Container manufacturing process

Abstract

A method for manufacturing a plurality of containers (30, 30', 30'') intended to receive all or part of an order of items, each container consisting of a box (10, 10', 10'') and a lid (20, 20', 20''), the method comprising: the manufacture of boxes having a dimension (A) common to all boxes (10, 10', 10'') and which constitutes for each box (10, 10', 10'') one of its width or its length, the other of its width or its length being adjusted according to the order which is intended for each box; and the manufacture of lids having: a dimension (B) common to all lids (20) and which constitutes, for each lid (20, 20', 20''), one of its widths or its lengths, the other of its widths or lengths being adapted so that each lid (20, 20', 20'') can be paired with one of the boxes (10, 10', 10''). Figure from the abstract: Figure 2

Description

Title of the invention: Method for manufacturing containers technical field

[0001] This disclosure relates to the field of packaging and, in particular, to the manufacturing processes for containers of various sizes. The invention is particularly concerned with, but not limited to, logistics systems for assembling orders. Previous technique

[0002] In a logistics system for order preparation, such as an ASRS (Automatic Storage and Retrieval System), it is known to group orders into boxes whose size is appropriate for the order, neither too small nor too large. For example, it is known to manufacture cartons of the "American-style box" or RSC (Regular Slotted Container) type, whose width, length, and height are each independently adjusted so that the carton properly accommodates the various items that make up an order. Other types of containers are also used, such as Fefco 0406, 0452, or 0453 containers. This packaging philosophy is sometimes called "3D Packing" because the three dimensions of the container can be adjusted as required.This principle requires the use of complex machines, such as the CVP Impack® or CVP Everest® machines from Sparck Technologies®, the X7, Ml or EM7 machines from Packsize LLC®, the Opera machine from Panotec® or the CartonWrap® machine from CMC®. US documents 2024 / 0092514 A1 and WO 2020 / 146334 A1 show examples of such machines.

[0003] Also, a major drawback of "American-style" containers is that they have top flaps that must remain open until the order is complete. Open flaps complicate the transport and storage of these containers, as well as access to the inside of the container when the operator or robot is loading the items. The flaps in the open position can assume unpredictable positions, sometimes threatening the stability of the container or the safety of its handling. Finally, the overall compactness of the system is affected since containers with open flaps are taller and sometimes wider than containers with closed flaps.

[0004] An alternative, to avoid the need for upper flaps, is to use lids that cover containers without flaps (5-sided boxes). In practice, only two or three different sizes of lids will be used. For For a given lid size, all containers must have a fixed width and length, corresponding to the lid's dimensions. Only the height of the containers can vary to adjust the dimensions to a specific order. This can be described as "1D Packaging," since only one dimension of the box changes: its height.

[0005] By acting on only one dimension of the container, the machine to be used is simpler, but the container dimensions are not optimized in relation to the cumulative volume of the items in an order. In other words, most containers are too wide and / or too long for their contents. This leads to the transport of oversized packages, which penalizes transport, since the trucks are at full capacity, whereas smaller containers would allow each truck to be loaded more and thus reduce the number of trucks in circulation for a given number of orders. Incidentally, oversized containers also mean wasted raw materials. In both cases, the environment suffers.

[0006] There is therefore a need for an order packaging solution that can operate with machines that are not complex while optimizing the volume of cartons and minimizing material waste, linked to containers that are oversized compared to the order they contain. Summary

[0007] This disclosure improves the situation.

[0008] A method is proposed for manufacturing a plurality of containers intended to receive all or part of an order of items, each container consisting of a box with a rectangular cross-section and a lid with a rectangular cross-section, the method comprising: the manufacture of boxes, such that all the boxes have: a first dimension common to all the boxes and which constitutes for each box its width or its length, and a second dimension which constitutes for each box its width or its length, the second dimension being adjusted for each box according to the order intended for it;and the manufacture of lids, all lids having: a first dimension common to all lids, which constitutes the width or length of each lid, and a second dimension which constitutes the width or length of each lid, the second dimension being adjusted for each lid so that each lid can be matched to one of the boxes.

[0009] The principle of sharing a common dimension while adjusting the second dimension according to the specifics of each order or each part of an order presents several significant advantages for production and logistics.

[0010] First, by standardizing the dimensions of the boxes and lids, the complexity of the manufacturing machine is considerably reduced. This means that the equipment used to produce these components can be simplified, which reduces production costs, maintenance requirements, and the risk of malfunctions. A less complex machine is easier to manage and repair, which improves production continuity and reduces downtime. The machine is less complex because the cutting and bending tools can be laterally fixed since the lateral dimension, perpendicular to the feed direction, is fixed, and in general, the tools do not need to be movable to adjust to two variable dimensions (for example, for bending or gluing the lid flaps, or for bending / gluing the box components).

