Apparatus and method for packaging corrugated boxes

Abstract

An apparatus (1) for automatically wrapping a packaging blank (3) on a side wall of a corrugated box (2), the packaging blank (3) having a base (301) and a number of flaps (302, 303, 304, 305) connected thereto, the apparatus (1) comprising a number of folding heads (5) for folding the flaps of the packaging blank (3) and enclosing an outer portion thereof. Each folding head (5) includes a pair of fingers (502A) positionable on the inside of the box (2) and movable toward and away from each other so that the fingers (502A) are in sliding contact with the packaging blank on the inner surface of the box side wall and are movable relative to each other.

Description

[Technical field]

[0001] The present invention relates to an apparatus and method for packaging corrugated boxes. [Background technology]

[0002] In the industry, an automatic line for producing wrapped boxes comprises two different stages: in the forming stage, the box is formed from a specially shaped paper or cardboard, which forms a blank consisting of a base and a number of flaps connected to the base and designed to be folded against the base to form the side walls of the box; in the next stage, the box is wrapped by applying a pre-glued packaging blank to the box. The packaging blank is a flat blank with a base of similar shape to the base of the box and flaps connected to the base and designed to be folded to cover the side walls of the box.

[0003] An automatic line for producing wrapped boxes comprises various stations at which corresponding respective working machines are arranged. Typically, an automatic line for producing wrapped boxes comprises: a gluing machine for gluing the packaging blanks, a former for forming boxes from the respective cardboard blanks, a positioning device for receiving the boxes from the former and bonding them to the respective packaging blanks received from the gluing machine (positioning the base of the box on the base of the flat packaging blank), and a packaging machine for receiving the assembly of boxes bonded to the packaging blanks from the positioning device and providing the finished boxes in the outfeed.

[0004] Specifically, packaging involves two steps: in a first step, the side flaps of the packaging blank are moved upwards to an upright position, while in a second step (also called tucking), the flaps are folded towards the inside of the box so that they at least partially cover the inner surface of the box side wall.

[0005] Conventionally, the packaging stage employs a die block that is movable along the vertical direction and acts against the base of the box. The die block is inserted snugly into the box and is held within the box in contact with the walls and bottom of the box. The die block works in conjunction with a number of folding elements to interact with the flaps of the packaging blank and fold them upwards to a vertical position so that they can be further folded towards the inside of the box.

[0006] The applicant has noted an increasing market demand for automated lines for producing wrapped boxes of various formats or sizes, even in small batches, as required, which are flexible with regard to changeover, i.e. changing from the production of boxes of a first format to the production of boxes of a second format, with regard to changing one or more parts of the line, in particular the die blocks, which must be of the same size as the boxes.

[0007] However, applicant has realized that these operations have several drawbacks: since the die block must be the same size as the box being packaged, every time a different box format is produced, the operator must change the die block used to package the box, which is time consuming and further requires having (and therefore stocking) as many different die blocks as there are box formats being produced, which inevitably creates all sorts of stock management problems.

[0008] Therefore, some solutions have been developed that eliminate the need for die blocks. Patent documents WO2015 / 079342A1 and BO2010A000658 in the name of the same applicant as the present application describe examples of known folding or wrapping devices for packaging boxes without the use of die blocks for folding the flaps of the packaging blank towards the inside of the box. Another example of a known device for packaging cardboard boxes is disclosed in patent document CN111516295A.

[0009] In this regard, however, applicants perceive a need for further improvements in non-die block packaging to address various problems.

[0010] One problem perceived by the applicant in connection with automated lines for producing wrapped boxes is to further reduce machine downtime during format changeovers.

[0011] Another problem which the applicant feels the need to address is that of making lines (particularly with regard to packaging machines) particularly high performance in terms of speed or production capacity.

[0012] Another problem which the Applicant feels the need to address is that of making the line particularly flexible, ie suitable for manufacturing boxes of a wide variety of formats.

[0013] Another problem which the Applicant feels the need to address is that of being able to produce boxes of particularly high quality, for example by minimizing wrinkles or other defects in the packaging blanks or by making the edges and corners of the boxes particularly sharp ("clean edges"). Summary of the Invention

[0014] It is an object of the present disclosure to provide an apparatus and method for packaging corrugated boxes to improve upon the prior art discussed above.

[0015] This object is fully achieved by the apparatus and method of the present disclosure as characterized in one or more of the appended claims.

[0016] According to one aspect, the present disclosure provides an apparatus for automatically wrapping a packaging blank into a side wall of a box. The box is preferably made of cardboard. The blank has a base and a plurality of flaps connected thereto. The blank is preferably made of paper. The box is coupled to the base of the blank. In an exemplary embodiment, the apparatus comprises a plurality of folding heads. The plurality of folding heads are configured to perform a plurality of folding operations. The plurality of folding operations may include folding flaps of the packaging blank from a horizontal position to a vertical position such that an inner portion of each flap adheres to an outer surface of the side wall of the box and an outer portion of each flap protrudes vertically from the box. The plurality of folding operations may also include folding an outer portion of the flap from a vertical position to a horizontal position. The plurality of folding operations may also include further folding the outer portion of the flap from a horizontal position to a vertical position toward the inside of the box, whereby the outer portion of the flap adheres to an inner surface of the side wall of the box.

[0017] In an exemplary embodiment, the apparatus includes a support structure. The support structure is configured to support a base of the packaging blank. Preferably, the support structure is configured to support the base of the packaging blank at least at each apex of the box. The support structure may be vertically movable such that the packaging blank and the box coupled thereto are vertically movable. The support structure may be configured to move the packaging blank and the box coupled thereto to various heights along the vertical direction.

[0018] The apparatus may also include a control unit configured to receive input data, the input data may represent a programmed size of each box to be packed, and the control unit configured to derive settings for the apparatus based on the input data.

[0019] The apparatus may comprise a number of actuators. The actuators are connected to a control unit. The actuators are configured to move the folding head according to settings of the apparatus. This makes the apparatus suitable for boxes of different sizes.

[0020] In an exemplary embodiment, the plurality of folding heads includes a plurality of pairs of folding heads, for each pair of folding heads, which may simultaneously act on a respective pair of sides of the box, and the folding heads constituting the pair of folding heads are spaced apart from each other along the working direction thereof.

[0021] According to one aspect of the disclosure, the support structure may include a plurality of pairs of support bars. Preferably, the plurality of pairs of support bars correspond to a plurality of pairs of folding heads. In an exemplary embodiment, for each pair of support bars, the bar is oriented transversely to the working direction of the corresponding pair of folding heads. The support bars constituting each pair of support bars may be movable toward or away from each other. In an exemplary embodiment, the support bars are displaceable depending on the setting of the device to support corresponding edges of the bottom wall of the box.

[0022] This configuration makes it possible for the support bar to be adapted to all kinds of boxes of various sizes, and to support the sides of the box that the twin folding heads act on.

[0023] Alternatively, the support structure may include a plate that supports a central portion of the bottom wall of the box.

[0024] According to another aspect of the present disclosure, the device may include an arm configured to operatively couple with the folding head. The arm may have at least one rotational movement.

[0025] The arms are configured to move from an inactive position where they are spaced from the side walls of the box to an active position where they contact the inner surface of the side walls of the box to support the inner surface of the side walls of the box. This configuration avoids the need to move the box while the flaps of the packaging blank are being folded, thus preventing the formation of wrinkles on the inside of the box, especially if the paper used in the packaging blank is stiff.

[0026] According to one aspect of the disclosure, each folding head of a plurality of folding heads of the apparatus includes a pair of fingers.

[0027] The fingers constituting each pair of fingers are mutually movable towards and away from each other. The pair of fingers are displaceable inside the box so that they can move relative to each other in sliding contact with the packaging blank on the inner surface of the side wall of the box. This solution makes it possible to obtain a more accurate fold and prevents wrinkles when the flap is folded towards the inside of the box.

[0028] It should be noted that the applicant intuitively realized that by providing a device which acts on the flaps at the sides of the packaging blanks at the wrapping stage, independently of the geometrical characteristics (height, width) of the side walls to which these flaps are glued, it would be possible to obtain a particularly flexible line and a consistently high-quality production. In this connection, the applicant discovered that by providing the machine with a pair of fingers which can move relative to one another in sliding contact with the flaps folded inside the box so that they can be glued to the inner surface of the box, the wrapping operation becomes independent of the length of the side walls, i.e. the box format, since the fingers can move from a minimum distance from one another to a maximum distance which can be suitably set by the operator.

[0029] In an exemplary embodiment, each of the pairs of fingers is movable along a first axis toward and away from a corresponding wall of the box. The mutual movement of the fingers constituting the pair of fingers is performed along a second horizontal axis. The second horizontal axis is perpendicular to the first horizontal axis. In one example, the support structure and each pair of fingers are also movable vertically relative to each other. The support structure and each pair of fingers are movable from a raised configuration, in which the pair of fingers is located above the box, to a lowered configuration, in which the pair of fingers is located inside the box. This solution makes it possible to fold the outer portion of the flap from a vertical position to a horizontal position using the pair of fingers, and to fold the outer portion of the flap from a horizontal position toward the inside of the box. Furthermore, for each folding head, the fingers constituting the corresponding pair of fingers are mutually movable between a first position in which they are located at a minimum distance from each other and a second position in which they are located at a maximum distance from each other.

