Support tray and corresponding production method

Abstract

Support tray (10) for elongated elements (200) obtained from a single blank (110). The support tray (10) comprises: an upper transverse wall (11) provided with a plurality of first holes (25) for positioning the elongated elements (200), a lower transverse wall (12) parallel to the upper transverse wall (11) and provided with a plurality of second holes (26) axially aligned with the first holes (25), each of the second holes (26) being encircled by deformable flaps (28) configured to be bent, and at least a first side wall (13) and a second side wall (15) opposite each other, perpendicular to the upper (11) and lower (12) transverse wall, and extending from said upper transverse wall (11) beyond the lower transverse wall (12) so as to define respective support legs (19, 20).

Description

[0001] “SUPPORT TRAY AND CORRESPONDING PRODUCTION METHOD”

[0002] FIELD OF THE INVENTION

[0003] The present invention concerns a support tray for elongated elements, for example tubular or stick or bar shaped, in particular, but not limited to, of the flexible or deformable type, for example smoking articles such as cigarettes, cigars, cigarillos or suchlike. The present invention also concerns a process for making the support tray.

[0004] BACKGROUND OF THE INVENTION Packages, or packets, for containing elongated elements, for example tubular or stick or bar shaped, for example smoking articles, such as cigarettes, cigars, cigarillos, or suchlike are known.

[0005] In the case of smoking articles, these are normally grouped in such a way as to define, as a whole, a parallelepiped, around which an internal containing casing, or internal wrapper, is then wrapped, which is then inserted into an external containing body, thus forming the packet.

[0006] However, a disadvantage of such known packets is that they are not suitable for containing elongated elements of the type in question and having a variable crosssection, for example having a frustoconical shape, because, since these are arranged against each other, each smoking article could be crushed and / or ruined, thus compromising its integrity.

[0007] In this regard, solutions are known that provide a box-shaped package in which there is a support tray having a wall parallel to the bottom of the containing body and provided with a plurality of positioning holes for the elongated elements, keeping them positioned individually and, therefore, separated from each other.

[0008] An example of these solutions is described in document GB 2040884, which describes stackable trays each having a plurality of holes, each configured to receive objects such as yoghurt pots or plant pots, for example.

[0009] Other solutions known in the art describe box-shaped packages in which the support tray is conformed so as to have two walls parallel to each other and to the bottom of the containing body, and both provided with a plurality of positioning holes. Each positioning hole of the upper wall is axially aligned with a respective positioning hole of the lower wall, so that a same oblong element, for example a vial, a flask or a bottle, passes through both of them. Some examples of these types of packages are described in documents US 5057282, US 3682597, EP 1989119 and JP Hl 135081.

[0010] However, known solutions have the disadvantage that they are rather complex and that special, bulky and expensive equipment is required to make them.

[0011] Furthermore, the processes for making such support trays or the respective packages, as well as for preparing such trays to receive and support the elongated elements, can also be rather elaborate and complex.

[0012] There is therefore the need to perfect a support tray that can overcome at least one of the disadvantages of the state of the art.

[0013] In particular, one purpose of the present invention is to provide a support tray that is easy to produce and has low production costs.

[0014] Another purpose of the present invention is to provide a support tray by means of a production process that is simple and highly efficient. The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages.

[0015] SUMMARY OF THE INVENTION

[0016] The present invention is set forth and characterized in the independent claims. The dependent claims describe other characteristics of the present invention or variants to the main inventive idea.

[0017] In accordance with the above purposes and to resolve the technical problem disclosed above in a new and original way, also achieving considerable advantages compared to the state of the prior art, a support tray is provided according to the present invention for supporting elongated elements, in particular smoking articles, which is obtained from a single blank shaped and folded so that the support tray comprises: an upper transverse wall provided with a plurality of first holes for positioning the elongated elements, a lower transverse wall parallel to the upper transverse wall and provided with a plurality of second holes axially aligned with the first holes, each of the second holes being encircled by deformable flaps configured to be bent, and at least a first side wall and a second side wall opposite each other, perpendicular to the upper and lower transverse wall and extending from the upper transverse wall beyond the lower transverse wall, so as to define respective support legs.

[0018] In accordance with one aspect of the present invention, each of the support legs comprises an end portion which consists of two superimposed and joined with glue panels of the blank formed by a portion of a first side panel hinged to the upper transverse wall, and by a second side panel hinged to the lower transverse wall, wherein the respective end portions protrude from the lower transverse wall.

