents generated by the first leg are effective in forming the longitudinal seal.
When a new reel of packaging material is joined to an existing one, the margins of respective aluminum layers are interrupted. In this case, there is the risk that the area close to the margins is not heated and, therefore, not completely sealed, by the known sealing device. In particular, the Applicant has found that eddy current tends to close far from the margins of the aluminum layers, so causing the incomplete sealing of the margins.
Moreover, the Applicant has found that eddy currents tend to create a cold spot within the sealing area and a hot spot outside the sealing area, so that the longitudinal sealing could be not perfect.
A need is also felt within the industry to obtain a heat pattern as uniform as possible in the sealing area.
It is an object of the present invention to provide an induction sealing device, designed to meet at least one of the above requirement in a straightforward, low-cost manner.
According to the present invention, there is provided an induction sealing device, for heat sealing packaging material for forming a seal in a packaging material, as claimed in Claim 1.
Furthermore, the present invention relates to a method of forming a seal in a packaging material, as claimed in claim 10.
A preferred, non-limiting embodiment of the present invention will be described by way of example with reference to the accompanying drawings, in which:
Number 1 in
Machine 1 preferably produces sealed packages 2 of a pourable food product, such as pasteurized or UHT milk, fruit juice, wine, peas, beans, etc.
Machine 1 may also produce sealed packages 2 of a food product that is pourable when producing packages 2, and sets after packages 2 are sealed. One example of such a food product is a portion of cheese, that is melted when producing packages 2, and sets after packages 2 are sealed.
The packaging material has a multilayer structure substantially comprising a base layer for stiffness and strength, which may be defined by a layer of fibrous material, e.g. paper, or mineral-filled polypropylene material; and a number of layers of heat-seal plastic material, e.g. polyethylene film, covering both sides of the base layer.
More specifically, web 3 is fed along path P by guide members 5, e.g. rollers or similar, and successively through a number of work stations, of which are shown schematically: a station 6 for applying a sealing strip 9 (shown enlarged in thickness in
Machine 1 also comprises a fill device 12 for pouring the sterilized or sterile-processed food product continuously into tube 10 of packaging material; and a jaw-type forming assembly (not shown) for gripping, sealing, and cutting tube 10 along equally spaced cross sections to form a succession of packages 2.
More specifically, at station 6, a longitudinal edge 11, parallel to path P, of web 3 is first heated, e.g. by heat induction, to melt the plastic layer. Web 3 has a longitudinal edge 15 opposite edge 11 and also parallel to path P.
Next, a portion 16 (
Finally, strip 9 is pressed onto longitudinal edge 11, e.g. by means of rollers not shown.
More specifically, sealing strip 9 is made of heat-seal plastic material.
Strip 9 prevents edge 11 from absorbing the food product once tube 10 and seal 14 of the tube are formed, and also provides for improving the gas-barrier performance and physical strength of seal 14.
Station 7 comprises a number of forming assemblies 13 arranged successively along path P, and which interact gradually with web 3 to fold it into the form of tube 10.
More specifically, forming assemblies 13 comprise respective numbers of rollers defining respective compulsory packaging material passages, the respective sections of which vary gradually from a C shape to a substantially circular shape.
More specifically, the axes of the rollers in each forming assembly 13 lie in a relative plane transversal, perpendicular in the embodiment shown, to path P.
Forming assemblies 13 gradually form tube 10, so that edge 15 is located outwards of edge 11 with respect to the axis of tube 10. More specifically, when forming tube 10, strip 9 is located inside tube 10, and the inner face of edge 15 is superimposed partly on portion 17 of strip 9, and partly on the outer face of edge 11 (
Station 8 comprises a heating induction sealing device 30 for heating edge 15 and locally melting the polyethylene layer of edge 15. Heat is transmitted by conduction from edge 15 to edge 11 and strip 9, so as to locally melt the polyethylene layer of edge 11 and the heat-seal material of strip 9.
Station 8 also comprises a number of forming rollers 21 defining a compulsory circular passage for tube 10; and one or more rollers 22 for pressing portion 17 of strip 9, and portion 16 of strip 9 and edge 11 onto the face of edge 15 inside tube 10, so that the polyethylene layers of edges 11, 15 and the heat-seal material of strip 9 blend completely to form the molecular bonds defining seal 14 of tube 10.
More specifically, rollers 21 are located outside tube 10, and pressure rollers 22 inside tube 10.
Station 8 also comprises an annular support 29 which surrounds tube 10 and support rollers 21.
