Description

According to a first aspect, the present disclosure relates to an apparatus for manufacturing a cardboard tray from a sheet of cardboard.

According to a second aspect, the present disclosure relates to a method of manufacturing a cardboard tray from a sheet of cardboard using an apparatus according to the first aspect of the present disclosure.

Cardboard trays are widely used for different applications and are available in numerous forms and dimensions.

The present disclosure provides an apparatus and a method for manufacturing a cardboard tray comprising a receiving space and an uninterrupted flange arranged for connecting a foil said uninterrupted flange for closing said receiving space of said cardboard tray from a sheet of cardboard. The sheet of cardboard comprises sheet portions defining a bottom wall, side walls connected, via respective first folding lines, to said bottom wall and first and second flange parts connected, via respective second folding lines, to said side walls at a side of said side walls facing away from said bottom wall.

The apparatus according to the first aspect of the present disclosure comprises: a first folding unit arranged for folding said sheet of cardboard towards, preferably in, a first direction for the purpose of obtaining a receptacle defining said receiving space of said cardboard tray by folding each of said side walls about said respective first folding lines relative to said bottom wall towards, preferably in, said first direction; a second folding unit arranged for folding said sheet of cardboard in a second direction for the purpose of folding each of said first flange parts of said flange parts in said second direction; a third folding unit arranged for folding said sheet of cardboard in a third direction, for the purpose of folding each of said second flange parts of said flange parts in said third direction such that said second flange parts overlap said first flange parts in an overlapping region thereof; a dispensing unit arranged for providing an adhesive to said sheet of cardboard for the purpose of mutually connecting said first flange parts and said second flange parts in said overlapping region, via said adhesive, for realizing said cardboard tray.

The term cardboard may refer to a variety of heavy paper-like materials, including but not limited to, card stock, corrugated fibreboard or paperboard. Cardboard is a recyclable and/or reusable material. Producing the cardboard tray from a single sheet of cardboard prevents unnecessary waste of materials of which the cardboard is produced.

The sheet of cardboard consists of one piece. The sheet of cardboard is either supplied individually to the apparatus or a plurality of cardboard sheets, for examples a batch of stacked cardboard sheets, is supplied to the apparatus. Because the sheet of cardboard comprises folding lines, the sheet of cardboard can easily by folded by the apparatus into its final shape of the cardboard tray. The cardboard tray manufactured by the apparatus has a relative high strength while requiring only a relative small amount of paper. It was further the insight of the inventor to add and design the flange parts for improved strength of the cardboard tray. Neighbouring flange parts are adhered to each other by the apparatus for realizing an uninterrupted flange along a circumference of the cardboard tray, which is both advantageous for improved strength and provides a sufficient area for connecting a foil for closing the cardboard tray at an upper side. With closing the cardboard is meant that the bottom wall, the side walls and the foil bound the receiving space of the cardboard tray.

A further advantage of the cardboard tray is that there is no need for tacks and string in order to retain the cardboard tray in its folded position, while maintaining a relative high strength, which is furthermore advantageous for the complexity and cost of the apparatus according to the present disclosure.

A yet further advantage of the cardboard tray according to the present disclosure is that by providing an uninterrupted flange that, apart from the overlap region, is formed of a single layer of said sheet of cardboard allows to realise a cardboard tray using a relative little amount of material. This is beneficial for realising a relative cost effective cardboard tray manufactured by the apparatus. In addition, using only a relative little amount of material is beneficial for realising a cardboard tray having a relative low weight. A relative low weight is advantageous for the complexity and cost of the apparatus according to the present disclosure.

By providing a first folding unit arranged for folding said sheet of cardboard towards, preferably in, the first direction, the side walls may be folded about the respective first folding lines, by the first folding unit, relative to said bottom wall such that the side walls, after folding by the first folding unit, are provided in the first direction, or alternatively at least one of the side walls, preferably all of the side walls, are folded toward said first direction, by the first folding unit, for the purpose of obtaining a cardboard tray that may be released relatively easily from the receiving organ. In an embodiment wherein the side walls are folded towards said first direction, without actually achieving the first direction, the opposite side walls are diverging away from each other.

In an example, said apparatus comprises a receiving organ arranged for receiving said receptacle. This is beneficial for realising and maintaining a predetermined shape of the receptacle.

