Apparatus and method for forming an integral product protector with cushioning elements in a packaging carton

Abstract

The invention relates to a device for producing integrated product protection with cushioning elements in a packaging carton from a blank comprising a bottom wall, side walls adjoining the bottom wall on opposite sides, and a wall flap adjoining at least one side of the bottom wall, to which a strip flap and a cushioning flap are attached on one side opposite the bottom wall, and a side flap is attached on each of the opposite sides, comprising a first cushion forming tool containing a number of cushion forming means that can be positioned on the wall flap of the flat blank, and a first folding tool for folding the strip flap and the cushioning flap at a right angle relative to the wall flap into an intermediate position.with a second folding tool for folding the upholstery flap at a right angle relative to the strip flap into a further intermediate position, so that the upholstery flap is brought into a position parallel to the wall flap, with a second upholstery forming tool comprising a number of upholstery forming means which, in a starting position, are arranged laterally offset to the upholstery forming means of the first upholstery forming tool and which, taking with them fastening tabs of the upholstery flap, are movable perpendicular to the wall flap in the direction of it, so that a number of upholstery elements are formed from the upholstery flap, each having a main surface running parallel to and at a distance from the wall flap and angled heel elements adjoining it on opposite sides, wherein the heel element has a fastening tab which lies flat against the wall flap.

Description

[0001] The invention relates to a device and method for producing integrated product protection with cushioning elements in a packaging carton.

[0002] From DE 20 2022 103 459 U1, cushioning for packaging cartons is known, consisting of several layers of corrugated cardboard. This cushioning is glued onto a die-cut blank, so that the desired packaging carton is subsequently produced by folding the blank accordingly. A disadvantage of the known packaging carton is that it consists of several components. It is desirable to produce a packaging carton with integrated cushioning from a single blank.

[0003] From DE 10 2019 114 102 A1, a packaging carton is known which has a bottom wall and side walls adjoining it on opposite sides, wherein the side walls each have a cushioning element with a square cross-section, formed by repeatedly folding over a partial side flap of a blank. A disadvantage of the known packaging carton is that, due to the long flat surface of the cushioning element, the item to be packaged must be inserted with a precise fit.

[0004] The object of the present invention is therefore to provide a device and a method for producing integrated product protection with cushioning elements in such a way that improved product protection in a packaging carton is ensured in a simple manner, in particular the corner edge protection is to be improved.

[0005] To solve this problem, the device according to the invention has the features of claim 1.

[0006] According to the invention, a number of upholstery elements are formed in a simple manner by interlocking two upholstery forming tools, each of which has rod-shaped ribs. The forming process is achieved by linearly moving the means of a first upholstery forming tool and a second upholstery forming tool towards each other, with an upholstery flap of the blank being arranged between the upholstery forming means. The arrangement of the upholstery forming means of the first upholstery forming tool, preferably designed as rod-shaped ribs, and the upholstery forming means of the second upholstery forming tool, preferably designed as rod-shaped ribs, offset in the longitudinal direction of the upholstery flap, results in a number of raised upholstery elements being produced in a simple manner.By subsequently folding side flaps and side walls, a packaging carton can be easily produced that has an inner wall (end wall) fitted with cushioning elements. The first cushioning mold and the second cushioning mold thus form a pressure and counter-pressure unit that together create the shape of the cushioning elements.

[0007] According to a preferred embodiment of the invention, the cushioning elements are arranged such that a folded fastening tab of the cushioning element can be attached not only to a wall flap but also to opposing side flaps of the wall flap. This results in improved corner edge protection of the packaging carton. A fold line of the fastening tab runs along a corner edge of the packaging carton. The fastening tab associated with the corner area of ​​the packaging carton lies directly against the side flap, which in turn is attached to a side wall of the packaging carton. This results in a three-layer structure on one side of the corner area. On the other side of the corner area, the cushioning element projects upwards from the wall flap or the wall running perpendicular to the side wall (end wall).

[0008] According to a further development of the invention, the rod-shaped strips of the first cushion forming tool have a length such that a free end face of the rod-shaped strip serves as a stop surface for actuating a first folding tool. Advantageously, only a linear slide is required to fold the cushion flap or the strip flap, which is moved parallel to the stop surface of the free end face of the rod-shaped strip.

