Packaging apparatus and process

Abstract

A process of packaging includes providing a bottom support, providing a top film, and forming a closed chamber where a portion of the bottom support, a product and a portion of the top film are housed. The further includes sealing the portion of the bottom support to the portion of the top film along a sealing band circumscribing the product to sealingly house the product in a volume and forming one or more hollow structures by sealing a part of the portion of the top film to a part of the portion of the bottom support at one or more selected seal zones. Before forming the hollow structure, the part of the portion of the top film and of the portion of the bottom support destined to form the hollow structure are maintained separate at a distance the one from the other.

What is claimed is: 
     
         1 . A method of packaging comprising the following steps:
 providing a bottom support;   providing a top film; and   forming a closed chamber that houses:
 a portion of the bottom support, 
 a product above the portion of the bottom support, and 
 a portion of the top film above the product and the portion of the bottom support; 
   wherein, when the portion of the bottom support, the product, and the portion of the top film are located inside the closed chamber, the method further includes:
 sealing the portion of the bottom support to the portion of the top film along a sealing band circumscribing the product to sealingly house the product in a volume between the portion of the top film and the portion of the bottom support, and 
 forming a hollow structure by sealing a part of the portion of the top film to a part of the portion of the bottom support at a selected seal zone; 
   wherein, before forming the hollow structure, the part of the portion of the top film and the part of the portion of the bottom support that will form the hollow structure are maintained separate at a distance from each other.   
     
     
         2 . The method of  claim 1 , further comprising:
 inflating a gas into the closed chamber between the portion of the top film and the portion of the bottom support;   wherein the inflating occurs while the portion of the bottom support, the product, and the portion of the top film located are inside the closed chamber.   
     
     
         3 . The method of  claim 2 , wherein the inflating occurs while the part of the portion of the top film and the part of the portion of the bottom support that will form the hollow structure are maintained separate at a distance from each other. 
     
     
         4 . The method of  claim 1 , wherein, before forming the hollow structure and while the part of the portion of the top film and the part of the portion of the bottom support that will form the hollow structure are maintained separate at a distance from each other, portions of the top film and bottom support that do not include the part of the portion of the top film and the part of the portion of the bottom support that will form the hollow structure are in contact with each other. 
     
     
         5 . The method of  claim 1 , wherein forming the closed chamber comprises relatively moving an upper tool and a lower tool between:
 an open condition, where the upper tool and the lower tool define an open chamber and allow access of the portion of the bottom support, the product, and the portion of the top film into the open chamber; and   a closed condition, where the upper tool and the lower tool are proximate to each other and delimit the closed chamber;   wherein the upper tool comprises:
 an active surface which directly faces the portion of the top film during the closed condition, and 
 an outer closing surface surrounding the active surface of the upper tool; and 
   wherein the lower tool comprises:
 an active surface which directly faces the portion of the bottom support during the closed condition, and 
 an outer closing surface surrounding the active surface of the lower tool. 
   
     
     
         6 . The method of  claim 5 , wherein:
 during the open condition, the outer closing surfaces of the upper and lower tools are spaced from each other and the active surfaces of the upper and lower tools are spaced from each other; and   during the closed condition, the active surfaces of the upper and lower tools are spaced from each other and the outer closing surfaces are proximate to each other.   
     
     
         7 . The method of  claim 5 , wherein, during the closed condition, the portion of the top film and the portion of the bottom support are maintained separate at a distance from each other by adhering the portion of the top film to the active surface of the upper tool and by adhering the portion of the bottom support to the active surface of the lower tool. 
     
     
         8 . The method of  claim 5 , wherein the active surface of the upper tool lower includes first holes and wherein adhering the portion of the top film to the active surface of the upper tool comprises withdrawing gas through the first holes. 
     
     
         9 . The method of  claim 5 , wherein the active surface of the lower tool comprises second holes and wherein adhering the portion of the bottom support to the active surface of the lower tool comprises withdrawing gas through the second holes. 
     
     
         10 . The method of  claim 1 , further comprising the following further steps:
 creating an access to the volume,   withdrawing gas from the volume to have the portion of the top film adhere to the product.   
     