[0030] Preferably, for each folding head, a pair of fingers are displaceable inside the box with the fingers in a first position. Each folding head may be configured to move the pair of fingers away from each other from a first position to a second position with the fingers in a lowered configuration. Each folding head may be configured to move the pair of fingers from a second position to a first position when the fingers move towards each other with the fingers in a raised configuration. This configuration makes it possible to obtain higher efficiency and higher speeds.

[0031] The plurality of actuators may include a slide actuator configured to move the fingers toward and away from one another, the slide actuator configured to move the fingers between a first position in which the fingers are positioned at a minimum distance from one another and a second position in which the fingers are positioned at a maximum distance from one another, the second position being set according to a setting of the apparatus.

[0032] In an exemplary embodiment, the support structure is adapted to move along a vertical direction between a first stop at a first height and a second stop at a second height. The second height is lower than the first height. Preferably, the folding head is configured to fold the flaps of the packaging blank from a horizontal position to a vertical position with the support structure located at the first stop, and to fold the outer portions of the flaps from a vertical position to a horizontal position and from a horizontal position to a vertical position with the support structure located at the second stop, such that the outer portions of the flaps are in close contact with the inner surface of the side wall of the box. This solution allows for high speed production of packaged boxes and reduced dimensions of the device. In an exemplary embodiment, each folding head may also comprise a horizontal blade. The horizontal blade is connected to an actuator and moves horizontally parallel to the bottom wall of the box. The plate is configured to move towards and away from the corresponding wall of the box. The blade is configured to fold the outer portions of the flaps of the packaging blank from a vertical position to a horizontal position. The blade may include a groove. A pair of fingers are operatively inserted inside the grooves, this configuration allowing for more precise folding.

[0033] According to another aspect of the present disclosure, an apparatus according to one or more aspects of the present disclosure may include multiple columns.

[0034] It should be noted that in the step of folding the side flaps from a horizontal position to a vertical position, the columns take the place of the die blocks.

[0035] In this regard, the Applicant intuitively realized that providing a device for supporting the bottom wall of the box to be packaged during the step of folding the flaps of the packaging blank from a horizontal to a vertical position, independently of the geometric characteristics of the box (height, width), would contribute to obtaining a particularly flexible line.

[0036] In this regard, the applicant has discovered that by providing a plurality of vertical and horizontally movable columns that can be positioned inside the box at least at each apex of the box and on the inner surface of the bottom wall of the box, it is possible to fold the flaps without the use of die blocks and regardless of the length of the side walls, i.e., regardless of the box format.

[0037] The columns preferably extend along a vertical direction. In an exemplary embodiment, the columns are horizontally movable. Preferably, the columns are vertically movable relative to the folding head. The columns may be disposed inside the box on an inner surface of a bottom wall of the box. Preferably, the columns are disposed inside the box at least at each apex of the box such that the bottom wall of the box is operably disposed between the support structure (in accordance with one or more aspects of the present disclosure) and the columns.

[0038] In one example, the apparatus also includes a horizontal tray. The tray may be vertically movable. The plurality of columns are operatively connected to the tray.

[0039] In an exemplary embodiment, the control unit may be programmed to move multiple columns horizontally depending on the setup of the device.

[0040] In an exemplary embodiment, the apparatus includes a packaging configuration, in which a plurality of columns are fixed to the tray and move along a vertical direction.

[0041] The apparatus may also include a setup configuration, in which the columns are horizontally movable relative to the tray such that the columns are horizontally displaceable, the columns being horizontally displaceable depending on a setup of the apparatus.

[0042] In an exemplary embodiment, the tray is provided with a central through hole. The apparatus may also comprise a rod. The rod is preferably movable along a vertical direction. The rod may pass through the central through hole of the tray. The apparatus may also comprise a disk. In an exemplary embodiment, the disk is connected to a lower end of the rod. The disk is configured to contact a central portion of the inner surface of the bottom wall of the box. Preferably, the tray is vertically movable independent of the vertical movement of the rod. It should be noted that the use of said rod with the disk allows the bottom wall of the box to be supported in the absence of a column. In another example embodiment, the apparatus may be rod-less.

[0043] In one example, the columns are configured to contact the inner surface of the bottom wall of the box in the active position. Furthermore, the columns are configured to be spaced apart from the inner surface of the bottom wall of the box in the inactive position. Preferably, the columns are configured to operate in conjunction with the support structure to press the bottom wall of the box located between them in the active position. The apparatus may include an adjustment system for format change. In one example, the adjustment system for format change is connected to the columns 7. In one example, the adjustment system for format change is also connected to the support structure 4. The adjustment system for format change is configured to adjust the movement of the columns and the support structure to adapt their positions to the type of box to be packaged. In particular, the adjustment system for format change moves the columns closer to or away from each other. The adjustment system for format change also moves the support bars closer to or away from each other. In particular, the adjustment system for format changes coordinates the movement of the multiple columns and support bars in a coordinated manner, so that for each box to be packaged, the multiple columns and corresponding support bars move simultaneously according to the settings of the apparatus, so that, for each box, at least at each apex of the box, the bottom wall of the box is operably positioned between the multiple columns and support bars.

[0044] In one example, the disk is configured to contact a central portion of an inner surface of a bottom wall of the box when the multiple columns are spaced from the box in the inactive position.

[0045] According to another aspect of the disclosure, the apparatus may include an in-feed for receiving a box and a packaging blank coupled thereto. The in-feed may extend along the forward direction. The apparatus also includes an out-feed for releasing the wrapped box.

[0046] In an exemplary embodiment, the apparatus includes a first packaging station and a second packaging station. Preferably, the first packaging station includes a first subset of the plurality of folding heads and the second packaging station includes a second subset of the plurality of folding heads. The folding heads are folding heads according to one or more aspects described in the present disclosure. In an exemplary embodiment, the first and second packaging stations are spaced apart from each other along a horizontal direction perpendicular to the vertical direction. The first and second packaging stations may each include a support structure according to one or more aspects described in the present disclosure. The apparatus may also include a transfer device. The transfer device is preferably movable relative to each support structure. The transfer device is configured to transfer the box and the packaging blank coupled thereto along the forward direction.

[0047] Alternatively, the packaging stations may be spaced apart from one another along the vertical direction.

[0048] In an exemplary embodiment, the first packaging station is located upstream of the second packaging station with respect to the forward path of the box from the infeed to the outfeed. The transfer device is configured to transfer the box and the packaging blank coupled thereto from the first packaging station to the second packaging station. This configuration allows high speed operation of the device. Preferably, the transfer device is configured to transfer the box and the packaging blank coupled thereto from the first packaging station to the second packaging station by a translational movement along the horizontal direction. Preferably, the transfer device is configured to transfer the box and the packaging blank coupled thereto from the first packaging station to the second packaging station such that the forward path is aligned with the forward direction of the box at the infeed.

[0049] In an exemplary embodiment, the transfer device is configured to simultaneously grip two successive boxes of a series of boxes and move them along a forward path.

[0050] The apparatus may include an actuator for moving the transfer device. The actuator is connected to a control unit. The control unit is programmed to move the transfer device. Preferably, the control unit is configured to move the transfer device relative to the forward path from the infeed to the outfeed, forward from the first position to the second position, further forward from the second position to the third position, and backward from the third position to the first position. At each station, the support structure may be configured to movably support a base of the packaging blank and a base of the box coupled thereto. In an exemplary embodiment, at the first and second packaging stations, the packaging blank and the box coupled thereto are movable along a first vertical axis and a second vertical axis, respectively. In one example, the first vertical axis and the second vertical axis are horizontally spaced apart from each other. Each packaging station may have a first height and a second height. The second height is less than the first height. The transfer device is preferably configured to grip a box positioned at the first height. In an exemplary embodiment, at each station, the support structure is configured to perform a downward movement to move the box from the first height to the second height, and an upward movement to move the box from the second height to the first height.

[0051] It should be noted that the applicant intuitively realized that it would be possible to obtain a particularly high speed line by providing two packaging stations spaced apart from one another along a horizontal direction, rather than two stations spaced apart from one another vertically. In this connection, the applicant discovered that it would be possible to significantly increase the production speed by providing two packaging stations spaced apart from one another along a horizontal direction, with the first station being located upstream of the second station, and by performing a first subset of the plurality of folding operations in the first station and a second subset of the plurality of folding operations in the second station.

[0052] In one example, the support structure includes a plurality of support bars corresponding to the plurality of folding heads at at least the first packaging station. The plurality of support bars are made according to one or more aspects described in the present disclosure. The plurality of support bars are movable toward and away from each other so that they can be displaced to support corresponding edges of the bottom wall of the box.

[0053] In an exemplary embodiment, the folding heads include a plurality of tilters at at least the first packaging station configured to fold flaps of the blank from a horizontal position to a vertical position such that an inner portion of each flap contacts an outer surface of a side wall of the box and an outer portion of each flap protrudes vertically from the box.

