"Blank, box, apparatus and process for packaging elongated articles" Field of the invention

The present invention relates to a blank for packaging elongated articles, the relevant box thus obtainable, and a process and apparatus for packaging said articles in said box.

In particular the invention blank is a one-piece blank that can be folded and erected to form a box that can house elongated articles such as vials, miniature bottles, ampoules, syringes or similar articles having a substantially cylindrical body. In the following description and claims reference will be made to vials, but the scope of the invention should not be limited to the box housing vials only. Background of the invention

Boxes provided with an internal support for retaining vials or ampoules or similar elongated articles and made from a one-piece blank, are known in the art. In particular the internal support for the vials is obtained from foldable sections that can be erected in such a way that a plurality of holes arranged on two contra-positioned sections of the internal support are concentric and parallel for immobilizing the body of vials or similar articles at least in two portions of their body. US 5402889 in the name of Bosch GmbH describes a box that is obtained from an L-shaped blank. The box is provided with an internal support obtained from a folded flap that is glued to the front wall of the box. This embodiment has the drawback that the internal support can receive the vials or other elongated articles only after the box is completely erected and formed. Moreover, the internal support is not secured in its position with respect to the front wall, and in case the box is accidentally dropped the vials or ampoules inside the box could break.

EP-B-1259432, assigned to the present Applicant, describes a box, obtained from a single blank, that is provided with an internal support for vials of the above mentioned type. The blank is provided with a foldable flap or tab that is

engaged with the internal support to keep the support erected during the vials inserting step. Thanks to this improvement, it is possible to insert the vials before the box is formed and glued, with the relevant advantage of a much easier packaging process. This box has the drawback that the means for retaining the support are foldable flaps or tabs projecting from additional lateral walls of the box, that are to be folded after the erection of the lateral walls of the box and laterally inserted into the internal vial support (or glued to it), thus involving an additional step in the packaging process. Further the interlocking of the flaps or tabs with the internal support suffers of the intrinsic difficulty of this operation that requires a perfect alignment of the internal support and of the flaps/tabs to be inserted therein. WO 01/64519 discloses in greater detail a possible apparatus for packaging the box taught in EP1259432. This apparatus comprises two linear conveyors that transport blanks, initially in a flattened position, along different working station in which each blank is folded and the vials or similar articles are inserted inside the box.

The apparatus is provided with forming means to erect the internal support and with pushing means to keep the support erected in a centered position for facilitating the next operation of inserting elongated articles in the box. The apparatus is cumbersome and reflects the problems of the boxes it has to erect and package. Summary of the invention It is an object of the present invention to solve the above mentioned problems and to provide a box for vials, ampoules, miniature bottles or similar elongated articles, obtained from a blank in one piece, that is easy to erect and that will not move from the required position during the insertion of the vials into the internal support. An additional object of the present invention is to provide a method and an apparatus for folding the aforementioned blank and inserting the elongated

articles inside the internal support of the box, which simplify the packaging operations and make use of the smallest possible number of handling elements for the erection of the box.

Another object of the invention is to provide a compact packaging apparatus of simple and economic production.

Such objects are achieved by the blank of the invention that comprises an internal support restrained to lateral sections of the front wall in which the support is glued, characterized according to claim 1. Advantageously each lateral section is provided with a cutout that receives a relative engaging flap laterally projecting from a section of the support for centering the internal support and avoiding the support to rotate or to move during the operations of inserting elongated articles.

According to an aspect of the invention each lateral section is provided with a cutout substantially "U" shaped and located at the free edge of said lateral section. The cutout is aligned with the linking section of the support after the erection of the internal support to receive the lateral flaps. According to a further aspect of the invention, the height of each erected first lateral section is greater than the height of said erected support. The lateral contra-positioned engaging flaps have transversal dimensions slightly smaller that the longitudinal dimension of the two cutouts in such a way that the cutout can internally receive the flap after both the internal support and lateral sections are erected so that the bottom side of the cutouts is substantially flush to the relative engaging flap. In this way any relative rotation of the erected support with respect to the base wall of the box is prevented in both directions by the presence of the two lateral sides of the cutouts.

