High speed assembly of a cartridge and cover

Abstract

A method for packaging a product in which a lid is fitted to a box. The lid top is oriented at an angle to the processing direction in which the box is conveyed. The lid is engaged with the box by initiating contact between the front panel of the lid and the box as the front panel is moved, and then engaging the back panel with the box. The box captures the lid by the front panel of the lid as the box is conveyed in the processing direction, and the remainder of the lid is subsequently fitted to the box.

Description

Technical Field

[0001] A method for assembling boxes and covers. Background Technology

[0002] High-speed assembly of boxes and lids is a critical process that can impact packaging line productivity. Typically, cardboard or corrugated boxes and lids are fitted together to form a closed package after the box is filled with goods. Methods for shifting one or both of the box and lid are common. In these shifting methods for assembling the box and lid together, one or both of the box and lid undergo a movement with start and stop.

[0003] In one type of relocation method, the filled box is moved to and secured in a cover-fitting station while the cover is assembled onto the box. After the cover is assembled onto the box, the box and cover are moved away from the cover-fitting station. In another relocation method, the cover is moved to and secured in a cover-fitting station while the box is assembled onto the cover. After the box is assembled onto the cover, the box and cover are moved away from the cover-fitting station.

[0004] Displacement methods are generally slow. Starting, stopping, and controlling the movement of the object being moved takes time. This time can be reduced by applying greater acceleration at startup, greater deceleration before stopping, and greater speed during movement. Sudden starts or stops can generate considerable forces through changes in the momentum of the moving parts of the equipment and the object being moved. Therefore, there are practical limitations to the operating speed of displacement methods.

[0005] In a typical product packaging process, blanks are erected to form boxes and covers. The blanks are constructed from cardboard or corrugated paper. Folding the cardboard or corrugated paper deforms the blanks, which have various panels, flaps, tabs, slots, etc., transforming them into three-dimensional structures. Adhesives, interlocking tabs and slots, and friction are used to position the panels and flaps to maintain the structural integrity of the box and cover. When the cardboard or corrugated paper is folded, stress is generated near and at the fold lines. These stresses may not completely dissipate before the box and cover are constructed and assembled. Residual stress can cause warping of various panels and flaps of the box and cover, especially for large, unsupported panels. The warping of the box and cover may be inconsistent because the dimensions of the panels and flaps that make up the box and cover may differ. This inconsistency in warping can complicate the use of displacement methods to assemble the cover to the box, especially when the tolerances for assembling the cover to the box are small.

[0006] Given these limitations, there remains an unresolved need for high-speed methods for assembling kit boxes and covers. Summary of the Invention

[0007] A method for packaging a product (1), the method comprising the steps of: manufacturing the product, wherein the product is a base treatment composition; providing a box holder system (120); providing a box (10) movable on or in the box holder system; moving the box in a processing direction (MD) at a box speed (TV) via the box holder system; providing a dispensing system; and dispensing the product into the box via the dispensing system.

[0008] A cover engagement system is provided above the box holder system and downstream of the dispensing system; a cover (60) movable in the cover engagement system is provided, wherein the cover includes a front panel (70), a back panel (80) opposite to and upstream of the front panel, and a cover top (90) extending from the front panel to the back panel, wherein the cover top is oriented at an angle (β) of about 0.5 degrees to about 20 degrees relative to the processing direction; the cover is engaged with the box via the cover engagement system to close the box, thereby forming a closed package (110), wherein the cover is engaged with the box by initiating contact between the front panel and the box when the box moves in the processing direction, and then engaging the back panel with the box; and the closed package is shipped. Attached Figure Description

[0009] Figure 1 It's a box.

[0010] Figure 2 It's a cover.

[0011] Figure 3 It is a box with a cover.

[0012] Figures 4A to 4D The cover is shown being gradually assembled into the box.

[0013] Figure 5 It is a packaging line used to dispense products into boxes and assemble covers into the boxes to seal the packaging.

[0014] Figure 6 It is a box with fins.

[0015] Figure 7 It is a cross-sectional view of a cover with inwardly folding flaps along the front and rear panels.

[0016] Figure 8 It is a cross-sectional view showing the winglets being assembled to the inwardly folding winglets to secure the cover to the box.

[0017] Figure 8A It is a partial view, such as Figure 8 The label indicates that the flaps are fitted to the inwardly folding flaps to secure the cover to the box.

[0018] Figure 9 The packaging has a cover with holes that allow the user to access the inwardly folding flaps to open the package.

[0019] Figure 10 It is a cover engagement system used for feeding a cover captured by a box.

[0020] Figure 11 It is a box holder system.

[0021] Figure 12 A buffer system is shown for assembling a cover kit into a box after the cover has been captured.

[0022] Figure 13 The product shown is a substrate-treated composition. Detailed Implementation

[0023] This document describes a high-speed method for assembling a cover kit into a box. This method can be part of an end-to-end method for packaging products. The product can be any type of product that can be shipped in cardboard or corrugated paper packaging comprising a box and cover kit assembled together. The product can be a base treatment composition. The product can be a base treatment composition selected from: garment treatment compositions, hard surface treatment compositions, washing machine treatment compositions, hair treatment compositions, skin treatment compositions, oral care compositions, cosmetic compositions, nail treatment compositions, air treatment compositions, dish treatment compositions, disposable absorbent articles, and topical or ingestible health care compositions. The base treatment composition may contain ingredients selected from: surfactants, bleaching agents, fabric softeners, and combinations thereof.