Preferably, the shape and/or dimensions of the inner part of the receiving organ are in compliance with the dimensions of the sheet of cardboard, the receptacle and/or the cardboard tray, wherein the dimension of the bottom portion of the receiving organ is in compliance with the bottom wall of the cardboard tray and/or the dimensions of the side portions of the receiving organ in compliance with the side walls of the cardboard tray.

The shape and/or dimensions of the inner part of the receiving organ are preferably substantially equal to the shape and/or dimensions of the outer part of the portion of the receptacle and/or the cardboard tray defined by the bottom wall and the side walls of the receptacle and/or the cardboard tray. The height of the side portions of the receiving organ is preferably substantially equal to the height of the side walls of the cardboard tray, such that the second folding lines are positioned substantially at the height. This is beneficial for realising a relative reliable folding of the first flange parts. The receiving organ may function as a support for supporting the receptacle and the first flange parts during folding, by the second folding unit.

In an example, neighbouring side walls of said side walls are provided with a locking part that is connected, via a third folding line, to one of said neighbouring side walls and wherein another of said neighbouring side walls is provided with a locking opening, wherein said receiving organ is arranged such that during said folding, by said first folding unit, said locking part is forced through said locking opening by said receiving organ.

The locking part is produced of the same sheet of cardboard, resulting in efficient use of the sheet of cardboard, minimizing waste of cardboard material and resulting in additional strength of the resulting cardboard tray.

In an example, said receptacle is obtained by pressing, by said first folding unit, said sheet of cardboard at least partly in said receiving organ.

Preferably, said first folding unit is arranged for pressing said sheet of cardboard at least partly in said receiving organ for obtaining said receptacle.

Preferably, before folding is performed by the first folding unit, the cardboard sheet is supplied on top of the receiving organ, wherein the cardboard sheet is substantially parallel, more preferably parallel, to the bottom portion of the receiving organ. More preferably, the bottom wall of the receptacle and/or the cardboard tray is positioned substantially above the bottom portion of the receiving organ.

In an example, said apparatus comprises a plurality of said receiving organs and wherein a respective receiving organ of said plurality of receiving organs is arranged to be moved from said first folding unit to said third folding unit, via said second folding unit, wherein said second folding unit is further arranged for folding each of said first flange parts while said receptacle is received by said respective receiving organ; said third folding unit is further arranged for folding each of said second flange parts while said receptacle is received by said respective receiving organ and wherein said third folding unit is yet further arranged for connecting said first flange parts and said second flange parts in said overlapping region, via said adhesive, while said receptacle is received by said respective receiving organ.

Preferably, all receiving organs of the plurality of receiving organs are identical. More preferably, the inner shape and/or dimensions of all receiving organs of the plurality of receiving organs are identical.

Preferably, the apparatus comprises a transportation unit, like a conveyer belt or the like.

In an embodiment, the transportation unit is arranged for moving the respective receiving organ of the plurality of receiving organs. More preferably, the transportation unit is arranged for moving the respective receiving organ of the plurality of receiving organs from said first folding unit to said third folding unit, via said second folding unit.

The respective receiving organ of the plurality of receiving organs can either be fixed to the transportation unit or detachable connected to the transportation unit.

In another embodiment, the transportation unit is arranged for moving the cardboard sheet and/or the receptacle and/or said cardboard tray. More preferably, the transportation unit is arranged for moving the cardboard sheet and/or the receptacle and/or said cardboard tray from said first folding unit to said third folding unit, via said second folding unit.

Preferably, the first folding unit and/or the second folding unit and/or the third folding unit and/or the dispensing unit are further comprising a receiving organ arranged for receiving the cardboard sheet and/or the receptacle and/or the cardboard tray.

In this embodiment, the cardboard sheet and/or the receptacle and/or the cardboard tray is supplied from the transportation unit to the receiving organ comprised by one or more of: the first folding unit arranged for folding said sheet of cardboard towards, preferably in, a first direction for the purpose of obtaining a receptacle defining said receiving space of said cardboard tray by folding each of said side walls about said respective first folding lines relative to said bottom wall, towards, preferably in, said first direction; the second folding unit arranged for folding said sheet of cardboard in a second direction for the purpose of folding each of said first flange parts of said flange parts in said second direction; the third folding unit arranged for folding said sheet of cardboard in a third direction, for the purpose of folding each of said second flange parts of said flange parts in said third direction such that said second flange parts overlap said first flange parts in an overlapping region thereof; the dispensing unit arranged for providing an adhesive to said sheet of cardboard for the purpose of mutually connecting said first flange parts and said second flange parts in said overlapping region, via said adhesive, for realizing said cardboard tray.