[0011] Furthermore, the flexibility afforded by adjusting the second dimension to meet the specific needs of each order allows for customization without significantly increasing production complexity. Each order can be tailored to precisely meet the customer's requirements, whether it be the size, volume, or shape of the boxes. This customized approach ensures that the products are perfectly suited to their contents, thereby improving the protection and presentation of the goods.

[0012] By optimizing the adjustable dimensions for each order, the efficiency of the volume occupied by the containers is also maximized. This means that product storage and transport become more efficient, as containers can be filled optimally, reducing empty space and minimizing logistics costs. Better use of storage and transport space results in reduced warehousing and distribution costs.

[0013] In summary, this strategy of sharing a common dimension and adjusting the second dimension according to individual orders simplifies manufacturing operations, reduces costs, and improves logistical efficiency. It makes it possible to reconcile standardization and customization, thus offering a flexible and economical solution for the production of boxes and lids.

[0014] In this application, height is the vertical dimension of a box in its normal orientation, that is, when the bottom of the box is at the bottom and the opening for filling it is at the top. Similarly, for a lid, height is the vertical dimension when the lid is in its normal orientation, for example, covering the box. Width and length are two transverse dimensions of the box or lid; they are perpendicular to the height. The length is longer than the width. In this document, height, width, and length are understood to be the usable dimensions, that is, the internal dimensions of the box or lid, not taking into account the thickness of the material, which is often negligible. Furthermore, it goes without saying that two boxes with the same usable width will also have the same overall width when made from a sheet of the same thickness. The common dimension of the boxes can therefore also be considered as the external width or length of the lid or the box itself.

[0015] In the present application, the box and the lid have a rectangular cross-section in a horizontal plane. However, the teachings of the present application also apply to other forms of containers, for example with boxes of polygonal cross-section (hexagon, octagon), boxes having rounded edges, or even barrels of circular or elliptical cross-section.

[0016] For the manufacture of the box and the lid, flexible materials are preferred, such as cardboard or paperboard, possibly multi-layered and / or corrugated, etc. However, the present application can equally apply to plastic materials, malleable metals, synthetic fiber felts (for example recycled PET) or natural materials (particleboard or laminated wood, compressed paper, corn starch, animal leather, etc.).

[0017] By "all the boxes," "all the lids," and "a first common dimension," it should be understood that all the boxes manufactured on a production line share a common dimension, which for a given box may be its width (and for another box it may be its length), and the same applies to the lids. In other words, all the boxes can be divided into two groups: those for which the common dimension is the width, and those for which the common dimension is the length, and the same applies to the lids.

[0018] If, for a given box (or lid), the first dimension is its width, then the second dimension is its length, and vice versa. In the particular case of a box with a square cross-section, the first and second dimensions are equal, and the width is inseparable from the length.

[0019] The common dimension of the boxes (usable width or length of the boxes) is close to the common dimension of the lids (usable width or length of the lids), so that the lid can be fitted onto the box, possibly with a slight gap. Indeed, the common dimension of the lids is equal to the common dimension of the boxes plus twice the thickness of the box material (=sheet thickness, when the box is made from a sheet). As the material thickness is very small (less than 10%, preferably less than 5%, or even less than 2% or less than 1% of the common dimension of the boxes), the common dimension of the lids is between 100% and 120% of the common dimension of the boxes, preferably between 100% and 110% of the common dimension of the boxes, more preferably between 100% and 104% of the common dimension of the boxes. Preferably 100% and 102% of the common dimensions of the boxes. The value of 100% is generally excluded.

[0020] It follows from the above that, for example, if a predetermined dimension of 40 cm is agreed upon for a box production line and a paired lid production line, then each box has either a width or a length (or both) of 40 cm, and each lid has either a width or a length (or both) between 40 cm and 48 cm. If the material thickness is 5 mm and a lid mounting clearance of 1 mm is chosen for the box, then the common dimension of the lids (usable width or length) can be 40 + 0.5*2 + 0.1*2 = 41.2 cm. A thicker material and / or a larger clearance will lead to a larger common dimension for the lids.

[0021] In another respect, at the end of the box manufacturing stage, all the boxes have the same height. This strategy promotes simplicity of the machines and processes because it is not necessary to adjust the box size to demand, even if it means suboptimizing the container volume.