[0024] The method uses box 10, such as Figure 1 As shown. Box 10 and cover may be formed of cardboard or corrugated paper. The cardboard and corrugated paper materials may contain pulp. The cardboard or corrugated paper may have a thickness of 1 mm to about 3 mm. The cardboard or corrugated paper may be a laminated material. The cardboard or corrugated paper may contain pulp. The cardboard or corrugated paper may contain colorants, preservatives, plasticizers, UV stabilizers, oxygen, fragrances, recycled materials, moisture-proof layers, and combinations thereof. The corrugated paper may comprise a laminate of two cardboard sheets having a grooved layer disposed between the two cardboard sheets. Each of box 10 and cover may be a single-piece die-cut cardboard or corrugated paper having a face of box 10 or cover and a pattern of flaps extending from these faces or panels. Box 10 or cover may be erected by combining a combination of flaps or a combination of flaps and faces or panels to stand box 10 or cover upright. The flaps and / or surfaces or panels can be joined together by adhesive, thermal bonding, fitting tabs into slots, and engaging interlocking structures.

[0025] Box 10 can be conveyed in the machining direction MD. Box 10 may include a front side 20 and a back side 30 upstream of the front side. Box 10 may include a front side 40 and a rear side 50 opposite to the front side 40. The front side 40 and the rear side 50 extend from the front side 20 to the back side 30 in the machining direction MD. Box 10 may include an outer peripheral edge 15 defining a top opening of box 10. Box 10 may have a longitudinal axis L aligned with the machining direction MD.

[0026] The method uses a cover of 60, such as Figure 2 As shown. The cover 60 may be formed of cardboard or corrugated paper. The cover 60 may include a front panel 70, a back panel 80 opposite to and upstream of the front panel 70, and a cover top 90 extending from the front panel 70 to the back panel 80. The cover 60 may include a pair of opposing cover side outer peripheral edges 100. The cover 60 may be fitted into a box 10 to form a closed package 110. Figure 3 If the cover 60 is made of corrugated paper, the grooves can be aligned or substantially aligned with the fold lines between the cover top 90 and the front panel 70, and between the cover top 90 and the back panel 70. This arrangement provides clear fold lines between the cover top 90 and the front panel 70, and between the cover top 90 and the back panel 70.

[0027] exist Figures 4A to 4D Following the assembly process shown, the cover 60 can be fitted onto the box 10. The cover 60 can move within a cover engagement system located above the box carrier system carrying the box 10. It should be understood that the box 10 moves in the machining direction MD. The cover 60 also moves such that the velocity component of the cover 60 in the machining direction MD is greater than the velocity component of the cover 60 in a direction orthogonal to the machining direction MD. The velocity component of the cover 60 in the machining direction MD can be five, seven, ten, fifteen, or twenty times greater than the velocity component of the cover 60 in the direction orthogonal to the machining direction MD. The cover 60 can approach the box 10 above the machining direction MD at an approach angle β, which is approximately 0.5 degrees to approximately 20 degrees, optionally approximately 0.5 degrees to approximately 10 degrees, optionally approximately 1 degree to approximately 5 degrees, or optionally approximately 4 degrees, with the apex of the approach angle oriented downstream in the machining direction MD.

[0028] like Figure 4BAs shown, before the cover 60 initially contacts the box 10, the cover 60 guides the box 10 in the machining direction MD. As the box 10 moves in the machining direction MD, the cover 60 is engaged with the box 10 by bringing the front panel 70 of the cover 60 into contact with the box 10 as the front panel 70 moves, and then engaging the back panel 80 of the cover 60 with the box 10. In operation, the cover 60 is fed toward the box 10 in such a manner that the front panel 70 of the cover is in a guide position above the box 10 in the machining direction, and the front surface 20 of the box 10 catches up with and contacts the front panel 70 of the cover 60. Figure 4C As shown, once the front panel 20 of the box 10 contacts the front panel 70 of the cover 60, the back panel 80 of the cover 60 tilts towards the back panel 30 of the box 10, positioning the back panel 80 of the cover 60 in place to fit over the back panel 30 of the box 10. Figure 4D As shown, with the front panel 70 and back panel 80 of the cover 60 positioned above the front panel 20 and back panel 30 of the box 10, respectively, the cover 60 is in a fully engaged position with the box 10, thereby closing the packaging. A mechanism may be provided downstream of the position where the cover 60 and the box 10 are joined to fully engage the cover 60 and the box 10.

[0029] The cover 60 may have a pair of opposing cover-side outer peripheral edges 100 extending between the front panel 70 and the back panel 80 of the cover 60. The box 10 may have an outer peripheral edge 15 defining the top opening 12 of the box 10. When the front panel 70 of the cover 60 initially contacts the front face 20 of the box 10, about 5% to about 50%, optionally about 10% to about 40%, optionally about 15% to about 30%, and optionally about 10% to about 25% of each cover-side outer peripheral edge are located below the outer peripheral edge 15 of the box 10. By positioning the cover 60 and the box 10 in such a way that the cover 60 is slightly tilted relative to the box 10, and when the box 10 catches up with the cover 60, the cover 60 engages with the box 10 sufficiently so that the box 10 grips the cover 60, and the cover 60 can slide into the appropriate position above the box 10, or the cover 60 can be further manipulated to engage the cover 60 with the box 10 more completely.

[0030] The cover engagement system moves the cover 60 at a reference speed RV. The reference speed RV can be constant or variable and is not zero. Similarly, the box carrier system moves the box 10 in the processing direction MD at a box speed TV. The box speed TV can be constant or variable and is not zero. One or both of the cover engagement system and the box carrier system may have controls that allow the reference speed RV of the cover and / or the box speed TV of the box to be controlled separately. The control system may employ a vision system, which includes a camera, an image acquisition system, and image analysis software connected via a programmable logic controller. The vision system is capable of measuring the parts, verifying the positions of the parts, and identifying the shapes of the parts. Based on input from the vision system, the control system can influence the process by changing the reference speed RV of the cover and the box speed TV. Optionally, one or more photoelectric monitors may be provided to detect the presence of parts of the cover and box, as well as the positions of components of the assembly equipment, and the control system may receive such input and operate the cover engagement system based on such input.

