EP3107811B1

EP3107811B1 - Method for obtaining boxes and blank usable in the method

Info

Publication number: EP3107811B1
Application number: EP15702296.3A
Authority: EP
Inventors: Aldo Pozzoli
Original assignee: Pozzoli SpA
Current assignee: Pozzoli SpA
Priority date: 2014-02-21
Filing date: 2015-02-04
Publication date: 2018-11-07
Anticipated expiration: 2035-02-04
Also published as: WO2015124430A1; EP3107811A1

Description

The present invention relates to a method, according to the preamble of claim 1, for obtaining boxes, particularly of the collapsible type, and to a blank according to the preamble of claim 9, that can be used in the method.
Currently, boxes made of solid cardboard or corrugated cardboard, optionally coupled to an external coating sheet that can be used for decorative purposes, or boxes provided by way of layers of mutually coupled cardboard are known.
All these boxes typically have, at the edges, creases created during the manufacture of the die-cut element in order to allow its folding thereat and the consequent formation of the walls, of the lid, of the sides and/or of the bottom of the box.
The creases, besides affecting negatively the aesthetics of the finished box, often prevent the portions of the box connected by them to be mutually freely rotatable through 360°. For example, the creases prevent the box from being flattened reversibly when the material of the box is particularly rigid, because in this case the creases allow angularly limited folds beyond which the box can be ruined, due to the formation of ripples and/or tears.
For this reason, the already glued boxes obtained from a single die-cut element that is made of particularly rigid cardboard are not of the collapsible type and therefore cannot be supplied flat to the user without the risk of causing ripples and of preventing, unless secondary packaging is used, the memory effect caused by the creases.
It is also known to use, as alternative to creases, a scoring, i.e., a region in which the material is partially removed so as to obtain a groove with a V-shaped cross-section at a folding line. The scoring, however, still suffers from the problem of having limitations in the folding angles. In particular, scoring allows folds through less than 270°. US 2007/0151685 discloses a method and a blank for manufacturing boxes according to the preamble of claims 1 and 9 respectively. The aim of the present invention is to provide a method for manufacturing boxes and a corresponding blank that are capable of improving the background art in one or more of the aspects indicated above.
Within this aim, an object of the invention is to provide a method for manufacturing boxes and a corresponding blank which, though using traditional techniques for coupling, die-cutting and folding-gluing, allow to obtain a box made of rigid cardboard with an external surface that is substantially free from unevenness in the edge regions.
Another object of the invention is to provide a method for manufacturing boxes and a corresponding blank that allow to obtain rigid cardboard boxes that are reversibly collapsible without damage, so that they can be provided, even already glued, but with an extremely reduced volume, to the corresponding user.
Another object of the invention is to provide a method for manufacturing boxes that is highly reliable, relatively easy to provide and at competitive costs.
This aim and these and other objects that will become better apparent hereinafter are achieved by a method for manufacturing boxes, comprising the steps of:

obtaining a blank, comprising a supporting layer, which is preferably a layer of cardboard;
obtaining a die-cut element by die-cutting the blank;
folding said die-cut element to obtain a box;

obtaining slit-like openings on the supporting layer, the slit-like openings being surrounded along all of their perimeter by the material of the supporting layer;
coupling at least one first covering sheet with a first face of the supporting layer, so that each one of the slit-like openings is closed on one side by said at least one first covering sheet;

The aim and objects of the invention are also achieved by a blank for manufacturing boxes, comprising a supporting layer, such as a cardboard layer, and at least one first covering sheet, which is coupled to a first face of the supporting layer, characterized in that the supporting layer comprises a plurality of slit-like openings, along each of which it is possible to obtain a respective edge of the box, each one of said slit-like openings being closed on one side by said at least one first covering sheet and being surrounded along all of its perimeter by the material of the supporting layer.
Further characteristics and advantages of the invention will become better apparent from the description of preferred but not exclusive embodiments of the method and of the blank according to the invention, illustrated by way of non-limiting example in the accompanying drawings, wherein:

