Method for manufacturing a box

Abstract

The present invention relates to a method for manufacturing a box made from a plate, comprising the following steps: - applying a finish to at least one first face of a plate; then - grooving, on a second face distinct from the first, of the plate so as to obtain V-shaped grooves on the plate; - cutting the plate along a contour so that some edges of the contour are at least partially beveled; - applying glue to at least some of the beveled edges; - folding the box along the grooves so that the complementary beveled edges come into contact and adhere in pairs, said edges in contact being parallel in pairs.

Description

[0001] The present invention relates to the field of boxes, in particular cardboard boxes.

[0002] It finds applications in particular in the manufacture of boxes known as bell boxes, more commonly called assembled boxes or rigid boxes, formed by a body and a lid that fit together, the applications of which are, for example, shoe boxes or even macaron boxes. State of the art

[0003] Known in the prior art is US patent US5337916A describing shallow boxes formed by folding a blank of corrugated cardboard or equivalent sheet material in which a filler is sandwiched between an inner liner and an outer liner. V-shaped grooves extend parallel to the edges and define the perimeter of the bottom of the box. On the faces forming the edge of the box, grooves are also made to allow the top portion to be folded over the bottom portion, in order to double the thickness of the side face.

[0004] This prior art solution optionally proposes applying an adhesive to both the V-groove and the internal lining of the internal and external walls forming the side faces.

[0005] This solution is suitable for producing thin, flat pizza-type boxes with unsightly double-thickness side walls. It also requires the use of corrugated cardboard blanks or those with a core and inner and outer linings that are poorly suited to luxury cardboard packaging.

[0006] Also known in the state of the art is patent application US20140014713A1 describing another example of a corrugated cardboard box with folded tabs.

[0007] We also know the patent application US2010323867 proposing the following steps: step 1, providing a base panel, an inner layer paper and an outer layer paper; step 2, separately gluing the inner layer paper and the outer layer paper on both surfaces of the base panel; step 3, defining a plurality of grooves on the surface of the base panel which is glued with the inner layer paper, to form a polygonal panel surrounded by the plurality of grooves, and a plurality of side panels connected to the edges of the panel; step 4, applying viscous glue to the side walls of the grooves; step 5, folding the side panels to be substantially vertical to the panel, connecting each side wall of the groove to another corresponding side wall of the groove via viscous glue, thereby forming the finished product of the paper packaging box. Disadvantages of the prior art

[0008] The state-of-the-art solutions are all based on the use of corrugated cardboard with a fluted paper core covered on both sides with a cardboard sheet.

[0009] To ensure the connection between the side faces, it is necessary to have a sufficient contact surface, which is obtained, in the solution proposed by American patent US5337916, by applying the edge of the folded edge of the side face against the cardboard sheet covering the folded edge of the adjacent side face.

[0010] The outer surface of the body and lid of the box according to this prior art solution has the appearance of the outer sheet of corrugated cardboard, which is generally not decorated. If a more elegant appearance is desired, it is necessary to subsequently affix a decorative sheet to the produced cardboard element, which complicates the production.

[0011] It is therefore necessary to fold the side face to create an extra thickness, and limit the height of the side faces to form flat boxes. These solutions are not suitable for luxury cardboard packaging for items such as chocolates, watches, jewelry and more generally products that must be presented in packaging that enhances their value. Solution provided by the invention

[0012] The present invention improves the situation. It is based primarily on the use of a solid sheet of cardboard, not corrugated cardboard, with a thickness of between 1 millimeter and 3 millimeters, and preferably between 1.3 and 2.5 millimeters, for the production of boxes known as "bell boxes".

[0013] Secondly, it is based on a blank having a rectangular base extended on each of its sides by a rectangular panel whose width (measured perpendicular to the side common to the base) is equal to the height of the box or lid after shaping. Unlike the solutions of the aforementioned prior art where the width of the panels is greater than the height of the box because they provide a flap intended to double the thickness of the panel to facilitate gluing on the edge.