[0031] Optionally, the cartridge speed TV may change in response to the detection position of the cover 60, such that when the front panel 70 initially contacts the cartridge 10, approximately 5% to approximately 50%, optionally approximately 10% to approximately 40%, optionally approximately 15% to approximately 30%, and optionally approximately 10% to approximately 25% of the outer peripheral edge 100 of each cover side are located below the outer peripheral edge 15. Further optionally, the reference speed (RV) of the cover 60 may change in response to the detection position of the cartridge 10, such that when the front panel 70 initially contacts the cartridge 10, approximately 5% to approximately 50%, optionally approximately 10% to approximately 40%, optionally approximately 15% to approximately 30%, and optionally approximately 10% to approximately 25% of the outer peripheral edge 100 of each cover side are located below the outer peripheral edge 15.

[0032] Changing one or both of the reference speed RV and the box speed TV can help ensure that the front panel 70 of the cover is in an acceptable or even optimal position relative to the front face 30 of the box 10, thereby providing engagement between the cover 60 and the box 10 in the aforementioned manner. This differs from a method where the box 10 is conveyed on a conveyor at a uniform pitch and the cover engagement system feeds the cover 60 at regular intervals to engage with the box 10. Such a system may have the following drawbacks: minute variations in the box spacing may cause the cover 60 to be improperly fitted into the box or even not fitted into the box at all. Furthermore, the cover engagement system must be precisely synchronized with the box carrier system to properly fit the cover 60 into the box 10. The ability to control and change one or both of the reference speed RV and the box speed TV overcomes these drawbacks.

[0033] like Figure 5As shown, the high-speed method described herein for assembling a cover kit into a box can be part of an end-to-end method for packaging product 1. The steps of this method may include manufacturing product 1. Product 1 may be a substrate treatment composition. A box carrier system 120 may be provided. A box 10 may be provided, and the box may move in or on the box carrier system 120. Box 10 may move via the box carrier system 120 in the processing direction MD at a box speed TV. The box speed TV may be constant or variable.

[0034] A dispensing system 130 may be provided, and product 1 may be dispensed into box 10 via the dispensing system 130. A cover engagement system 140 may be provided above box carrier system 120 and downstream of dispensing system 130. A cover 60 may be oriented at an angle β relative to the processing direction, the cover having a front panel 70 and a back panel 80 opposite to and upstream of the front panel 70, the angle being from about 0.5 degrees to about 20 degrees, optionally from about 2 degrees to about 15 degrees, optionally from about 5 degrees to about 10 degrees.

[0035] The dispensing system 130 may include a product hopper positioned above the box holder system 120. The hopper holds a certain amount of product 1 to be dispensed into the box 10. For example, if it is assumed that package 110 contains ten product 1s, the hopper holds ten product 1s to be dispensed into the box 10. The system may be located upstream of or integrated with the hopper, and this system counts the quantity or weight of the product dispensed into the hopper. The weighing system may be a multi-head rotary weigher. A suitable weighing system may be the CCW-RV weighing system purchased from ISHIDA (https: / / www.ishida.com / ww / en / ) in Kyoto, Japan. The opening and closing of the hopper may be controlled by a controller that receives information about the position of the box 10 and the appropriate weight, count, or volume of product contained in the hopper. When all logical conditions are met, the controller may generate a start signal to open the hopper. The controller may then instruct the hopper to be refilled with the appropriate weight, quantity, or volume of product to be dispensed the next time it is opened.

[0036] The cover 60 engages with the box 10 via the cover engagement system 140 to close the box 10, thereby forming a closed package 110. As the box 10 moves in the processing direction MD, the cover 60 is engaged with the box 10 by initiating contact between the front panel 70 and the box 10 while the front panel 70 is moving, and then engaging the back panel 80 with the box 10. Importantly, both the box 10 and the cover 60 are moving when contact between the front panel 70 and the box 10 is initiated, which distinguishes this method of assembling the cover 60 to the box 10 from those methods of assembling the cover 60 to the box 10 while the box 10 is fixed, and those methods of assembling the box 10 to the cover 60 while the cover 60 is fixed. Similarly, this method differs from methods that hold the cover 60 in a fixed position and tilt it at an angle opening towards the upstream direction, and drive the box 10 to contact the cover 60, thereby assembling the cover 60 to the box 10. In the method described herein, when the cover 60 and the box 10 are initially in contact with each other, the cover 60 moves at a reference speed RV, and the box moves at a box speed TV.

[0037] The front panel 70 may initially engage with the box 10 at a merging position 150 along the box carrier system 120. The cover engagement system 140 may also include a cover guide 160 above the box carrier system 120 at or downstream of the merging position 150. The cover guide 160 may be downstream of the merging position 150 and closer to the box carrier system 120 than at the merging position 150. The cover guide 160 may contact the cover top 90 to fit the cover 60 onto the box 10. The cover guide 160 may be a wedge that pushes the cover 60 to fit into the box 10. The cover guide 160 may be a strip positioned at a small angle relative to the machining direction MD to force the cover 60 into the box.

[0038] After the cover 60 is assembled into the box 10, the closed package 110 can be shipped. For example, the closed package 110 can be shipped to a distributor or distribution facility and further shipped along the supply chain until it reaches the user's location where the user can open the package 110 by removing the cover 60, retrieve the product 1 from the box 10, and use the product 1.

[0039] Box 10 may have a front fold-back portion 42, which is an integral extension of the front 40 that folds inward toward the interior of box 10 along the front fold line 44. Figure 6 Similarly, the box 10 may have a rear fold-back portion 52, which is an integral extension of the rear 50 that folds inward toward the interior of the box 10 along the rear fold line 54. The front fold-back portion 42 and the rear fold-back portion 52 may provide additional rigidity to the outer periphery 15 of the box 10.