Figure 1 is a view of a blank according to a first embodiment of the invention;
Figure 2 is an exploded view of the blank of Figure 1 when a second covering sheet is applied;
Figure 3 is a view of a die-cut element obtained from the blank of Figure 1;
Figure 4 is a partial cutout view of a die-cut element obtained from the blank of Figure 2 and with both covering sheets coupled to the intermediate supporting layer;
Figure 5 is a view of a box with a quick-lock bottom obtained from the die-cut element of Figure 4, usable particularly for containing a bottle;
Figure 6 is a view of the box of the preceding figure with the lid open;
Figure 7 is a view of the box of the preceding figure with the neck stoppers opened as well;
Figure 8 is a sectional view of the box of the preceding figure, taken along a plane that is perpendicular to the longitudinal axis of extension of the box;
Figure 9 is a view of a detail of the preceding figure, related to the gluing region of the side walls of the box;
Figure 10 is a view of the box of Figure 5 in the unfolded configuration;
Figure 11 is an exploded view of a blank according to a second embodiment of the invention;
Figure 12 is a view of a die-cut element obtained from the blank of the preceding figure;
Figure 13 is a view of a case obtained from the die-cut element of the preceding figure that can be used for example to contain shoes or eyeglasses depending on its size.

With reference to the figures, a blank according to the invention, generally designated by the reference numeral 1 or 101, depending on the embodiment considered herein, comprises a supporting layer 1a, 101a and a first covering sheet 1b, 101b coupled to a first face of the supporting layer 1a, 101a.
The supporting layer 1a, 101a is preferably a cardboard layer, 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 1.11 mm, and a grammage comprised between 400 g/m² and 750 g/m². 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).
The cardboard of the supporting layer 1a, 101a, as an alternative, can be corrugated cardboard.
The cardboard layer 1a, 101a, by means of a first die-cutting operation, has a plurality of through slits 2, 102, along each one of which a respective edge 21, 121 of the box 20, 120 will be obtained.
The slits 2, 102 are longitudinally extended openings obtained by means of a die-cutting machine, which have a transverse dimension that is much smaller than their longitudinal dimension, for example comprised between 1.5 mm and 3 mm, preferably approximately 2 mm, depending on the thickness of the supporting layer. Indicatively, the transverse dimension of the through slits 2, 102 can be chosen equal to twice the thickness of the supporting layer 1a, 101a.
The through slits 2, 102, termed herein also slit-like openings, are openings formed in the supporting layer 1a, 101a, meaning that on the plane of the blank 1 they are surrounded along all of their perimeter by the material of the supporting layer 1a, 101a, i.e., by cardboard. In this manner, the supporting layer 1a, 101a is self-supporting and can be handled easily though having through slits, for example by a feeder of a coupling machine.
The slit- like openings 2, 102 are preferably arranged at all the edges 21, 121 along which the subsequent die-cut element 8 or 9 or 109 must be folded in order to define the tubular side wall of the box 20, so that there is a single slit 2, 102 on each one of the edges 21, 121. For example, in the case of a parallelepipedal box such as the one of Figures 5 and 13, the slits 2, 102 are four in number and coincide with the four parallel edges 21, 121 of the parallelepiped, at right angles to the mouth of the box.
Optionally, further slits 3, 103 can be provided at other edges or folding lines of the die-cut element 8 or 9 or 109, for example, in a transverse direction with respect to the slits 2, 102. The further slits 3, 103 must not cross, hoverer, the slits 2, 102, in order to allow that the supporting layer 1a, 101a be self-supporting and therefore be handled easily for the subsequent operations.