Sealing device 30 is, in particular, movable together with support 29 between a raised position and lowered position along a direction which is parallel to path P shown respectively in
Sealing device 30 comprises a pair of inductors 31, 32; inductor 31 comprises a portion 35 facing inductor 32 and defining with inductor 32 a passage 28 for edge 15, and a portion 36; sealing device 30 is selectively arrangeable in a first configuration, in which alternate currents flow within inductors 31, 32; portion 35 of inductor 31 and inductor 32 inductors 31, 32 are configured to generate a magnetic flux M1 transversally to direction A, when sealing device is arranged in the first configuration; portion 36 of inductor 31 is configured to generate a magnetic flux M2 having a main component transversal to path P, when sealing device 30 is arranged in the first configuration.
Portion 36 of inductor 31 comprises legs 200, 201 within which alternate current flows, in use, in opposite direction; leg 200 is configured to induce, in use, a portion 300 of eddy current (shown with a dashed line in
Legs 200, 201 face each other along a direction C orthogonal to direction B. Advantageously, leg 201 is configured to induce a portion 301 of eddy current within area 202 of edge 15 to be sealed onto strip 9 and edge 11; legs 200, 201 have a length along a direction B parallel to direction A and transversal to direction C; legs 200, 201 are nonsymmetrical relative to direction B, so that seal 14 is formed as continuous along direction C.
In this way, both legs 200, 201 of portion 36 of inductor 31 are effective in inducing respective portions 300, 301 of eddy current within area 202.
In other words, substantially the whole eddy current induced by portion 36 of inductor 31 circulate within area 202.
Furthermore, due to the nonsymmetrical shape of legs 200, 201, the pattern of eddy current and, therefore, the heat-pattern is very uniform within area 200.
In this way, the formation of a cold area, and therefore of a non-sealed region between legs 200, 201 is substantially prevented, so ensuring the continuity of seal 14 along direction C.
Sealing device 30 may be also selectively arranged in a second configuration, in which alternate current flows within portion 36 of inductor 31 only and no alternate current flows within inductor 32 and portion 35 of inductor 31.
When sealing device 30 is arranged in the second configuration, magnetic flux M1 is not generated and portion 36 generates only magnetic flux M2.
Portions 35, 36 define respectively the top and the bottom of relative inductor 31.
In detail, when edge 15 enters passage 28, it is still detached from edge 11 and strip 9 (see
Edge 15 overlaps edge 11 and strip 9 as it is fed in front of portion 36 of inductor 31. Sealing device 30 substantially comprises (
Body 40, 41 are releasably connected to each other, in the embodiment shown through a plurality of screws.
Bodies 40, 41 extend along relative axes B parallel to direction A and define therebetween passage 28.
Body 40 is also connected to a plate 39 which is, in turn, fixed to support 29 (
In detail, each body 40, 41 comprises (
Support 45 is sandwiched between housing 43 and relative insert 38.
Supports 44; 45 also comprise a pair of faces 48a, 48b; 49a, 49b opposite to each other (
Faces 48a, 48b are arranged towards the packaging material of tube 10 and have respective upper parts which cooperate with plastic housing 42, 43 (
Faces 49a, 49b are arranged towards insert 38 (
Support 44 substantially comprises (
Crossbar 53 extends from the middle of arm 51 towards a bottom end of arm 52.
In detail, arm 52 extends upwardly from crossbar 53 and for a length which is less than the half of the length of arm 51 measured along axis B.
Support 45 substantially comprises:
Arm 62 protrudes from crossbar 63 on the opposite of arm 61.
In detail, arm 62 extends upwardly from crossbar 63 and for a length which is less than the half of the length of arms 51, 61 measured along axis B.
The length of crossbars 53, 63 measured orthogonally to axis B is substantially identical.
The length of arm 52, 62 measured parallel to axis B is identical.
Furthermore, inductors 31, 32 of each pair are embedded between two insulating layers.
Inductor 31 comprises (
In detail, a top half 74 of serpentine 70 and serpentine 71 are arranged in top half 54 of arm 51 and form portion 35 of inductor 31.
A bottom half 79 of serpentine 70 and serpentine 72 are arranged in bottom half 55 of arm 51 and form portion 36 of inductor 31.
L-shaped portion 73 is arranged inside crossbar 53 and arm 52 of support 44.
Portion 77, 78 are parallel to each other and are arranged inside crossbar 53.
Bottom half 55 of arm 51 is sloped relative to top half 54 of such arm 51 (
Bottom half 79 of serpentine 70 defines leg 200 and serpentine 72 defines leg 201.
Inductor 32 comprises (
Serpentines 81, 82 are housed within arm 61.