[0040] The front wing 46 extends along the front 40 from the outer periphery along 15. The front wing 46 extends from the front 40 to the distal end 47 of the front wing. The rear wing 56 extends along the rear 50 from the outer periphery along 15. The rear wing 56 extends from the rear 50 to the distal end 57 of the rear wing. The front wing 46 and the rear wing 56 may be formed by cutting lines in the front 40 and rear 50, respectively. The front fold-back portion 42 and the rear fold-back portion 52 may extend deeper into the housing 10 than the cutting lines forming the boundaries of the front wing 46 and the rear wing 56.

[0041] If the box is constructed of corrugated paper, the front fold line 44 and the rear fold line 56 can be orthogonal to the groove. For corrugated paper, folds perpendicular to the groove can provide a flexible hinge around the fold. For the box 10 described herein, this flexibility can be used to form a closure system that engages the cover 60 with the box 10, allowing for multiple opening and closing.

[0042] The blank from which the box 10 is erected may include cutting lines defining the shape and size of the front flap 46 and the rear flap 56, and these cutting lines may be positioned such that the front flap 46 and the rear flap 56 are positioned as needed when the box 10 is erected. As part of the method of erecting the box 10 from the blank, the front fold-back portion 42 and the rear fold-back portion 52 may be folded toward the interior of the box 10. The portions of the front fold-back portion 42 and the rear fold-back portion 52 extending from the front flap 46 and the rear flap 56, respectively, may unfold and point upward after the box 10 is erected. When the box 10 is erected and the front fold-back portion 42 and the rear fold-back portion 52 are folded toward the interior of the box 10, the front flap 46 and the rear flap 56 may protrude upward from the outer periphery of the box 10 along a 15.

[0043] As part of the method of packaging product 1, front flap 46 and rear flap 56 are folded outward away from the interior of box 10, and then cover 60 is engaged with box 10. When cover 60 is engaged with box 10, front flap 46 and rear flap 56 remain downward. Front flap 46 and rear flap 56 can be folded outward via a pair of folding tracks associated with box carrier system 120. As box 10 is conveyed downstream, the folding tracks can capture the distal ends of the flaps, and the downstream movement of box 10 and the formation of the folding tracks can cause front flap 46 and rear flap 56 to bend outward away from the interior of box 10, such that the distal ends of the respective flaps are oriented toward the bottom of box 10.

[0044] As a non-restrictive example, such as Figure 7 As shown, the cover 60 may be provided with a engagement mechanism that cooperates with the front wing 46 and the rear wing 56. Figure 7This is a cross-sectional view of the cover 60 viewed from an upstream direction toward the back panel 80. The cover 60 may also include a front panel inward folding flap 172 extending from the front panel 170 and a rear panel inward folding flap 182 extending from the rear panel 180. The front panel 170 and the rear panel 180 may extend together from the front panel 70 to the back panel 80. Furthermore, the front panel inward folding flap 172 and the rear panel inward folding flap 182 may be located between the front panel 170 and the rear panel 180.

[0045] When the cover 60 is assembled into the box 10, the distal ends of the front wing 46 and the rear wing 56 can engage with the ends 190 of the inward folding wing 172 of the front panel and the inward folding wing 182 of the rear panel, respectively. Figure 8 When the cover 60 is properly assembled into the box 10, an audible clicking sound is produced by the engagement of the front flap 46 and the rear flap 56 with the ends 190 of the front panel inward folding flap 172 and the rear panel inward folding flap 182, respectively. This audible clicking sound can be monitored during the assembly process and is used as a quality assurance measure to detect that the locking mechanism is properly engaged. Furthermore, when the packaging 110 is used in a consumer's home, the audible clicking sound produced when the cover 60 is properly assembled into the box 10 can signal to the consumer that the packaging 110 is properly closed.

[0046] Optionally, the cover 60 may be provided with a cover insert projecting from the inward-facing surface of the cover top 90. The size and dimensions of the cover insert may be designed to fit within the interior space of the box 10 near the top of the outer periphery 15 of the box 10. The cover insert may be a piece of cardboard or corrugated paper, optionally a folded piece of cardboard or corrugated paper, bonded to the inward-facing surface of the cover top 90. The cover insert may have a structure similar to that disclosed in U.S. Patent Application 63 / 299,582, which is a flat insert, a portion of which is spaced apart from the interior of the cover top when the cover 60 is upright. The spaced-apart portion projecting towards the interior space of the box during assembly may help guide the cover 60 to fit properly with the box 10.

[0047] The user can unlock the cover 60 from the box 10 by pushing the front wing 46 and the rear wing 56 to disengage the distal ends of the front wing 46 and the rear wing 56 from the ends 190 of the inward folding wing 172 of the front panel and the inward folding wing 182 of the rear panel, respectively. The front wing 46 and the rear wing 56 rotate about the hinge formed by the front folding line 44 and the rear folding line 54. The front wing 46 can be accessed through the hole 200 in the front panel 170. The rear wing 56 can be accessed through the hole 200 in the rear panel 180. Figure 9The engagement of the ends of the faceplate and the inwardly folding faceplate of the panel can be inspected by a vision system or other sensors visible on and / or around the hole 200. For example, the presence of the faceplate can be detected by measuring the color behind the hole 200. If the faceplate is in the proper position, a first color can be detected. If the faceplate is not in the proper position, the color of the rear side of the front panel and the rear panel can be detected as a second color, and a system fault is generated to refuse packaging when the second color is detected or the first color is not detected.