[0054] The apparatus may also include a plurality of columns according to one or more aspects of the present disclosure. The plurality of columns may include a first group of columns and a second group of columns. Preferably, the first and second packaging stations include the first and second groups of columns, respectively. The plurality of columns are preferably oriented perpendicular to the working direction of the corresponding pair of folding heads at each packaging station. In an exemplary embodiment, the plurality of tilters and the plurality of columns may be configured to operate in conjunction with one another to fold the blanks from a horizontal position to a vertical position.

[0055] Additionally, the apparatus according to the present disclosure may include an arm. In an exemplary embodiment, the plurality of folding heads includes a wrapping device. The plurality of wrapping devices may include a horizontal blade. The horizontal blade is configured to move horizontally parallel to a bottom wall of the box. The blade is configured to rotate about an axis of rotation from a first position where the blade is parallel to the bottom wall of the box to a second position where the blade is perpendicular to the bottom wall of the box to fold the outer portions of the flaps from a horizontal position to a vertical position such that the outer portions of the flaps are in intimate contact with the inner surface of the side wall of the box.

[0056] Alternatively, the multiple folding heads may include a pair of fingers according to the present disclosure.

[0057] In one embodiment, the first packaging station includes a first pair of tilters and a first pair of wrapping devices, and the second packaging station includes a second pair of tilters and a second pair of wrapping devices. The first pair of tilters are positioned at 90 degrees relative to the second pair of tilters. The first pair of wrapping devices are positioned at 90 degrees relative to the second pair of wrapping devices. This configuration allows a box to be wrapped with a pair of flaps of a blank at the first station and another pair of flaps of a blank at the second packaging station.

[0058] Preferably, at each wrapping station, the pair of wrapping devices is spaced apart from the pair of tilters along the vertical direction. This solution makes it possible to reduce the dimensions of the devices.

[0059] In another embodiment, the first packaging station comprises two pairs of tilters and the second packaging station comprises two pairs of wrapping devices, which allows the flaps to be folded from a horizontal position to a vertical position at the first station and the flaps to be folded (or rather wrapped) into the box at the second station.

[0060] The apparatus may also include an alignment device configured to receive the box and associated packaging blank and align it with the conveyor belt, which preferably extends along a horizontal direction.

[0061] According to one aspect, the present disclosure provides a method for packaging a corrugated box with a blank. The blank has a base and a number of flaps attached to side walls of the box. The method includes receiving the box coupled to the blank base. The method includes placing the blank base and coupled box on a support structure. The support structure can be movable along a vertical direction.

[0062] The method includes folding the flaps of the packaging blank from a horizontal position to a vertical position such that an inner portion of each flap adheres to an outer surface of a sidewall of the box and an outer portion of each flap projects vertically from the box. The method includes folding the outer portions of the flaps from a vertical position to a horizontal position. The method includes folding outer flaps of the packaging blank toward the inside of the box from a horizontal position to a vertical position whereby the outer flaps adhere to the inner surface of the sidewall of the box.

[0063] The method includes providing a plurality of folding heads configured to perform a plurality of folding operations, which may include folding flaps of a packaging blank from a horizontal position to a vertical position and folding the flaps toward the inside of the box (i.e., wrapping the flaps within the box).

[0064] According to one aspect of the disclosure, the method may include providing each folding head with a pair of fingers, the fingers constituting each pair of fingers being movable relative to one another toward and away from one another.

[0065] The method also includes positioning the fingers at least partially within the box. The method includes moving the fingers relative to one another in sliding contact with a packaging blank on an inner surface of a side wall of the box.

[0066] In one example, the method also includes: - for each pair of fingers, moving said fingers along a first horizontal axis toward or away from a corresponding wall of the box to a horizontal position parallel to a bottom wall of the box; - for each pair of fingers, moving the support structure and each pair of fingers vertically relative to one another from a raised configuration in which the pair of fingers are located above the box to a lowered configuration in which the pair of fingers are located inside the box to fold the outer portion of the flap into a vertical position inside the box; for each pair of fingers, in the lowered configuration, in sliding contact with an inner surface of the side wall and moving the fingers relative to one another along a second horizontal axis orthogonal to the first horizontal axis.

[0067] In one example, the step of disposing the fingers within the box includes moving the pair of fingers from a raised configuration to a lowered configuration with the pair of fingers disposed adjacent to one another at central portions of corresponding side walls of the box, preferably in the lowered configuration the pair of fingers move away from one another in alternating directions along the second horizontal axis.

[0068] The method may include the steps of moving the fingers from a lowered configuration to a raised configuration when the fingers are spaced apart from one another and moving the fingers closer to one another when the fingers are in the raised configuration.

[0069] The method may include moving the box and packaging blank vertically between a first stop at a first height and a second stop at a second height less than the first height. Preferably, the step of folding the flaps from a horizontal position to a vertical position is performed at the first stop and the step of folding outer portions of the flaps into the box is performed at the second stop.

[0070] In one example, the step of folding the outer portions of the flaps from a vertical position to a horizontal position may be performed by a horizontal blade, preferably moving parallel to the bottom wall of the box and horizontally against a corresponding side of the box, and further, each pair of fingers may be operably inserted into a groove formed in a corresponding blade.

[0071] According to one aspect of the disclosure, the method may include providing a plurality of columns. In one example, the method includes horizontally displacing the plurality of columns. Preferably, the plurality of columns is displaced such that at least each vertex of the box is vertically aligned with a corresponding one of the plurality of columns.

[0072] The method may include vertically moving the columns relative to the folding head. In one example, while the flaps are being folded from a horizontal position to a vertical position, the flaps contact an inner surface of a bottom wall of the box such that the bottom wall of the box is disposed between the support structure and the plurality of columns at at least all apexes of the box.

[0073] In one example, the method includes providing a horizontal tray. Preferably, a plurality of columns are connected to the tray. Vertically moving the plurality of columns may include vertically moving the tray.

[0074] Also, in one example, during the step of horizontally moving the plurality of columns relative to the tray, the plurality of columns are slidably connected to the tray. Alternatively, the step of horizontally moving the plurality of columns relative to the tray may include removing the plurality of columns from the tray and horizontally moving the plurality of columns relative to the tray.

[0075] Horizontal movement of multiple columns can be achieved depending on the setup of the device.

[0076] The method may also include providing a tray having a central through hole.

[0077] The method may include providing a rod for insertion through a central through hole in the tray.The method may include providing a disk connected to a lower end of the rod.

[0078] In one example, the method may include inserting the disk into the box against a central portion of an inner surface of a bottom wall of the box.

[0079] The method may include moving the rod vertically independent of the vertical movement of the tray.

[0080] The method may include moving the support structure, together with the packaging blank and the box coupled thereto, along a vertical direction to various heights.

[0081] The method may also include inserting the columns into the box such that the columns contact an inner surface of a bottom wall of the box. In one example, there may be a step of moving the columns downwardly into an active configuration in which the columns contact an inner surface of the bottom wall of the box such that the columns act in conjunction with a support structure to press against the bottom wall of the box disposed therebetween.

[0082] The method may also include moving the plurality of columns upwardly to an inactive configuration, in which the plurality of columns are spaced from an inner surface of the box.

[0083] There may also be a step of maintaining the disk in contact with a central portion of the inner surface of the bottom wall of the box during the step of moving the plurality of columns upwardly.

[0084] According to one aspect of the disclosure, the method may include receiving a box coupled to a base of the packaging blank at an in-feed. The in-feed may extend along the forward direction.

[0085] The method may also include releasing the wrapped box at the outfeed. In one example, the method includes providing an apparatus including a first packaging station and a second packaging station. Additionally, the plurality of folding heads may include a first pair of folding heads spaced apart from one another along a first working direction and a second pair of folding heads spaced apart from one another along a second working direction perpendicular to the first working direction. In one example, the first pair of folding heads forms part of the first packaging station and the second pair of folding heads forms part of the second packaging station. In one example, for each pair of folding heads, the plurality of pairs of folding heads simultaneously act on a corresponding respective pair of sides of the box.

[0086] At the first packaging station, the support structure may include a first pair of support bars oriented transversely to the first working direction, and at the second packaging station, the support structure may include a second pair of support bars oriented transversely to the second working direction. The support bars are made according to one or more aspects of the present disclosure.

[0087] Preferably, the first and second packaging stations are spaced apart from each other along a horizontal direction perpendicular to the vertical direction. The method includes performing a first subset of the folding operations at the first packaging station and performing a second subset of the folding operations at the second packaging station. The method may include supporting the base of the blank and the box coupled thereto by its support structure (according to the present disclosure) at each packaging station. The method may include transporting the box and the blank coupled thereto in a forward direction by a transport device that is movable relative to each of the support structures. In one example, the first packaging station is located upstream of the second packaging station with respect to the forward path of the box from the in-feed to the out-feed. In one example, the first subset of the folding operations is performed at the first packaging station and the second subset of the folding operations is performed at the second packaging station. The method may include transporting the box from the first packaging station to the second packaging station by a translational movement of the box aligned with the forward direction of the box at the in-feed.