[0014] Thirdly, the invention is based on cutting the edges of the side panels intended to be joined at an angle of 45° at an angle, to form a bevel, and to apply glue to at least part of these bevels. The width of these bevels is 1.4 times the thickness of the plate, which provides a sufficient connecting surface to ensure the holding of the side faces of bell-shaped boxes, and not just flat boxes.

[0015] To this end, the present invention provides a method of manufacturing a box having the characteristics set out in claim 1.

[0016] For the purposes of this patent, the term “plate” shall mean a solid material without cells opening onto the edge.

[0017] The method according to the invention, providing for the finishing on at least one first face of a plate, then the shaping with gluing of the faces only by an adhesive applied to the beveled edges of the panels forming the side faces, makes it possible to eliminate a complex step of laminating a covering paper. In fact, the first face of the plate is finished before any cutting, gluing or folding operations.

[0018] Thus, it is not necessary to laminate a covering paper onto a cardboard structure to ensure the aesthetics of the box, as is done in the prior art.

[0019] The term "ennobling" of a face means any treatment of the face in order to give it particular characteristics, in particular particular technical and / or aesthetic qualities. For example, qualities of resistance to humidity, resistance to UV rays, resistance to scratches, reflection of light for certain wavelengths or even relief. For this purpose, a coating may be applied, for example a layer of paint, a printing of pigments or even the lamination of a covering paper. The coating may also be a protective coating of the plate, for example a waterproofing agent or a fire retardant. The treatment of the face may also be obtained by the creation or application of an embossing on the plate.

[0020] Grooving on the plate means making V-shaped grooves on the plate. The grooves can be made by milling the plate, i.e. using a V-grooving cutter. The grooves can be made by notching the plate, i.e. using two blades facing each other and forming a V-shaped angle.

[0021] The angle of the V-grooves can be 90° if you want to obtain a box with uprights perpendicular to the base. It is also possible to opt for different angles in order to have uprights not perpendicular to the base once the box is assembled. The grooving is advantageously rectilinear.

[0022] Advantageously, all the edges of the cut-out plate contour that will be glued are cut at an angle.

[0023] Advantageously, the board is a board formed from cardboard. It can be single-layer or multi-layer, but without open cells on the edges. For example, cardboard is defined by ISO 5651:1989. The board can also be formed from plastic such as PVC or acetate. The board can also be formed from balsa wood. However, corrugated cardboard does not constitute a board within the meaning of this patent.

[0024] According to the invention, the application of the glue comprises, for each two complementary beveled edges, the application of slow-setting glue on at least one of the two complementary beveled edges.

[0025] This allows for effective bonding of each of the two complementary beveled edges. Since the adhesion between two complementary beveled edges is reinforced, even in the absence of covering paper, the flaps are firmly bonded together.

[0026] According to the invention, the application of the glue comprises, for each two complementary beveled edges, the application of dots of quick-setting glue on at least one of the two complementary beveled edges.

[0027] This saves time when folding the box. In fact, once the folding is done and the complementary edges are in contact, it is necessary to maintain the shape of the box until the glue has "set", i.e. is sufficiently dry and / or polymerized. By using a fast-setting glue, the time required to hold the box in shape while the glue sets is reduced, so the folding station can move on to another box.

[0028] The use of quick-setting glue dots can be combined with the use of slow-setting glue on at least one of the two complementary beveled edges. This allows for a combination of strength and speed of assembly.

[0029] Thus, the application of glue may comprise, for each two complementary beveled edges, the alternating application of lines of slow-setting glue and dots of fast-setting glue on at least one of the two complementary beveled edges.

[0030] According to one embodiment, the method further comprises, once the box has been folded, the application of at least one heat-sealed adhesive tape to the second face so that the adhesion between two complementary beveled edges is reinforced.

[0031] The adhesive tape is placed on the inside of the box to avoid any unsightly excess thickness. The adhesive tape is placed to reinforce the adhesion between two complementary beveled edges.