[0022] Alternatively, at the end of the box manufacturing stage, each box has a height adjusted according to the order for which it is intended. Here, the scale promotes the compactness of the container without unduly complicating the manufacturing process.

[0023] According to another aspect, the box manufacturing step comprises the steps of: feeding a first manufacturing line with a sheet; for each box, forming on the sheet two first parallel fold lines, spaced apart by the first dimension common to all boxes, and arranged at equal distances respectively from a first and a second edge of the sheet; for each box, forming on the sheet two second parallel fold lines, spaced apart by the second dimension of the box, the second fold lines being perpendicular to the first fold lines; optionally for each box, cutting the sheet parallel to the second fold lines, so as to obtain a third and a fourth edge such that the second lines are arranged at equal distances respectively from the third and fourth edge;For each box, cut the sheet along four cutting lines that join the intersections of the first and second lines at the first and second edges, or alternately at the third and fourth edges; and for each box, fold the sheet along the first and second fold lines. This technique allows you to obtain boxes of the desired size from simple folding and cutting steps. These "equal distances" form the height of the box.

[0024] According to another aspect, no cut is made parallel to the first fold lines. Thus, the dimension of the sheet in the direction perpendicular to the The second line remains intact for the boss of the company, which simplifies manufacturing.

[0025] Alternatively, the box manufacturing step includes, for each box, a step consisting of cutting the sheet parallel to the first fold lines and at a distance from the first lines corresponding to the height of the box adjusted according to the order for which it is intended. This method minimizes the volume of the containers.

[0026] According to another aspect, the lid manufacturing step comprises the steps of: feeding a second manufacturing line with a sheet; for each lid, forming on the sheet two first parallel fold lines, spaced apart by the first common dimension of the lids, and arranged at equal distances respectively from a first and a second edge of the sheet; for each lid, forming on the sheet two second parallel fold lines, spaced apart by the second dimension of the lid, the second fold lines being perpendicular to the first fold lines; for each lid, cutting the sheet parallel to the second fold lines, so as to obtain a third and a fourth edge such that the second lines are arranged at equal distances respectively from the third and fourth edge;Optionally, for each lid, cut four rectangular notches in the sheet whose sides are parallel to the four edges and whose two vertices, respectively, at each rectangular notch are formed by a point of intersection of the first and second lines and a vertex of the four edges; and for each lid, fold the sheet along the first and second fold lines. These "equal distances" form the height of the lid.

[0027] It should be noted that the cuts made on the sheet of the box or lid are given above as an example and that other cuts can be envisaged to allow easy folding of the sheet.

[0028] According to another aspect, the sheet feeding the first and / or second production line is a continuous sheet wound onto a reel or arranged in accordion-folded plates. This type of feeding allows for optimal adjustment of the dimensions of the boxes and lids without the machine needing a complicated device to transfer the sheet to the folding or cutting station.

[0029] According to another aspect, the sheet feeding the first and / or second production line is a sheet of constant width, measured perpendicular to the first fold lines. This type of raw material conveniently simplifies obtaining patterns of constant width since it is not necessary to cut parallel to the first fold lines. This feeding method is particularly advantageous for the lid, the height of which can always be the even regardless of the height of the box, or for a series of boxes of the same height.

[0030] In an alternative that leads to the use of a slightly more complex machine, the sheet feeding the first and / or second production line is a sheet from multiple supply sources of sheets of identical or different widths, measured perpendicular to the first fold lines. Feeding sheets of different widths makes it possible to optimize the amount of material used, or to obtain cutting scraps with dimensions of interest for secondary use, or to obtain flaps, after folding, that give the box / lid greater or lesser rigidity.

[0031] According to another aspect, between two successive manufacturing steps, the sheet advances in the first and / or second production line in a direction parallel to the first fold lines of the box and / or lid. Forming folds parallel to the direction of advance allows, with relatively simple machine components (for example, side guides), for ensuring that the fold lines are straight and parallel to the edges of the sheet.

[0032] The invention also relates to a method of preparing orders comprising the steps of, for any order: determining the dimensions of a container intended to receive all or part of the order, one of the dimensions of the container being fixed in a predefined manner and independently of the order; manufacturing the container comprising a box and a lid in accordance with one of the methods described above; placing in the box the items composing all or part of the order; and covering the box with the lid.

[0033] According to another aspect, the height of the boxes is adjusted by cutting or folding after the items have been placed in the box.

[0034] According to another aspect, at least one third production line operating similarly to the first production line and / or at least one fourth production line operating similarly to the second production line are planned. This makes it possible to increase productivity and multiply the technical advantages of compactness with simple machines.