Among the operations that follow the first die-cutting for the creation of the slit- like openings 2, 102 and the optional further slits 3, 103 there is the one for coupling at least one first covering sheet 1b, 101b with a first face of the supporting layer 1a, 101a. This coupling can be obtained by interposing a layer of glue between the first sheet 1b, 101b and the first face of the supporting layer 1a, 101a.
With this operation, by means of which it is possible to cover substantially the entire first face of the supporting layer 1a, 101a, each one of the slit- like openings 2, 102 and of the optional further slits 3, 103 is closed on one face, so as to provide the mechanical support needed by the future die-cut element 8 or 9 or 109 at said slits 2, 102 and 3, 103.
The first covering sheet 1b, 101b is preferably made of paper and therefore can be printed easily with decorative patterns prior to its application on the supporting layer 1a, 101a.
Moreover, the first covering sheet 1b, 101b has a larger extension than the supporting layer 1a, 101a along at least one direction, so that a flap 5, 105 of the first covering sheet 1b, 101b protrudes beyond a corresponding edge 4, 104 of the supporting layer 1a, 101a and can be folded onto said edge 4, 104 in the coupling machine with the interposition of glue, obtaining a folded flap 6, 106 that is useful for concealing on the outside the material of the supporting layer 1a, 101a of the box, which otherwise would be necessarily visible from the outside of the box following the second die-cutting step, described hereinafter.
Preferably, the supporting layer 1a, 101a is coupled also to a second covering sheet 1c, 101c, which covers substantially the entire face of the supporting layer 1a, 101a opposite to the first face, with the interposition of a layer of glue. In this manner, each one of the slit- like openings 2, 102 and of the optional further slits 3, 103 is closed on both sides by the covering sheets 1b, 101b, 1c, 101c, obtaining a greater strength of the edges 21, 121 at the slits in the final box 20, 120.
The covering sheets 1b, 101b and 1c, 101c are useful for increasing the overall stiffness of the blank and, therefore, of the final box.
The coupling operation can be obtained by means of a traditional coupling machine, adapted to receive the supporting layer 1a, 101a and the covering sheets 1b, 101b and 1c, 101c by means of corresponding feeders and to interpose a layer of glue between the covering sheets 1b, 101b and 1c, 101c and the corresponding faces of the supporting layer 1a, 101a.
The covering sheets 1b, 101b and 1c, 101c are both preferably made of paper, for example with a grammage comprised between 90 g/m² and 300 g/m², for example comprised between 130 g/m² and 150 g/m², and with a thickness comprised, for example, between 60 microns and 200 microns, more preferably between 70 microns and 150 microns.
In a second die-cutting step, the blank composed of the supporting layer 1a, 101a, the first covering sheet 1b, 101b and the optional second covering sheet 1c, 101c is cut along a contour 7 that corresponds to the perimeter of the die-cut element 8 or 9 or 109, which, once folded and glued, will constitute the finished box 20, 120.
In this second die-cutting step, creases and/or scorings can be optionally performed at secondary folding lines, all substantially directed transversally with respect to the slit- like openings 2, 102, for example along the folding lines 12, 112 of a quick- lock bottom 13, 113 of the box, the folding lines 14a-14b, 114a-114b of the lid 15, 115, and/or the folding lines 16a-16b-16c of the neck stoppers 17.
The contour 7 surrounds a portion of the blank 1 that contains the slit- like openings 2, 102 and that crosses them transversely. By way of the presence of the first covering sheet 1b, 101b and of the optional second covering sheet 1c, 101c, the second die-cutting operation that cuts transversely the slit- like openings 2, 102 at the contour 7 allows to obtain a die-cut element that can be folded easily through approximately 360° along the respective direction of the slit- like openings 2, 102 without damage and without forming ripples.