The relative heights K ¹ and K of the erected supporting portion and of the lateral portions at the cutout positions are such as to allow the flaps to be folded over the lateral sections. Moreover, a chamber is thus defined between the linking section of the support and the back wall of the box. Advantageously the chamber can

house a separate insert or a leaflet or an illustrative brochure before the lid portion is folded for closing the box.

A further object of the invention is a box as obtainable from the above discussed blank. The invention blank is folded and glued following the method according to claim 8. This method is carried out by an apparatus according to claim 11.

In the present invention the apparatus for packaging vials or similar articles comprises two carousel circular conveyors that reduce the size of the machine. Furthermore the apparatus comprises forming means to erect the support and, contextually, to bring the support to a standstill position.

Brief description of the drawings

The invention will now be described in more detail with reference to the enclosed drawings which are by way of example and not limiting, where:

Figure 1 is a plan view of a blank according to a preferred embodiment of the present invention;

Figure 2 is a plan view of the blank in figure 1 in a first step of the packaging process.

Figure 3 is a perspective view of the blank of fig. 1 in a second step of the packaging process, with lateral sections erected. Figure 4 is a perspective view of the blank of fig. 1 in a third step of said process, with supporting portion erected.

Figure 5 is a schematic top view of the packaging apparatus according to the invention.

Figure 6 is a schematic perspective view of the feed station of the machine of figure 2;

Figure 7 shows a perspective view of the forming means for erecting the support of the blank according to the invention ;

Figure 8 shows a sectional view of a box according to the invention.

With reference initially to figures 1-4, the blank 1 according to the invention comprises a lid portion 2, provided with a flap 3 and a tab 4, a plurality of

adjacent sections, defining a longitudinal axis A-A of the blank 1 , connected to said lid portion 2 and comprising a back wall 7, a base wall 5 and a front wall 6 of the erected blank 1. The back wall 7 is connected with lid portion 3,4. Blank 1 also comprises first lateral sections 8 connected to the front wall 6, second lateral sections 9 connected to said back wall 7 and a plurality of sections extending along axis A-A and forming the internal support 10 for vials or other elongated articles. Said first, 8, and second, 9, lateral sections form double lateral walls of the box obtained from blank 1. The elongated articles (20, fig. 8) can be vials, miniature bottles or similar articles, preferably having a cylindrical body, a neck and a head; other shapes of elongated articles, e.g. having a substantially cylindrical body or syringes, can be housed in the invention box by providing suitably shaped retaining holes in supporting portion 10. As shown in fig. 1 , the internal supporting portion 10 is composed by adjacent sections (11-15) extending along axis A-A from front wall 6. The support 10 comprises two sections 12,14 that are joined by a linking section 13 in correspondence of the two respective ends 30, 31 and equipped with a plurality of housing holes 16, 16' to house and retain vials 20. According to the shown embodiment the housing holes 16,16' are aligned and arranged in two rows on each backdrop section 12, 14, respectively, number of rows or housing holes can be chosen. Also the position of the housing holes 16 can be different, i.e. every hole 16 can be staggered or misaligned according to the requirements of the box and depending on the elongated articles shape and dimensions. In any case, holes 16 and 16' will be paired and vertically aligned when the support section 10 is erected, so as to house the vials ( see e.g. fig. 8).

According to an advantageous embodiment of the invention the holes 16 ¹ on the supporting section 12 are smaller than holes 16 on section 14 and are provided with retaining means 17 for gripping and retaining the neck or the body of a vial 20 when it is inserted inside the housing holes 16 and 16'.

Said retaining means 17 comprise a plurality of slits 18 that converge on the hole 16' for temporarily and reversibly increasing the dimensions of said holes 16'. In this way, when inserting vial 20, the area around the hole 16' is pushed out, sliding on the neck or the body of the elongated article. The elasticity of blank material allows the retaining means 17 to exert a force able to retain the neck or the body of the vial or ampoule to the support. Slits 18 preferably have points of retention 22 that cooperate to immobilize the article, but give away to easily remove the article from box S. In fig. 1 , holes 16 ¹ are surrounded by weakning lines 23 cut along the perimeter of polygons circumscribing the holes; in particular Figure 1 shows squares circumscribing the holes 16. Further details on preferred embodiments of the holes 16,16' and the supporting portion 10 are disclosed at paragraphs [0018]-[0029] of EP-B-1259432. As shown in figures 2 and 3, the support 10 before the erection is folded along folding line 6a, between section 11 and 6, and the two sections 11 and

15 are glued to the front wall 6 of the box S in correspondence of glue points

42 and 43 of section 6 in order to secure said internal support 10 to the

_.blank 1.