[0088] In one example, the plurality of columns (according to the present disclosure) includes a first group of columns and a second group of columns. Preferably, the first and second wrapping stations respectively include first and second groups of columns. The plurality of columns are oriented perpendicular to the working direction of the folding heads of each corresponding pair.

[0089] More specifically, the method may include receiving the box and associated blank at a first elevation at a first packaging station in-feed, and folding a first pair of flaps of the packaging blank at the first packaging station from a horizontal position to a vertical position.

[0090] The method includes moving the boxes and blanks coupled thereto, along with their respective support structures, along a first vertical axis at a second height in a first packaging station, the second height being less than the first height.

[0091] The method also includes folding outer portions of the first pair of flaps toward the inside of the box from a vertical position to a horizontal position and then from the horizontal position to a vertical position, such that the outer portions fit tightly against the inner surface of the side wall of the box.

[0092] Preferably, the method includes moving the box to a first height of a first packaging station. In one example, the method includes transferring the box to the first height of a second packaging station by a transfer device.

[0093] The method includes folding a second pair of flaps of the packaging blank from a horizontal position to a vertical position at a second packaging station.

[0094] The method includes moving the box and the blank coupled thereto, together with the respective support structures, along a second vertical axis at a second height to a second packaging station. The second height is less than the first height. In one example, the first vertical axis and the second vertical axis are horizontally spaced apart from one another. The method also includes folding outer portions of the second pair of flaps from a vertical position to a horizontal position and from the horizontal position to a vertical position toward the inside of the box, whereby the outer portions are in intimate contact with an inner surface of a side wall of the box. Preferably, the method includes moving the box to a first height to a second packaging station. [Brief description of the drawings]

[0095] This and other features will become more apparent from the following description of preferred embodiments, illustrated by way of non-limiting example in the accompanying drawings, in which: [Figure 1] 1 shows a corrugated box produced by the forming apparatus and an open packaging blank, and shows the box after it has been wrapped with the blank by the apparatus of the present invention, with its bottom wall positioned over the packaging blank. [Diagram 2] 1 shows a packaging blank with inner and outer portions of each flap. [Diagram 3] A pair of folding heads are shown. [Figure 4] 1 shows a pair of folding heads in axonometric views from different angles. [Diagram 5] 1 shows a folding head with arms and rotating blades. [Figure 6] Shown is a folding head without tilt. [Figure 7] 1 shows an apparatus with two packaging stations. [Figure 8] The two packaging stations are shown in axonometric views from different angles. [Figure 9] 1 shows the folding head of the packaging station. [Figure 10] FIG. 1 is a side view of two packaging stations. [Figure 11] The first packaging station is shown in axonometric views at different angles. [Figure 12-15] Each column of the packaging station is shown. [Figure 16] 1 shows a transfer device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0096] With reference to the accompanying drawings, the numeral 1 denotes an apparatus for packaging a box 2 with a packaging blank 3. Preferably, the box 2 is made from cardboard, paperboard or the like. More specifically, the box 2 denotes a container comprising a plurality of side walls 202, 203, 204, 205 and a bottom wall 201. The side walls 202, 203, 204, 205 are interconnected by the bottom wall 201. The side walls 202, 203, 204, 205 (and the bottom wall 201) each have an inner and an outer surface.

[0097] Additionally, side walls 202, 203, 204, 205 each extend in a direction away from bottom wall 201 from a lower or connected end to an upper or free end.

[0098] More specifically, the illustrated box has a pair of end walls 202, 203 (or short walls) and a pair of side walls 204, 205 (or long walls).

[0099] The blank 3 is preferably made of paper. The packaging blank 3 has a base 301 and a number of flaps 302, 303, 304, 305 connected to the base 301. The flaps constituting the number of flaps of the packaging blank 3 are connected to each other and each can face and be joined to a corresponding respective wall 202, 203, 204, 205 of the box 2. In this case, each flap wraps both sides (inner and outer) of the side walls 202, 203, 204, 205 of the box 2.

[0100] The packaging blank 3 also comprises four side flaps 306, 307, 308, 309. The side flaps 306, 307, 308, 309 define partial deployment of the two flaps 304, 305 of the blank 3 to completely and uninterruptedly cover all four side walls 202, 203, 204, 205.

[0101] Furthermore, each of the flaps 302, 303, 304, 305 is composed of two portions, an inner portion 302a, 303a, 304a, 305a adjacent the base 301 and an outer portion 302b, 303b, 304b, 305b spaced apart from the base 301 of the blank 3.

[0102] It should be noted that the adhesive is applied to some parts of the blank 3 by a gluing device 14 upstream of the apparatus 1. Alternatively, the adhesive may be applied over the entire surface of the packaging blank 3.

[0103] Before reaching the device 1, the box 2 is received by the forming device 15 and placed on a pre-glued packaging blank 3 such that the bottom wall 201 of the box rests on the base 301 of the packaging blank 3 (Figure 1).

[0104] The former 15, the conveyor belt 13, the gluing device 14 and the packaging device 1 constitute a line 100 for producing wrapped boxes in a continuous cycle from formed blanks 17 and packaging blanks.

[0105] The line 100 also comprises a positioning device 16 which receives boxes from the forming device 15, bonds them to corresponding packaging blanks received from the gluing device 14 (places the bottom of the box on the base of the flat packaging blank) and feeds them to the packaging device 1.

[0106] The device 1 may comprise a support structure 4. The support structure 4 is configured to support a base 301 of the packaging blank 3 and a box 2 coupled thereto. The support structure 4 may be configured to support the base 301 of the packaging blank 3 at least at each apex of the box 2. The support structure 4 may be movable along a vertical direction V. The vertical direction V means a direction parallel to gravity. The support structure 4 may be configured to move the packaging blank 3 and a box 2 coupled thereto to different heights along the vertical direction V.

[0107] In an exemplary embodiment, the apparatus 1 comprises a plurality of folding heads 5 configured to fold the flaps 302, 303, 304, 305 of the packaging blank 3 from a horizontal position to a vertical position such that an inner portion 302a, 303a, 304a, 305a of each flap 302, 303, 304, 305 adheres to an outer surface of the side wall 202, 203, 204, 205 of the box 2 and an outer portion 302b, 303b, 304b, 305b of each flap protrudes vertically from the box 2. The multiple folding heads 5 are also configured to fold the outer portions 302b, 303b, 304b, 305b of the flaps 302, 303, 304, 305 from a vertical position to a horizontal position, and further fold the outer portions 302b, 303b, 304b, 305b of the flaps from a horizontal position to a vertical position towards the inside of the box 2 such that they fit tightly against the inner surface of the side wall of the box 2.

[0108] In an exemplary embodiment, the plurality of folding heads 5 includes a plurality of pairs of folding heads. Preferably, for each pair of folding heads 5, the folding head acts simultaneously on a corresponding respective pair of side surfaces (or side walls 202, 203 and 204, 205) of the box 2.

[0109] Preferably, the folding heads 5 constituting each pair of folding heads are spaced apart from one another along the respective working direction W.

[0110] In an exemplary embodiment, the support structure 4 comprises a plurality of pairs of support bars 401. The plurality of pairs of support bars 401 may correspond to a plurality of pairs of folding heads 5. Preferably, for each pair of support bars 401, the bar is oriented transversely to the working direction W of the respective pair of folding heads 5. The support bars 401 are movable toward and away from each other in order to support corresponding edges of the bottom wall of the box. The device may also comprise a control unit. The control unit may be configured to receive input data. The input data preferably represents the size of each box 2 to be packed. The control unit is programmed to derive settings of the device 1 based on the input data. In this regard, the support bars 401 are movable toward and away from each other so that they can be displaced to support corresponding edges of the bottom wall 201 of the box 2 depending on the settings of the device 1.

[0111] Alternatively, the support structure 4 may comprise a plate which supports a central portion of the bottom wall 201 of the box 2 and the packaging blank 3 joined thereto.

[0112] The folding heads 5 may comprise a plurality of tilters 501 configured to fold the flaps 302, 303, 304, 305 of the packaging blank 3 from a horizontal position to a vertical position, whereby the inner portion 302a, 303a, 304a, 305a of each flap is in intimate contact with the outer surface of the side wall 202, 203, 204, 205 of the box 2 and the outer portion 302b, 303b, 304b, 305b of each flap protrudes vertically from the box 2. The tilters 501 may be movable in a vertical direction V relative to the support structure 4 to fold the flaps 302, 303, 304, 305 of the blank 3. In one example, the support structure 4 is stationary relative to the tilter 501, and the tilter 501 comprises an upward movement in the vertical direction V. The sliding contact between the tilter 501 and the flaps 302, 302, 304, 305 of the packaging blank 3 occurs when the flaps of the packaging blank 3 are folded from a horizontal position to a vertical position. As a result, the inner portion 302a, 303a, 304a, 305a of each flap 302, 302, 304, 305 is in close contact with the outer surface of the side wall 202, 203, 204, 205 of the box 2 due to pre-gluing, and the outer portion 302b, 303b, 304b, 305b of each flap protrudes vertically from the box 2. Alternatively, the support structure 4 includes a vertical downward movement while the tilter 501 remains stationary.