[0048] The cover engagement system 140 is a mechanism for positioning the cover 60 so that the cover 60 can be captured by the box 10 as the box 10 moves downstream in the processing direction MD. For example... Figure 10 As shown, the cover engagement system 140 may include a cover travel path 210 facing and oriented at an angle β toward the bracket system 120. The cover travel path 210 may be positioned between two cover actuators 220. The cover actuators 220 may move the cover 60 by contacting the cover 60. The cover actuator 220 may be a belt. The cover actuator may be a roller. The counter-rotating cover actuators 220 may move the cover 60 by contacting the front panel 170 and the rear panel 180, thereby pushing or pulling the cover 60 in the downstream direction. The tangential speed of the cover actuators 220 may be individually controlled and is controllable, so that the movement of the cover 60 may be synchronized with the movement of the cassette 10, such that the cassette 10 captures the cover 60 as it moves in the downstream direction. Figure 10 Each cover driver 220 is visible to the observer, and optionally there are opposing cover drivers 220 that are not visible on the opposite side. That is, when viewed downstream, the cover drivers 220 may be present on the left and right sides of the machining direction MD.

[0049] The cover 60 can be tightly fitted to the box 10 to provide a robust connection between the cover 60 and the box 10 for the closed package 110. If the fit between the cover 60 and the box 10 is tight, a method of operating at a fixed rate with little or no control over the movement of one or both of the cover 60 and the box 10 may not be sufficient to enable the box 10 to hold the cover 60 when it is closed with the box 10.

[0050] Precise control of the movement of box 10 can be provided by a bracket system 120 comprising multiple linear motion vehicles 230. Figure 11The bracket system 120 can be a horizontally oriented track system that controls the movement of individual linear motorized vehicles 230. A suitable linear motorized track system can be an ITRAK system purchased from Rockwell Automation. Boxes 10 can be transported by adjacent linear motorized vehicles 230. Each linear motorized vehicle 230 may have a restraint plate 240 attached thereto. The restraint plate 240 may be orthogonal to the machining direction MD. Each box 10 may be held by the restraint plate 240 of an adjacent linear motorized vehicle 230. In operation, adjacent pairs of linear motorized vehicles 230 can be controlled individually or in pairs to hold the box 10 between the restraint plates 240 of the adjacent linear motorized vehicles 230.

[0051] The spacing P between the boxes 10 can be non-constant and individually controlled. The position of a single box 10 can be controlled to match the position of the cover 60 assembled to it. A vision system or sensor can detect the position and speed of the cover 60, and a computer system can adjust the speed of the box 10 so that the cover 60 is captured by the box 10 when the box 10 passes the position where the cover 60 merges with the box 10.

[0052] The carrier system 120 can be configured to transport the box 10 when it is compressed in the longitudinal direction, causing the front 40 and rear 50 to bend outward away from the longitudinal axis L. This outward bending of the front 40 and rear 50 can occur during the manufacture of the flat cardboard or corrugated paper. The amount of bending can be increased by the force applied by the carrier system 120 in the processing direction MD and in the direction opposite to the processing direction MD, compared to the amount of bending that may occur due to the manufacture of the flat cardboard or corrugated paper and the amount of bending that may occur due to the conversion of the flat cardboard or corrugated paper into the three-dimensional box 10. Bending the front 40 and rear 50 outward, or having an outwardly bent front 40 and rear 50, can help provide a tight fit between the cover 60 and the box 10, as well as a secure engagement of the locking mechanism. As a non-limiting example, in the carrier system 120 employing linear motorized carriers 230, the box 10 can be bent by controlling or setting the spacing between adjacent linear motorized carriers 230. The spacing between adjacent linear motorized vehicles 230 can be set to be less than the distance between the front 20 and back 30 of the box 10 under unloaded conditions (as measured between the outer surfaces). Software operating the adjacent linear motorized vehicles 230 can be programmed to control the required amount of bending at different locations along the bracket system 120, which may vary depending on the location. The panel of the cover 60 aligned with the front 40 and back 50 can also be bent due to the folded base between the cover top 90 and the panel of the cover 60 aligned with the front 40 and back 50. If corrugated paper is used to form the cover 60 and the fold lines are perpendicular to the grooves, the panel of the cover 60 aligned with the front 40 and back 50 can be bent outwards.

[0053] When the cover 60 engages with the box 10, the cover 60 and the box 10 can be engaged by gradually pressing the front 40 and the rear 50 toward each other along the longitudinal axis L. As the box 10 is conveyed downstream in the processing direction MD, the base constituting the front 40 and the rear 50 may be compressed when the box 10 is pressed between adjacent linear motorized carriers 230.

[0054] As previously stated and as Figure 7 As shown, the cover 60 may include a front panel inward folding flap 172 and a rear panel inward folding flap 182. The size and dimensions of the cover 60 may be designed to fit snugly to the box 10, so that the box 10 can be securely closed. For a cover configured to include the front panel inward folding flap 172 and the rear panel inward folding flap 182, when the cover 60 is engaged with the box 10 from the front panel 70 to the back panel 80, the cover is engaged with the box 10 by gradually pressing the front 40 and the rear 50 toward each other along the longitudinal axis L using the front panel inward folding flap 172 and the rear panel inward folding flap 182.

[0055] Once the housing 10 has captured the front panel 170 or the front panel inward folding flap 172, the cover 60 is at least partially fitted to the housing 10. As the housing 10 moves further downstream in the machining direction MD, the cover 60 can be further fitted to the housing 10 by providing a buffer 250 to push the cover 60 onto the housing 10. Figure 12 The buffer 250 may be configured to provide a reaction surface, with at least a portion of the cover 60 contacting this reaction surface. The distance between a portion of the buffer 250 and the carrier system 120 may be reduced depending on the distance in the machining direction. The buffer 250 may act as a wedge to push the cover 60 down onto the box 10 as the box 10 and cover 60 are conveyed downstream in the machining direction. While the box 10 is held and under the control of the carrier system 120, the cover 60 may be further fitted into the box 10 downstream of the position where it was initially captured. The cover 60 may be fitted into the box 10 as the box 10 and cover 60 move in the machining direction MD. The buffer 250 may have a smooth surface that engages with the cover 60, allowing the cover to slide easily along the buffer 250. The smooth surface of the buffer 250 may be a polished steel or aluminum surface or a plastic material, such as acetal or other plastic materials with a low coefficient of friction and a smooth finish.

