Thermoforming for Plastic Package Shaping

Compact packaging apparatus and process for making supports and packages for food products. The apparatus has a thermoforming station to make supports from plastic film, and a packaging station to close products in the supports. The key innovation is a cutting station upstream of thermoforming that separates larger sheets from a roll into smaller sheets. This allows using smaller feed rolls with shorter replacements compared to continuous film. The smaller sheets are then thermoformed into supports. The smaller sheets also allow higher production speed since each cut defines a separate sheet. The apparatus also has features like vacuum plates to transfer the sheets between stations.

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Clear, rigid medical packaging that can be sterilized by autoclave steam without warping or shrinking. The packaging is made by extruding a crystalline thermoplastic like PET, then partially stretching the film, heating it, and thermoforming it into the final shape. This process limits crystal growth to small spherulites rather than large crystals that cause warpage. The film is then sealed around the device and steam sterilized. The spherulitic crystals provide clarity and strength, but the restricted crystal growth prevents warping during sterilization. The packaging can be made by coextruding layers of different thicknesses that are split and stacked by multiplier units to form the final multilayer structure.

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Packaging material with high barrier properties and transparency for food containers. The packaging is made by thermoforming a laminate sheet with at least two layers. The base layer contains a propylene-based resin with smectite crystals. The laminate is formed at temperatures below the melting point of the propylene resin. This allows thermoforming the laminate into containers without separating the layers. The smectite crystals in the base layer provide barrier properties while the low temperature thermoforming preserves transparency.

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A method to form a bubble valve for sealing and dispensing fluids from flexible packages. The method involves using two aligned formable films, like thermoformed sheets, where one is placed on top of the other. Channels are sealed between them to create a pathway. Then both films are thermoformed into pockets simultaneously. Finally, a separate film is sealed over the bottom of the pockets to trap air and form the bubble valve. This allows precise alignment and registration of the pockets compared to forming them separately.

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Compact packaging machine for making supports and packages using a continuous film. The machine has a feed roll, cutting station, thermoforming station, and packaging station connected by conveyors. The feed roll unwinds film into strips which are thermoformed into supports. These are moved to the packaging station where they receive a top film. The machine has sensors, a control unit, and a compact layout for space efficiency. The feed roll uses a driving roll parallel to the unwind axis. The continuous film feed allows smaller rolls and shorter changeovers vs discrete sheets.

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Thermoforming packaging machine and method for deforming packaging material that provides reliable deformation with high quality packaging while avoiding damage or tearing. The machine has a stamp that oscillates slightly during movement in the receptacle. The oscillation has a smaller amplitude than the stamp's travel distance and a higher frequency than the movement time. This counter-movement briefly separates the stamp from the material. A control unit adjusts oscillation based on measured material temperature.

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Thermoforming packaging machine with improved quality deep-drawing of packaging material. The machine has a stamp with compressed air openings that direct air towards the material during deformation. This prevents direct stamp contact and creates an air cushion. A control system monitors stamp pressure and adjusts stamp movement and compressed air flow to maintain consistent deformation conditions.

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Thermoforming packaging machine that automatically adjusts processing parameters to maintain consistent packaging quality even as material properties change. The machine has sensors to measure characteristics like thickness during/after deformation. A control unit sets operating parameters for future deformations based on measured values and target values. If a measured value deviates too much, it changes the parameter. This allows the machine to compensate for variations in starting material or environment without operator intervention.

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Method for producing and filling application packages for liquid pharmaceuticals using thermoforming that allows easy breakage of the package at a predetermined point for controlled dispensing. The method involves heating and forming a multi-layered plastic sheet into the package shape using molds. The outer layers are thermoformable polymers like PP or PE, the inner layer has a barrier like EVOH, and an intermediate layer between. The key innovation is forming a thin region in the intermediate layer between the outer layers. This thin region breaks easily when the package is squeezed to dispense the drug, allowing controlled dosing. The thinning can be done by heating or mold design. The package layers protect the drug and prevent interactions.

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A method for producing and filling an administration packaging for a pharmaceutical product, like a pipette, that allows easy opening and dispensing of the contents. The method involves thermoforming the packaging from a multi-layer plastic sheet. A key feature is heating and forming the sheet to shape without creating a separate breaking zone. This eliminates the need for additional steps like perforating or scoring to create a weakened area. The packaging can be made on a thermoforming machine with a heating section and mold. The sheet is partially heated and formed into the packaging shape. The result is a packaging that can be easily opened by squeezing or pinching a section of the plastic between thumb and forefinger to initiate tearing. This simplifies dispensing compared to conventional pipettes that require cutting or peeling a seal.

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Packaging method and closing station for improving vacuum forming of product covers in packaging machines like thermoformers and tray sealers. The closing tool has an upper part with a molded body and an inner wall defining a mold space. Openings in the inner wall connect to vacuum sources. A cover film is sucked into the mold space via some openings for a first time window, then both sets of openings for a second time window. This sequenced vacuum sequencing prevents collapsing the cover film during the transition.