[0019] In accordance with another aspect of the present invention, the support tray also comprises a third and a fourth side wall opposite each other and perpendicular to the first and second side wall, the first, second, third and fourth side walls defining with them a side skirt around the upper and lower transverse wall. The third and fourth side wall extend from the upper transverse wall beyond the lower transverse wall, defining further respective support legs, each of which comprises a further end portion which consists of two further superimposed and joined with glue panels of the blank formed by a portion of a third side panel hinged to the upper transverse wall, and by a fourth side panel hinged to the lower transverse wall, wherein the respective end portions protrude from the lower transverse wall.

[0020] In accordance with some embodiments of the present invention, the first holes of the upper transverse wall are circular and / or the deformable flaps are hingedly arranged around the second holes. In accordance with another aspect of the present invention, each of the first holes is circular and has a first diameter such as to allow the passage of the elongated elements, and the second holes have a respective central circular portion having a respective second diameter which is smaller than the first diameter of the first holes. The present invention also concerns a blank for forming a support tray for elongated elements, in particular smoking articles, comprising: a first main panel provided with a plurality of first holes; a second main panel aligned with the first main panel and provided with a plurality of second holes encircled by deformable flaps configured to be bent; a first and a second larger central panel connected, on opposite sides, to the first main panel; and a first and a second smaller central panel connected, on opposite sides, to the second main panel.

[0021] The first larger central panel being contiguously adjacent to the first smaller central panel. Moreover, when the blank is folded, the first and second main panel are configured to define the upper and lower transverse wall, respectively.

[0022] In accordance with another aspect of the present invention, the first and second smaller central panel are configured to be respectively superimposed and stably joined with glue to an end portion of the first and second larger central panel. On the first and second smaller central panel there being a layer of adhesive material that, when the first and second smaller central panel are suitably folded, is able to keep them stably joined to the first and second larger central panel, respectively. In this way, the first and second side wall are formed, thus defining the respective support legs.

[0023] In accordance with another aspect of the present invention, the blank further comprises: a first and a second larger side panel connected, on opposite sides, to the first main panel; and a first and a second smaller side panel connected, on opposite sides, to the second main panel and configured to be respectively superimposed and stably joined with glue to an end portion of the first and second larger side panel. In this way, the third and fourth side wall are formed, thus defining the further respective support legs.

[0024] The present invention also concerns a process for making the support tray for elongated elements, in particular smoking articles, by consecutive folding of panels of the blank.

[0025] In accordance with one aspect of the present invention, the process provides to glue a first and a second smaller central panel to a lower end portion of a first and a second larger central panel, respectively, thus forming respectively a first and a second side wall of the support tray and defining respective support legs, wherein each of the support legs consists of two superimposed and joined panels of the blank.

[0026] In accordance with one aspect of the present invention, the process comprises a shaping step in which the blank, starting from an initial flattened configuration, is shaped into a three-dimensional upright configuration, determining the geometry of the support tray. In particular, in the shaping step, a first and a second main panel, partially superimposed and in contact with each other, are separated from each other and spaced apart to bring each other in parallel, thus forming the upper and lower transverse wall which, in the upright configuration, are perpendicular to the first and second side wall.

[0027] In accordance with another aspect of the present invention, the process comprises further folding steps, subsequent to the shaping step, in which a first and a second smaller side panel are folded towards the support legs, and in which a first and a second larger side panel are folded so that a respective lower end portion thereof is superimposed and then stably joined with glue to the first and second smaller side panel, thus forming respectively a third and a fourth side wall of the support tray and defining further respective support legs consisting of two superimposed and joined panels of the blank. DESCRIPTION OF THE DRAWINGS

[0028] These and other aspects, characteristics and advantages of the present invention will become apparent from the following description of some embodiments, given as a non-restrictive example with reference to the attached drawings wherein:

[0029] - fig. 1 is a three-dimensional view of a support tray for elongated elements, according to the present invention;

[0030] - fig. 2 is a section three-dimensional view of the support tray of fig. 1;

[0031] - fig. 3 is a section three-dimensional view of the support tray of fig. 1 provided with a plurality of elongated elements;

[0032] - figs. 3a and 3b are enlarged, detailed views of fig. 3, in which construction details of the support legs of the support tray of fig. 1 are visible;

[0033] - fig. 4 is a top view of a blank according to the present invention, from which the support tray of fig. 1 is obtained;

[0034] - figs, from 5 to 12 are a schematic representation of an operating sequence to make the support tray of fig. 1 ; - fig. 13 is a top view of another embodiment of a blank according to the present invention.