[0056] After the back panel 80 is assembled into the housing 10, the housing 10 and the enclosed cover 60 can be transferred from the carrier system 120 to the downstream conveyor 260. A second buffer 250 can be positioned above the downstream conveyor 260 to further fit the cover 60 into the housing 10. The second buffer 250 can be wedge-shaped or positioned to present a wedge-shaped surface to the cover 60 as the housing 10 and cover 60 are further conveyed downstream in the processing direction MD.

[0057] After the cover 60 is assembled into the box 10 to form a closed package 110, the closed package 110 can be shipped from the location where it was assembled. The closed package 110 can be shipped to a distribution center, customer, or consumer to ultimately reach the location where the user opens the package 110 to use or consume its contents.

[0058] The engagement mechanism between the cover 60 and the box 10 provides a quality assurance check that the cover 60 is securely engaged with the box 10. The package 110 can be removed from the downstream conveyor 260 by a picking robot or other device that picks up the package 110 by gripping or otherwise lifting the cover 60. The cover 60 can be gripped from below the outer peripheral edge 100 of the cover side, or between the front panel 70 and the back panel 80, or between the cover panels oriented in the direction of the front 40 and the rear 50 of the box 10, or a combination thereof. The cover 60 can optionally be lifted by a suction device applied to the top 90 of the cover. The weight of the product 1 in the box 10 will be supported or substantially supported by the engagement mechanism between the cover 60 and the box 10. If the package 110 is securely closed, the package 110 can be successfully picked up by the cover 60, and the cover 60 will not detach from the box 10. If the engagement mechanism fails to engage properly, the cover 60 may detach from the box 10, indicating that the package 110 is not securely closed. The box 10 and its contents may remain on the conveyor 260 and be transferred to a secondary processing area, where a pick-up device can transfer the detached cover to the secondary processing area.

[0059] The substrate treatment composition 2 may be a water-soluble unit dose article ( Figure 13 The item may be a small bag. One to about 200, optionally about 10 to 100, optionally about 10 to about 40 water-soluble unit doses may be dispensed into each box 10 as it passes under the dispensing system 130. The size and dimensions of each box 10 may be designed to contain the aforementioned number of water-soluble unit doses. Each box 10 may have an internal volume of about 500 mL to about 5000 mL, optionally about 800 mL to about 4000 mL.

[0060] Water-soluble articles can be formed from a water-soluble film encapsulating a substance used for surface treatment. These substances can be laundry detergents, dishwashing liquids, or similar products. The water-soluble film can be a polyvinyl alcohol film. Water-soluble unit-dose articles can be single-compartment or multi-compartment sachets. The compartments can be arranged side-by-side or stacked. Each water-soluble sachet can weigh from about 10g to about 40g, or optionally from about 15g to about 35g.

[0061] combination :

[0062] The following are examples. :

[0063] A. A method for packaging a product (1), the method comprising the following steps:

[0064] Manufacturing the product, wherein the product is a base-treated composition;

[0065] Provides a box holder system (120);

[0066] Provides a box (10) that is movable on or in the box holder system;

[0067] The cassette is moved in the processing direction (MD) at a cassette speed (TV) via the cassette carrier system;

[0068] Provide a distribution system;

[0069] The product is dispensed into the box via the dispensing system;

[0070] A cover engagement system is provided above the box holder system and downstream of the dispensing system;

[0071] A cover (60) movable in the cover engagement system is provided, wherein the cover includes a front panel (70), a back panel (80) opposite to and upstream of the front panel, and a cover top (90) extending from the front panel to the back panel, wherein the cover top is oriented at an angle (β) of about 0.5 degrees to about 20 degrees relative to the processing direction.

[0072] The cover is engaged with the box via the cover engagement system to close the box, thereby forming a closed package (110), wherein the cover is engaged with the box by initiating contact between the front panel and the box as the box moves in the processing direction, and then engaging the back panel with the box; and

[0073] The sealed packaging is then shipped.

[0074] B. The method according to paragraph A, wherein the cover engagement system comprises:

[0075] A cover travel path, the cover travel path being oriented toward and at the angle to the bracket system, wherein the cover travel path is disposed between two cover actuators (220) opposite to each other, wherein the cover actuators move the cover by contacting the cover.

[0076] C. The method described in paragraph B, wherein each cover driver is selected from belts, rollers, and combinations thereof.

[0077] D. The method according to any one of paragraphs A to C, wherein the front panel initially engages with the box at a merging location along the box holder system, wherein the cover engagement system further includes a cover guide above the box holder system at or downstream of the merging location, wherein the cover guide is closer to the box holder system downstream of the merging location than at the merging location, wherein the cover guide contacts the top of the cover to assemble the cover onto the box.

[0078] E. The method according to any one of paragraphs A to D, wherein the cover has a pair of opposing cover-side outer peripheral edges (100) extending between the front panel and the back panel, and the box has an outer peripheral edge (15) defining a top opening (12) of the box, wherein about 5% to about 50% of each cover-side outer peripheral edge is located below the outer peripheral edge when the front panel initially contacts the box.

[0079] F. According to the method described in paragraph E, the method further includes the following steps:

[0080] The cover is moved at a reference speed (RV) via the cover engagement system;

[0081] The box speed is changed in response to the detection position of the cover, such that when the front panel initially contacts the box, about 15% to about 50% of the outer peripheral edge of each cover side is located below the outer peripheral edge.