According to the invention, at least one and preferably both lateral sections 8 are provided with a cutout 25 located at the periphery, i.e. at the free edge 8a of each first lateral section 8. The cutout 25 can be "U" shaped and is arranged in such a way as to be aligned with the linking section 13 of the support 10 after it is erected. In the shown preferred embodiment of the invention (fig. 3), the linking section 13 of the erected support and the two cutouts 25 share their symmetrical axis B-B and F-F perpendicular to the longitudinal axis A-A of the blank 1. As it will be readily apparent to the skilled person, the linking section 13 and the two cutouts 25 can also have respective symmetrical axis parallel to each other instead of coincident without being outside the scope of the invention. The linking section 13 of the supporting portion 10 comprises two laterally

contra-positioned engaging flaps 26, that preferably have substantially the same transversal dimension, i.e. width L as the linking section 13. In any case the longitudinal dimension P of the cutout 25, i.e. the side of the cutout parallel to the A-A axis of blank 1 , is such as to receive and house flaps 26 in order to secure in an erected position the supporting portion 10, as is shown in fig. 3. In a preferred embodiment, cutout, width P is slightly greater than width L of the respective engaging flap 26 in order that the cutout 25 can receive flap 26 after both support 10 and first lateral sections 8 are erected by sliding flaps 26 over and along edges 8a of flaps 8, as better disclosed hereinafter. In the shown preferred embodiment (fig 4 and 8 ) the height K ¹ Of erected first lateral sections 8 is greater than the height K of the erected support 10, so that the bottom side 28 of the cutouts 25 is substantially flush with section 13 and engaging flap 26. Whit this embodiment, flaps 26 are retained inside the respective cutout 25 in a very reliable way. As a matter of fact the relative rotation of the erected support 10 with respect to the base wall 5 of the box S is prevented in either direction by the presence of the two lateral sides 33,34 of the cutouts 25 that are close or engaged to the two lateral sides 35,36 of the flap 26. In this way rotations of the support are avoided and a sure centering and retaining in erected condition of the support is obtained with the consequence that the inserting of the vials or the like inside the hole of the support is simple and efficient, thus saving time and costs in the packaging process.

The cutout 25 can have shapes different from the above mentioned "U" shape, e.g. a dovetail shape can be used so as to increase the reliability of the securing step.

As above described the height K ¹ of each erected first lateral section 8 is greater than the height K of said erected support 10. This feature results in two advantages. First the lateral sides 33 and 34 of cutout 25 can have greater extension than what it would be possible if K ¹ was substantially the same as K. Second, as shown in fig 8, a chamber 40 is defined between

linking section 13 and back wall 7 of the erected blank. Advantageously the chamber 40 can house a separate insert or leaflet or illustrative brochure, 41.

The width of second lateral sections 9 is the same or slightly greater than the width of sections 8 and such as to have an easy folding of sections 9 over sections 8 when the box is formed.

Second lateral sections 9 comprise a tab 44 that couples to the lid portion 2 of the box S during the closing step of box S in a way known per se, according to which foldable tab 4 of lid 2 is interlocked during the folding operation inside the box S between the two tabs 44 of the second lateral sections 9 and the front wall of the box S.