[0113] The device 1 may include an arm 6. The arm 6 is configured to work in conjunction with the folding head 5 to prevent the box 2 from moving out of position while the flaps 302, 303, 304, 305 of the packaging blank 3 are being folded. The arm 6 may have at least one rotational movement. The arm 6 is configured to move from an inactive position, in which it is away from the side walls 202, 203, 204, 205 of the box 2, to an active position, in which it is in contact with the inner surface of the side walls 202, 203, 204, 205 of the box so as to support the inner surface of the side walls 202, 203, 204, 205 of the box. This configuration makes it possible to prevent the formation of wrinkles on the inside of the box 2, especially if the paper used for the packaging blank 3 is stiff.

[0114] The multiple folding heads 5 may include a wrapping device 502 for folding the outer portions 302b, 303b, 304b, 305b of the flaps 302, 303, 304, 305 from a vertical position to a horizontal position towards the inside of the box 2.

[0115] According to one aspect of the invention, the wrapping devices 502 of the folding heads 5 each comprise a pair of fingers 502A. The fingers constituting the pair of fingers 502A may be movable along a first horizontal axis H1 toward and away from the corresponding side walls 202, 203, 204, 205 of the box 2. In one example, each of the folding heads 5 includes a first vertical motion actuator VA1 for moving the fingers 502A in a vertical direction V. Each of the folding heads 5 also includes a first longitudinal motion actuator HA1 for moving the fingers 502A in a horizontal direction H toward and away from the corresponding side walls of the box 2.

[0116] Preferably, each folding head 5 also comprises a horizontal blade 502B. The horizontal blade 502B is connected to the actuator A1 and moves along a horizontal direction H perpendicular to the vertical direction V. The horizontal blade 502B is configured to move parallel to the bottom wall 201 of the box 2 and to move towards and away from the corresponding walls 202, 203, 204, 205 of the box 2. In other words, the horizontal blade 502B allows the outer parts 302b, 303b, 304b, 305b of the flaps 302, 303, 304, 305 to be folded from a vertical position to a horizontal position. Preferably, the horizontal blade 502B includes a through groove. In this solution, a pair of fingers 502A is operably inserted inside the groove. Preferably, the fingers 502A and the blade 502B move simultaneously towards and away from the respective walls 202, 203, 204, 205 of the box 2.

[0117] Moreover, in the exemplary embodiment, the support structure 4 and each pair of fingers 502A are also vertically movable relative to each other from a raised configuration in which the pair of fingers is located above the box 2 to a lowered configuration in which the pair of fingers 502A is located at least partially inside the box 2. In one example, the fingers 502A can perform a downward movement in the vertical direction V to fold the outer parts 302b, 303b, 304b, 305b of the flaps 302, 303, 304, 305 inside the box 2. Alternatively, the support structure 4 and the box 2 can move upwards, while the opposing action between the fingers 502A and the outer parts of the flaps of the packaging blank causes the flaps to be folded (i.e., wrapped) inside the box 2. More specifically, the fingers constituting a pair of fingers 502A can be mutually movable toward and away from each other. Furthermore, the pair of fingers 502A is preferably displaceable inside the box 2 so that the fingers 502A can move relative to each other in sliding contact with the packaging blanks 3 on the inner sides of the side walls 202, 203, 204, 205 of the box 2. The relative movement of the fingers 502A constituting the pair of fingers is performed along a second horizontal axis H2, which is perpendicular to the first horizontal axis H1. In an exemplary embodiment, the fingers 502A constituting a corresponding pair of fingers are mutually movable between a first position in which they are located at a minimum distance from each other and a second position in which they are located at a maximum distance from each other. Preferably, the pair of fingers 502A is displaceable inside the box 2 with the fingers 502A in the first position. Preferably, each folding head 5 is configured to move the fingers 502A of the pair of fingers 502A away from each other from the first position to the second position with the fingers 502A in the lowered configuration. In this manner, the fingers 502A move horizontally inside the box 2 along the entire length of each side wall 202, 203, 204, 205 of the box. Furthermore, each folding head 5 is configured to move the fingers 502A from the second position to the first position when the pair of fingers move toward each other while in the raised configuration. The apparatus may include multiple actuators. In one example, the multiple actuators include slide actuators.The slide actuator is configured to move the fingers 502A toward and away from each other between a first position where the fingers 502A are located at a minimum distance from each other and a second position where the fingers 502A are located at a maximum distance from each other, the second position being set according to the settings of the device 1. In an exemplary embodiment, the wrapping device 502 may also comprise a plurality of hands 502E. The plurality of hands 502E is configured to fold the four side flaps 306, 307, 308, 309 of the blank 3 so that they are in close contact with parts of the inner surfaces of the long side walls 204, 205 of the box 2. Preferably, the plurality of hands 502E are configured to be movable horizontally and vertically to fit the size of the box to be wrapped. Each of the folding heads 5 includes a second vertical movement actuator VA2 for moving the hand 502E in a vertical direction V. The folding heads 5 also include a second longitudinal movement actuator HA2 for moving the hand 502E in a horizontal direction H.

[0118] In an exemplary embodiment, the folding heads 5 include a plurality of support plates 503. Preferably, the plurality of support plates 503 are parallel to the side walls 202, 203, 204, 205 of the box 2. The plurality of support plates 503 are configured to be movable from an operative position in which they are spaced apart from the side walls of the box 2 to a non-operative position in which they contact the side walls of the box. In one example, in the operative position, the side walls 202, 203, 204, 205 of the box 2 are positioned and pressed between the support plates 503 and the fingers 502A.

[0119] According to one embodiment of the present disclosure, the wrapping device 502 may include a rotating blade 502C. In this case, the device may not have fingers 502A. The rotating blade 502C is configured to move horizontally parallel to the bottom wall 201 of the box 2. Furthermore, the rotating blade 502C is configured to rotate about a rotation axis from a first position where the rotating blade 502C is parallel to the bottom wall 201 of the box 2 to a second position where the rotating blade 502C is perpendicular to the bottom wall of the box 2 in order to fold the outer portions 302b, 303b, 304b, 305b of the flaps from a horizontal position to a vertical position such that they are in intimate contact with the inner surfaces of the side walls 202, 203, 204, 205 of the box 2.

[0120] According to another aspect of the present disclosure, the folding head 5 may not have a tilter 501. In this solution, the wrapping device 502 includes a fixed plate 502D. The fixed plate 502D is arranged between the fingers 502A of the pairs of fingers. In this solution, the fixed plate 502D may be configured to be movable along the vertical direction V with respect to the box 2 together with the fingers. When the box 2 is moving downwards (or the folding head 5 is moving upwards), the sliding contact between the fixed plate 502D and the inner portions 302a, 303a, 304a, 305a of the blank 3 causes the flaps 302, 303, 304, 305 of the packaging blank 3 to fold from a horizontal position to a vertical position, so that the inner portions 302a, 303a, 304a, 305a of each flap are in close contact with the outer surfaces of the side walls 202, 203, 204, 205 of the box 2 and the outer portions 302b, 303b, 304b, 305b of each flap protrude vertically from the box 2.

[0121] In the exemplary embodiment, the support structure 4 is adapted to move along a vertical direction V between a first stop at a first height and a second stop at a second height that is lower than the first height.

[0122] Preferably, the plurality of folding heads 5 are configured to fold the flaps 302, 303, 304, 305 of the packaging blank 3 from a horizontal position to a vertical position when the support structure 4 is located at a first stop. The plurality of folding heads 5 are also configured to fold the outer portions 302b, 303b, 304b, 305b of the flaps from a vertical position to a horizontal position and further from a horizontal position to a vertical position such that the outer portions are in intimate contact with the inner surfaces of the side walls 202, 203, 204, 205 of the box 2 when the support structure 4 is located at a second stop.

[0123] According to one aspect of the disclosure, the apparatus 1 may include a plurality of columns 7. The plurality of columns 7 preferably extend along a vertical direction V. The columns may be horizontally and vertically movable relative to the folding head 5. In an exemplary embodiment, the plurality of columns 7 may be disposed inside the box 2 on an inner surface of the bottom wall 201 of the box at least at all vertices of the box 2, such that the bottom wall 201 of the box is operatively disposed between the plurality of columns 7 and the support structure 4. In particular, the plurality of columns are movable toward and away from each other along a horizontal direction H. The columns are horizontally movable relative to the folding head, such that the columns may be disposed inside the box on an inner surface of the bottom wall of the box.

[0124] In one example, the apparatus also comprises a horizontal tray 8. The horizontal tray 8 is preferably disposed above and parallel to the support structure 4. The horizontal tray 8 may be vertically movable. In one example, a number of columns 7 are operatively connected to the tray 8. Thus, the horizontal tray 8 may be movable along a vertical direction V together with the number of columns 7. The plate and the columns are movable by an actuator A2. The apparatus 1 may include a container C for accommodating connecting wires of the columns 7. The connecting wires are used to move the columns.

[0125] In one example, the control unit may be configured to move a number of columns 7 horizontally depending on the settings of the device 1 .