[0082] G. According to the method described in paragraph E, the method further includes the following steps:

[0083] The cover is moved at a reference speed (RV) via the cover engagement system;

[0084] The reference velocity changes in response to the detection position of the box, such that when the front panel initially contacts the box, approximately 15% to approximately 50% of the outer peripheral edge of each cover side is located below the outer peripheral edge.

[0085] H. The method described in any of paragraphs A through G, wherein the box comprises:

[0086] The front side (20) and the back side (30) upstream of the front side;

[0087] A front (40) and a rear (50) opposite to the front, wherein the front and the rear extend from the front side to the rear side in the processing direction;

[0088] An outer peripheral edge (15) defines the top opening of the box (15);

[0089] A front wing (46) extends along the front edge from the outer periphery;

[0090] A rear wing (56) extends along the rear from the outer periphery;

[0091] The method further includes the steps of: folding the front wing and the rear wing away from the top opening, then engaging the cover with the box, and keeping the front wing and the rear wing downward while engaging the cover with the box.

[0092] I. The method according to any one of paragraphs A to H, wherein the cover further comprises a front panel and a rear panel opposite to the front panel, wherein the front panel and the rear panel extend from the front panel to the back panel, wherein the front panel includes a front panel inward folding flap along at least a portion of the front panel, wherein the rear panel includes a rear panel inward folding flap along at least a portion of the rear panel, wherein the front panel inward folding flap and the rear panel inward folding flap are located between the front panel and the rear panel.

[0093] J. The method according to any one of paragraphs A to I, wherein the substrate treatment composition comprises an ingredient selected from: surfactants, bleaching agents, fabric softeners, and combinations thereof.

[0094] K. The method described in any of paragraphs A to J, wherein a plurality of said boxes are arranged in the box holder system, wherein the spacing between said boxes is non-constant and is individually controlled.

[0095] L. The method according to any one of paragraphs A to K, wherein the box carrier system comprises a plurality of linear motorized vehicles, wherein a limiting plate orthogonal to the processing direction is attached to each linear motorized vehicle, wherein each box is held by a limiting plate of an adjacent linear motorized vehicle.

[0096] M. The method described according to any one of paragraphs A through L, wherein the box comprises:

[0097] The front side and the back side upstream of the front side;

[0098] A front and a rear opposite to the front, wherein the front and the rear extend from the front side to the rear side in the processing direction;

[0099] The box has a longitudinal axis aligned with the processing direction, and the front and rear sides are curved outwards away from the longitudinal axis.

[0100] N. The method according to any one of paragraphs A through M, wherein the box comprises:

[0101] The front side and the back side upstream of the said front side; and

[0102] Front (40) and rear (50), the front and the rear extending from the front side to the rear side in the processing direction;

[0103] The box has a longitudinal axis aligned with the processing direction, and when the front panel contacts the box, the front and rear bend outward away from the longitudinal axis;

[0104] When the cover is engaged with the box, the cover is engaged with the box by gradually pressing the front and the back toward each other along the longitudinal axis.

[0105] O. According to the method described in paragraph N, the cover further includes a front panel and a rear panel opposite to the front panel, wherein the front panel and the rear panel extend from the front panel to the back panel, wherein the front panel includes a front panel inward folding flap along at least a portion of the front panel, wherein the rear panel includes a rear panel inward folding flap along at least a portion of the rear panel, wherein the front panel inward folding flap and the rear panel inward folding flap are located between the front panel and the rear panel, wherein when the cover is engaged with the box from the front panel to the back panel, the cover is engaged with the box by gradually pressing the front and the rear towards each other along the longitudinal axis with the front panel inward folding flap and the rear panel inward folding flap.

[0106] P. The method described in any of paragraphs A through O, wherein the box and the cover comprise corrugated paper.

[0107] Q. According to the method described in any of paragraphs A through P, wherein the box comprises:

[0108] The front side (20) and the back side (30) upstream of the front side;

[0109] A front (40) and a rear (50) opposite to the front, wherein the front and the rear extend from the front side to the rear side in the processing direction;

[0110] The outer peripheral edge defines the top opening of the box (15);

[0111] A front wing extending along the front edge from the outer periphery;

[0112] A rear wing extending along the rear from the outer periphery;

[0113] The method further includes the steps of: folding the front wing and the rear wing away from the top opening, then engaging the cover with the box, and while engaging the cover with the box, keeping the front wing and the rear wing downwards.

[0114] The cover further includes a front panel and a rear panel opposite the front panel, wherein the front panel and the rear panel extend from the front panel to the back panel, wherein the front panel includes a front panel inward folding flap along at least a portion of the front panel, wherein the rear panel includes a rear panel inward folding flap along at least a portion of the rear panel, wherein the front panel inward folding flap and the rear panel inward folding flap are located between the front panel and the rear panel, wherein when the cover is engaged with the box, the front flap is mechanically engaged with the front panel inward folding flap, and the rear flap is mechanically engaged with the rear panel inward folding flap.

[0115] The dimensions and values ​​disclosed herein should not be construed as strictly limited to the precise numerical values ​​cited. Rather, unless otherwise specified, each such dimension is intended to represent the cited value and a range around which it is functionally equivalent. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm”.

[0116] Unless expressly excluded or otherwise limited, every reference cited herein, including any cross-references or related patents or patent applications, and any patent application or patent claiming priority to or benefiting from it, is incorporated herein by reference in its entirety. Reference to any reference is not an endorsement of it as prior art to any disclosed or protected art herein, nor is it an endorsement of any such invention, either on its own or in combination with any one or more references. Furthermore, where any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in referenced documents, the meaning or definition given to that term in this invention shall prevail.

[0117] While specific embodiments of the invention have been illustrated and described by way of example, it will be apparent to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. Therefore, it is intended that all such changes and modifications falling within the scope of the invention be covered by the appended claims.

