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Title:
METHOD FOR MANUFACTURING FLAT FOLDING BOXES AND RELATED BOX
Document Type and Number:
WIPO Patent Application WO/2018/069745
Kind Code:
A1
Abstract:
A method for manufacturing flat folding boxes (80), comprising the steps of: - providing slit-like windows (11, 12) on a supporting layer (1) preferably made of cardboard; - fixing at least one cover sheet (21, 22) on one face of the supporting layer (1); - die-cutting the supporting layer (1) coupled to the cover sheet (21); - first folding of the die-cut element along first slit-like windows (11); - second folding of the die-cut element along second slit-like windows (12), so as to form a collapsed container body (81) of the box (80); - coupling the collapsed container body to a lid (82) of the box.

Inventors:
POZZOLI, Aldo (Via Cascina Perina 43, Inzago, 20065, IT)
Application Number:
IB2016/056065
Publication Date:
April 19, 2018
Filing Date:
October 11, 2016
Export Citation:
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Assignee:
POZZOLI S.P.A. (Via G. Di Vittorio 11, Inzago, 20065, IT)
International Classes:
B31B50/26; B31B70/92; B65D5/42; B65D5/56; B31B105/00; B31B110/35; B31B120/30; B31B120/40; B31B120/50; B65D5/24; B65D5/68
Domestic Patent References:
WO2015124430A12015-08-27
Foreign References:
US5934474A1999-08-10
JPS6332121U1988-03-02
Attorney, Agent or Firm:
MODIANO, Micaela (Modiano & Partners, Via Meravigli 16, Milano, 20123, IT)
Download PDF:
Claims:
CLAIMS

1. A method for manufacturing flat folding boxes (80), comprising the steps of:

- providing slit-like windows (11, 12) on a supporting layer (1, la), which comprises preferably a layer of card or cardboard;

- fixing at least one cover sheet (21, 22) on one face of said supporting layer (1, la), so that each one of said slit-like windows (11, 12) is closed by said at least one cover sheet (21, 22);

- obtaining a die-cut element (30) by die-cutting said supporting layer

(1, la) coupled to said at least one cover sheet (21);

- first folding of said die-cut element along first slit-like windows (11) of said slit-like windows;

- second folding of said die-cut element along second slit-like windows (12) of said slit-like windows, so as to form a collapsed container body (81) of said box (80);

- coupling of said collapsed container body to a lid (82) of said box.

2. The method according to claim 1, wherein said first slit-like windows (11) are substantially mutually parallel and adjacent to first mutually opposite flaps (31a, 31b) of said die-cut element (30), so that said first flaps (31a, 31b) are folded along said first slit-like windows (11) in said first folding step.

3. The method according to claim 2, wherein said second slit-like windows (12) are directed substantially transversely with respect to said first slit-like windows (11) and are adjacent to second mutually opposite flaps (32a, 32b) of said die-cut element (30), so that said second flaps (32a, 32b) are folded along said second slit-like windows (12) in said second folding step.

4. The method according to claim 3, wherein a layer of glue is interposed between said first flaps (31a, 31b) and said second flaps (32a, 32b) at the end regions (33 ) of said first and/or second flaps.

5. The method according to one or more of the preceding claims, wherein said slit-like windows further comprise third slit-like windows ( 13) in said first and/or second flaps, said third slit-like windows ( 13 ) being substantially oblique with respect to said first and second slit-like windows ( 1 1 , 12) and being provided between two end portions of said first and second slit-like windows ( 1 1 , 12).

6. The method according to claims 4 and 5, wherein said end regions (33) in which said layer of glue is applied are delimited by said third slit- like windows ( 13), said end portions of said first slit-like windows ( 1 1 ) and a portion of the perimetric edge of said die-cut element (30).

7. The method according to one or more of the preceding claims, wherein said supporting layer ( 1 , l a) comprises fourth and/or fifth slit-like windows ( 14, 15) that are substantially parallel to said first and/or second slit-like windows ( 1 1 , 12), respectively, and wherein said first and/or second flaps (3 1 a, 3 1 b, 32a, 32b) comprise respective first and/or second lobes (34a, 34b, 35a, 35b) that can be folded respectively along said fourth and/or fifth slit-like windows ( 14, 1 5) after said die-cutting.

8. The method according to one or more of the preceding claims, further comprising the step of applying a pressure-activated adhesive (50) adapted to keep said first and second flaps (3 1 , 32) in an upright position when the container body (81 ) is in the erected configuration.