In an example, said apparatus comprises a rotation arrangement arranged for rotating said plurality of receiving organs about a rotation axis for the purpose of said movement of said receiving organs from said first folding unit to said third folding unit, via said second folding unit. This is advantageous for the size, cost and/or dimensions of the apparatus. In addition, providing a rotation arrangement allows for a relative fast movement of the receiving organs from the first folding unit towards the second folding unit and from the second folding unit towards the third folding unit.

Preferably, said rotation arrangement is arranged for rotating, during moving of said receiving organ from said first folding unit towards said second folding unit and during moving from said second folding unit towards said third folding unit, said receiving organ about said rotation axis.

In an embodiment of said rotation arrangement, said rotation arrangement comprises a second rotation axis for the purpose of said movement of said receiving organs from said first folding unit to said third folding unit, via said second folding unit, wherein in between said rotation axis and said second rotation axis, said receiving organs are translated in a longitudinal direction for moving said receiving organs from said first folding unit to said third folding unit, via said second folding unit.

In an example, said apparatus comprises an ejecting arrangement arranged for ejecting said receptacle and/or said cardboard tray from said receiving organ.

In an example, said dispensing unit comprises a dispensing arrangement arranged for dispensing said adhesive, preferably a hot melt adhesive, for said connecting of said first flange parts and said second flange parts in said overlapping region.

In an example, said second folding unit and said third folding unit are arranged such that both said second direction and said third direction are in a flat virtual plane, preferably wherein said flat virtual plane is parallel to said bottom wall.

Preferably, said first direction, said second direction and said third direction are orthogonal.

It is noticed, that the apparatus according to the first aspect of the invention may furthermore comprise mechanical and/or electrical elements that are known to the person skilled in the art, in order to preserve and automated manufacturing process and for controlling the process.

In a second aspect there is provided a method of manufacturing a cardboard tray from a sheet of cardboard using an apparatus according to the first aspect, said cardboard tray comprising a receiving space and an uninterrupted flange arranged for connecting a foil to said uninterrupted flange for closing said receiving space of said cardboard tray, wherein said sheet of cardboard comprises sheet portions defining a bottom wall, side walls connected, via respective first folding lines, to said bottom wall and first and second flange parts connected, via respective second folding lines, to said side walls at a side of said side walls facing away from said bottom wall, wherein said method comprises the steps of: folding, by said first folding unit, each of said side walls about said respective first folding lines relative to said bottom wall towards, preferably in, said first direction thereby obtaining said receptacle defining said receiving space of said cardboard tray; folding, by said second folding unit, each of said first flange parts of said flange parts in said second direction; dispensing, by said dispensing unit, said adhesive, preferably said hot melt adhesive, in said overlapping region of said first flange parts and said second flange parts; folding, by said third folding unit, each of said second flange parts in said third direction such that said second flange parts overlap said first flange parts in said overlapping region thereof; connecting, by said third folding unit, said first flange parts and said second flange parts in said overlapping region for realizing said cardboard tray.

In an example, during said step of folding, by said first folding unit, said receptacle is obtained by pressing said sheet of cardboard at least partly in said receiving organ.

In an example, said method further comprises the steps of: moving said respective receiving organ holding said receptacle from said first folding unit to said second folding unit; and moving said respective receiving organ holding said receptacle from said second folding unit to said third folding unit.

In an example, said method further comprises the steps of: ejecting, by said ejecting arrangement, said cardboard tray from said respective receiving organ; and moving said respective receiving organ to said first folding unit.

In an example, said method comprises the step of: rotating, by said rotation arrangement, said plurality of receiving organs about said rotation axis for said moving of said receiving organs from said first folding unit to said third folding unit, via said second folding unit.

It is noted that the advantages and definitions as disclosed with respect to the examples of the first aspect of the invention, also corresponds to the examples of the second aspect of the invention, being the method of manufacturing a cardboard tray from a sheet of cardboard using an apparatus according to the first aspect of the invention.