[0035] According to another aspect, the process includes the use of at least one additional production line manufacturing boxes, each of the additional production lines being associated with a common box dimension value. Several of these additional production lines may share the same common box dimension value; or each additional production line may be associated with its own specific value. Thus, it is possible to produce several series of boxes, each series forming a group of boxes sharing a common dimension. Thus, the expression "all the boxes" can be considered in The relationship with all the boxes in a series of boxes is a key factor. Series can be evenly distributed across a range of values: for example, one production line with a common value of 5 cm boxes, another with 10 cm boxes, and so on up to 100 cm. Alternatively, the distribution of the number of production lines can be correlated with the demand for boxes of certain dimensions. Thus, a bell curve can be used: several production lines may have similar values ​​between 20 and 60 cm, while a very small number of production lines may offer boxes with a common dimension below or above this range.

[0036] Similarly, the process may include the use of additional production lines to produce series of lids, all the lids in the same series having a common dimension.

[0037] It is understood that the various examples listed above are conceivable alone or in any combination. Brief description of the drawings

[0038] Other features, details and advantages will become apparent from reading the detailed description below, and from analyzing the attached drawings, on which:

[0039] [Fig-1] shows a container.

[0040] [Fig. 2] represents a group of containers sharing the same dimensions.

[0041] [Fig. 3] describes the successive steps in a process for manufacturing a box.

[0042] [Fig. 4] illustrates the successive steps in a process for manufacturing a lid.

[0043] [Fig. 5] details a diagram of a manufacturing process.

[0044] [Fig.6] shows a diagram of an order preparation process. Description of the implementation methods

[0045] Fig. 1 shows a box 10 and a lid 20, together forming a container 30. The box 10 is essentially parallelepiped-shaped, formed of five faces: a base 11 and four side walls 12, 13, 14, 15. The lid 20 is parallelepiped-shaped and has a ceiling 21 and four side walls 22, 23, 24, 25. The side walls 12-15, 22-25 are flat and parallel in pairs.

[0046] The box 10 has a width of 110, a length of L10 and a height of H10. The lid 20 has a width of 120, a length of L20 and a height of H20.

[0047] The height H20 of the lid 20 may be less than the height H10 of the box 20. For example, the height H20 is less than 30% of H10, or even less than 10% of H10.

[0048] The width 120 and length L20 of the lid 20 are slightly greater than the width 110 and length L10 of the box 10. For a snug fit, the width 120 (or length L20) will be equal to 110 (or L10) plus twice The material thickness of the lid. The material thickness is the distance between an internal surface and an external surface of a side wall of the lid. For a fit with a mounting gap, the width 120 (or L20) will be greater than 110 (or L10) plus twice the material thickness of the lid.

[0049] The box 10 and the lid 20 here have a rectangular cross-section (in a horizontal cutting plane when the box and lid are in their normal orientation). Other cross-sections can be considered, notably polygonal (triangular, hexagonal, etc.) or rounded (elliptical, circular, etc.). The benefits of compactness and ease of manufacture obtained with a container of rectangular cross-section are transferable to a container with a different cross-section.

[0050] The box 10 and the lid 20 can be made of the same material. Alternatively, the box 10 and the lid 20 can be made of different materials, the box for example being made of a more robust, more rigid material than the lid.

[0051] The box 10 and / or the lid 20 can be obtained by folding and cutting from a continuous feed of a sheet that is wound or folded accordion-style. The sheet can be made of cardboard or other flexible materials, such as synthetic fiber felts (e.g., recycled PET) or natural materials (particleboard or laminated wood, compressed paper, corn starch, animal leather, etc.).

[0052] In one embodiment, the box 10 and / or the lid 20 can be obtained by assembling panels. In this case, the panels can be made of a rigid (non-flexible) material such as plastics, plywood, or metal. The assembly technique will be adapted to the material in question, for example, assembling wooden panels using nails or staples, assembling metal parts by screws or welding, etc. Indeed, although the present application focuses on bending and cutting processes, the benefits described herein (compactness of the container and simplification of the manufacturing machine) are also obtained with other materials and other manufacturing technologies.

[0053] Fig. 2 shows a series of three containers 30, 30', 30" obtained by the manufacturing process described above. In this series of containers, all the boxes 10, 10', 10" share a common dimension A, and all the lids 20, 20', 20" share a common dimension B. For the boxes 10 and 10' (and the lids 20 and 20' respectively), this common dimension A (and B respectively) is the width, while each of these two boxes 10 and 10' has its own length. The 10" box (and the 20" lid respectively) has a length equal to A (and B respectively). The 10" box also has a height larger than the other boxes 10, 10', while the three lids 20, 20', 20” have the same height.