9. The method according to one or more of the preceding claims, wherein said step of obtaining slit-like windows comprises cutting said first slit-like windows ( 1 1 ) in said supporting layer ( 1 ), anchoring a backing sheet ( l a) on at least one face of said supporting layer ( 1 ) and cutting said second slit-like windows ( 12) in said supporting layer (1 ) coupled to said backing sheet ( l a).

10. A box (80), characterized in that it comprises a container body (81 ) according to one or more of the preceding claims associated with a lid (82) which, when the container body (81 ) is in the collapsed configuration, accommodates said collapsed container body and, when the container body (81 ) is in the erected configuration, is suitable to close a mouth of said container body (81 ).

Description:
METHOD FOR MANUFACTURING FLAT FOLDING BOXES AND RELATED BOX

The present invention relates to a method for manufacturing flat folding boxes in association with a separate lid. The invention also relates to the box that can be manufactured with the method.

Boxes are currently known which are formed by a flat folding container body and by a separate rigid lid that is adapted to accommodate between its perimetric walls the container body in the flat folded configuration. In this manner, the boxes can be stored with a reduced volume and can be assembled directly by the end user by virtue of the provision of self-adhesive strips adapted to keep the perimetric walls of the container body in an upright position.

However, these boxes have the drawback of having a container body with multiple rigid layers that must be mutually glued, and therefore are time-consuming to manufacture with less than optimum results at the folding lines.

Moreover, once the box is assembled by the end user, it has surface discontinuities along some of the internal side walls, in particular on the walls where the layers of internal and external rigid cardboard layers are mutually glued.

The aim of the present invention is to provide a method for manufacturing flat folding boxes in association with a separate lid capable of improving the background art in one or more of the aspects described above.

Within this aim, an object of the invention is to provide a method for manufacturing boxes which, despite using traditional methods for coupling, die-cutting and folding-gluing, allow to obtain a flat folding rigid cardboard box that has folding lines without uneven regions and can be assembled easily by an end user starting from the collapsed configuration.

Another object is to provide a method for manufacturing flat folding boxes in association with a separate lid with which it is possible to obtain a box the container body of which, in the containment configuration, has internal side walls that are substantially free from discontinuities.

Another object of the invention is to provide a method for manufacturing collapsible boxes that is highly reliable, relatively easy to provide and at competitive costs.

This aim, as well as these and other objects that will become better apparent hereinafter, are achieved by a method for manufacturing according to claim 1 , optionally combined with one or more of the dependent claims.

The aim and objects of the invention are also achieved by a box according to claim 10.

Further characteristics and advantages of the invention will become better apparent from the description of a preferred but not exclusive embodiment of the method and of the box according to the invention, illustrated by way of nonlimiting example in the accompanying drawings, wherein:

Figure 1 is an exploded view of the supporting layer made of rigid cardboard, slit with slit-like windows and coupled to a backing sheet;

Figure 2 is an exploded view of the supporting layer made of rigid cardboard, slit with the slit-like windows openings and coupled to cover sheets on both faces;

Figure 3 is a view of a die-cut element according to the invention obtained starting from the supporting layer coupled to the cover sheets of the preceding figure;

Figure 4 is a view of the partially collapsed container body obtained by folding two first flaps of the die-cut element of the preceding figure and by adding adhesive strips;

Figure 5 is a view of the insertion, in the respective lid, of the completely collapsed container body, obtained by folding further two more flaps of the container body of the preceding figure; Figure 6 is a view of the manner in which the container body of Figures 4 or 5 is erected;

Figure 7 is a view of the fixing with pressure-activated adhesive of two lobes of the container body;

Figure 8 is a view of the coupling of the container body in the erected configuration with the lid of Figure 5.

With reference to the cited figures, a box 80 according to the invention comprises a container body 81 and a respective lid 82 adapted to close completely the mouth of the container body 81 when it is in the erected configuration.

Both the container body 81 and the lid 82 preferably have a prismlike shape, i.e., are provided respectively with a bottom 83, 84 and with perimetric walls 85 and 86.

The container body 81 is obtained starting from a blank which comprises a rigid supporting layer 1 provided with a plurality of slit-like windows, in particular first windows 1 1 and second windows 12 directed transversely to the first windows 1 1 , so as to define respective folding directions in order to erect perimetric walls 85 of the container body 81 which essentially correspond to bottom edges of the container body.

Preferably, the first windows 1 1 are substantially mutually parallel and the second windows 12 are directed substantially at right angles to the first windows 1 1 , so as to cross the first windows 1 1.