U-shaped portion 83 substantially comprises:
Stretches 89a, 89b, 89c are respectively housed inside arm 61, 62 and crossbar 63.
Each serpentine 70, 71, 81, 82 has a length along axis B of relative body 40, 41 and extends, along its length, at varying distances from axis B of relative body 40, 41.
Each serpentine 70, 71, 81, 82 comprises a plurality of repeated modules 100 identical and adjacent to each other.
Each module 100 substantially comprises (
When sealing device 30 is assembled, arms 52, 62; top half 54 of arm 51 and arm 61; and crossbars 53, 63 face each other from opposite sides of passage 28 along relative direction C. In the same way, serpentine 71, 82; top half 74 of serpentine 70 and serpentine 81; and L- and U-shaped portions 73, 83 face each other from opposite sides of passage 28 along relative direction C.
Top half 74 of serpentine 70 and serpentine 81 are arranged on the same side (right side in
Homologous points of top (bottom) half 74 (79) of serpentine 70 and serpentine 71 (72) are arranged at a first constant distance measured along relative direction C from each other.
In the same way, homologous point of serpentines 81, 82 are arranged at the first constant distance measured along relative direction C from each other.
Stretches 101 of leg 200 (201) are arranged at a second distance measured along direction C from stretches 102 of the same leg 200 (201).
The value of this second distance is less than or equal to the first constant distance between legs 200, 201.
As a result, stretches 101 of leg 200 are interposed between stretches 102 of leg 201 parallel to direction B and are aligned with or even arranged on the opposite side of stretches 102 of leg 201 along direction C with respect to stretches 102 of leg 200.
With reference to
Inductor 31 comprises:
Electric contacts 91, 93 are electrically connected to each other by using a conductive element (only schematically shown in
Electric contact 94 is electrically connected to a negative pole of a power/current generator 99, when sealing device 30 is arranged both in the first and in the second configuration (
Electric contact 90 is electrically connected to a positive pole of the power/current generator 99, when sealing device 30 is arranged in the first configuration (
Electric contact 92 is electrically connected to a positive pole of the power/current generator 99, when sealing device 30 is arranged in the second configuration (
Electric contacts 94 and 90 or 92 are, in the embodiment shown, electrically connected to the power/current generator 99 by using conductive bars.
When sealing device 30 is in the first configuration (
In particular, circuit Cl comprises serpentines 70, 71, 72, serpentines 81, 82 and U-shaped portion 83 (
When sealing device 30 is in the second configuration, portion 36 and L-shaped portion 73 of inductor 31 define a closed electric circuit C2 (
In particular, circuit C2 comprises L-shaped portion 73, serpentine 72 and bottom half 79 of serpentine 70.
As a matter of fact, serpentine 71 and top half 74 of serpentine 70 are no longer connected to the positive pole of power/current generator 99 and therefore no alternate current may flow therein.
In the very same way, inductor 32 is no longer electrically connected to the positive pole of power/current generator 99 and therefore no alternate current may flow therein.
When sealing device 30 is set in the first configuration, at a given time, the alternate current flows in the same direction along top half 74 of serpentine 70 and along serpentine 81. Current also flows in the same direction along serpentines 71, 82 (see
The operation of machine 1 is described starting from a condition in which sealing device 30 and support 29 are in the raised position (
Web 3 is unwound off reel 4 and fed along path P.
More specifically, web 3 is fed by guide members 5 along path P and through successive stations 6, 7, 8.
At station 6, edge 11 is heated, and portion 16 of strip 9 is applied to the face of edge 11 eventually facing inwards of packages 2. Once portion 16 is applied to edge 11, portion 17 projects from edge 11.
Next, web 3 interacts gradually with forming assemblies 13, and is folded to superimpose edges 11, 15 and form tube 10 not yet sealed longitudinally.
More specifically, forming assemblies 13 fold web 3 so that strip 9 is located inside the as yet unsealed tube 10, edge 15 is located radially outwards of edge 11 and portion 17 with respect to the axis of tube 10 still to be sealed longitudinally, and edge 11 is located radially outwards of portion 16 of strip 9.
Seal 14 is formed, in station 8, by sealing to the inner face of edge 15 portion 17 of strip 9 and the face of edge 11 on the opposite side to portion 16.
More precisely, sealing device 30 heats edge 15 to melt the polyethylene layer; heat is transmitted by conduction from edge 15 to edge 11 and strip 9 to melt the polyethylene layer of edge 11 and the heat-seal material of strip 9.
In detail, edge 15 enters passage 28 and remains detached from edge 11 as it travels between inductor 32 and portion 35 of inductor 31.