[0009] According to a further development of the invention, an adhesive tool enables the application of adhesive dots to side walls and cushioning flaps, so that after folding the packaging carton, a multi-layered bond of cardboard layers is formed in a corner area of ​​the packaging carton. Advantageously, this provides improved corner edge protection.

[0010] According to a further development of the invention, the rod-shaped ribs of the second upholstery forming tool have a sloping side flank along their longitudinal side, so that when the second upholstery forming tool is moved relative to the first upholstery forming tool, carrying the upholstery flap with it, at least one upholstery element is formed which is raised above the wall flap by means of a sloping surface. Because the rod-shaped ribs of the second upholstery forming tool are arranged at the end of their linear movement at the same height as the rod-shaped ribs of the first upholstery forming tool and thus next to them, the fastening tabs of the upholstery element can be laid flat on the wall flap or the side tabs of the wall flap and bonded to it.

[0011] According to a further development of the invention, the clear distance between the adjacent rod-shaped strips of the second cushion forming tool corresponds to the width of a stop surface of the cushion element. This clear distance thus defines the width of the stop surface of the cushion element.

[0012] The first and second upholstery forming tools preferably serve not only to shape the majority of upholstery elements, but also, in addition, the free ends of their rod-shaped strips serve as stop surfaces during the folding process. Furthermore, a support element of the second upholstery forming tool serves to support the strip flap. Advantageously, this allows the strip flap to be maintained in its perpendicular position to the wall flap during the shaping of the upholstery elements.

[0013] To solve the problem, the invention has the features of claim 11.

[0014] The particular advantage of the device according to the invention with a robot unit is that the production throughput can be further increased. A robot arm of the robot unit can continuously perform the folding steps one after the other, whereby at the end of the movement the final shape of the upholstery element is achieved by shaping means (strips).

[0015] Folding is achieved using an integrated linear and rotary movement of the robot arm.

[0016] To solve the problem, the invention has the features of claim 15.

[0017] The advantage of the method according to the invention lies in the fact that a simple shaping of cushioning elements is created by folding and moving towards each other first and second rod-shaped strips arranged laterally offset from one another. The cushioning shaping is an integral part of the process for manufacturing the packaging carton with integrated product protection. Advantageously, this allows the production of the cushioning elements to be integrated into the manufacturing of the packaging carton, thus saving time, and the packaging carton and cushioning can be produced from a single blank.

[0018] According to a further development of the inventive method, fastening flaps of the cushioning elements are glued to a wall flap or side flaps thereof, so that stable cushioning or a stable packaging carton is created.

[0019] Exemplary embodiments of the invention are explained in more detail below with reference to the drawings.

[0020] They show: Fig. 1 A perspective view of a blank of a packaging carton in an initial position in which all die-cut parts of the blank lie in one plane, Fig. 2 a perspective view of the blank according to Figure 1 with integrated product protection after the production of padding on opposite end faces of the blank, Fig. 3 a perspective view of the produced packaging carton in one end face, Fig. 4 a section through the packaging carton along the section line III-III in Figure 3Fig. 5 a view of the blank in its end region after production of adjacent cushioning elements on one side of a wall flap, Fig. 6a a representation of folding tools and cushion forming tools at the beginning of the production of the cushioning elements, wherein the end flaps, side flaps and a bottom of the packaging carton to be folded are still in a cutting plane, Fig. 6b a representation of the blank after actuating a first folding tool to erect an end cushioning flap and an end strip flap, Fig. 6c a representation of the blank after actuating a second folding tool to bring the cushioning flap into a position parallel to the wall flap, wherein the wall flap runs in the plane of the bottom, Fig. 6 a representation of the blank when actuating a second cushion forming tool, which is moved in the direction of a first cushion forming tool, Fig.Fig. 7a a side view of the device for producing the upholstery elements, in which the wall flap and the upholstery flap are located in a common cutting plane, Fig. 7b a side view of the device after actuation of the first folding tool, Fig. 7c a side view of the device after actuation of the second folding tool, Fig. 7a a side view of the device after moving the second upholstery forming tool in the direction of the first upholstery forming tool, Fig. 8a a representation of a robot tool immediately before folding the upholstery flap, Fig. 8b a representation of the cut after actuation of the robot tool, by means of which the upholstery flap and the strip flap have been brought into an upright position relative to the wall flap, Fig. 8c a representation of the robot tool during further folding of the upholstery flap towards a position parallel to the wall flap, and Fig.8. Your illustration of the cutting process during the movement of the robot arm towards the wall flap, whereby the upholstery flap is carried along to shape the upholstery elements.