[0035] We must clarify that the phraseology and terminology used in the present description, as well as the figures in the attached drawings also in relation as to how described, have the sole function of better illustrating and explaining the present invention, their purpose being to provide a non-limiting example of the invention itself, since the scope of protection is defined by the claims.

[0036] To facilitate comprehension, the same reference numbers have been used, where possible, to identify identical common elements in the drawings. It is understood that elements and characteristics of one embodiment can be conveniently combined or incorporated into other embodiments without further clarifications. DESCRIPTION OF SOME EMBODIMENTS OF THE PRESENT INVENTION

[0037] With reference to fig. 1, a support tray 10 according to the present invention is suitable to support elongated elements 200 in a substantially upright position.

[0038] According to possible embodiments, the support tray 10 is insertable into a containing body 101 to thereby form a box-shaped package containing the plurality of elongated elements 200.

[0039] The oblong or elongated elements 200 can, for example, be tubular or stick or bar shaped, in particular but not exclusively of a flexible or deformable type, and comprise a lower end 201 and an upper end 202 (fig. 3).

[0040] According to preferred embodiments, shown in fig. 3, the elongated elements 200 are smoking articles with a frustoconical shape, wherein the lower end 201 is defined by the mouth end, which is able to be brought at the mouth of the consumer and can be provided with a filter, and the upper end 202 is defined by the lighting end, which can be lit to smoke the smoking article. As shown, the lower end 201 has a smaller cross-section than the upper end 202.

[0041] The support tray 10 is made starting from a single flexible blank 110 (fig. 4), as will be described in detail below.

[0042] Preferably, the blank 110 is made of a sheet material, for example cardboard, paperboard, paper or similar materials, and has a thickness such that it can be easily folded, while guaranteeing that a sufficiently rigid and resistant structure is created, capable of supporting the elongated elements 200.

[0043] In particular, the blank 110 is shaped and folded in such a way that the support tray 10 (fig. 1) essentially comprises an upper transverse wall 11, a lower transverse wall 12 parallel and opposite the latter, and at least a first side wall 13 and a second side wall 15 opposite each other and perpendicular to the upper and lower transverse wall 11, 12.

[0044] The support tray 10 has a parallelepiped shape, wherein the upper and lower transverse wall 11, 12 and the first and second side wall 13, 15 can have a rectangular or square shape.

[0045] The first and second side wall 13, 15 have respective lower end parts which extend beyond the lower transverse wall 12, on the opposite side with respect to the upper transverse wall 11, and define two corresponding support legs 19, 20. In particular, each support leg 19, 20 consists of a superimposition and a stable joining with glue of respective portions of at least two panels 113a, 113b, 115a, 115b of the blank 110 (fig. 3a), as will be described in detail below. According to preferred embodiments, the support tray 10 also comprises a third side wall 16 and a fourth side wall 17, opposite each other and perpendicular to the first and second side wall 13, 15, thus defining a side skirt 14 around the upper and lower transverse wall 11, 12.

[0046] We must clarify that the third and fourth side wall 16, 17 can also have a rectangular or square shape, preferably coordinated with the shape of the first and second side wall 13, 15, so that the support tray 10 has the aforementioned parallelepiped shape. We must clarify that that the side walls 13, 15, 16, 17 have the function of giving a certain rigidity to the structure of the support tray 10.

[0047] Therefore, the support tray 10 advantageously comprises two further support legs 21, 22, defined by corresponding lower end parts of the third and fourth side wall 16, 17 which extend beyond the lower transverse wall 12, on the opposite side with respect to the upper transverse wall 11. In particular, each further support leg 21, 22 consists of a superimposition and a stable joining with glue of respective portions of at least two panels 116a, 116b, 117a, 117b of the blank 110 (fig. 3b), as will be described in detail below.

[0048] We must clarify that at least the respective lower end portions of the first, second, third and fourth side wall 13, 15, 16, 17 have a higher stiffness than the upper and lower transverse wall 11, 12.

[0049] In this way, the support tray 10 has the advantage of being more stable and of having a structure able to withstand any accidental deformations.