[0032] Other characteristics and advantages of the invention will appear on examining the detailed description below, and the appended drawings in which: There Figure 1A is a top view of a cut plate before gluing and folding produced according to a first embodiment. The Figure 1B is a sectional view of a cut plate before gluing and folding produced according to a first embodiment. The Figure 1C is a top view of a covering paper of a first embodiment. The Figure 1D is a perspective view of an element of a box mounted according to a first embodiment. The Figure 2A is a top view of a cut plate before gluing and folding produced according to a second embodiment. The Figure 2B is a sectional view of a cut plate before gluing and folding produced according to a second embodiment. The Figure 2C is a perspective view of an element of a box mounted according to a second embodiment. The Figure 3A is a diagram illustrating the steps of a method according to a particular embodiment of the invention. Figure 3Bis a top view of a first face of a cut plate before gluing and folding produced according to another embodiment of the invention. The Figure 3C is a top view of a second face of the same plate cut before gluing and folding produced according to another embodiment of the invention. The 3D figure is a perspective view of an element of a box mounted according to another embodiment of the invention. The Figure 4A illustrates a SYS system according to the invention. The Figure 4B is a diagram representing the method according to the invention. General principles for making a bell box

[0033] Plate 10 according to the Figure 1Acut before gluing and folding, provides four rectangular panels 11 and a rectangular bottom 14. The rectangular panels 11 and the bottom 14 are separated by lines cut at mid-thickness 12. These lines cut at mid-thickness 12 are cuts of the plate which are not made in its entire thickness as shown in the Figure 1B . There Figure 1B represents a sectional view of the plate of the Figure 1A according to view IB. Such a mid-cut allows the plate to be folded along these lines. Such a fold is clean.

[0034] The edges of the panels 11 are straight edges, that is to say edges perpendicular to the plane of the view. The edges 13 are the edges on which glue is applied to glue the panels 11 two by two. Once the folds have been made along the line cut at mid-measure 12, the flaps 11 are held in a vertical position relative to the base 14 while the previously applied glue sets. The plate thus cut, glued and folded is called a cardboard structure. Covering of the cardboard structure according to the prior art

[0035] In the prior art, this cardboard structure is first shaped, and after its shaping and the hardening of the glue, coated with a covering paper.

[0036] A 15 cover paper according to the Figure 1Chas flaps 17 and a central portion 16. Secondary flaps 18 are contiguous to the flaps 17 of the covering paper 15. This covering paper 15 is laminated to the cardboard structure by applying glue to the covering paper 15, then arranging the covering paper 15 on the cardboard structure by making the central portion 16 of the covering paper 15 coincide with the bottom 14 of the cardboard structure.

[0037] The flaps 17 of the covering paper 15 are then glued against the panels 11 of the cardboard structure. The secondary flaps 18 are then glued against the panels 11 of the cardboard structure. Thus, the exterior of the cardboard structure is covered by the covering paper 15.

[0038] This gives an element of the box 19, namely the body of the box or the lid of the box, covered with a coating giving it an aesthetic quality as illustrated in the Figure 1D . The lid and the body of the box are distinguished in the case of bell boxes (more commonly called mounted boxes or rigid boxes) by the size of the bottom 14 of each of the elements, the bottom 14 of the lid being wider and longer than the bottom 14 of the body, so that the two elements 19 of the box can fit together correctly. In addition, the covering paper 15, once glued to the cardboard structure, ensures the solidity of the elements of the box 19, in particular due to the second flaps 18 which cover the edges of the element of the box 19 adjacent to the edges 13 of the flaps 11 on which the glue has been applied.

[0039] In this case, several layers of covering paper 15 are superimposed in the vicinity of the edges 13. These extra thicknesses 20 can be considered unsightly and can accelerate the wear of the box due to increased friction between the two elements of the same box. Finally, the folds made along the line cut at mid-grain 12 cause roundings along these lines 12 once the box is assembled as illustrated in Figure 1D .