[0126] Furthermore, in one example, the device 1 may comprise a packaging arrangement in which a number of columns 7 are fixed to a tray 8 for movement along a vertical direction V.

[0127] The apparatus may also comprise a setup in which the columns 7 are horizontally movable relative to the tray 8 such that the columns can be horizontally displaced depending on the setup of the apparatus. In particular, in this setup, the columns 7 are mutually movable toward or away from each other along the horizontal direction H depending on the setup of the apparatus, so that at least each apex of the box 2 to be wrapped is supported by one of the columns.

[0128] The tray 8 may also include a central through-hole 801. The device 1 may include a rod 9. In one example, the rod 9 is movable along a vertical direction V. The rod 9 may be inserted into the central through-hole 801 of the tray 8.

[0129] In the exemplary embodiment, the disk 10 is connected to the lower end of the rod 9. The disk 10 is configured to contact a central portion of the inner surface of the bottom wall 201 of the box 2.

[0130] Preferably, the tray 8 is vertically movable independently of the vertical movement of the rods 9 .

[0131] More specifically, the multiple columns 7 are configured to contact an inner surface of the bottom wall 201 of the box 2 in the active position. In an exemplary embodiment, the multiple columns 7 are configured to operate in conjunction with the support structure 4 to press the bottom wall 201 of the box 2 disposed therebetween in the active position. In the active position, the multiple columns 7 are configured to remain in contact with the bottom wall 201 of the box and press it at each vertex of the box 2 along an edge of the bottom wall 201 of the box 2 supported by the support structure 4.

[0132] The columns 7 are also configured to be spaced apart from the inner surface of the box 2 in the inactive position. In one example, the disk 10 is configured to contact a central portion of the inner surface of the bottom wall 201 of the box 2 when the columns 7 are spaced apart from the box 2 in the inactive position. In one example, the columns 7, tray 8 and disk 10 (along with the rod 9) are configured to lower into the box 2 when the box 2 and blank 3 are at an initial height at which they are received by the device 1. The columns 7, tray 8 and disk 10 may be configured to remain in contact with the inner surface of the bottom wall 201 of the box 2 during relative movement between the support structure 4 and the tilter 501 to fold the flaps 302, 302, 304, 305 of the packaging blank from a horizontal position to a vertical position. Preferably, the columns 7 are configured to be spaced apart from the box 2 such that after the inner portions 302a, 303a, 304a, 305a of the flaps of the blank 3 have been folded, the wrapping device 502 can interact with the box 2 to fold the outer portions of the flaps of the blank 3. The disk 10 is configured to remain in contact with the box and to support the inner surface of the bottom wall 201 of the box 2. The rod 9 can move upwards together with the disk 10 and the support structure 4 to bring the wrapped box 2 to its initial height.

[0133] According to another aspect of the present disclosure, the apparatus 1 may comprise an infeed I. The infeed I is configured to receive the box 2 and the packaging blank 3 coupled thereto along the forward direction F. The apparatus 1 may also comprise an outfeed O for releasing the box 2 when it is packaged. In an exemplary embodiment, the apparatus 1 comprises a first packaging station S1 and a second packaging station S2. The first packaging station S1 may comprise a first subset of the plurality of folding heads 5. The second packaging station S2 may comprise a second subset of the plurality of folding heads 5'. Preferably, the first and second packaging stations are spaced apart from each other along a horizontal direction H perpendicular to the vertical direction V. The first and second packaging stations may each comprise a respective support structure 4, 4' according to the present disclosure. In an exemplary embodiment, the apparatus 1 also comprises a transfer device 11. The transfer device may be movable relative to each of the support structures 4, 4' for transferring the box 2 and the packaging blank coupled thereto along the forward direction F.

[0134] In an exemplary embodiment, the first packaging station S1 is located upstream of the second packaging station S2 with respect to the forward path of the box from the infeed I to the outfeed O. Preferably, the transfer device 11 is configured to transfer the box 2 and the packaging blank 3 coupled thereto from the first packaging station S1 to the second packaging station S2. In one example, the transfer device 11 is configured to transfer the box 2 and the packaging blank 3 coupled thereto from the first packaging station S1 to the second packaging station S2 by translating the box along a horizontal direction H without rotating the box such that the forward path is aligned with the forward direction F of the box at the infeed. Preferably, the transfer device 11 is configured to simultaneously grip two consecutive boxes of the series of boxes and move them along the forward path. The plurality of actuators may comprise an actuator A3 for moving the transfer device 11. More specifically, the control unit may be programmed to move the transfer device 11 with respect to the forward path from the infeed I to the outfeed O. The control unit may be programmed to move the transfer device 11 forward in a forward direction F from a first position to a second position, further forward from the second position to a third position, and backward in a direction opposite to the forward direction F from the third position to the first position. The transfer device 11 is configured to grip one box of the infeed I and one box of the first packaging station S1 in the first position. In one example, the transfer device 11 is configured to grip one box of the first packaging station S1 and one box of the second packaging station S2 in the second position. The transfer device 11 is configured to grip one box of the second packaging station S2 and one box of the outfeed of the device 1 in the third position. The transfer device 11 is movable along a horizontal direction H. In one example, the transfer device 11 is movable along a forward direction F between the first packaging station S1 and the second packaging station S2.

[0135] According to one embodiment, the transfer device 11 comprises a pair of transfer rods TR. The pair of transfer rods is oriented along a forward direction F. The pair of transfer rods is spaced apart from each other along a lateral direction parallel to the horizontal direction H and perpendicular to the forward direction F. In one example, the pair of transfer rods TR is configured to hold two boxes together. The pair of transfer rods TR is configured to hold the side walls 204, 205 of the boxes. Furthermore, the pair of transfer rods 11 is movable towards and away from each other to adapt to the dimensions of the boxes to be packed. In particular, the pair of transfer rods TR can be moved towards and away from each other along the lateral direction to grip and release the boxes. The pair of transfer rods TR is movable along the forward direction F to move the boxes along the forward direction.

[0136] In one example, the pair of transfer rods TR is configured to take two successive boxes simultaneously. In one example, the transfer device 11 is configured to transfer the boxes from the first packaging station S1 to the second packaging station S2 and from the second packaging station S2 to the outfeed O of the device. In particular, the pair of transfer rods may be configured to move between a first position, in which the transfer rod takes a first box of the first packaging station S1 and a second box of the second packaging station, and a second position, spaced apart from the first position along the forward direction, in which the transfer rod takes a first box of the second packaging station and a second box of the outfeed O of the device 1. Furthermore, the transfer device 11 may include a suction device SD for lifting a front flap 302 of the packaging blank 3 coupled to the box 2. In one example, the suction device is arranged downstream of the first packaging station S1. The suction device lifts the front flap 302 of the packaging blank 3 coupled to the box 2 during the transfer of the box from the first packaging station S1 to the second packaging station S2. In one example, the suction device is disposed between the first packaging station and the second packaging station. The suction device is movable along a forward direction F. In one example, the suction device comprises at least one suction cup. In one example, the suction cup is coupled to a corresponding transport rod TR. The position of the suction cup along the feed direction F is adjusted by a guide G1. Furthermore, the initial position of the transport rod TR for holding each box 2 is adjusted via an actuator A3 and an adjustment screw SC1.

[0137] It should be noted that the support structure 4, 4' and the first and second subsets of the plurality of folding heads 5, 5' are according to the present disclosure.

[0138] Thus, each of the support structures 4, 4' may comprise a number of support bars 401 corresponding to the number of folding heads 5, 5'. Preferably, the support bars are movable toward and away from each other so that they can be displaced to support corresponding edges of the bottom wall 201 of the box 2. Furthermore, the support structures 4, 4' may be configured to movably support the base 301 of the packaging blank 3 and the box 2 coupled thereto such that the blank and the box coupled thereto are movable at the first and second packaging stations S1, S2 along a first vertical axis V1 and a second vertical axis V2, respectively. The first and second vertical axes are horizontally spaced apart from each other. In one example, each packaging station may have a first height and a second height lower than the first height. Preferably, the transfer device 11 is configured to grip the box 2 positioned at the first height. In an exemplary embodiment, at each packaging station, the support structures 4, 4' are configured to perform a downward movement to move the box from the first height to the second height. At each packaging station, the support structures 4, 4' may also be configured to perform an upward movement for moving the boxes 2 from the second height to the first height.

[0139] In the exemplary embodiment, the apparatus includes multiple columns 7' (according to one or more aspects of the present disclosure) at each of the stations.

[0140] Preferably, the plurality of columns 7 comprises a first group of columns 7 and a second group of columns 7'. In one example, the first and second wrapping stations S1, S2 comprise first and second groups of columns, respectively. At each wrapping station, the plurality of columns are oriented perpendicular to the working direction W, W' of the respective pair of folding heads 5, 5'.