The present disclosure will now be explained by means of a description of apparatuses for manufacturing a cardboard tray from a sheet of cardboard in accordance to the first aspect of the present disclosure and methods of manufacturing a cardboard tray from a sheet of cardboard in accordance to the second aspect of the present disclosure, in which reference is made to the following schematic figures, in which:

Fig. 1 - Fig. 5 disclose the manufacturing of a cardboard tray from a sheet of cardboard in subsequent steps in accordance with the present disclosure;

Fig. 6 discloses a schematic diagram of an apparatus for manufacturing a cardboard tray from a sheet of cardboard in accordance to the first aspect of the present disclosure;

Fig. 7 discloses a schematic diagram of another apparatus for manufacturing a cardboard tray from a sheet of cardboard in accordance to the first aspect of the present disclosure;

Fig. 8 discloses a method of manufacturing a cardboard tray from a sheet of cardboard in accordance to the second aspect of the present disclosure. Fig. 9 discloses another method of manufacturing a cardboard tray from a sheet of cardboard in accordance to the second aspect of the present disclosure.

Figure 1 to figure 5 disclose in subsequent steps the manufacturing of a cardboard tray 201 from a sheet of cardboard 203. Axis A, B and C define first direction A, second direction B third direction C respectively.

Figure 1 discloses the sheet of cardboard 203, comprising a bottom wall 209 and side walls 211 connected to the bottom wall 209 via first folding lines 213. The sheets of cardboard 203 further comprises first flange parts 215 and second flange parts 217. The flange parts 215, 217 are connected to the side walls 211 via second folding lines 219 and are positioned at a side of the side walls 211 facing away from the bottom wall 209. Two side walls 211 are provided with a locking part 227 that is connected to the side walls 211 via a third folding line 229. The other two side walls 211 are provided with a locking opening 231.

By folding the side walls 211 about the first folding lines 213 relative to the bottom wall 209 towards the first direction A, the receptacle 221 of figure 2 is obtained, thereby defining a receiving space 205. By folding the two first flange parts 215 in the second direction B, the intermediate cardboard product of figure 3 is obtained. An adhesive 225 is added to the flange parts provided at opposite sides of the first flange part 215. By subsequently folding the two second flange parts 217 in the third direction C, such that the second flange parts 217 overlap the first flange parts 215 in an overlapping region 223 thereof, the first flange parts 215 and the second flange parts 217 are mutually connected in the overlapping region 223 via the adhesive, realizing the cardboard tray 201 of figure 5. The cardboard tray 201 comprises an uninterrupted flange 207 arranged for connecting a foil for closing the receiving space 205 of the cardboard tray 201 .

Above described steps are automated and executed by apparatus 1 of figure 6 and apparatus 101 of figure 7. Operation of the apparatus 1 , 101 is as follows: A stack of sheets of cardboard 203 is supplied to the apparatus 1 ,101 , after which a single sheet of cardboard 203 is applied on the top of a receiving organ 11 , 111. The respective receiving organ 11 , 111 is moved to a first folding unit 3, 103.

The first folding unit 3, 103 is arranged for folding the sheet of cardboard 203 toward, preferably in, the first direction A. more specifically for folding each of the side walls 211 about the respective first folding lines 213 relative to the bottom wall 209 towards the first direction A. For this purpose, the sheet of cardboard 203 is pressed by the first folding unit 3, 103 in the receiving organ 11 , 111 for obtaining the receptacle 221 . During the pressing of the folding unit 3, 103, the locking parts 227 are forced through the receiving locking openings 231 , which is an approach known to the person skilled in the relevant art.

Subsequently, the respective receiving organ 11 , 111 holding the receptacle 221 is moved from the first folding unit 3, 103 to a second folding unit 5, 105. The second folding unit 5, 105 is arranged for folding the sheet of cardboard 203 in the second direction B, by folding each of the first flange parts 215 in the second direction B. While holding the receptacle 221 , in the receiving organ 11 , 111 , the receptacle 221 is folded during this manufacturing step into the intermediate cardboard product disclosed in figure 3.

The respective receiving organ 11 , 111 holding the intermediate cardboard product is subsequently moved from the second folding unit 5, 105 to a dispensing unit 9, 109. The dispensing unit 9, 109 is arranged for providing the adhesive 225 to the sheet of cardboard 203 for mutually connecting the first flange parts 215 and the second flange parts 217 in the overlapping region 223. The adhesive, for example a hot melt adhesive, is provided by a dispensing arrangement 17, 117.

After the adhesive 225 is provided, the respective receiving organ 11 , 111 holding the intermediate cardboard product is moved from the dispensing unit 9, 109 to a third folding unit 7, 107. The third folding unit 7, 107 is arranged for folding the sheet of cardboard 203 in the third direction C, for folding each of the second flange parts 217 in the third direction C such that the second flange parts 217 overlap the first flange parts 215 in the overlapping region 223, for realizing the cardboard tray 201 as a final product.