[0040] To laminate the covering paper 15 onto the cardboard structure, the covering paper is coated or sprayed, then the center 16 of the covering paper 15 is aligned with the outer face of the bottom 14 of the cardboard structure. The flaps 17 of the covering paper 15 are then folded over the flaps 11 of the cardboard structure. To ensure the solidity of the box, the flaps 17 of the covering paper 15 cover the edges 13 of the flaps 11 on which glue dots have been applied. Thus, several layers of covering paper 15 overlap in the vicinity of the edges 13. This unsightly excess thickness can also accelerate the wear of the box in these areas due to increased friction. In addition, the folds made along the line cut at mid-measure 12 cause rounding along these lines 12 once the box is assembled ( Figure 1D ). Presentation of the embodiments according to the invention

[0041] Plate 200 according to the Figure 2A cut before gluing and folding, provides four rectangular panels 210 and a bottom 240. The flaps 210 and the bottom 240 are separated by rectilinear grooves 220. These rectilinear grooves 220 have a V-shaped section as illustrated in the Figure 2B which represents the sectional view of the plate of the Figure 2A according to view IIB.

[0042] These rectilinear grooves of V-section 220 can be produced by milling the plate with a 90° milling cutter or by notching the plate using two V-shaped blades. The rectilinear grooves of V-section 220 are arranged on the face which will be inside the box element 290, namely inside either the body of the box or the lid of the box.

[0043] The straight grooves with a V-shaped section 220 allow the plate to be folded along these same grooves. Such folding is clean.

[0044] The plate, once cut and milled, reveals the edges of the beveled flaps 210. These bevels are arranged so that once the flaps 210 are folded back, the complementary beveled edges 230 face each other two by two.

[0045] The two side edges 230 are beveled at an angle of 45°. The side edges 230 are the edges of a flap 210 which come into contact with the side edges 230 of an adjacent flap 210, and which will form, after shaping, the edges of the box perpendicular to the bottom 240.

[0046] The outer edge of the flap 210, opposite the groove 220, is straight, without bevel.

[0047] Before folding, glue is applied to these 230 beveled edges.

[0048] The glue is preferably a quick-drying fluid glue, for example a cyanoacrylate glue, applied with a nozzle whose cross-section corresponds approximately to the width of the bevel, i.e. 1.4 times the thickness of the plate.

[0049] The application of glue in the grooves 220 is optional, and according to one variant, the glue is applied only to the bevels 230, excluding the grooves 220.

[0050] Once the folds have been made along the rectilinear V-section grooves 220, the flaps 210 are held in a vertical position relative to the base 240 while the previously applied glue sets, in order to obtain a cardboard structure.

[0051] A 15 cover paper according to the Figure 1Cas described above is laminated to the cardboard structure by applying glue to the covering paper 15, then placing the covering paper 15 on the cardboard structure by making the central part 16 of the covering paper 15 coincide with the bottom 240 of the cardboard structure.

[0052] The flaps 17 of the covering paper 15 are then glued against the flaps 210 of the cardboard structure. The secondary flaps 18 are then glued against the flaps 210 of the cardboard structure. Thus, the exterior of the cardboard structure is covered by the covering paper 15.

[0053] This produces an element of the box 290, namely the body of the box or the lid of the box, covered with a coating giving it an aesthetic quality as illustrated in the Figure 2C. In addition, the covering paper 15, once glued to the cardboard structure, ensures the solidity of the elements of the box 290, in particular due to the second flaps 18 which cover the edges of the element of the box 290 adjacent to the edges 230 on which the glue has been applied.

[0054] In this case, several layers of covering paper 15 are superimposed in the vicinity of these edges. These extra thicknesses 299 can be considered unsightly and can accelerate the wear of the box due to increased friction between the two elements of the same box. This method nevertheless has the advantage of making it possible to manufacture box elements 290 with clean edges once the box is mounted as illustrated in Figure 2C .

[0055] There Figure 3A is a top view of a first face 301 of a plate according to an embodiment of the invention.

[0056] The 300 plate according to the Figure 3Acut according to a pattern, provides four flaps 310 and a bottom 340. The first face 301 of the plate 300 is ennobled. The first face 301 of the plate 300 is treated in order to give it particular characteristics, in particular particular technical and / or aesthetic qualities.

[0057] For example, increasing the resistance of the first face 301 of the plate 300 to humidity, UV rays or even scratches. The first face 301 of the plate 300 can also be given light reflection properties for certain wavelengths. For this purpose, a coating can be applied, for example a layer of paint, a pigment print or even the lamination of a covering paper. The coating can also be a protective coating for the plate, for example a waterproofing agent or a fire retardant.