Edge 15 overlaps edge 11 and strip 9, as it travels in front of portion 36 of inductor 31.
Sealing device 30 is arranged in the first configuration, during the normal operation of machine 1.
In detail, electrical contact 94 is electrically connected to the negative pole of generator 99 and electrical contact 90 is electrically connected to the positive pole of generator 99 (
As a result, closed circuit C1 is formed within inductors 31, 32 and alternate current flows therein. The alternate current flowing in circuit C1 generates magnetic flux M1 (directed substantially orthogonally to path P) and magnetic flux M2 (directed substantially transversal to path P).
More precisely, leg 200 of portion 36 of inductor 31 induces portion 300 of eddy currents within area 202 to be sealed of edges 11, 15 and strip 9; leg 201 of portion 36 of inductor 31 induces portion 301 of eddy currents within area 202 to be sealed of edges 11, 15 and strip 9.
As a result, substantially the whole eddy current induced by portion 36 of inductor 31 circulates within area 202 (
Next, tube 10 is fed through the circular passage defined by rollers 21, 22. Edges 11, 15 and strip 9 are compressed between rollers 21, 22 to blend the polyethylene layer of edges 11, 15 and the heat-seal material of strip 9, and so form the molecular bonds defining seal 14 of the finished tube 10.
The longitudinally sealed tube 10 is filled continuously with the pourable food product by device 12, and is then fed through the jaw-type forming assembly (not shown) where it is gripped, sealed, and cut along equally spaced cross sections to form a succession of packages 2.
The advantages of sealing device 30 according to the present invention will be clear from the foregoing description.
In particular, leg 200—formed by bottom half 79 of serpentine 70—of portion 36 of inductor 31 induces portion 300 of eddy currents within area 202; and leg 201—formed by serpentine 72—of portion 36 of inductor 31 induces portion 301 of eddy currents within area 202, as shown in
In this way, substantially the whole eddy currents induced by legs 200, 201 close within area 202 to be sealed of edge 15, 11 and strip 9, thus highly increasing the effectiveness of the sealing carried out by sealing device 30.
On the contrary, only a part 401 (
As a result, eddy current 403 tends to close far from area 402 to be sealed in the prior art solution.
Moreover, due to the fact that stretches 101 of leg 200 are aligned with or even arranged on the opposite side of stretches 102 of leg 201 along direction C with respect to stretches 102 of leg 200, stretches 101 of leg 200 are housed within stretches 102 of leg 201 along direction C.
In other words, legs 200, 201 “penetrate” into each other.
Accordingly, the resulting magnetic flux, and therefore the heat pattern, reaches a substantial uniform value on area 200. Such value is enough high to avoid the formation of cold points or channels within area 200.
In this way, the formation of a cold area, and therefore of a non-sealed region between legs 200, 201 is substantially prevented, so ensuring the continuity of seal 14 along direction C.
Furthermore, legs 200, 201 have a length parallel to direction B and are nonsymmetrical relative to direction B, and web 3 of packaging material moves relative to sealing device 30 parallel to direction B.
As a result, as packaging material advances relative to sealing device 30, each point of sealing area 202 is arranged in front of, and is therefore heated by, either of leg 200 or leg 201.
Accordingly, the risk that a cold channel forms along area 202 is dramatically reduced and substantially null.
In this respect, the Applicant has found that hot points are likely to be generated within the area to be sealed of edges 15, 11 and strip instead of outside such an area as in the prior art described in the introductory part of the present description.
The Applicant has also found that sealing device 30 is particularly advantageous in the presence of alluminium layer margins 500 due to the joining of a new reel 4 to an existing reel 4.
In particular, the Applicant has found that the eddy currents tends to circulate very close to the portion of the aluminum margin layers 500 arranged in the sealing zone (
Accordingly, the formation of not-sealed region is substantially prevented.
Support 44, 45 and inductors 31, 32 form a printed circuit board. This allows manufacturing inductors 31, 32 shaped in very different way with a reduced impact on manufacturing cost.
Clearly, changes may be made to sealing device 30 as described and illustrated herein without, however, departing from the scope of the present invention as defined in the accompanying Claims.
Sealing device 30, in particular, may also be used in station 6 for sealing portion 16 of strip 9 to the face of edge 11 eventually facing inwards of packages 2.
Sealing device 30 could also comprise only inductor 31.
Number | Date | Country | Kind |
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11165021.4 | May 2011 | EP | regional |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/EP2012/057463 | 4/24/2012 | WO | 00 | 11/1/2013 |