[0021] A cardboard box 1 is used to package items such as furniture panels, floor coverings, and the like. Figure 3 Figure 1 shows a packaging carton open at the top, which can be joined to make it ready for shipping with an additionally manufactured lid part.

[0022] The packaging carton 1 can be made of cardboard or corrugated board material, as is usually the case with packaging for mail order.

[0023] The packaging carton 1 has a bottom wall 2, side walls 3 projecting perpendicularly from the bottom wall 2 on opposite sides, and end walls 4 projecting perpendicularly from the bottom wall 2 on opposite sides, so that a packaging carton 1 open at the top is formed for receiving items. The opposite side walls 3 extend perpendicularly to the opposite end walls 4. The opposite side walls 3 and the opposite end walls 4 are parallel to each other. Each side wall 3 has a longitudinal flap made from a single blank extending along its entire length.

[0024] Padding is integrated into the end walls 4, which in the present embodiment is formed by three padding elements 5 arranged at a distance from one another. The padding elements 5 extend on an inner side of the end wall 4. Each padding element 5 has raised main sections 6 that serve as a stop surface for the item to be packaged. In addition, each padding element 5 has a shoulder section 10 adjoining the main section 6 on both sides, which is each angled. The shoulder section 10 has a fastening tab 7 on a side facing away from the main section 6, which rests against an outer flat wall section 8 of the end wall 4 and is preferably bonded to it. In the corner area of ​​the packaging carton 1, an end fastening tab 7' of the padding element 5 preferably runs in adhesive contact with a side flap 12 of the side wall 3.

[0025] Furthermore, the heel section 10 has a sloping surface 9 via which the fastening tab 7 is connected to the main section 6 of the cushioning element 5.

[0026] In the present embodiment, the inclined surfaces 9, on which the fastening tabs 7 directly abut the wall section 8 (wall flap 11) form an angle φ 1 of 70° with the wall section 8.

[0027] Preferably, the number or size of the cushioning elements 5 is selected such that the end-side fastening tab 7' of the heel section 10 runs in a corner area, namely in contact with the side flap 12 or side wall 3. A fold line between the fastening tab 7' and the adjoining inclined surface 9' of the heel section 10 runs directly along the corner fold line between the side flap 12 and the end wall 4 of the packaging carton 1. The inclined surface 7' forms an angle φ 2 of 40° with the wall flap 11 or the end wall 4. The corner-side inclined surface 9' is thus shallower than the non-corner-side inclined surfaces 9 of the cushioning elements 5. In this way, improved corner edge protection is ensured. This gives the cushioning elements 5 a stability that prevents the contact surfaces 6 from buckling under strong mechanical stress from the item being packaged.

[0028] According to an alternative embodiment of the invention (not shown), the inclined surface 9 can also rise from the plane of the fastening tab 7 at an angle φ 1 between 70° and 90°. Alternatively, the inclined surface 9' can also rise from the plane of the wall flap 11 at an angle between 30° and 70°.

[0029] According to an alternative embodiment of the invention, not shown, the surface between the fastening tabs 7, 7' and the main section 6 of the cushioning element 5 can also rise at a right angle, i.e. perpendicular to the main section 6 and the fastening tab 7, 7', whereby there is a risk of buckling if the cushioning element 5 is subjected to excessive mechanical stress.

[0030] As from Figure 2 and 3As can be seen, the padding elements 5 are connected to each other by strip flaps 13 running over the entire length of the front wall 4, which increases the mechanical stability of the padding elements 5.

[0031] The end wall 4 is formed by folding an end flap, which consists of a wall flap 11 adjoining the bottom wall 2 immediately, as well as strip flaps 13 and pad flaps 14 adjoining the wall flap 11 in one direction, and opposite side flaps 12 adjoining the wall flap 11 laterally.

[0032] The cardboard blank has the side walls 4 as its first sections and the wall flaps 11 with side flap 12, strip flap 13, and padding flap 14 as its second sections. The wall flap 11 adjoins the bottom wall 2 on one side. Opposite side flaps 12 adjoin the bottom wall 2 on opposite sides. A connecting line or fold line between the side flaps 12 and the bottom wall 2 runs perpendicular to a connecting line or fold line between the wall flap 11 and the bottom wall 2. A strip flap 13 adjoins the wall flap 11 on one side opposite the bottom wall 2, and the padding flap 14 adjoins the strip flap 13 on one side facing away from the wall flap 11.