[0058] Pigment printing includes digital printing such as laser or inkjet, offset printing, screen printing, flexography or even heliography.

[0059] The treatment of the face 301 of the plate 300 may also result in a deformation thereof, for example by embossing the plate 300.

[0060] The treatment of the plate may also be a combination of several of the treatments mentioned above, for example printing the face 301 of the plate 300 and embossing the plate 300.

[0061] The second face 302 of the plate 300 cut according to a pattern is illustrated in Figure 3B .

[0062] On the second face 302 of the plate 300 the flaps 310 and the bottom 340 are separated by rectilinear grooves 320. These rectilinear grooves 320 have a V-shaped section as illustrated in the Figure 3Cwhich represents the sectional view of the plate of the Figure 3A And 3B according to view IIIB. These rectilinear grooves with a V-shaped section 320 can be made by milling the plate with a 90° cutter or by notching the plate using two V-shaped blades.

[0063] The edges 330 of the flaps 310 are beveled. These are the edges 330 of the flaps 310 which face each other two by two when the latter 310 are folded.

[0064] This second face 302 of the plate 300 can also be refined. That is to say that treatments such as those previously stated can be applied to this second face 302 of the plate.

[0065] There 3D figureillustrates an element 390 of a box produced according to an embodiment of the invention. By element 390 of a box is meant the body of the box or the lid of the box. These are boxes called bell boxes, more commonly called mounted boxes or rigid boxes, composed of a box body and a box lid, these two elements being distinguished by the size of their respective bottom and the size of their flaps.

[0066] The outer surface of the element 390 of the box corresponds to the first face 301 of the plate 300. Consequently, the outer surface of the element 390 is finished according to at least one of the treatments previously mentioned.

[0067] Furthermore, as illustrated in the 3D figure the edges of element 390 are straight or sharp edges that are not rounded.

[0068] The inner surface of the element 390 of the box corresponds to the second face 302 of the plate 300. A heat-sealed adhesive tape 350 is disposed between two adjacent flaps 320 on the inner surface. Advantageously, the heat-sealed adhesive tape 350 overlaps the edge formed by these two adjacent flaps 320.

[0069] There Figure 4A illustrates a system SYS according to the invention. The system SYS comprises a device and a plate. The device DISP is adapted to produce from the PLA plate an element 390 of the box according to a method according to the invention. More particularly, the device DISP comprises a tool OUTI adapted to produce from the PLA plate an element 390 of the box according to a method according to the invention. The device comprises at least one processor and a memory.

[0070] PLA board can be made from cardboard, for example, cardboard as defined by the Carton standard: ISO5651:1989. The board can also be made from plastic materials such as PVC or acetate, or from balsa wood. Manufacturing method according to the invention

[0071] The steps illustrated in the diagram of the Figure 4B represent the method according to the invention. 1 - The first step S1 of the method is a finishing step consisting of applying a treatment to at least one first face (the outer face after shaping) of the flat PLA plate, before shaping. The treated face corresponds to the first face 301 of the plate cut according to a pattern 300 once steps S2 and S3 have been carried out.

[0072] The surface treatment of the PLA sheet can be embossed. The treatment can be the application of a coating applied to give the PLA sheet resistance to humidity, UV and / or even scratches. The treatment can be the application of a coating obtained by printing pigment on the surface of the PLA sheet. The treatment can be the application of a protective coating of the PLA sheet, such as waterproofing or flame retardant.

[0073] Plaque treatment can also be a combination of several of the treatments mentioned above.

[0074] Step S2 of the process is a grooving step. The grooving is carried out in order to obtain V-shaped grooves on a second face of the PLA sheet (the face corresponding to the inside of the box after shaping). The grooves are made along two parallel lines along a first axis and along two parallel lines along a second axis. The two axes are perpendicular. The V-shaped section of the grooves is illustrated in Figure 3C Grooving can be done by milling the plate with a 90° cutter or by notching the plate using two V-shaped blades.