The slit-like windows of the supporting layer 1 can also comprise third windows 13 which are substantially oblique with respect to the first and second windows 1 1 and 12 and are provided between two end portions of the first and second windows 1 1 and 12 starting substantially from the crossing point.

The supporting layer 1 is preferably a layer of cardboard, for example rigid cardboard of the FBB, WLC, SBB or SUB type, and can have a thickness comprised between 0.4 mm and 1 .5 mm, more preferably comprised between 0.74 mm and 1 . 1 1 mm, and a grammage comprised between 400 g/m 2 and 750 g/m 2 . The stiffness of the cardboard layer can be comprised between 30 mN.m and 300 mN.m, for example comprised between 100 mN.m and 250 mN.m along at least one direction (MD or CD).

As an alternative, the cardboard of the supporting layer 1 can be corrugated cardboard.

The slit-like windows used in the invention are through openings, obtained by means of a die-cutting unit, which have a transverse dimension that is much smaller than their longitudinal dimension, comprised for example between 1 .5 mm and 3 mm, preferably approximately 2 mm, based on the thickness of the supporting layer 1 . By way of indication, the transverse dimension of the slit-like windows can be chosen equal to twice the thickness of the supporting layer 1 .

The slit-like windows 1 1 , 12, 13 are surrounded substantially along their entire perimeter by the material of the supporting layer 1 , in particular around their short side, prior to the die-cutting operation along the perimeter of the supporting layer. In this manner, the supporting layer 1 supports itself when it has to be coupled to internal or external cover sheets and can be maneuvered easily despite having through slits, for example maneuvered by a feeder of a coupling machine.

The slit-like windows 1 1 , 12, 13 are arranged at all the edges along which the subsequent die-cut element 30 must be folded in order to form the container body 81 , so that there is a slit on each one of these edges.

Preferably, in the method according to the invention the provision of the slit-like windows comprises: a first die-cutting pass in order to provide the first windows 1 1 and optionally other slit-like windows 13, 14 which do not intersect the first windows 1 1 on the supporting layer 1 ; the coupling of a backing sheet l a, for example made of paper, with at least one face of the supporting layer 1 thus die-cut; and a second die-cutting pass in order to provide the second windows 12 and optionally other slit-like windows 15 in the supporting layer 1 coupled to the backing sheet l a.

In this manner, after the second die-cutting pass the multilayer element 1 + 1 a supports itself by virtue of the backing sheet that covers all the slit-like windows 1 1 , 13, 14 obtained with the first die-cutting pass, despite the fact that they are intersected by the slit-like windows 12, 1 5 obtained with the second die-cutting pass.

After the obtainment of the slit-like windows 1 1 , 12, 13, 14, 15, an internal cover sheet 21 and/or an external cover sheet 22 is fixed by coupling to a corresponding face of the supporting layer 1 , which is slit with the slit-like windows and is coupled to the backing sheet l a.

The cover sheets 21 and 22 are constituted substantially by material in sheet form, which can optionally be printed with decorative patterns prior to its application. The cover sheets 21 and 22 are useful to increase the overall rigidity of the slit-like supporting layer 1 and therefore of the container body 81 .

The operation for coupling to the cover sheets 21 and 22 can be obtained by means of a traditional coupling machine, which is adapted to receive, by virtue of respective feeders, the supporting layer 1 slit with the slit-like windows, optionally coupled to the backing sheet l a, and to interpose a layer of adhesive between the cover sheet and one face of the supporting layer 1.

The cover sheets 21 and 22 are both preferably made of paper, for example with a gram weight comprised between 60 g/m 2 and 300 g/m 2 , particularly comprised between 90 g/m 2 and 150 g/m 2 , and more preferably equal to 90 g/m 2 , and with a thickness comprised for example between 60 microns and 200 microns, more preferably between 70 microns and 150 microns.

After the die-cutting and coupling operations described above, a die- cut element 30 is obtained by means of an additional die-cutting pass on the external perimeter of the supporting layer 1 coupled to the cover sheets 21 and/or 22 and optionally to the backing sheet l a. In this die-cut element, substantially all the slit-like windows, and in particular the windows 1 1 , 12, 13, 14 and 15, are crossed by the perimetric edge of the die-cut element 30, which thus can be folded easily along the longitudinal axes of said windows.

In the preferred embodiments, in which the container body 81 has the shape of a parallelepiped, i.e., has a square or rectangular base, the slit-like windows form on the die-cut element 30 a grid formed by a plurality of quadrants.