[0050] The upper transverse wall 11 is provided with a plurality of first holes 25 defining respective housing seats for the elongated elements 200 (figs, from 1 to 3).

[0051] The first holes 25 are arranged according to a certain positioning matrix, for example they are aligned and equally spaced apart from each other so as to homogeneously occupy the entire surface of the upper transverse wall 11. Furthermore, the first holes 25 preferably have a circular shape and a first diameter DI (figs. 2 and 4) having a size such as to accommodate each elongated element 200 with minimum play.

[0052] We must clarify that, in the case of frustoconical shaped smoking articles, the first diameter DI can have a size that is intermediate between the diameter of the lower end 201 and that of the upper end 202. The lower wall 12 is provided with a plurality of second holes 26 (fig. 2) axially aligned with the first holes 25 and configured so that the elongated elements 200 also pass through them.

[0053] Each of the second holes 26 is encircled by deformable flaps 28 configured to be bent by the elongated elements 200. In a first embodiment, shown in figs. 1-12, the deformable flaps 28 are contiguous, defined by through radial incisions 27 and hingedly arranged perimetrically around the second holes 26.

[0054] The deformable flaps 28 have the function of elastically deforming to delimit the second holes 26, which define a further housing seat for a corresponding elongated element 200, that is, a central opening having a size such as to allow the easy passage thereof, at the same time stably holding it by interference and stably keeping it in an upright position.

[0055] According to preferred embodiments, the second holes 26 have a circular shape.

[0056] Specifically, the second holes 26 have a second diameter D2 that is smaller than the first diameter DI of the first holes 25. For example, the second diameter D2 can have a size such that, in the absence of deformation of the deformable flaps 28, the regular passage of the lower end 201 of the elongated element 200 would be impeded.

[0057] According to possible embodiments, the radial incisions 27 can have an extension such as to define a closed annular profile, from which the deformable flaps 28 depart, having an external diameter DE even greater than the first diameter DI of the first holes 25. We must clarity that the external diameter DE is represented ideally in figs. 2 and 4 with a dashed line.

[0058] The blank 110 (fig. 4), although advantageously in a single body, is suitably shaped and comprises at least: a first main panel 111 which is configured to define, when the blank 110 is folded, the upper transverse wall 11; a second main panel 112 aligned with the first main panel 111 along an axis of symmetry X and configured to define, when the blank 110 is folded, the lower transverse wall 12; a first larger central panel 113a and a second larger central panel 115a which are connected, on opposite sides, to the first main panel 111 along the axis of symmetry X, and a first smaller central panel 113b and a second smaller central panel 115b which are connected, on opposite sides, to the second main panel 112 along the axis of symmetry X.

[0059] We must clarify that the first main panel 111 comprises the plurality of first holes 25 and that the second main panel 112 comprises the plurality of second holes 26.

[0060] According to some embodiments, the first and second larger central panel 113a and 115a, when the blank 110 is folded, are configured to define the first and second side wall 13, 15.

[0061] Furthermore, the first larger and smaller central panel 113a, 113b are connected to each other and, when the blank 110 is folded, the first smaller central panel 113b is configured to be superimposed and stably joined with glue to an end portion of the first larger central panel 113a, thus defining a first support leg 19.

[0062] The second larger and smaller central panel 115a and 115b are arranged on opposite sides with respect to each other and, when the blank 110 is folded, the second smaller central panel 115b is configured to be superimposed and stably joined with glue to an end portion of the second larger central panel 115a, thus defining a second support leg 20.

[0063] According to other embodiments, not shown in the drawings, the first and second side wall 13, 15 are respectively defined by the partial superimposition and stable joining with glue of the first and second smaller central panel 113b, 115b with the first and second larger central panel 113a, 115a. We must specify that, on the first smaller central panel 113b there is a layer of gluing, or adhesive, material Ml which is able to contact the corresponding end portion of the first larger central panel 113a and, when activated, allows to keep the first smaller central panel 113b glued and stably joined to it.

[0064] Moreover, there is also a layer of gluing, or adhesive, material Ml on the second smaller central panel 115b, which is able to contact the corresponding end portion of the second larger central panel 115a and, when activated, allows to keep the second smaller central panel 115b glued and stably joined to it.

[0065] By way of a non-limiting example, the gluing, or adhesive, material Ml can be a heat-sealable material, for example a heat-activated glue.