[0141] The columns 7, 7' may be horizontally and vertically movable. In one example, the columns are in contact with the inner surface of the bottom wall 201 of the box 2 at least at all vertices of the box 2, so that the bottom wall 201 of the box is located between the support structure 4, 4' and the columns 7, 7' at at least all vertices of the box. In particular, in the first and second groups of columns 7, 7', the columns are movable toward or away from each other such that, at each packaging station, the columns 7, 7' are located on the side walls 202, 203 or 204, 205 of the box to be packaged at at least each vertex of the box 2. In one example, the columns 7, 7' of the first and second groups include a plurality of vertex columns C1 supporting each vertex of the box 2 and a plurality of central columns C2, C3 supporting the inner surface of the side wall of the box. Each central column of the plurality of central columns C2, C3 is located between two vertex columns C1. In one example, at the first packaging station S1, in the set configuration, the vertex columns C1 are located at the corresponding vertices of the box. Furthermore, the central column C2 is disposed between each two apex columns C1 on the long sides of the box 2 to support the side walls 204, 205 of the box 2 at the center positions of the side walls 204, 205 of the box 2. Furthermore, in the second packaging station S2, the apex columns C1 are disposed at the corresponding apexes of the box. Furthermore, the central column C3 is disposed between each two apex columns C1 on the short sides of the box 2 to support the side walls 202, 203 of the box 2 at the center positions of the side walls 202, 203 of the box 2. Thus, in one example, the first group of columns 7 is disposed along the first horizontal axis H1 to support the long sides of the box, and the second group of columns 7' is disposed along the second horizontal axis H2 to support the short sides of the box.

[0142] In one example, each packaging station S1, S2 includes a pair of longitudinal crossbars T1. The longitudinal crossbars constituting each pair of longitudinal crossbars T1 are spaced apart from one another. The longitudinal crossbars extend in a longitudinal direction. The longitudinal crossbars extend along a second horizontal axis H2. The longitudinal crossbars T1 are mutually movable toward and away from one another. The longitudinal crossbars are movable along a first horizontal axis H1. In particular, the position of the longitudinal crossbars T1 is adjusted by an actuator BA and a number of adjustment screws SC2. In one example, the columns slide along the longitudinal crossbars T1. In particular, the apex columns slide along the longitudinal crossbars T1. Furthermore, each packaging station S1, S2 may include a pair of longitudinal rods B. Each longitudinal rod of each pair of longitudinal rods is integral with the corresponding longitudinal crossbar T1. The longitudinal rods B extend along a second horizontal axis H2. In one example, the apex columns C1 are coupled to the longitudinal rods B. Furthermore, the apex column slides on the longitudinal rod along a second horizontal axis H2 depending on the setting of the device. In particular, the apex column C1 is moved along the longitudinal rod B by a moving guide G2. The device 1 also includes a pair of transverse crossbars T2. The crossbars are spaced apart and extend in a transverse direction. The transverse crossbars extend along a first horizontal axis H1. The transverse crossbars T2 are arranged perpendicular to the pair of longitudinal crossbars T1. The transverse crossbars are mutually movable toward and away from each other. The transverse crossbars are movable along a second horizontal axis H2. In one example, the columns are also movable by the transverse crossbars. In particular, in one example, the central column C2 of the first packaging station S1 is coupled to the transverse crossbar T2. Furthermore, the central column C3 of the second group of columns 7' of the second packaging station S2 is coupled to the longitudinal crossbar T1.

[0143] In one example, the apparatus includes an adjustment system for format change. The adjustment system for format change is connected to a number of columns 7. The adjustment system for format change is configured to move the columns horizontally towards or away from each other in order to adapt the columns to the type of box (i.e. the size of the box) to be packed. In one example, the adjustment system for format change includes vertical crossbars and horizontal crossbars. Thus, in one example, the adjustment system for format change moves the columns by the vertical crossbars T1 and / or the horizontal crossbars T2.

[0144] In one example, the apex columns C1 of the first and second packaging stations are movable along the second horizontal axis H2 by the longitudinal rods B and along the first horizontal axis H1 by the mutual movement of the longitudinal crossbars T1 towards and away from each other. Furthermore, the central column C2 of the first packaging station is movable along the second horizontal axis H2 by the mutual movement of the transverse crossbars T2 towards and away from each other, and the central column C3 of the second packaging station S2 is movable along the first longitudinal axis H1 by the mutual movement of the longitudinal crossbars T1 towards and away from each other. It should be noted that each central column C2, C3 is equidistant from the two apex columns C1 between which the central column C2, C3 is located.

[0145] In one example, the central column C2 of the first packaging station S1 is rotated 90 degrees relative to the central column C3 of the second packaging station S2, and the support bar 401 of the first packaging station S1 is rotated 90 degrees relative to the support bar 401' of the second packaging station S2. In one example, each of the first and second packaging stations includes an adjustment system for format change. Furthermore, the adjustment system for format change is also connected to the support bar. In one example, the adjustment system for format change coordinates the movement of the columns 7, 7' and the corresponding support bars 4, 4' in each packaging station S1, S2, so that for each box to be packaged, the columns and the corresponding support bars move simultaneously according to the settings of the device, so that for each box, at least at each apex of the box, the bottom wall of the box is operatively positioned between the columns and the support bars.

[0146] In particular, the adjustment system for format changes moves the columns and support bars for each box so that the apex of the box is supported by the apex column C1, the central portions of the side walls 203, 203, 204, 205 are supported by the central columns C2, C3, and the bottom wall 201 of the box is operably positioned between a plurality of columns 7, 7' and support bars 401, 401'.

[0147] It should be noted that the present invention also provides an embodiment in which the device comprises a single packaging station with several columns. In this embodiment example, the several columns can be moved by the adjustment system for the format change, in particular by the longitudinal crossbar T1 and / or the transverse crossbar T2. Furthermore, in the embodiment example in which a single packaging station is provided, the adjustment system for the format change can move the columns and the corresponding support bars according to the solutions described for the embodiment in which two packaging stations are provided.

[0148] In one example, the plurality of tilters 501, 501' and the plurality of columns 7, 7' of the folding heads 5, 5' of each packaging station are configured to work in conjunction to fold the flaps 302, 303, 304, 305 of the blanks 3 from a horizontal position to a vertical position.

[0149] In the exemplary embodiment, the first packaging station S1 includes a first pair of tilters 501 according to the present disclosure. The first packaging station S1 also includes a first pair of wrapping devices 502 according to the present disclosure.

[0150] The second packaging station S2 includes a second pair of tilters 501' according to the present disclosure and a second pair of wrapping devices 502' according to the present disclosure. The first pair of tilters 501 may be positioned at 90 degrees relative to the second pair of tilters 501'. The first pair of wrapping devices 502 may be positioned at 90 degrees relative to the second pair of wrapping devices 502'. Thus, the first station is configured to wrap a pair of side walls of the box 2, e.g., long walls 204, 205. The second packaging station S2 may be configured to wrap another pair of side walls of the box 2, e.g., short walls 202, 203.

[0151] In an exemplary embodiment, in each of the packaging stations S1, S2, the pair of wrapping devices 502', 502' is spaced apart from the pair of tilters 501, 501' along the vertical direction V. In this solution, the support structure 4, 4' of each packaging station S1, S2 is preferably configured to operate in conjunction with the tilters 501, 501' to fold the pair of flaps 302, 303, 304, 305 from a horizontal position to a vertical position such that each of the outer portions 302b, 303b, 304b, 305b of the flaps protrudes vertically from the box 2 at a first height. The support structure is also configured to operate in conjunction with the wrapping devices 502, 502' to fold the outer portions 302b, 303b, 304b, 305b of the pair of flaps at a second height towards the inside of the box.

[0152] In another exemplary embodiment (not shown), the first packaging station S1 comprises two pairs of tilters 501, 501' and the second packaging station S2 comprises two pairs of wrapping devices 502, 502'. In other words, the first station may be configured to fold the flaps 302, 303, 304, 305 from a horizontal position to a vertical position such that the outer portion 302b, 303b, 304b, 305b of each flap projects vertically from the box 2. The second station may be configured to receive the box 2 with the inner portion 302a, 303a, 304a, 305a of each flap 302, 303, 304, 305 attached to the outer surface of the side wall 202, 203, 204, 205 of the box 2 and the outer portion 302b, 303b, 304b, 305b of each flap projects vertically from the box 2. The second station is also configured to fold the outer portions 302b, 303b, 304b, 305b of each flap towards the inside of the box such that the outer portions 302b, 303b, 304b, 305b of each flap are in close contact with the inner surfaces of the side walls 202, 203, 204, 205 of the box 2. Furthermore, in the first packaging station S1, two pairs of tilters 501, 501' are spaced apart from each other along the vertical direction V, and in the second packaging station S2, two pairs of wrapping devices 502, 502' are spaced apart from each other along the vertical direction V.