[0033] There are grooves 15 for fold edges between the bottom wall 2 on the one hand and the respective side walls 3 and the wall flap 11 on the other hand, as well as cutting lines 16 for perforations between the inclined surface 9, 9' and the fastening tab 7, 7'.

[0034] In Figure 5 The finished upholstery elements 5 are shown, with the upholstery elements 5 arranged at intervals from each other in the extension direction E of the end wall 4. The fastening tabs 7 of the upholstery elements 5 are bonded to the wall flap 11. The main section 6 of the upholstery element 5 is raised above the wall flap 11 and has a height and can be spaced a distance a from the wall flap 11, which corresponds to the width of the strip flap 13. The strip flap 13 is connected exclusively to the main section 6 of the upholstery element 5. The upholstery elements 5 are thus wing-shaped.

[0035] The fastening tabs 7' of the end-arranged upholstery elements 5 facing the side flaps 12 do not rest on the wall flap 11 like the other fastening tabs 7, but rather on the side flap 12. Thus, these end-side fastening tabs 7' are bonded to the side flap 12, and the side flap 12 is bonded to the side wall 3. As can be seen from Figure 4 As can be seen, an edge protection is formed in a corner area of ​​the packaging carton 1, which is formed by a multi-layer arrangement consisting of the end fastening flap 7', side flap 12 and the side wall 3.

[0036] In the present embodiment, the fastening flap 7 or the end fastening flap 7' extends from the main section 6 of the cushioning element 5 to such an extent that, when the packaging carton 1 is unfolded, a free end edge 17 of the end fastening flap 7' lies in the plane of the main sections 6 of the cushioning elements 5. The side flaps 12 extend perpendicular to the common fold line with the wall flap 11, so that they form a larger common contact surface with the side wall 3 than the common contact surface between the end fastening flap 7' and the side flap 12.

[0037] As from Figure 4 As can be seen, the main sections 6 of the cushioning elements 5 form a common plane against which the item to be packaged can rest and is supported by the cushioning elements 5.

[0038] For the production of the integrated product protection or the cushioning elements 5, the invention comprises a first cushioning mold 18 and a second cushioning mold 19.

[0039] The first upholstery forming tool 18 has a number of rod-shaped strips 20 corresponding to the number of upholstery elements 5, which serve as upholstery forming means and are placed on the wall flaps 11 of the flat blank Z. The second upholstery forming tool 19 also has a number of rod-shaped strips 21 corresponding to the number of upholstery elements 5. At the beginning of the manufacturing process, the second upholstery forming tool 19 is located outside the blank Z, see figure. Figure 6a .

[0040] As from Figure 6aAs can be seen, the free ends 22 of the rod-shaped strips 20 of the first cushion forming tool 18 are flush with the groove 15, via which the strip flap 13 is connected to the wall flap 11. By means of a first folding tool 23, which is designed as a linearly movable folding tool, the strip flap 13 and the cushion flap 14 are brought from the cutting plane into an upright or perpendicular position to the wall flap 11 in a first folding step, intermediate position according to Figure 6b .

[0041] The second upholstery forming tool 19 forms upholstery shaping means for the formation of the upholstery element 5 and positioning means for folding the upholstery flap 14 in a second folding step. The positioning means bring the upholstery flap 14 into the folded position parallel to the wall flap 11. This forms a folding upholstery forming unit 19, which consists of a second upholstery forming tool and a second folding tool. This folding upholstery forming unit 19 has an edge 32 that is moved perpendicular to the plane of extension of the upholstery flap 14, so that this upholstery flap 14 is folded by a further 90° and thus a U-shape is formed from the wall flap 11, the strip flap 13 and the upholstery flap 14.

[0042] The free ends 24 of the rod-shaped strips 21 of the second cushion forming tool 19 lie flat against the cushion flaps 14, so that the U-shape is maintained.

[0043] Furthermore, the folding cushion form assembly 19 has a support element 31 by means of which the strip flap 13 is supported in a position perpendicular to the wall flap 11, see. Figure 6c This ensures that the strip flap 13 is held in an upright position relative to the wall flap 11 after further cushion shaping.