[0066] In accordance with preferred embodiments, a first and a second larger side panel 116a, 117a are connected to the first main panel 111 on opposite sides with respect to the axis of symmetry X, and a first and a second smaller side panel 116b, 117b are connected to the second main panel 112 on opposite sides with respect to the axis of symmetry X.

[0067] According to some embodiments, the first and second larger side panel 116a and 117a, when the blank 110 is folded, are configured to define the third and fourth side wall 16, 17. The first smaller side panel 116b, when the blank 110 is folded, is configured to be superimposed and stably joined with glue to an end portion of the first larger side panel 116a, thus defining a third support leg 21.

[0068] The second smaller side panel 117b, when the blank 110 is folded, is configured to be superimposed and stably joined with glue to an end portion of the second larger side panel 117a, thus defining a fourth support leg 22.

[0069] According to other embodiments, not shown in the drawings, the third and fourth side wall 16, 17 are respectively defined by the partial superimposition and stable joining with glue of the first and second smaller side panel 116b, 117b with the first and second larger side panel 116a, 117a. In general, the blank 110 is configured to be suitably folded and shaped, or divaricated, or indented, passing from a flattened configuration to an upright configuration. Specifically, the first and second main panel 111, 112, which in such flattened configuration are partially superimposed and in contact with each other, are able to be reciprocally separated and spaced apart to bring each other in parallel, thus forming the upper and lower transverse wall 11, 12, which are also perpendicular at least to the first and second side wall 13, 15, already defined by the superimposition and stable joining with glue of the first and second smaller central panel 113b, 115b with the first and second larger central panel 113a, 115a, respectively. In other words, the support tray 10 consists of an articulated parallelogram, or quadrilateral, comprising a frame, or mechanism, defined by the second side wall 15 with the second support leg 20, two cranks defined by the upper and lower transverse wall 11, 12, respectively, and a connecting rod defined by the first side wall 13 with the first support leg 19, wherein the passage from the flattened configuration to the upright configuration is achieved through a rotation of the two cranks.

[0070] With reference to fig. 13, another embodiment of a blank according to the present invention is described, indicated with reference number 110’, which is configured to make another version of the support tray of the present invention.

[0071] The elements of the blank 110’ common to the blank 110 described above are indicated by the same reference numbers.

[0072] In particular, the blank 110’ differs from the blank 110 on the shape of the second holes 26 made on the second main panel 112.

[0073] Each of the second holes 26 is encircled by the deformable flaps 28.

[0074] The shape of the deformable flaps 28 is such as to give each second hole 26 a multi-lobed or polygonal shape.

[0075] In the example shown, the shape of each hole 26 is tri-lobed. In other embodiments, not shown, a quadri-lobed shape can be provided, or even having a number of lobes other than three or four, for example two or five.

[0076] In the case of a multi-lobed shape, the different lobes are preferably connected by curved lines with curvature such as to be curved towards the center of the respective hole. In the case of a polygonal shape, the sides of the polygon are defined by broken lines in which the lines are oriented so as to define zones protruding towards the center at the median zone interposed between two edges.

[0077] In this embodiment, each deformable flap 28 has a curved portion 28a facing the center of the respective second hole 26 and is configured to be bent. Preferably, the curved portion 28a is defined by an arc of circumference having a center outside the respective second hole.

[0078] Preferably, each deformable flap 28 is convex, since they are curved towards the center of the hole.

[0079] The shape of the deformable flaps 28 is such that it is possible to define a circular area inside each second hole 26, having the aforementioned diameter D2.

[0080] The process for making the support tray 10 described heretofore comprises the following steps.

[0081] Initially, an initial shaping step can be provided in which the blank 110 is suitably shaped to make the support tray 10.

[0082] For example, the blank 110 can be supplied already with the first and second main panel 111, 112 provided with the first holes 25 and with the second holes 26, respectively, as defined above. Alternatively, in the shaping step, the first holes 25 can be made on the first main panel 111 and the second holes 26 can be made on the second main panel 112, in accordance with the embodiments described above.

[0083] In accordance with possible embodiments and / or operating variants, the process can comprise a first main folding step.

[0084] In this first main folding step the blank 110 is initially folded so that the first smaller central panel 113b contacts and is superimposed with an end portion of the first larger central panel 113a (fig. 6). Then, by means of the adhesive material Ml, the first smaller central panel 113b is glued and stably joined to the first larger central panel 113a, thus forming the first side wall 13.