[0054] According to one variant of the manufacturing process of this disclosure, the height H10 of each box can be adjusted as desired. According to a second variant, all boxes share the same height H10.

[0055] Fig. 3 illustrates the successive steps of an example of manufacturing a box 10.

[0056] A sheet 100 (rolled or accordion-folded) feeds the production line. Sheet 100 is placed on a conveyor (for example a conveyor belt) which moves it forward in the X direction. Sheet 100 thus travels through several successive manufacturing stations; the numbers 100, 106, 114, 118, 124 and 126 designate the sheet in its successive states.

[0057] The sheet 100 is substantially flat in a plane (X, Y), with two edges 102, 104 parallel to the X axis. It has a width in the Y direction, perpendicular to X, which is denoted Y100.

[0058] In the illustrated example, the sheet has a constant width in the Y direction. Alternatively, in an example not shown but mentioned above, more complex feeding systems with several types of sheets of different widths can be used. Thus, in the first case, the boxes have varying heights. Changes in height from one box to another can be achieved by folding back a flap and / or cutting the box after it has been folded. Alternatively, changes in box height can be achieved by feeding the machine with sheets of varying widths (sheet width = box width + 2x height). In the second case, the boxes all have the same height. Feeding with sheets of the same width is preferred. However, variable sheet widths are possible by folding back a flap and / or cutting the box after it has been folded.In both cases, situations not requiring flap folding or cutting allow for the simplest possible machine. Situations requiring flap folding or cutting result in a slightly more complex machine, but not as complex as when the three dimensions of the box are variable.

[0059] The sheet 106 reaches a station where the first two fold lines 108, 110 are formed on the sheet. These lines 108, 110 are spaced apart by a dimension A, which is the dimension common to all boxes. The lines 108, 110 are equidistant from their respective edges 102, 104. This distance can be H10, the height of the box 10, or a distance greater than H10. In this case, a height adjustment step can be performed, either by cutting the pattern (before or after folding the box), or by folding the sheet.

[0060] The bend lines 108, 110 can be made by punches whose X and Y position is fixed, which simplifies the machine compared to a machine with punches that must be adjustable to obtain boxes of different dimensions as opposed to the boxes in this disclosure sharing a common dimension A.

[0061] At the next station, two second fold lines 114, 116 are formed in the sheet 112. These lines 114, 116 are parallel to each other and perpendicular to the first lines 108, 110. In the illustrated case, these two fold lines are separated from each other by a length L10. In other cases, this distance may be the width 110, the distance A then being the length of the box.

[0062] The intersections of the first and second lines, which will form the corners of the base of the box, are marked C, D, E and F.

[0063] At the next station, the sheet 118 is cut parallel to Y, so as to form two edges 120, 122. The edges 120, 122 are spaced from the second lines 114, 116 by the same distance, which can be the height H10 of the box, or another distance which (as for the first lines) will be rectified by cutting or folding.

[0064] In some cases, the edge 122 may have been formed by a previous cut. Indeed, the edge 122 of a sheet 118 may coincide with the edge 120 of the immediately preceding sheet 118. If this is the case, in the previous step, the two second fold lines 114, 116 are positioned relative to this cut edge during the passage of the preceding sheet 118.

[0065] The intersections of the fold lines with the edges 102, 104, 120, 122 are marked G, H, I, J, K, L, M and N. Figure 3D identifies the elements that will form the base 11, and the side walls 12-15 of the box.

[0066] In order to fold sheet 124 back on itself to form the box, cutouts are necessary. In a first variant, lines CN, DI, EJ and FM will be cut as illustrated in Figure 3E. In a second variant, not illustrated, lines CG, DH, EK and FL will be cut.

[0067] In a third variant, the cutouts can be rectangles as shown in connection with the manufacture of the lid in figure 4E.

[0068] Figure 3F shows a sheet 126 being folded along the fold lines to form a box 10. The base 11 and two side walls 12, 13 of the box are annotated for reference.

[0069] The manufacturing line uses standard means to apply bend lines (e.g. linear punches) and cuts (cutting rollers, knives, etc.) which need not be described in more detail.

[0070] The steps described in Figures 3A to 3F are repeated to obtain several boxes sharing the same dimension A along the Y direction, and for which the dimension in X is specific to each box.