Claims

1. A method for packaging a product (1), the method comprising the following steps: Manufacturing the product, wherein the product is a base-treated composition (2). Provides a box holder system (120); A box (10) movable on or in the box holder system is provided, the box including a front (20) and a back (30) upstream of the front. The box is moved in the processing direction (MD) at a box speed (TV) via the box carrier system; Provide a distribution system (130); The product is dispensed into the box via the dispensing system; A cover engagement system (140) is provided above the box holder system and downstream of the dispensing system. A cover (60) movable in the cover engagement system is provided, wherein the cover includes a front panel (70), a back panel (80) opposite to and upstream of the front panel, and a cover top (90) extending from the front panel to the back panel, wherein the cover top is oriented at an angle (β) of about 0.5 degrees to about 20 degrees relative to the processing direction. The cover is engaged with the box via the cover engagement system to close the box, thereby forming a closed package (110), wherein the cover is engaged with the box by initiating contact between the front panel and the box as the box moves in the processing direction, and then engaging the back panel with the box, wherein once the front of the box contacts the front panel of the cover, the back panel of the cover tilts toward the back of the box, which positions the back panel of the cover in place to fit over the back of the box; as well as The sealed packaging is then shipped.

2. The method of claim 1, wherein the cover engagement system comprises: A cover travel path, the cover travel path being oriented toward the bracket system and at the angle to the box bracket system, wherein the cover travel path is disposed between two cover actuators (220) opposite to each other, wherein the cover actuators move the cover by contacting the cover.

3. The method of claim 2, wherein each cover driver is selected from belts, rollers, and combinations thereof.

4. The method according to any one of the preceding claims, wherein the front panel is initially engaged with the box at a merging position (150) along the box carrier system, wherein the cover engagement system further includes a cover guide (160) above the box carrier system at or downstream of the merging position, wherein the cover guide is closer to the box carrier system downstream of the merging position than at the merging position, wherein the cover guide contacts the top of the cover to assemble the cover onto the box.

5. The method of claim 1, wherein the cover has a pair of opposing cover-side outer peripheral edges (100) extending between the front panel and the back panel, and the box has an outer peripheral edge (15) defining a top opening (12) of the box, wherein about 5% to about 50% of each cover-side outer peripheral edge is located below the outer peripheral edge when the front panel initially contacts the box.

6. The method according to claim 5, further comprising the following step: The cover is moved at a reference speed (RV) via the cover engagement system; The box speed is changed in response to the detection position of the cover, such that when the front panel initially contacts the box, about 15% to about 50% of the outer peripheral edge of each cover side is located below the outer peripheral edge.

7. The method according to claim 5, further comprising the following step: The cover is moved at a reference speed (RV) via the cover engagement system; The reference velocity changes in response to the detection position of the box, such that when the front panel initially contacts the box, approximately 15% to approximately 50% of the outer peripheral edge of each cover side is located below the outer peripheral edge.

8. The method of claim 1, wherein the box comprises: The front side (20) and the back side (30) upstream of the front side; A front (40) and a rear (50) opposite to the front, wherein the front and the rear extend from the front side to the rear side in the processing direction; Outer peripheral edge (15), the outer peripheral edge defining the top opening of the box; A front wing (46) extends along the front edge from the outer periphery; A rear wing (56) extends along the rear from the outer periphery; The method further includes the steps of: folding the front wing and the rear wing away from the top opening, then engaging the cover with the box, and keeping the front wing and the rear wing downward while engaging the cover with the box.

9. The method of claim 1, wherein the cover further comprises a front panel (170) and a rear panel (180) opposite to the front panel, wherein the front panel and the rear panel extend from the front panel to the back panel, wherein the front panel includes a front panel inward folding flap (172) along at least a portion of the front panel, wherein the rear panel includes a rear panel inward folding flap (182) along at least a portion of the rear panel, wherein the front panel inward folding flap and the rear panel inward folding flap are located between the front panel and the rear panel.

10. The method of claim 1, wherein the box and the cover comprise corrugated paper.

11. The method of claim 1, wherein a plurality of said boxes are arranged in the box carrier system with a spacing (P) between said boxes, wherein said spacing between said boxes is non-constant and is individually controlled.

12. The method of claim 1, wherein the box carrier system comprises a plurality of linear motorized vehicles (230), wherein a limiting plate (240) orthogonal to the processing direction is attached to each linear motorized vehicle, wherein each box is held by a limiting plate of an adjacent linear motorized vehicle.

13. The method of claim 1, wherein the box comprises: The front side (20) and the back side (30) upstream of the front side; A front (40) and a rear (50) opposite to the front, wherein the front and the rear extend from the front side to the rear side in the processing direction; The box has a longitudinal axis (L) aligned with the processing direction, and the front and rear sides are curved outward away from the longitudinal axis.

14. The method of claim 1, wherein the box comprises: The front side (20) and the back side (30) upstream of the front side; and Front (40) and rear (50), the front and the rear extending from the front side to the rear side in the processing direction; The box has a longitudinal axis (L) aligned with the processing direction, and when the front panel contacts the box, the front and rear bend outward away from the longitudinal axis; When the cover is engaged with the box, the cover is engaged with the box by gradually pressing the front and the back toward each other along the longitudinal axis.

15. The method according to claim 14, The cover further includes a front panel (170) and a rear panel (180) opposite the front panel, wherein the front panel and the rear panel extend from the front panel to the back panel, wherein the front panel includes a front panel inward folding flap (172) along at least a portion of the front panel, wherein the rear panel includes a rear panel inward folding flap (182) along at least a portion of the rear panel, wherein the front panel inward folding flap and the rear panel inward folding flap are located between the front panel and the rear panel, wherein when the cover is engaged with the box from the front panel to the back panel, the cover is engaged with the box by gradually pressing the front and the rear towards each other along the longitudinal axis with the front panel inward folding flap and the rear panel inward folding flap.

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