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A method for producing packaging using a thermoformer machine that reduces cutting waste and improves packaging quality. The method involves cutting the lower web partially upstream and partially in the sealing station. Before forming, the lower web is cut along the packaging contour. During forming, the lower web is cut again. This allows precise cutting without excess material. The upstream cut removes the web around the packaging, while the in-sealing cut completes the separation.

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Recyclable packaging film suitable for thermoforming that provides proper protection for food products while enabling recyclability. The film has a unique structure with a barrier layer sandwiched between compatibilizer layers. The barrier layer contains a low weight (≤5%) of ethylene vinyl alcohol (EVOH) to block moisture and gases. The compatibilizer layers bind the other film layers together. The outer and inner layers contain polyolefins like LDPE and LLDPE. The film layers are made from monomaterials like LLDPE to facilitate recycling. The compatibilizer layers contain maleated LDPE to improve adhesion between layers. This structure provides mechanical strength, thermal resistance, and deep drawing capability while maintaining compatibility between the polyolefin layers for recycling.

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High stiffness, transparent, food contact material compositions for packaging applications like food packaging articles. The compositions contain polypropylene, hydrocarbon resin, and optionally a nucleating agent. The polypropylene is a blend of two different types, one with low melt flow rate and one with high melt flow rate. The hydrocarbon resin is a low molecular weight thermoplastic polymer derived from unsaturated hydrocarbons. This blend provides improved stiffness, clarity, barrier properties, thermoformability, and optical properties compared to conventional PP compositions.

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A forming station for a thermoforming packaging machine that reduces cycle time and improves film thickness distribution in deep-drawn packaging. The forming station has an upper mold with a fixed forming die that moves towards the lower mold. During closing, the die partially forms the film between the molds. This saves a step compared to lowering the die after closing. Compressed air or vacuum finishes shaping the pack.

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Thermoformable multilayer films for packaging applications that provide barrier properties similar to PVC films but can be recycled. The films have a structure with an inner core layer sandwiched between two outermost skin layers. The skin layers contain blends of polymers like HDPE, cyclic olefin copolymers, functionalized polymers, and mineral fillers. This allows recyclability while maintaining thermoformability. The films can be used to make blister and medical device packages with reduced shrinkage and distortion compared to PVC films.

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Thermoformable, multi-layer films and thermoformed webs formed from such films having one or more thermoformed cavities contained therein. The films have a structure of at least two layers produced through coextrusion or lamination of a core layer and one or more outermost (skin) layers. The films are suitable for thermoforming into blister packages for pharmaceuticals and medical devices. They have properties equivalent to traditional PVC blister films but can be recycled in existing mechanical recycling streams. The films have a core layer of HDPE and LDPE sandwiched between outer layers containing polyethylene, cyclic olefin copolymers, functionalized polymers, mineral fillers, and dispersing agents.

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Thermoforming packaging machine with a compact layout that requires less space compared to conventional machines. The key feature is arranging the film source, forming station, and sealing station in a linear product line, with the film source having an upper film storage device above the lower film supply roll. This allows the lower film tension to be regulated without needing a separate storage device between the source and forming station. This reduces the horizontal length of the machine compared to having separate storage. The vertical arrangement of the film source components also makes access easier.

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Blister packaging machine with a thermoforming device that reduces deformation and warpage of molded blister sheets compared to conventional methods. The machine has molds with localized heating and compressed air blowing. The heating mold only heats the pocket-forming area, then retracts when the film is stretched into the pocket. The forming mold has air blowing pores at the bottom and around the hole. This quick heating prevents excessive thinning of the top sheet. It also allows stacking without warping since the pockets are not thicker than the rest of the sheet.

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Automatic dishwashing pouch with multiple cavities for separate detergent portions, formed by thermoforming a sheet with a non-uniform heating profile to increase cavity depth and wall thickness. The heating profile provides higher temperatures and longer heating times to regions of the sheet that will undergo the most deformation during thermoforming. This allows the cavities to have deeper volumes and thicker walls compared to uniform heating.

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A manufacturing process for thermoformed containers with secure closures using a moving part that extends into the mold to create features like protrusions and indentations. The process involves heating a thermoplastic sheet, transferring it to a mold, securing a movable part with a working face inside the mold, extending the working face to form protrusions in the sheet, cooling the sheet, retracting the working face, and removing the container. The movable part allows creating undercuts without needing a custom mold for each variation. The protrusions engage indentations on the lid to secure closure.

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Multilayer film with improved moldability for packaging applications. The film has specific properties that enable good moldability during thermoforming processes like thermoforming to form concave storage containers. The key features are: a storage modulus between 1.5-3.5 GPa, and a temperature range of 10-80°C where the storage modulus is measured. This allows the film to have a wide range of temperatures where it has suitable properties for molding. The film can also contain layers like a barrier layer with low crystallinity resins like amorphous or plant-derived crystalline resins, and an outer layer or base layer with amorphous resins.