[0071] Fig. 4 illustrates the successive stages of an example of manufacturing a lid 20.

[0072] A sheet 200 (rolled or accordion-folded) feeds into the production line. The sheet 200 is placed on a conveyor (for example, a conveyor belt) which moves it forward in the X direction. The sheet 200 thus travels through several successive production stations; the numbers 200, 206, 214, 218, 224, and 226 designate the sheet in its successive states.

[0073] The sheet 200 is substantially flat in a plane (X, Y), with two edges 202, 204 parallel to the X axis. It has a width in the Y direction, perpendicular to X, which is denoted Y200.

[0074] The sheet 206 reaches a station where the first two fold lines 208, 210 are formed on the sheet. These lines 208, 210 are spaced apart by a dimension B, which is the dimension common to all the lids. The lines 208, 210 are equidistant from their respective edges 202, 204. This distance can be H20, the height of the lid 20, or a distance greater than H20. In this case, a height adjustment step can be performed, either by cutting the pattern (before or after folding the lid) or by folding the sheet.

[0075] The fold lines 208, 210 can be made by punches whose position in X and Y is fixed, which simplifies the machine compared to a machine with punches which must be adjustable to obtain lids of different dimensions as opposed to the lids of the present disclosure sharing a common dimension B.

[0076] At the next station, two second fold lines 214, 216 are formed in the sheet 212. These lines 214, 216 are parallel to each other and perpendicular to the first lines 208, 210. In the illustrated case, these two fold lines are separated from each other by a length L20. In other cases, this distance may be the width 120, the distance B then being the length of the lid.

[0077] The intersections of the first and second lines, which will form the corners of the ceiling of the lid, are marked C, D, E and F.

[0078] At the next station, the sheet 218 is cut parallel to Y, so as to form two edges 220, 222. The edges 220, 222 are spaced from the second rows 214, 216 by the same distance, which can be the height H20 of the lid, or another distance which (as for the first rows) will be rectified by cutting or folding.

[0079] In some cases, the edge 222 may have been formed by a previous cut. Indeed, the edge 222 of a sheet 218 may coincide with the edge 220 of the immediately preceding sheet 218. If this is the case, in the previous step, the two second fold lines 214, 216 are positioned relative to this cut edge during the passage of the preceding sheet 218.

[0080] The intersections of the fold lines with the edges 202, 204, 220, 222 are marked G, H, I, J, K, L, M and N. Figure 4D identifies the elements that will form the ceiling 21, and the side walls 22-25 of the lid.

[0081] In order to fold sheet 224 over itself to form the lid, cutouts are necessary. In this example, rectangles CGON, DIPH, EKQJ and FMRL will be cut, where O, P, Q and R are the intersections of edges 202, 204, 220, and 222.

[0082] It is understood that the cutouts shown for the manufacture of the box in relation to Figure 3E can alternatively be chosen.

[0083] Figure 4F shows a sheet 226 being folded along the fold lines to form a lid 20. The ceiling 21 and the side walls 22-25 of the lid are annotated for reference.

[0084] The manufacturing line uses standard means to apply bend lines (e.g. linear punches) and cuts (cutting rollers, knives, etc.) which need not be described in further detail.

[0085] The steps described in Figures 4A to 4F are repeated to obtain several lids sharing the same dimension B along the Y direction, and for which the dimension in X is specific to each lid, according to a corresponding box dedicated to receiving items from an order.

[0086] Fig. 5 represents a method 1000 for manufacturing a box and a lid.

[0087] The process 1000 includes a process 1100 for manufacturing the box and a process 1200 for lid manufacturing.

[0088] Some steps of the illustrated process may be optional.

[0089] At step 1110, in connection with figure 3A, a sheet feeds a first production line, dedicated to boxes.

[0090] At step 1120, in relation to figure 3B, the first fold lines are made in the sheet. They are parallel and spaced apart by dimension A.

[0091] In step 1130, in relation to Figure 3C, second fold lines are made, parallel and spaced apart by the width or length of the box, depending on what A represents for that given box. The second fold lines are perpendicular to the first fold lines. In an alternative, the second fold lines (parallel to Y) can be made before forming the first fold lines (parallel to X).

[0092] In step 1140, as shown in Figure 3D, the upstream and downstream edges of the sheet are cut parallel to the second fold lines. The edges and the second fold lines are equidistant from each other. In an alternative, the second fold lines are formed after cutting at least one, or even both, edges.

[0093] At step 1150, in relation to Figure 3E, the cuts along the second or first fold lines, between the intersections of these lines and the edges, are made.