[0044] In the folded position of the cushion flap 14 according to Fig. 6cThe second upholstery forming tool 19, with its rod-shaped ribs 21, is located above the first upholstery forming tool 18, with its rod-shaped ribs 20. The rod-shaped ribs 20 of the first upholstery forming tool 18 and the rod-shaped ribs 21 of the second upholstery forming tool 19 are arranged transversely to the grooves 15 or cutting lines 16 of the upholstery flap 14, offset from one another, so that linear movement of the second upholstery forming tool 19 towards the first upholstery forming tool 18 until reaching an end position of the second upholstery forming tool 19... forms upholstery elements 5. The rod-shaped ribs 21 of the second upholstery forming tool 19 press the fastening flaps 7, 7' onto the wall flap 11 or the side flaps 12. In an end position according to Figure 6dThe rod-shaped strips 21 of the second cushion forming tool 19 and the rod-shaped strips 20 of the first cushion forming tool 18 are arranged alternately and at the same height next to each other at a distance from each other.

[0045] The rod-shaped strips 21 of the second cushion forming tool 19 are trapezoidal in cross-section with a central main surface and inclined side flanks 26 adjoining it on both sides.

[0046] During the movement of the rod-shaped ribs 21 of the upholstery forming tool 19 towards the wall flap 11, the inclined surfaces 9, 9' and the fastening tab 7, 7' are formed by folding at the grooves 15 and cutting lines 16 of the upholstery flap 14, whereby the rod-shaped ribs 20 of the first upholstery forming tool 18, for the formation of the main section 6, maintain the upholstery flap 14 at the required distance from the wall flap 11. The side flanks 25 of the rod-shaped ribs 20 of the upholstery tool 18 do not have any inclined surfaces. The side flanks 26 of the rod-shaped strips 21 of the second upholstery tool 19 are chamfered, so that by arranging the rod-shaped strips 20 of the first upholstery forming tool 18 and the side flanks 26 of the second upholstery forming tool 19, the inclined surfaces 9, 9' and the fastening tabs 7, 7' are formed, see Figure 6d.

[0047] The second cushion forming tool 19 has a hold-down device 33 which, in an end position of the second cushion forming tool 19, presses against the main section 6 of the cushion flap 14. This ensures that the main section 6 of the cushion element 5 does not bulge, but remains flat.

[0048] It is evident that the second cushion forming tool 19 is moved linearly in a first direction of movement according to the arrow in Figure 6b as a folding tool and by linear movement in a second direction of movement, which is perpendicular to the first direction of movement, leads to an offset arrangement of the rod-shaped strips 20, 21 of the first cushion forming tool 18 and the second cushion forming tool 19, wherein the first cushion forming tool 18 and the second cushion forming tool 19 are arranged in a common plane and thus lead to the shaping of the cushion elements 5.

[0049] Furthermore, an adhesive tool (not shown) is provided for applying adhesive points 27 to the cushion flap 14 and to the side walls 3, so that, in the finished folded position of the blank Z, the fastening tabs 7, 7' are bonded to the wall flap 12 and the side flap 12, respectively, and the side flap 12 is bonded to the side wall 3. The application of the adhesive points 27 preferably takes place before the packaging blank Z is positioned under the first cushion forming tool 18 and before the cushion flap 14 is folded into the perpendicular position to the wall flap 11. Figure 6b .

[0050] After the upholstery elements 5 have been manufactured, see. Figure 5, can be completed in its usable form by further folding of the side flaps 12 relative to the wall flap 11 and subsequently by further folding of the wall flap 11 to the bottom wall 2 and subsequently by further folding of the side flaps 3 of the blank forming the respective side walls 3 of the packaging carton 1 into an upright position.

[0051] According to an alternative embodiment of the invention, which is not shown, the cushioning elements 5 can also be arranged on only a single end wall 4 instead of on two opposing end walls 4.

[0052] According to a further alternative embodiment not shown, the cushioning elements 5 can additionally or alternatively also be arranged along the at least one side wall 3.

[0053] The wall flap 11, in its fully folded state, forms the flat wall section 8 of the packaging carton 1 and simultaneously the outer surface of the end wall 4. The strip flap 13 forms a top surface of the end wall 4, with the strip flap 13 running parallel to the bottom wall 2 in its finished state. The cushioning elements 5 form an inner surface of the end wall 4.

[0054] It should be noted that a clear distance between the adjacent rod-shaped strips 21 of the second cushion forming tool 19 corresponds to a width b of the main section 6 of the cushion element 5.