The forming of the box from the blank 1 proceeds as follows: first, sections 14 and 15 are folded along fold line 31 (extending between sections 13 and 14) are superimposed to at least sections 13 and 12. Then, the thus folded blank is folded again along folding line 6a between section 6 and section 11 and section 11 is glued to the front wall 6 of the blank in correspondence of a glue area 42. In the same step sections 14 and 15 are interposed between section 6 and the sections 11 ,12 and 13. Section 15 is thus glued to section 6 in correspondence of a second glue area 43 so that the internal support 10 is fixed to the front wall 6 (Fig. 2) and can later be erected to be perpendicular to wall 6 as shown in fig 3 and 4. The blank in the partially glued condition shown in fig. 2 is the blank that is actually fed to the packaging machine of the invention, preferably after a further folding step (see fig. 6). Starting from fig 2 condition, first lateral sections 8 are folded substantially at a right-angle with respect to the front wall 6 along the fold lines between section 6 and lateral sections 8 to their final position. During this operation flaps 26 are temporarily folded together with the first lateral sections 8; the folding of flaps 26 is temporary and is opposite to and against the "natural" folding direction of flaps 26 as imported to them by relevant folding lines 26a. In the subsequent folding step (Figures 3, 7) the support 10 is erected, i.e.

the sections 12,14 are folded respectively along the fold lines between the sections 12 and 11 and between the sections 15 and 14. During this step the flaps 26 move from a first position A where they are folded together with first lateral sections 8 to a second position B where they engage inside the respective cutouts 25, being substantially in the same plane as the linking section 13 of the support 10, or slightly angled to it. In this way the support 10 is centered vertically with respect to the front wall 6 of blank 1 and is prevented from rotating or sliding from this standstill position. It should be noticed that the standstill position of the support was reached without any further folding operation, but only thanks the elastic return of the blank material, namely of the flaps 26. As previously mentioned, flaps 26 are defined by folding lines 26a that oppose the first folded position (i.e. together with lateral sections 8, fig 3) and facilitate the engagement position of fig. 4. As hereinafter disclosed, the flaps 26 are preferably held close to or substantially in correspondence to their folding lines 26a to facilitate the following folding and glueing of the flaps when forming the box. The opened out support for housing elongated articles can thus be filled while the rest of the blank is still in flat position. During this step the vials or ampoules or the like are inserted inside the respective holes and held into them by the retaining means 17 of section 12 of supporting portion 10, as above described.

In the subsequent folding steps the remaining blank is folded around the structure formed by the internal support 10. In particular, the tabs 24 are folded and, in case, glued to section 5 which will form the base wall of the box S according the invention. At this point, section 7 is folded to contact the free sides 26 of each first lateral section 8. It should be noted that in this position section 7 and linking section 13 are not superimposed, but they define a chamber where it is possible to insert a brochure 60 or a leaflet or the like (fig. 8). Afterwards second lateral sections 9 are folded along the folding lines

between the section 9 and section 7, causing engaging flaps 16 to move towards first lateral section 8. At the end of this step second lateral sections 9 and engaging flaps 26 are superimposed to first lateral sections 8 previously provided with glue areas. After this step a brochure 60 or a leaflet or the like can be inserted inside the chamber 40. The box S so formed and filled, shown in figure 8, can now be closed by folding tabs 44 and, in turn, flap 3, finally inserting tab 4 into the box S body closed. The box S can comprise an adhesive strip to retain lid portion 2 to front portion 6 providing an anti-tampering protection of the vials or/and the miniature bottles or the like inside the box S when it is closed. Figure 5 shows an invention apparatus 100 for packaging vials 20, or other elongated articles starting from the blank 1 as above described. It comprises a first conveyor 101 and a second conveyor 102 for the handling of the blank 1 during the operations of folding the blank and inserting the vials 20 inside the same.

According to the invention, first conveyor 101 and second conveyor 102 are carousel conveyors mobile in rotation around respective vertical axis which handle each blank 1 of a set of blank 91 on curvilinear paths S1 and S2, thus reducing space in comparison with apparatus for packaging elongated articles comprising linear conveyors. Blanks are held vertically throughout their path along conveyors 101 and 102.

As shown in figures 5 and 6, the blank is fed to the first conveyor 101 by a feeding carrier 103 for a set of blanks 1 previously stored in a store (not shown). The feeding carrier 103 of fig 6 is a belt conveyor provided with two contra-positioned transversal teeth 160 at least partially in touch with one blank 1 of said set of blanks 1 in correspondence of first and/or second lateral sections 8,9 of the blank 1. Each blank 1 of said set of blanks is provided with a pre-glued internal support 10 in a flattened position, as shown in figure 2, and folded along the folding line 5a, between section 5 and

7, in such a way that the back wall 7 and lid portion 3,4 are superimposed to sections 11-13 of flat supporting portion 10.