[0094] At step 1160, in relation to figure 3F, each box is folded along the first and second fold lines.

[0095] Step 1170 is an optional step for leveling the box height. Depending on the sheet size (Y 100 in Figure 3A), it may be possible to cut the sheet parallel to X to obtain a box height specific to each box. This step 1170 can be performed at any point in the process: for example, even before step 1120, or even after filling the box with the items in the order.

[0096] At step 2110, in connection with figure 4A, a sheet feeds a first production line, dedicated to lids.

[0097] At step 2120, in relation to figure 4B, the first fold lines are made in the sheet. They are parallel to each other and spaced apart by dimension B.

[0098] In step 2130, in relation to Figure 4C, second fold lines are made, parallel and spaced apart by the width or length of the lid, depending on what B represents for that specific lid. The second fold lines are perpendicular to the first fold lines. In one embodiment, the second fold lines (parallel to Y) can be made before forming the first fold lines (parallel to X).

[0099] In step 2140, as shown in Figure 4D, the upstream and downstream edges of the sheet are cut parallel to the second fold lines. The edges and the second fold lines are equidistant from each other. In one embodiment, the second fold lines are formed after cutting at least one, or even both, edges.

[0100] At step 2150, in relation to figure 4E, the rectangular cutouts are made.

[0101] At step 2160, in relation to figure 4F, each box is folded according to the first and second fold lines.

[0102] Step 2170 is an optional step for leveling the lid height. Indeed, except in specific cases where the box is very low, the lid height can be kept constant regardless of the box dimensions. If necessary, the lid height can be adjusted in the same way as the boxes in step 1170.

[0103] Fig. 6 summarizes a 2000 order preparation process.

[0104] The process 2000 includes a step of determining the dimensions of the box 2100. One of the dimensions of the box is A (its length or its width). The others dimensions (width or length, and possibly height if it is not fixed for all boxes) are calculated so that the box can receive the items in the order, possibly taking into account the shock protection material that may be provided to protect the items during transport.

[0105] Depending on certain parameters, such as supplier lead times, it may be possible to choose to fill the box with only part of the order. The dimensions of the lid are determined from those of the box: the width and length of the lid are slightly greater than the width and length of the box, as explained above. The height of the lid can be predetermined and independent of the box dimensions.

[0106] In the next step 1000, in a first variant, the box and the corresponding lid are manufactured, according to the process mentioned above, after the dimensions of the box have been determined. In another variant, the box and the lid are selected from a pool of boxes and lids previously manufactured according to the process mentioned above.

[0107] The items are then placed 2200 in the box by an operator or by an automatic device such as a robotic gripper. A computing unit (for example, the one that determined the dimensions required for the box) can be used to indicate to the operator the ideal arrangement of the items in the box.

[0108] Optionally, the box can be set to a height of 1170 after the box has been filled.

[0109] Finally, the box is covered with the lid. Fastening methods (hot melt adhesive, staples, etc.) can be provided to secure the lid to the box.

[0110] The process may include preliminary steps, namely one or more of the following steps: making a product catalogue available to a user; the selection by that user of one or more products to form an order; payment of the order by the user; the acquisition and / or transport and / or storage of the items in the order from a supplier; and confirmation by an operator of the validity of the order.

[0111] The process may also include subsequent steps, such as transporting, storing and / or delivering the container to a user.

[0112] The present disclosure has focused on order preparation, but those skilled in the art will understand that the technical advantages described here for manufacturing series of containers extend beyond this single application.

Claims

Demands

1. A method (1000) for manufacturing a plurality of containers (30) intended to receive all or part of an order of items, each container (30) being made up of a box (10) of rectangular cross-section and a lid (20) of rectangular cross-section, the method comprising: - the manufacture of boxes (1100), such that all the boxes (10) have: - a first dimension (110, L10, A) common to all the boxes (10) and which constitutes for each box (10) its width (110) or its length (L10), and - a second dimension (110, L10) which constitutes for each box (10) its width or its length, the second dimension being adjusted for each box (10) according to the order intended for it;and - the manufacture of lids (1200), all the lids having: - a first dimension (120, L20, B) common to all the lids (20) and which constitutes for each lid (20) its width (120) or its length (L20), and - a second dimension (120, L20) which constitutes for each lid (20) its width or its length, the second dimension being adjusted for each lid (20), so that each lid (20) can be paired with one of the boxes (10).;

2. A method (1000) according to claim 1, wherein at the end of the box manufacturing step (1100), all the boxes (10) have the same height (H 10).