     
         11 . The method of  claim 10 , wherein creating the access to the volume and withdrawing the gas from the volume take place after sealing the portion of the bottom support to the portion of the top film along the sealing band. 
     
     
         12 . An apparatus comprising:
 a packaging assembly having an upper tool and a lower tool;   a top film supply assembly configured to supply a top film to the packaging assembly;   a bottom support supply assembly configured to supply a bottom support to the packaging assembly; and   a control unit communicatively coupled to the packaging assembly and configured to control operation of the packaging assembly;   wherein the upper tool and the lower tool are movable relative to one another between:
 at least one open condition, where the upper tool and the lower tool define an open chamber, wherein, during the open condition, the upper and lower tool are configured to allow access into the open chamber of a portion of the bottom support, of a product positioned on the portion of the bottom support, and of a portion of the top film, and 
 at least one closed condition, where the upper tool and the lower tool are proximate to each other and delimit a closed chamber; 
   further wherein the control unit is configured to command the packaging assembly to:
 position in the open condition and allow access into the open chamber for the portion of the bottom support, the product on the portion of the bottom support, and the portion of the top film, 
 position in the closed condition to house the portion of the bottom support, the product, and the portion of the top film inside the closed chamber, 
 seal the portion of the bottom support to the portion of the top film along a sealing band circumscribing the product to sealingly house the product in a volume between the portion of the top film and the portion of the bottom support, 
 form a hollow structure by sealing a part of the portion of the top film to a part of the portion of the bottom support at a selected seal zone, 
 before forming the hollow structure, maintain the part of the portion of the top film and the part of the portion of the bottom support separate at a distance from each other. 
   
     
     
         13 . The apparatus of  claim 12 , wherein the upper tool comprises an active surface, wherein the active surface of the upper tool is configured to face the portion of the top film receivable inside the closed chamber during the open condition, and wherein the upper tool further comprises an outer closing surface surrounding the active surface of the same upper tool. 
     
     
         14 . The apparatus of  claim 12 , wherein the lower tool comprises an active surface, wherein the active surface of the lower tool is configured to face the portion of the bottom support receivable inside the closed chamber during the closed condition, wherein the lower tool further comprises an outer closing surface surrounding the active surface of the same lower tool. 
     
     
         15 . The apparatus of  claim 12 , wherein:
 during the open condition:
 the outer closing surfaces of the upper tool and lower tool are spaced from each other, and 
 the active surfaces respectively of the upper tool and lower tool are spaced from each other; 
   during the closed condition, the active surfaces of the upper and lower tools are still spaced from each other while the outer closing surfaces are proximate to each other; and   during the closed condition, the active surfaces of the upper tool and the lower tool are configured to maintain the portions of the bottom support and of the top film separated.   
     
     
         16 . The apparatus of  claim 13 , wherein the active surface of the upper tool comprises first holes in fluid communication with a suction source, and wherein the suction source is configured to withdraw gas from the first holes to allow the portion of the top film to adhere the active surface of the upper tool. 
     
     
         17 . The apparatus of any one of claims from  16 , wherein:
 the active surface of the lower tool comprises second holes in fluid communication with a suction source; and   the suction source is configured to withdraw gas from the second holes to allow the portion of the bottom support to adhere the active surface of the lower tool.   
     
     
         18 . The apparatus of  claim 17 , wherein the suction source comprises either:
 a single suction source for serving both the upper tool and the lower tool; or   a first suction source for the upper tool and a second suction source for the lower tool that is distinct from the first suction source.   
     
     
         19 . The apparatus of  claim 17 , wherein the control unit is configured to:
 command the upper and lower tools to be in the closed condition; and   during the closed condition, command the suction source to withdraw gas from the first and second holes in order to separate the portion of the top film and the portion of the bottom support by adhering the portion of the top film to the active surface of the upper tool and by adhering the portion of the bottom support to the active surface of the lower tool.   
     
     
         20 . The apparatus of any one of claims from  13 , wherein the upper tool and the lower tool are relatively movable to the other between:
 the closed condition; and   a sealing condition where part of the active surface of the upper tool is proximate to part of the active surface of the lower tool to contact and seal the portions of the bottom support and of the top film received in the closed chamber to each other.