The blank 1 of Figure 1-2 is adapted to obtain a single box. In practice, it is preferable to use supporting layers of greater extension, within which is possible to contain a plurality of contours 7 and corresponding slits 2, 102 and 3, 103, with such arrangements as to limit waste as much as possible. In this case it is preferable that the contours 7 have at least one side that coincides with an edge 4, 104 of the supporting layer 1a, 101a, so that a folded flap can be created on that edge during the coupling between the supporting layer 1a, 101a and one of the covering sheets. For example, if the supporting layer has a dimension in the horizontal direction that is twice the one of Figure 1, it is possible to obtain two die-cut elements and the contour of the second die-cut element can be mirror-symmetrical and turned upside down with respect to the contour 7 of the first die-cut element, so that both contours share at the center of this "doubled" supporting layer the edge of the longitudinal wing 11 that is opposite with respect to the region of the folded flap 6, so that it is possible to apply a folded flap of the first sheet 1b also on the edge of the supporting layer that is opposite with respect to the edge 4.
Going back to the blank 1 of Figure 1, following the second die-cutting operation one obtains a die-cut element 8 such as the one of Figure 3, if the second covering sheet 1c, 101c is not present, or a die-cut element 9 such as the one of Figure 4 if both covering sheets 1b, 101b and 1c, 101c are coupled to the supporting layer 1a, 101a.
The die- cut element 8 or 9 or 109 thus obtained is constituted by a series of internal panels that are arranged side by side and completely separated from each other, by a distance equal to the transverse dimension of the slit- like openings 2, 102. These panels are held together by means of covering sheets 1b, 101b and 1c, 101c, which allow to define, at the slit- like openings 2, 102, hinge axes of the panels along which the box 20, 120 can be spread without practically encountering resistance and with no memory effect.
The die- cut element 8 or 9 or 109 thus obtained can be fed to a folding-gluing machine of the traditional type in order to form the final box 20, 120. In the case of a box with quick-lock bottom such as the one of the figures, the folding-gluing machine applies a layer of glue on the wing 11, 111, after folding it inward, and folds the die- cut element 8 or 9 or 109 so that the glue is interposed between the wing 11, 111 and the folded flap 6, 106.
The box, even after being assembled, for example glued between the wing 11, 111 and the folded flap 6, 106 as in the illustrated case, can be palletized in flattened form without damaging it and can be provided in this state to users even in large volumes too, saving a considerable amount of space.
The box can be made of very rigid cardboards as supporting layers 1a, 101a and, despite this, be still flattened and supplied in this configuration to the user. It is possible, therefore, to provide boxes that are particularly rigid, such as for example the boxes for bottles of sparkling wine or shoe boxes, in a format that can be collapsed completely without damage.
Moreover, by way of the invention it is possible to obtain a rigid cardboard box that has a smooth outer surface without raised portions or ripples due to creases of the known type.
Although the invention has been conceived particularly for boxes for bottles, eyeglasses and shoes, it can be used, however, more generally to contain any object.
The invention thus conceived is susceptible of numerous modifications and variations, and the details may further be replaced with other technically equivalent elements, as long as they do not depart from the scope of the invention which is defined by the appended claims.
In practice, the materials used, as well as the dimensions, may be any according to requirements and to 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.