3. Method (1000) according to claim 1, wherein at the end of the box manufacturing step (1100), each box (10) has a height (H10) adjusted according to the order intended for it.

4. A method (1000) according to any one of claims 1 to 3, wherein the box manufacturing step (1100) comprises the steps of: - feeding (1110) a first manufacturing line with a sheet (100); - for each box, forming (1120) on the sheet (106) two first fold lines (108, 110) parallel to each other, spaced apart by the first dimension (A) common to all boxes (10), and arranged at equal distances (H 10) respectively from a first (102) and a second edge (104) of the sheet (106); - for each box, form (1130) on the sheet (112) two second fold lines (114, 116) parallel to each other and spaced apart by the second dimension (110, L10) of the box (10), the second fold lines (114, 116) being perpendicular to the first fold lines (108, 110); - for each box, cut (1140) the sheet (118) parallel to the second fold lines (114, 116), so as to obtain a third and a fourth edge (120, 122) such that the second lines (114, 116) are positioned at equal distances (H10) respectively from the third and fourth edge (120, 122); - optionally, for each box, cut (1150) the sheet (124) along four cutting lines (CG, DH, EK, FL;or DI, EJ, FM, NC) which respectively join the intersections (C, D, E, F) of the first and second lines (108, 110, 114, 116) at the first and second edge (102, 104), or alternatively at the third and fourth edge (120, 122); and - for each box, fold (1160) the sheet (126) along the first and second fold lines (108, 110, 114, 116).;

5. Method (1000) according to claim 4 in combination with claim 2, wherein no cutting is carried out parallel to the first fold lines (108, 110).

6. A method (1000) according to claim 4 in combination with claim 3, wherein the box manufacturing step (1100) comprises, for each box, a step consisting of cutting (1170) the sheet (100, 106, 112, 124) parallel to the first fold lines (108, 110) and at a distance from the first lines (H 10) corresponding to the height of the box (H 10) adjusted according to the order intended for it.

7. A method according to any one of claims 1 to 6, wherein the lid manufacturing step (1200) comprises the steps of: - feeding (1210) a second manufacturing line with a sheet (200); - for each lid, forming (1220) on the sheet (206) two first fold lines (208, 210) parallel to each other, spaced apart by the first common dimension of the lids (B), and arranged at equal distances respectively from a first and a second edge of the sheet (202, 204); - for each lid, form (1230) on the sheet (212) two second fold lines (214, 216) parallel to each other and spaced apart by the second dimension of the lid (120, L20), the second fold lines (214, 216) being perpendicular to the first fold lines (208, 210);- for each lid, cut (1240) the sheet (218) parallel to the second fold lines (214, 216), so as to obtain a third and a fourth edge (220, 222) such that the second lines (214, 216) are arranged at equal distances (H20) respectively from the third and fourth edge (220, 222); - optionally, for each lid, cut (1250) in the sheet (224) four rectangular notches whose sides are parallel to the four edges (202, 204, 220, 222) and whose two respective vertices at each rectangular notch are formed by a point of intersection (C, D, E, F) of the first and second lines and a vertex (O, P, Q, R) of the four edges (202, 204, 220, 222); and - for each lid, fold (1260) the sheet (226) along the first and second fold lines.;

8. A method (1000) according to any one of claims 4 to 7, wherein the sheet (100, 200) feeding the first and / or second production line is a continuous sheet wound into a reel or arranged in accordion-folded plates.

9. A method (1000) according to any one of claims 4 to 8, wherein the sheet (100, 200) feeds the first and / or second line manufacturing is a sheet of constant width (Y 100, Y200), measured perpendicular to the first fold lines (108, 110, 208, 210).

10. A method (1000) according to any one of claims 4 to 9, wherein between two successive manufacturing steps (1110-1160, 1210-1260), the sheet (100, 200) advances in the first and / or second manufacturing line in a direction (X) parallel to the first fold lines (108, 110, 208, 210) of the box and / or lid.

11. A method (2000) for preparing an order comprising articles, the method comprising the steps of: - determining (2100) the dimensions of a box (10) of a container (30) intended to receive the articles, one of the dimensions of the box (A, 110, L10) being fixed in a predefined manner and independently of the order; - manufacturing (1000) the container (30) comprising the box (10) and a lid (20) in accordance with the method of any one of claims 1 to 10; - arranging (2200) the articles in the box (10); and - covering (2300) the box (10) with the lid (20).

12. Method (1000) according to claim 11, wherein the height (H 10) of the box (10) is adjusted by cutting or folding after arranging the articles in the box (10).

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