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Laminated film for tray laminating and a package with improved barrier properties, heat sealability, microwave oven resistance, and deep drawing capability. The laminated film has three layers: an outer layer with saponified ethylene-vinyl acetate copolymer, an intermediate layer with polyamide, and an inner layer with density greater than 0.950 kg/m3 containing polyethylene and a crystal nucleating agent. The total thickness is 30-100 µm. This film is laminated to a foamed resin tray sheet, then molded to create the final package. The laminated film provides better gas barrier, steam barrier, and seal strength compared to traditional films. The foam tray provides cushioning and prevents breakage during microwaving. The high density inner layer of the film allows deep drawing of the molded tray.

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Composite sheet for manufacturing lightweight packaging containers with improved processability and properties. The composite sheet has a low-melting-point polyester foam core sandwiched between unstretched polyester films. The films prevent breaking during container molding. The composite sheet elongates 200-500% at 160°C after heating. Molding involves preheating the foam to 40-200°C and cooling the container to 10-20°C. This allows forming lightweight containers with good rigidity and thermal resistance.

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Shrinking thermoplastic packaging material onto articles in a way that improves quality and reduces defects. The method involves determining the temperature-dependent shrinkage behavior of the packaging material using a specialized device. This data is used to optimize the shrinking process in a tunnel by matching the temperature levels to the known material characteristics. By tailoring the tunnel conditions to the specific packaging material, it reduces issues like folding, tearing, or poor edge sealing that can occur with suboptimal shrinking.

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Polypropylene-based resin composition for thermoforming that reduces periodic wall thickness fluctuations and improves uniformity during film and sheet molding compared to standard polypropylene. The composition contains 85-90% of a propylene polymer with MFR 2.0-10.0 g/10min and 10-15% low-density polyethylene with MFR 0.5-8.0 g/10min. This mixture provides better draw resonance resistance and melt tension to prevent drawbacks like meandering and ear shake during extrusion. The composition also has lower diameter variation and melt tension compared to just propylene. The composition can be used in packaging films and sheets that have improved uniformity and stability when thermoformed.

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Transparent food packaging that self-vents when cooked. The packaging consists of a thermoformable bottom film made from a specific biaxially oriented polyester film, and a sealable top film made from a coextruded polyester film. The bottom film is used to hold food like meat, fish or poultry, and the top film seals on it. When cooked, the bottom film expands and pressure builds inside, venting through the top film without splitting the seal. The bottom film properties like thickness, modulus, and haze are optimized for thermoforming and puncture resistance. The top film has a specific polyester composition and particle content for sealability and venting. The packaging provides improved functional properties like self-venting when cooked, clear visibility, and puncture resistance for food processing applications.

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Multilayer film for deep drawn packages that can be displayed upright and vacuum sealed like skin packs. The film has an outer layer containing polyester and a sealant layer with a resin melting point below 100°C. The outer layer thickness is 25-170 μm. This film allows close contact with contents without wrinkles and upright display when vacuum sealed in deep drawn packages. It can be manufactured using existing deep drawing equipment to make inexpensive packages with skin pack characteristics.

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Compact, high-speed packaging apparatus and process for forming plastic supports and packaging products using a continuous film. The apparatus has a feed roll with a cutting station that cuts strips from the film. These strips are thermoformed into supports. The supports are then packaged using a separate feed roll and station. This allows smaller feed rolls, longer change intervals, and higher yields compared to using thick film for supports. The apparatus also features sensors, conveyors, and a control unit.

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Forming extrusion-laminated film composites into three-dimensional shapes without damaging the integrity of the film layers. The composites have at least two film layers connected by an extruded polymer laminating medium layer. The extrusion process eliminates defects like air pockets and dust that can cause failure during forming. The extruded laminating layer allows the composite to be plastically shaped into permanent 3D forms without tearing or damage. The composite can be molded around forming axes like bending or deep drawing without breaking. This enables making packaged products like containers from the extrusion-laminated composite.

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Multi-cup packaging arrangement for snappable food products like yogurt cups that allows easy separation of individual portions. The packaging uses a thermoformed polypropylene sheet with cavities separated by spacers containing grooves on the bottom. Bending the sheet towards the top along the grooves snaps the packaging into separate segments with one or more cups in each. The groove depth is 25-80% of the sheet thickness. This allows unidirectional snapping while preventing breakage when bending in the opposite direction. The polypropylene sheet may contain up to 8% nucleating agents and 5% inorganic filler.

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A method for reliably producing packaging with a narrow flange width in deep-draw thermoforming machines. The method involves centering holes in the bottom film aligned with the packaging troughs. Pins engage the holes to center the film before sealing. This allows precise alignment without stretching the film. The film is also cut transverse to the direction before centering to prevent distortion. This enables narrow flange widths without compromising sealing and cutting tolerances.

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