[0055] According to a further embodiment of the invention according to the Figure 8a to 8dA robot unit R is provided with a robot arm 35 on which folding means are arranged. These means enable the first folding, the second folding of the upholstery flap 14, and the final shaping of the upholstery elements 5. For this purpose, the upholstery forming tool 19 is attached to the robot arm 35. Since the robot arm 35 is pivotally arranged about a pivot axis S, with the pivot axis S running parallel to a fold line extending between the wall flap 11 and the upholstery flap 14, after the robot arm 35 has moved linearly upwards, carrying the upholstery flap 14 with it and folding it by 90°, the upholstery flap 14 can subsequently and continuously be brought into a position parallel to the wall flap 11 by a pivoting movement of the robot arm 35. In addition to its pivoting movement about the pivot axis S, the robot arm 35 also performs a linear movement transverse to the fold line connecting the wall flap 11 and the upholstery flap 14.

[0056] As from the Figures 8a and 8b As can be seen, the robot arm 35 moves in a linear direction during the first folding process. For the second folding process according to Figure 8c The robot arm 35 is moved linearly and also pivoted about the swivel axis S. This is for shaping the upholstery elements 5 according to... Figure 8d The robot arm 35 is lowered linearly. In contrast to the previous embodiment, this movement can be performed continuously from the starting position to the end position, maintaining constant contact with the cushioning flap 14. A time interruption – as in the previous embodiment – ​​can be avoided, thus increasing the throughput.

Claims

1. Device for producing integrated product protection with cushioning elements in a packaging carton (1) from a blank (Z) comprising a bottom wall (2), side walls (3) adjoining the bottom wall (2) on opposite sides, and a wall flap (11) adjoining at least one side of the bottom wall (2), to which a strip flap (13) and a cushioning flap (14) are attached on one side opposite the bottom wall (2), and a side flap (12) is attached on each of the opposite sides, - comprising a first cushion forming tool (18) containing a number of cushion forming means (20) that can be positioned on the wall flap (11) of the flat blank (Z), - comprising a first folding tool (23) for folding the strip flap (13) and the cushioning flap (14) at a right angle relative to the wall flap (11) into an intermediate position,- with a second folding tool (21) for folding the upholstery flap (14) at a right angle relative to the strip flap (13) into a further intermediate position, so that the upholstery flap (14) is brought into a position parallel to the wall flap (11), - with a second upholstery forming tool (19) comprising a number of upholstery forming means (21) which are arranged laterally offset in a starting position to the upholstery forming means (20) of the first upholstery forming tool (18) and which, taking with them fastening tabs (7, 7') of the upholstery flap (14), are movable perpendicular to the wall flap (11) in the direction of it, so that a number of upholstery elements (5 ) are formed from the upholstery flap (14), each having a main surface (6) extending parallel to and at a distance (a) from the wall flap (11) and angled shoulder elements (10) adjoining it on opposite sides,wherein the heel element (10) has a fastening tab (7, 7') which comes to rest flat against the wall flap (11).

2. Device according to claim 1, characterized by the fact that the cushion-forming means of the first cushion-forming tool (18) and the second cushion-forming tool (19) are designed as rod-shaped strips (20, 21) and that the rod-shaped strips (20) of the first cushion-forming tool (18) have such a length that a free end (22) of the rod-shaped strips (20) serves as a stop surface for the strip flap (13) when the first folding tool (23) is actuated.

3. Device according to claim 1 or 2, characterized by the fact that the second cushion forming tool (19) has a support element (31) for supporting the strip flap (13) in a position perpendicular to the wall flap (11) when the second cushion forming tool (19) is actuated.

4. Device according to one of claims 1 to 3, characterized by the fact thatthe second cushion forming tool (19) has a hold-down device (32) which, in an end position of the second cushion forming tool (19), presses on the main section (6) of the cushion flap (14).

5. Device according to one of claims 1 to 4, characterized by the fact that the padding flap (14) is folded in such a way that the padding element (5) is firmly connected to the strip flap (13) exclusively via the main section (6) thereof.

6. Device according to any one of claims 1 to 5, characterized by the fact thatThe parallel rod-shaped strips (21) of the second cushion forming tool (19) are trapezoidal in cross-section with a main surface and inclined side flanks (26) adjoining it on both sides, so that the heel section (10) of the cushion element (5) with its fastening tab comes into contact with the wall flap (11) or side flap (12) in a flat manner and runs at an acute angle (φ1, φ2) with an inclined surface (9, 9') extending between the fastening tab (7, 7') and the main section (6).