Finally, the respective receiving organ 11 , 111 holding the final cardboard tray 201 is moved from the third folding unit 7, 107 to an ejecting arrangement 15, 115, where the cardboard tray 203 is ejected from the respective receiving organ. The empty receiving organ 11 , 111 is eventually moved to the beginning of the manufacturing process for receiving another sheet of cardboard 203. This enables a continue manufacturing process, in which the steps executed by first folding unit 3, 103, second folding unit 5, 105, dispensing unit 9, 109, third folding unit 7, 107 an ejecting arrangement 15, 115 are executed simultaneously.

In the embodiments of figure 6 and 7, the receiving organs 11 , 111 are fixed to a transportation unit 13, 113. The transportation unit 13, 113 is arranged for moving the receiving organs 111 between the abovementioned units. The transportation unit 13 of apparatus 1 is provided as a conveyer belt 13, arranged for moving the receiving organs 111 in a longitudinal direction L. The conveyor belt comprises a rotation axis r1 and a second rotation axis r2 arranged for rotating, during use, in rotation direction F

The transportation unit 113 of apparatus 101 is provided as a rotation arrangement 113 arranged for moving the receiving organs 111 about a rotation axis R in a direction F.

Figure 8 discloses method 301 in correspondence with apparatus 1 disclosed in figure 6. The method 301 comprises the steps of: folding 303, by the first folding unit 3, each of the side walls 211 about the first folding lines 213 relative to the bottom wall 209 in the first direction A, thereby obtaining the receptacle 221 ; moving 311 the respective receiving organ 11 holding the receptacle 221 from said the folding unit 3 to the second folding unit 5; folding 305, by the second folding unit 5, each of the first flange parts 215 in the second direction B; moving 313 the respective receiving organ 11 holding the receptacle (221) from the second folding unit 5 to the third folding unit 7. dispensing 321 , by the dispensing unit 9, an adhesive in the overlapping region 223 the first flange parts 215 and the second flange parts 217; folding 307, by the third folding unit 7, each of the second flange parts 217 in the third direction C, such that the second flange parts 217 overlap the first flange parts 215 in the overlapping region 223 thereof; connecting 309, by said third folding unit 7, the first flange parts 215 and the second flange parts 217 in the overlapping region 223 for realizing the cardboard tray 201 . ejecting 315, by the ejecting arrangement 15, the cardboard tray 203 from the respective receiving organ 11 ; and moving 317 the respective receiving organ 11 to the first folding unit 3.

Figure 9 discloses method 401 in correspondence with apparatus 101 disclosed in figure 7. The method 401 comprises the steps of: folding 403, by the first folding unit 103, each of the side walls 211 about the first folding lines 213 relative to the bottom wall 209 in the first direction A, thereby obtaining the receptacle 221 ; moving 411 , by rotating 419, by the rotation arrangement 113, the receiving organs 111 about the rotation axis R, the respective receiving organ 111 holding the receptacle 221 from said the folding unit 103 to the second folding unit 105; folding 405, by the second folding unit 105, each of the first flange parts 215 in the second direction B; moving 413, by rotating 419, by the rotation arrangement 113, the receiving organs 111 about the rotation axis R, the respective receiving organ 111 holding the receptacle 221 from the second folding unit 105 to the dispensing unit 109; dispensing 421 , by the dispensing unit 109, an adhesive in the overlapping region 223 the first flange parts 215 and the second flange parts 217; moving, by rotating 419, by the rotation arrangement 113, the receiving organs 111 about the rotation axis R, the respective receiving organ 111 from the dispensing unit 109 to the third folding unit 107. folding 407, by the third folding unit 107, each of the second flange parts 217 in the third direction C, such that the second flange parts 217 overlap the first flange parts 215 in the overlapping region 223 thereof; connecting 409, by said third folding unit 107, the first flange parts 215 and the second flange parts 217 in the overlapping region 223 for realizing the cardboard tray 201 . ejecting 415, by the ejecting arrangement 115, the cardboard tray 203 from the respective receiving organ 111 ; and moving 417 the respective receiving organ 111 to the first folding unit 103.

It is noticed that the above description of the figures describe one variation of many embodiments of the present disclosure. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims. In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article, “a” or “an” does not exclude a plurality. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.