Claims

A method for manufacturing boxes, comprising the steps of:
- obtaining a blank (1), comprising a supporting layer (1a, 101a), which is preferably a layer of cardboard;

- obtaining a die-cut element (8, 9, 109) by die-cutting said blank;

- folding said die-cut element (8, 9, 109) to obtain a box (20, 120);
characterized in that said step of obtaining the blank comprises the steps of:
- obtaining slit-like openings (2, 102) in said supporting layer (1a, 101a), said slit-like openings (2, 102) being surrounded on the plane of the blank along all of their perimeter by the material of the supporting layer (1a, 101a);

- coupling at least one first covering sheet (1b, 101b) with a first face of said supporting layer (1a, 101a), so that each one of said slit-like openings (2, 102) is closed on one side by said at least one first covering sheet (1b, 101b);
said folding being provided along at least said slit-like openings so that a respective edge (21, 121) of the box (20, 120) is obtained along each one of said slit-like openings.
The method according to claim 1, characterized in that each one of said slit-like openings (2, 102) is extended substantially along the entire length of the corresponding edge (21, 121) of the box (20, 120).
The method according to one or more of the preceding claims, characterized in that said slit-like openings (2, 102) are substantially mutually parallel.
The method according to one or more of the preceding claims, characterized in that said step of obtaining the blank further comprises a step of coupling at least one second covering sheet (1c, 101c) to a second face of said supporting layer (1a, 101a) that is opposite the first face, so that each one of said slit-like openings (2, 102) is closed on both sides respectively by said first and second covering sheets (1b-1c, 101b-101c).
The method according to one or more of the preceding claims, characterized in that said supporting layer (1a, 101a) is a layer of cardboard with a thickness comprised between 0.4 mm and 1.5 mm, more preferably comprised between 0.74 mm and 1.11 mm, and a grammage comprised between 400 g/m² and 750 g/m².
The method according to one or more of the preceding claims, characterized in that the material of said at least one first covering sheet and/or of said at least one second covering sheet is paper, with a grammage comprised between 90 g/m² and 300 g/m², more preferably comprised between 130 g/m² and 150 g/m², and with a thickness comprised between 60 microns and 200 microns, more preferably between 70 microns and 150 microns.
The method according to one or more of the preceding claims, characterized in that said at least one first covering sheet (1b, 101b) has a greater extension of said supporting layer along at least one direction so as to define a flap (5, 105) of said at least one first covering sheet (1b, 101b) that protrudes beyond an edge (4, 104) of said supporting layer (1a, 101a), in said step of coupling said at least one first covering sheet (1b, 101b) to said supporting layer (1a, 101a) said flap (5, 105) being folded onto said edge (4, 104) so as to obtain a folded flap (6, 106) on said edge (4, 104).
The method according to claim 7, characterized in that said folding step is followed by a gluing step, in which a layer of glue is interposed between said folded flap (6, 106) and a wing (11, 111) of the die-cut element (8, 9, 109).
A blank for manufacturing boxes, comprising a supporting layer (1a, 101a), such as a layer of cardboard, and at least one first covering sheet (1b, 101b), which is mated to a first face of said supporting layer (1a, 101a), characterized in that said supporting layer (1a, 101a) comprises a plurality of slit-like openings (2, 102), along each of which it is possible to obtain a respective edge (21, 121) of the box, each one of said slit-like openings being closed on one side by said at least one first covering sheet (1b, 101b) and being surrounded, on the plane of the blank, along all of its perimeter by the material of the supporting layer (1a, 101a).
The blank according to claim 9, characterized in that each one of said slit-like openings (2, 102) is extended substantially along the entire length of the corresponding edge (21, 121) of the box.
The blank according to one or more of the preceding claims, characterized in that said slit-like openings (2, 102) are substantially mutually parallel.
The blank according to one or more of the preceding claims, characterized in that it comprises at least one second covering sheet (1c, 101c) that is coupled to a second face of said supporting layer (1a, 101a) that is opposite the first face, so that each one of said slit-like openings (2, 102) is closed on both sides respectively by said first and second covering sheets.
The blank according to one or more of the preceding claims, characterized in that said supporting layer (1a, 101a) is a cardboard layer that has a thickness comprised between 0.4 mm and 1.5 mm, more preferably comprised between 0.74 mm and 1.11 mm, and a grammage comprised between 400 g/m² and 750 g/m².
The blank according to one or more of the preceding claims, characterized in that the material of said at least one first covering sheet and/or of said at least one second covering sheet is paper, with a grammage comprised between 90 g/m² and 300 g/m², more preferably comprised between 130 g/m² and 150 g/m², and with a thickness comprised between 60 microns and 200 microns, more preferably between 70 microns and 150 microns.
The blank according to one or more of the preceding claims, characterized in that it comprises at least one folded flap (6, 106) of said at least one first covering sheet (1b, 101b) on an edge of said supporting layer (1a, 101a).
A die-cut element (8, 9, 109) for manufacturing boxes according to the method of claim 1, characterized in that it comprises a portion a blank obtained by die-cutting the blank according to any of claims 9-15, the perimetric edge (7) of said portion surrounding, or passing through, said slit-like openings (2, 102).
A box (20, 120), characterized in that it comprises the die-cut element according to claim 16 or obtained by the method according to any of claims 1 to 8, folded along at least said slit-like openings (2, 102).
The box according to claim 17, characterized in that it can be collapsed reversibly, said slit-like openings (2, 102) being arranged along the edges (21, 121) along which the box is adapted to be flattened by folding said edges.
The box according to one or more of claims 17, 18 characterized in that said die-cut element comprises at least one folded flap (6, 106) of said at least one first covering sheet (1b, 101b) on an edge (4, 104) of said supporting layer (1a, 101a), a layer of glue being interposed between said folded flap and a wing (11, 111) of the die-cut element.