As shown in fig. 6, apparatus 100 comprises first retaining means 104 for gripping and transferring each blank 1 from said feeding carrier 103 to the first conveyor 101 , and a first "U" shaped blank housing means 110 secured to said first conveyor 101 for vertically housing each blank 1 coming from said feeding carrier 103. The apparatus 100 is further provided with forming means 105 (fig. 7) to erect said internal support 10 and, contextually, retain the support 10 in a standstill position. The forming means 105 comprise a mobile bracket 106 that moves between a lowered position A in which it touches the support 10 in flattened position, and a lifted position B corresponding to the erected position of supporting portion 10. It is to be observed that the erected and secured position of the support 10 is automatically reached only by means of vertically mobile bracket 105 and flaps 26, i.e. without any further means such as pushing means or the like as required by the prior art. The support portion 10 remains erected even when the forming means 105 return to their starting position. In fact when the mobile reference 105 reaches position B, the engaging flaps 26 of the support 10 insert inside the respective cutouts 25. In this way the internal support 10 is centered in a substantially right-angled position with respect to the front wall 6 and is prevented from rotating or sliding from this standstill position. Downstream (with respect to its rotation) of the location of means 105, along first conveyor 101 is provided at least one inserting means 120 to vertically insert the vials or the like inside holes 16,16' of the internal support 10. Further details on preferred embodiments of the inserting means 120 are disclosed at pag 6 [lines 26-29] and pag 7 [lines 01-17] of WO 01/64519. Preferably, apparatus 100 comprises sensors (not shown) for checking the proper arrangement of each vial 20 inside the respective hole 16,16' of the

support 10 and, in case, marking the box S not perfectely or completely filled. Sensors working with said inserting means 120 for vials 20 or elongated articles or the like are known in the art. Folding means for folding the tabs 24 connected to first lateral sections 8 according to the invention are provided downstream of inserting means.

Such folding means is known per se in the art. More details about conventional folding means are disclosed in WO 01/64519 at pag. 7 [lines 26-29] and pag. 8 [lines 01-04]. Following the packaging steps of generic blank 1 along path S1 , downstream of said first folding means, the conveyor 101 is provided with lifting means 130 to erect base 5 and back wall 7 of box S.

Said lifting means may be conventional or may also comprise two separated and curvilinear guides that are substantially helicoidal shaped and conformed in such a way that while the blank 1 moves along path S1 one guide folds base wall 5 along folding line between sections 5 and 6, and the second guide lifts back wall 7 along folding line 5a until touching first lateral sections 8 of the blank 1. Along path S1 (Figure 5), after lifting means 130 the conveyor 101 comprises distributing means to provide glue at least on second lateral sections 9 of the blank 1 in correspondence of the sides which mate with first lateral sections 8 and possibly also on flaps 26.

The apparatus 100 further comprises transfer means 140 to transfer blank 1 from first blank housing 110 to a second blank housing 200 provided on second conveyor 102. During this step second lateral sections 9 of blank 1 are folded along folding lines between section 6 and sections 8 so as to glue and secure them to sections 8. At the end of this step the flaps 26 of the support 10 are folded and interposed between first 8 and second 9 lateral sections. Second conveyor 102, comprises second folding means (not shown and known in the art) for folding tabs 44 connected to second lateral sections 8

and manipulating means 210 for inserting an illustrative leaflet or brochure 60 in the chamber 40 of the box S after the transfer of each blank 1 from relative first blank housing 110 to second blank housing 200. Finally the apparatus is provided with tilting means for folding the flap 3 along folding line between sections 3 and 5, turning means located after the tilting means 160 to reverse the tab 4 fixed at the closing flap 3 and evacuation means of the box S to expel each erected and packed box S from the relative second blank housing 140 placed after the tilting means to a final conveyor 250 to be stored.