[0075] Step S3 of the method is a cutting step. The cutting is carried out so as to obtain the cut plate 300 as described in Figures 3A And 3B . Such a plate 300 is cut according to a box pattern.

[0076] The PLA plate is cut along the center of the V of the grooves corresponding to the beveled edges 330. Thus, the edges 330 of the flaps 310 once the cutting step has been carried out are beveled. In the case where the V-section is a 90° section, the bevel obtained is 45° relative to the first surface.

[0077] If the dimensions of the PLA plate require it, the flaps can be shortened to adapt the depth of the box.

[0078] Steps S1, S2 and S3 can be performed in a different order than that set out.

[0079] In addition, the cutting step S3 can be included in the grooving step S2. Indeed, the grooving can be carried out so that along the slices 330 the grooving is deeper in order to achieve the cutting function.

[0080] The fourth step S4 of the process is a glue application step.

[0081] Two types of glue are applied to the wafers: a slow-setting glue, such as white glue, and a fast-setting glue, such as contact glue or cyanoacrylate glue, or hot-melt glue or fiber bonding glue. Both types of glue can be applied to the 330 wafers, but it is also possible to apply only slow-setting glue or only fast-setting glue.

[0082] The slow-setting glue can be applied to the entire surface of the 330 wafers. The slow-setting glue can be sprayed onto the 330 wafers. The slow-setting glue can also be applied using a brush or felt-tip pen.

[0083] The quick-setting adhesive can be applied in a few points on each 330 beveled edge, for example 2 points.

[0084] These adhesives can be applied using a robot equipped with a spray head or a lip nozzle.

[0085] The fifth step S5 of the method is a folding step. The folding of the cut plate 300 is carried out along the rectilinear grooves of V-section 320. Thus, the flaps 310 are folded so that the complementary beveled edges 330 come into contact two by two. The only surfaces in contact are the bevels of the adjacent flaps, without any excess thickness or connecting piece.

[0086] The flaps 330 are held in place for the time required for the glue to set, i.e. the time required for the two edges to adhere together in pairs. Since dots of fast-setting glue have been applied in addition to the slow-setting glue, the holding time of the flaps 330 is equivalent to the setting time of the fast-setting glue, which greatly reduces the time required to use the folding station of the machine performing this step.

[0087] This gives us an element 390 of the box.

[0088] It is possible while the flaps 310 are being held or once the flaps 310 have been held in place to place a heat-sealed adhesive tape 350 on the inner face of the element 390 of the box. The adhesive is applied between two adjacent flaps 320 so as to overlap the edge between these same two adjacent flaps 320.

[0089] The heat-sealed adhesive tape 350 makes it possible to reduce the need to hold the flaps 310 in place, since as soon as it is applied the heat-sealed adhesive tape 350 holds the flaps 310 in position.

[0090] To make a bell box, two elements are prepared as described above, one constituting the base, the other constituting the lid. Of course, the dimensions of the blanks intended for the base on the one hand and the lid on the other, are determined to allow for nesting.

[0091] Of course, the present invention is not limited to the embodiments described above as examples; it extends to other variants.

Claims

1. Method for producing a telescopic box made from a solid sheet, comprising the following steps: - applying a finish to at least a first face of a solid sheet prior to the shaping thereof; then - producing grooves in the sheet, on a second face which is different from the first face, so as to obtain V-shaped grooves in the sheet in order to separate rectangular panels 11 and a bottom 14 by lines cut halfway 12 - cutting the sheet along an outline having said four rectangular panels 11 and said rectangular bottom 14, such that the edges of the outline are at least partly beveled; - applying glue to at least part of the beveled edges; - folding the box along the grooves such that the complementary beveled edges come into contact and adhere in pairs, said edges which are in contact being parallel in pairs, characterized in that said gluing step comprises alternately applying lines of slow-setting glue and dots of fast-setting glue to at least one of the two complementary beveled edges.

2. Method according to one of the preceding claims, wherein applying the finish comprises applying a pigment print.

3. Method according to one of the preceding claims, wherein applying the finishing comprises applying a coating for protecting the sheet.

4. Method according to one of the preceding claims, wherein applying the finishing comprises embossing the sheet.

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