[0085] Then, the blank 110 is folded so that the first and second main panel 111, 112 are arranged perpendicular to the first larger and smaller central panel 113a, 113b and parallel to each other so that the first holes 25 and the second holes 26 are axially aligned (fig. 7).

[0086] Thereafter, the blank 10 is folded so that the first side wall 13 folds inward to contact and be superimposed with the first main panel 111, consequently making obliquely translate both the second main panel 112, so that it contacts the first main panel 111, and also the second smaller central panel 115b so that it contacts and is superimposed with an end portion of the second larger central panel 115a (fig. 8).

[0087] Then, by means of the adhesive material Ml, the second smaller central panel 115b is glued and stably joined to the second larger central panel 115a, thus forming the second side wall 15.

[0088] We must clarify that, in relation to the type of adhesive material Ml, the gluing between the first larger and smaller central panel 113a, 113b and between the second larger and smaller central panel 115a, 115b can be achieved in different ways. For example, in the event that the adhesive material Ml is a heat-sealable material, the latter is suitably heated and, therefore, activated to guarantee that these central panels remain glued together.

[0089] The blank 110 is thus in a flattened configuration (fig. 8), wherein the first and second main panel 111, 112 are partially superimposed and in contact with each other, and the first and second smaller central panel 113b, 115b are connected and glued to the first and second larger central panel 113a, 115a.

[0090] In accordance with possible embodiments and / or operating variants, the process can provide that the blank 110 is fed already in this flattened configuration, to perform multiple folding operations thereon able to form a support tray 10.

[0091] The process comprises a shaping, or divaricating, step in which from the flattened configuration the blank 110 is suitably shaped with an oblique translational movement, to make it assume a suitable three-dimensional shape, that is, an upright configuration that determines the geometry of the support tray 10. In particular, the first and second main panel 111, 112, partially superimposed and in contact with each other, are separated from each other and spaced apart to bring each other in parallel, thus forming the upper and lower transverse wall 11 , 12 which, in this upright configuration, are perpendicular to the first and second side wall 13, 15. In this shaping step, the first holes 25 are aligned with the second holes 26 and the two support legs 19, 20 (fig. 9) are essentially formed which, in the flattened condition, are substantially horizontal and do not perform their function.

[0092] In accordance with preferred embodiments, the process comprises a second main folding step, or forming step, in which the larger and smaller side panels 116a, 116b and 117a, 117b of the blank 110 are folded to define the third and fourth side wall 16, 17, thus forming the support tray 10.

[0093] In this second main folding step, the first and second smaller side panel 116b, 117b are folded inwards, so that they are perpendicular to the lower transverse wall 12 and adjacent to the support legs 19, 20 (fig. 10). Subsequently, another adhesive material M2, possibly similar to the adhesive material Ml (fig. 11), is applied on the first and second smaller side panel 116b, 117b, already folded. Alternatively, the adhesive material M2 can be applied on an end portion of the first and second larger side panel 116a, 117a.

[0094] The first and second larger side panel 116a, 1 17a are then folded so that their end portion is superimposed with the already folded first and second smaller side panel 116b, 117b. Then, by means of the adhesive material M2, the first and second smaller side panel 116b, 117b are glued to the first and second larger side panel 116a, 117a, defining the third and fourth side wall 16, 17, respectively, and forming the other two support legs 21, 22 (fig. 12).

[0095] In this way, a support tray 10 is formed that is more stable and less subject to oscillations, deformations and / or flattening.

[0096] The process also comprises a preparation step, in which the support tray 10 is suitably prepared for the insertion of the elongated elements 200 through the first holes 25 of the upper transverse wall 11 and into the second holes 26 of the lower transverse wall 12.

[0097] In this preparation step, it is provided to drive deforming members, for example with a cylindrical or frustoconical shape, in number equal to the first holes 25 and having sizes such that it is possible to pass through them with little play.

[0098] In particular, the preparation step comprises a deformation step, in which the deforming members are axially aligned with the first holes 25 and then driven, passing through the latter, until engaging and deforming the deformable flaps 28 in order to define the second holes 26 of diameter D2, axially aligned with the first holes 25, in which to insert the elongated elements 200.