At this point a first operation of folding the die-cut element 30 along the first slit-like windows 1 1 is performed so as to fold first flaps 3 l a-3 l b of the die-cut element onto the bottom panel 83 of the container body 81 of the box 80. The first flaps 3 l a-3 l b are the mutually opposite portions of the die- cut element 30 that are delimited by the outer edge thereof and by the first slit-like windows 1 1 and have end regions 33 on which a layer of glue is applied in order to anchor them to corresponding portions of second flaps 32a-32b of the same die-cut element 30. The end regions 33 are preferably delimited by the third slit-like windows 13, by the end portions of the first slit-like windows 1 1 and by the edge of the die-cut element 30.

The second flaps 32a-32b are the mutually opposite portions of the die-cut element 30 that are delimited by the outer edge thereof, by the second slit-like windows 12 and by the first slit-like windows 1 1.

In the particular embodiment shown, the die-cut element 30 is advantageously multilobed. In particular, the first flaps 3 l a-3 l b can have first lobes 34a-34b, which can be folded respectively onto the first flaps 3 l a-3 l b along fourth slit-like windows 14, which are substantially parallel to the first slit-like windows 1 1 and are obtained preferably in the same first die-cutting pass with which the first windows 1 1 are obtained. Furthermore, it is possible to provide second lobes 35a-35b which can be folded respectively onto the second flaps 32a-32b along fifth slit-like windows 1 5, which are substantially parallel to the second slit-like windows 12 and are obtained preferably in the same second die-cutting pass with which the second windows 12 are obtained.

In the preferred embodiment shown, a layer of glue is interposed also between the first lobes 34a-34b and the respective first flaps 3 1 a-3 1 b in order to mutually anchor them permanently, so that the folding and gluing machine can fold the first lobes onto the first flaps in order to obtain a double-thickness wall 85 of the container body 81 of the box. This layer of glue can be applied in the same step in which the glue is applied in the end regions 33, which is instead intended to render mutually integral the adjacent perimetric walls 85 of the container body 81 and allow the simultaneous lifting of all the perimetric walls 85 from the collapsed position to the upright position when the first flaps 3 1 a and 3 1 b are raised starting from the configuration of Figure 4.

After the mutual gluing of the end regions of the first flaps 3 1 a-3 l b and of the second flaps 32a-32b, a collapsed configuration of the container body 81 is defined with a second folding of the die-cut element 30 along the second slit-like windows 12, and said container body 81 can thus be accommodated within the respective lid 82.

Advantageously, the distance between the first slit-like windows 1 1 and the distance between the second slit-like windows 12, as well as the shape that they delimit, substantially coincide with the dimensions and the shape of the bottom 84 of the lid 82.

The second lobes 35a-35b can rotate freely with respect to the fifth

*

slit-like windows 15 when the container body 81 is in the collapsed or in any case flattened configuration, such as the one of Figures 4 and 5. However, they are provided with strips 50 of pressure-activated adhesive material adapted to keep the first and second flaps 3 l a-3 l b-32a-32b in an upright position when the container body 81 is in the erected configuration. These strips 50 are applied to the second lobes 35a-35b and are covered by a liner as long as the container body 81 is in the collapsed configuration.

The lobes 34a-34b and 35a-35b are particularly useful to hide the perimetric edges of the die-cut element 30, which due to the last die-cutting operation have a sharp edge that exposes the intermediate cardboard layer. The folding of the lobes 34a-34b and 35a-35b onto the respective flaps 3 1 a- 3 l b and 32a-32b in fact allows to expose externally the cover sheet material that covers the fourth-fifth slit-like windows 14 and 1 5, maintaining the surface continuity of the container body 81 also along the upper edge of the perimetric walls 85 and thus improving the overall aesthetics. The second lobes 35a-35b, which have a transverse dimension that is substantially equal to the height of the walls 85, also hide the internal surface discontinuities caused by the end regions 33 in the erected container body.

In practice it has been found that the box and the related manufacturing process according to the invention achieve fully the intended aim and objects.

Although the invention has been conceived in particular for boxes with a separate rigid lid provided with perimetric walls, it can in any case be used more generally in combination with separate lids of any type, even of the collapsible type, and adapted to be associated with the flattened container body.

The invention thus conceived is susceptible of numerous modifications and variations, all of which are within the scope of the appended claims; all the details may furthermore be replaced with other technically equivalent elements.

In practice, the materials used, as well as the dimensions, may be any according to the requirements and the state of the art.

Where technical features mentioned in any claim are followed by reference signs, those reference signs have been included for the sole purpose of increasing the intelligibility of the claims and accordingly such reference signs do not have any limiting effect on the interpretation of each element identified by way of example by such reference signs.