7. Device according to any one of claims 1 to 6, characterized by the fact that the second folding tool (21) has an edge (32) projecting over a free end (24) of the second cushion forming tool (19) for gripping the cushion flap (14) during folding.

8. Device according to any one of claims 1 to 7, characterized by the fact thatan adhesive tool for applying adhesive points (27) to the cushion flap (14) and the side wall (3) is provided, so that the fastening tabs (7) of the cushion flap (14) can be bonded to the wall flap (11) and / or so that the fastening tab (7') of a cushion element (5) arranged in the corner area of ​​the packaging carton (1) can be bonded to the side flap (12) of the wall flap (11).

9. Device according to any one of claims 1 to 8, characterized by the fact that a clear distance between the spaced rod-shaped strips (21) of the second cushion forming tool (19) corresponds to a width (b) of a central section (6) of the cushion element (5).

10. Device according to any one of claims 1 to 9, characterized by the fact thatthe second folding tool and the second cushion forming tool (19) form a common folding / cushioning assembly which is designed to be linearly movable in two directions perpendicular to each other, so that in a first direction of movement the cushion flap (14) is foldable relative to the strip flap (13) and that in a second direction of movement the fastening tabs (7, 7') of the cushion flap (14) are moved to be attached to the wall flap (11) or to the side flap (12) of the wall flap (11).

11. Device for producing integrated product protection with cushioning elements in a packaging carton (1), in particular according to one of claims 1 to 10, characterized by the fact thata robot unit (R) is provided with a robot arm (35) which is configured to: - fold the strip flap (13) and the padding flap (14) simultaneously relative to the fixed wall flap (11), - then fold the padding flap (14) further relative to the strip flap (13) so that the padding flap (14) runs parallel and offset to the wall flap (11), - then press the padding flap (14) against the wall flap (11) while taking with it and attaching a fastening tab (7, 7') of the padding flap (14) to the wall flap (11), so that a padding element (5) is formed with a main section (6) of the padding element (5) running parallel to the wall flap (11).

12. Device according to claim 11, characterized by the fact that The second cushion forming tool (19) is held on the robot arm (35) pivotably about a pivot axis (S) arranged parallel to a fold line running between the cushion flap (14) and the wall flap (11).

13. Device according to claim 11 or 12, characterized by the fact that the robot arm (35) is arranged to be movable in a three-dimensional space.

14. Device for manufacturing a packaging carton (1) comprising a device according to any one of claims 1 to 13, comprising a folding tool - for folding the side flaps (12) of the wall flap (11) into an upright position relative to the wall flap (11) provided with the cushioning elements (5), - for folding the wall flap (11) into an upright position relative to the bottom wall (2), - for folding the longitudinal flaps (Z) forming the respective side walls (3) of the packaging carton (1) into an upright position in which the longitudinal flap rests on the outside of the side flap (12) of the wall flap (11), - with an adhesive tool for applying adhesive dots to an inside of the side wall (3) so that the side wall (3) can be glued to the side flap (12) of the wall flap (11) and for applying adhesive dots (27) to the cushioning flap (14) so ​​that the fastening tab (7, 7') can be glued to the wall flap (11).

15. Method for producing product protection with cushioning elements (5) in a packaging carton (1) from a single blank (Z), wherein the cushioning element (5) is formed by folding and / or shaping a cushioning flap (14), comprising: - positioning rod-shaped strips (20) at a parallel distance on a wall flap (11) of the blank (Z), - folding a strip flap (13) adjoining the wall flap (11) and a cushioning flap (14) adjoining the strip flap (13) at a right angle, - subsequently folding the cushioning flap (14) at a further right angle, - moving second rod-shaped strips (21) in the direction of the rod-shaped strips (20) positioned on the wall flap (11), laterally offset from them, folding a shoulder element (10) of the cushioning flap (14) to form the cushioning elements (5).each having a raised main section (6) and a fastening tab (7, 7') resting on the wall flap (11).

16. Method according to claim 15, characterized by the fact that the fastening tabs (7) of the upholstery flap (14) are glued to the wall flap (11) and the end fastening tab (7') of the upholstery flap (14) is glued to the side flap (12) of the wall flap (11).

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