[0099] According to preferred embodiments, this deformation provides to elastically deform the deformable flaps 28 of the second holes 26 so as to adequately enlarge them for the insertion of the elongated elements 200.

[0100] This is particularly useful and advantageous in the case of flexible or deformable elongated elements 200, such as smoking articles or suchlike.

[0101] Then, in a subsequent insertion step, the elongated elements 200 are inserted in the support tray 10 passing through corresponding first holes 25 until engaging, with the respective lower end 201, the through openings generated by the deformation of the deformable flaps 28 that sustain a respective elongated element 200 by interference.

[0102] The process can comprise a packaging step, in which the support tray 10 is suitably inserted inside the containing body to form a box-shaped package.

[0103] It is clear that modifications and / or additions of parts may be made to the support tray 10 and to the process as described heretofore, without departing from the field and scope of the present invention, as defined by the claims.

[0104] For example, according to possible embodiments, in the event the support tray 10 comprises only two side walls 13, 15, once the shaping step has been carried out, the process comprises the preparing step, the inserting step and then the subsequent packaging step.

[0105] It is also clear that, although the present invention has been described with reference to some specific examples, a person of skill in the art will be able to achieve other equivalent forms of support tray, having the characteristics as set forth in the claims and hence all coming within the field of protection defined thereby.

[0106] In the following claims, the sole purpose of the references in brackets is to facilitate their reading and they must not be considered as restrictive factors with regard to the field of protection defined by the claims.

Claims

CLAIMS1. Support tray (10) for elongated elements (200), in particular smoking articles, obtained from a single blank (110; 110’) shaped and folded so that said support tray (10) comprises: an upper transverse wall (11) provided with a plurality of first holes (25) for positioning said elongated elements (200), a lower transverse wall (12) parallel to the upper transverse wall (11) and provided with a plurality of second holes (26) axially aligned with said first holes (25), each of said second holes (26) being encircled by deformable flaps (28) configured to be bent, and at least a first (13) and a second (15) side wall opposite each other, perpendicular to said upper (11) and lower (12) transverse wall, and extending from said upper transverse wall (11) beyond said lower transverse wall (12), so as to define respective support legs (19, 20), characterized in that each of said support legs (19, 20) comprises an end portion which consists of two superimposed and joined with glue panels of said blank (110; 110’) formed by a portion of a first side panel (113a, 115a) hinged to said upper transverse wall (11), and a second side panel ( 113b, 115b) hinged to said lower transverse wall ( 12), said respective end portions protruding from said lower transverse wall (12).

2. Support tray (10) according to claim 1, characterized in that it also comprises a third (16) and a fourth (17) side wall opposite each other and perpendicular to said first (13) and second (15) side wall, said first, second, third and fourth side walls defining a side skirt (14) around said upper (11) and lower (12) transverse wall, said third (16) and fourth (17) side wall extending from said upper transverse wall (11) beyond said lower transverse wall (12), defining further respective support legs (21 , 22), each of said further support legs (21 , 22) comprising a further end portion which consists of two further superimposed and joined with glue panels of said blank (110; 110’) and which is formed by a portion of a third side panel (116a, 117a) hinged to said upper transverse wall (11), and by a forth side panel (116b, 117b) hinged to said lower transverse wall (12), said respective further end portions protruding from said lower transverse wall (12).

3. Support tray (10) as in any one of the preceding claims, characterized in that the first holes (25) of said upper transverse wall (11) are circular and / or said deformable flaps (28) are hingedly arranged around the second holes (26).

4. Support tray (10) as in any one of the preceding claims, characterized in thateach of said first holes (25) is circular and has a respective first diameter (DI) such as to allow the passage of said elongated elements (200), and said second holes (26) have a respective central circular portion having a respective second diameter (D2) which is smaller than the respective first diameter (DI) of the first holes (25).

5. Support tray (10) as in any one of the preceding claims, characterized in that said blank (110; 110’) comprises: a first main panel (111) defining said upper transverse wall (11); a second main panel (112) aligned with said first main panel (111) and defining said lower transverse wall (12); a first (113a) and a second (115a) larger central panel connected, on opposite sides, to said first main panel (111); and a first (113b) and a second (115b) smaller central panel connected, on opposite sides, to said second main panel (112) and provided with a layer of adhesive material (Ml) which, when said blank (110; 110’) is bent, joins with glue said first (113b) and second (115b) smaller central panel to an end portion of said first (113a) and second (115a) larger central panel, thus forming said first (13) and second (15) side wall and defining the opposite end portions of said support legs (19, 20), said first larger central panel (113a) being contiguously adjacent to said first smaller central panel (113b).

6. Support tray (10) as in claim 5, when claims 3-5 depend on claim 2, characterized in that said blank (110; 110’) further comprises: a first (116a) and a second (117a) larger side panel connected, on opposite sides, to said first main panel (111); and a first (116b) and a second (117b) smaller side panel connected, on opposite sides, to said second main panel (112) and configured to be respectively superimposed and joined with glue to an end portion of said first (116a) and second (117a) larger side panel, thus forming said third (16) and fourth (17) side wall and defining the opposite end portions of said further respective support legs (21, 22).

7. Support tray (10) as in any one of the preceding claims, characterized in that each of said deformable flaps (28) has a curved portion (28a) facing the center of the respective second hole (26) and is configured to be bent, said curved portion (28a) belonging to an arc of the circle with a center outside the respective second hole (26).

8. Support tray (10) as in any one of the preceding claims, characterized in that each of said second holes (26) has a multi-lobed or polygonal shape with at leastthree sides which are curved towards the center of the second hole (26).

9. Support tray (10) as in any one of the preceding claims, characterized in that each of said deformable flaps (28) is convex.

10. Support tray (10) as in any claim 1-6, characterized in that each of said deformable flaps (28) is defined by radial incisions (27).

11. Blank (110; 110’) for forming a support tray (10) for elongated elements (200), in particular smoking articles, comprising: a first main panel (111) provided with a plurality of first holes (25); a second main panel (112) aligned with said first main panel (111) and provided with a plurality of second holes (26) encircled by deformable flaps (28) configured to be bent; a first (113a) and a second (115a) larger central panel connected, on opposite sides, to said first main panel (111); and a first (113b) and a second (115b) smaller central panel connected, on opposite sides, to said second main panel (112), characterized in that on said first (113a) and second (115b) smaller central panel there is a layer of adhesive material (Ml) to join with glue said first (113b) and second (115b) smaller central panel to an end portion of said first (113a) and second (115a) larger central panel, said first larger central panel (113a) being contiguously adjacent to said first smaller central panel (113b).

12. Blank (110; 110’) as in claim 11, characterized by further comprising: a first (116a) and a second (117a) larger side panel connected, on opposite sides, to said first main panel (111); and a first (116b) and a second (117b) smaller side panel connected, on opposite sides, to said second main panel (112) and configured to be respectively superimposed and joined with glue to an end portion of said first (116a) and second (117a) larger side panel.

13. Process for making a support tray (10) for elongated elements (200), in particular smoking articles, characterized by comprising folding steps in which said support tray (10) is formed by consecutive folding of panels (111, 112, 113a, 113b, 115a, 115b) of a blank (110; 110’) as in claim 11 or 12, and by comprising joining with glue the first (113b) and second (115b) smaller central panel to the lower end portion of the first (113a) and second (115a) larger central panel, respectively, thus forming respectively a first (13) and a second (15) side wall of said support tray (10) and defining respective support legs (19, 20), wherein each of said support legs (19, 20) consists of two superimposed and joined panels ofsaid blank (110; 110’).

14. Process as in claim 13, characterized by comprising a shaping step, in which said blank (110; 110’) starting from a flattened configuration is shaped into a three- dimensional upright configuration, and in that in said shaping step, the first (111) and the second (112) main panel of said blank (110; 110’), firstly are partially superimposed and in contact with each other, then are separated from each other and spaced apart to a position in which they are parallel each other, thus forming said upper (11) and lower (12) transverse wall perpendicular to said first (13) and second (15) side wall, in said upright configuration.

15. Process as in claim 14, characterized by comprising further folding steps, subsequent to said shaping step, in which the first (116b) and the second (117b) smaller side panel of said blank (110; 110’) are folded towards said respective support legs (19, 20), and in which the first (116a) and the second (117a) larger side panel of said blank (110; 110’) are folded so that a respective lower end portion thereof is superimposed and then joined with glue to said first (116b) and second (117b) smaller side panel, thus forming respectively a third (16) and a fourth (17) side wall of said support tray (10) and defining further respective support legs (21 , 22) consisting of two superimposed and joined panels of said blank (110; 110’).

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