[0153] In an exemplary embodiment, the plurality of pairs of brushes at the first station includes a first pair of tilters 501 and a second pair of tilters 501', and the plurality of pairs of wrapping devices at the second station includes a first pair of wrapping devices 502 and a second pair of wrapping devices 502'. At the first wrapping station S1, the first pair of tilters 501 is disposed at 90 degrees relative to the second pair of tilters 501'. Furthermore, at the second wrapping station, the first pair of wrapping devices 502 is disposed at 90 degrees relative to the second pair of wrapping devices 502'. Furthermore, at the first wrapping station, the first pair of tilters 501 is disposed at a distance from the second pair of tilters 501' along the vertical direction V. At the second wrapping station, the first pair of wrapping devices 502 is disposed at a distance from the second pair of wrapping devices 502' along the vertical direction V. In this solution, the support structure 4 of the first wrapping station S1 is preferably configured to operate in conjunction with the first pair of tilters 501 to fold a pair of flaps, e.g. flaps 304, 305, from a horizontal position to a vertical position at a first height, and to operate in conjunction with the second pair of flaps 501' to fold another pair of flaps, e.g. flaps 302, 303, from a horizontal position to a vertical position at a second height. In the second station S2, the support structure 4' is configured to operate in conjunction with the first pair of wrapping devices 502 to fold the outer parts of a pair of flaps, e.g. parts 304b, 305b, into the box at a first height, and to operate in conjunction with the second pair of wrapping devices 502' to fold the outer parts of another pair of flaps, e.g. parts 302b, 303b, into the box at a second height. The second height is lower than the first height.

[0154] In another embodiment, the first packaging station S1 may be arranged at a distance from the second packaging station S2 along the vertical direction V. In this solution, the packaging stations each comprise a pair of tilters 501 and a pair of wrapping devices 502. The pair of tilters 501 and the pair of wrapping devices 502 are arranged at 90 degrees relative to those of the second packaging station S2. Thus, the first packaging station may be configured to wrap a pair of side walls of the box 2, e.g. the long walls 204, 205, and the second packaging station S2 may be configured to wrap another pair of side walls of the box 2, e.g. the short walls 202, 203. The second station is preferably lower than the first station along the vertical direction V.

[0155] In the exemplary embodiment, the apparatus 1 also comprises an alignment device 12. The alignment device 12 is configured to receive the boxes 2 and the packaging blanks 3 coupled thereto at an infeed I of the apparatus 1 and to align the boxes 2 with a conveyor belt 13 extending along a horizontal direction H.

[0156] The adjusting device 12 is also configured to transfer the boxes 2 to the first packing station S1. The adjusting device 12 is movable in a forward direction F.

[0157] More specifically, the adjustment device 12 may include a plurality of suction cups 121 to slightly lift the flaps 302 of the blanks 3 at the infeed I of the device 1. In particular, the suction cups are operatively gripped against the front flaps of the blanks to lift the front flaps of the blanks at the infeed I of the device. The adjustment device 12 may also include a pair of rectangles 122 controlled by a motor M depending on the settings of the device to ensure that the boxes 2 are accurately positioned relative to the conveyor belt 13.

[0158] The pair of rectangles 122 operatively contact a box disposed therein to set the box's position relative to the conveyor belt. The adjustment device 12 may include more than one pair of rectangles 122.

[0159] According to an exemplary embodiment, the adjustment device 12 is configured to move synchronously with the transport rod TR. Thus, in one example, the transport rod TR and the adjustment device take three consecutive boxes at the same time. Moreover, the transport rod TR and the adjustment device transfer the boxes synchronously along the forward direction.

[0160] In particular, the transfer rod TR and the adjustment device 12 move between a first retracted position in which the framing device 12 takes a first box at the inlet I and the transfer rod TR takes a second and third box at the first and second packaging stations, respectively, and an advanced position spaced from the retracted position along the forward direction F in which the adjustment device 12 takes the first box at the first packaging station and the transfer rod TR takes the second and third boxes at the second packaging station and the outfeed I of the device, respectively.

[0161] According to one aspect, the present disclosure provides a method for packaging a corrugated box 2 with a packaging blank 3 (or simply "blank"). More specifically, the box 2 refers to a container comprising a plurality of side walls 202, 203, 204, 205 and a bottom wall 201. The side walls 202, 203, 204, 205 are interconnected by the bottom wall 201. The side walls 202, 203, 204, 205 (and the bottom wall 201) each have an inner surface and an outer surface.

[0162] Additionally, side walls 201, 202, 203, 204 each extend in a direction away from bottom wall 201 from a lower or connected end to an upper or free end.

[0163] More specifically, the illustrated box has a pair of end walls 202, 203 (or short walls) and a pair of side walls 204, 205 (or long walls).

[0164] The blank 3 is preferably made of paper. The packaging blank 3 has a base 301 and a number of flaps 302, 303, 304, 305 connected to the base 301. The flaps of the packaging blank 3 are connected to each other and each can face and be joined to a corresponding wall 202, 203, 204, 205 of the box 2. In this case, each flap wraps both sides (inner and outer) of the side walls 202, 203, 204, 205 of the box 2.

[0165] The packaging blank 3 also comprises four side flaps 306, 307, 308, 309. The side flaps 306, 307, 308, 309 define partial deployment of the two flaps 304, 305 of the blank 3 to completely and uninterruptedly cover all four side walls 202, 203, 204, 205.

[0166] Furthermore, each of the flaps 302, 303, 304, 305 is composed of two portions, an inner portion 302a, 303a, 304a, 305a adjacent the base 301 and an outer portion 302b, 303b, 304b, 305b spaced apart from the base 301 of the blank 3.

[0167] It should be noted that the adhesive is applied to some parts of the blank 3 by a gluing device upstream of the device 1. Alternatively, the adhesive may be applied to the entire surface of the packaging blank 3.

[0168] Before reaching the machine 1, the box 2 is received by the forming device and placed on a pre-glued packaging blank 3 such that the bottom wall 201 of the box rests on the base 301 of the packaging blank 3 (Figure 1).

[0169] The method includes receiving a box 2 coupled to a base 301 of a blank 3. Receiving the box 2 may include receiving the box 2 at an infeed I along a forward direction F.

[0170] The method may include the step of placing the base 301 of the blank 3 and the box 2 coupled thereto on a support structure 4. The support structure 4 may be movable along a vertical direction V. In one example, the method includes the step of providing a plurality of folding heads 5. The plurality of folding heads 5 are configured to perform a plurality of folding operations.

[0171] Multiple folding actions are - folding the flaps 302, 303, 304, 305 of the packaging blank 3 from a horizontal position to a vertical position such that the inner parts 302a, 303a, 304a, 305a of each flap are in close contact with the outer surfaces of the side walls 202, 203, 204, 205 of the box 2 and the outer parts 302b, 303b, 304b, 305b of each flap protrude vertically from the box 2; - folding the outer portions 302b, 303b, 304b, 305b of the flaps from a vertical position to a horizontal position and further folding the outer portions of the flaps from a horizontal position to a vertical position towards the inside of the box 2 so that they fit tightly against the inner surfaces of the side walls 202, 203, 204, 205 of the box 2.

[0172] In an exemplary embodiment, the multiple folding heads may include multiple tilters 501 configured to fold the flaps 302, 303, 304, 305 of the packaging blank 3 from a horizontal position to a vertical position, whereby an inner portion 302a, 303a, 304a, 305a of each flap contacts an outer surface of the box sidewall 202, 203, 204, 205 and an outer portion 302b, 303b, 304b, 305b of each flap protrudes vertically from the box 2. The multiple tilters 501 may be movable in a vertical direction V relative to the support structure 4 to fold the flaps 302, 303, 304, 305 of the blank 3. The multiple folding heads 5 may include a wrapping device 502 for folding the outer portions 302b, 303b, 304b, 305b of the flaps 302, 303, 304, 305 inside the box 2 from a vertical position to a horizontal position.

[0173] According to one aspect of the disclosure, the method may include providing a wrapping device 502 of each folding head 5 with a pair of fingers 502A. For each pair of fingers, the method may include moving the fingers 502A to a horizontal position parallel to the bottom wall 201 of the box 2 to move the fingers 502A toward or away from a corresponding wall of the box along a first horizontal axis H1. For each pair of fingers, the method may also include vertically moving the support structure 4 and each pair of fingers 502A relative to one another from a raised configuration in which the pair of fingers is located above the box 3 to a lowered configuration in which the pair of fingers 502A is located inside the box 2 to fold the outer portions 302b, 303b, 304b, 305b of the flaps into a vertical position inside the box 2.

[0174] The fingers 502A may be movable relative to one another toward and away from one another. More specifically, the method may include the steps of positioning the fingers 502A at least partially inside the box 2 and moving the fingers relative to one another in sliding contact with the packaging blanks 3 on the inner surfaces of the side walls 202, 203, 204, 205 of the box. In one example, the method also includes, for each pair of fingers 502A in the lowered configuration, moving the fingers relative to one another along a second horizontal axis H2, perpendicular to the first horizontal axis H1, in sliding contact with the inner surfaces of the side walls 202, 203, 204, 205. In one example, the method may include providing each wrapping device 502 with a horizontal blade 502B. Furthermore, the step of folding the outer portions of the flaps from a vertical position to a horizontal position may be performed by a horizontal blade moving horizontally parallel to the bottom wall 201 of the box 2 against the corresponding sides of the box (i.e., side walls 202, 203 and 204, 205). The blade 502B may include a through groove. In this solution, the fingers 502A of each pair are operably inserted inside a groove formed in the corresponding blade. Thus, the fingers and the blade 502B are moved simultaneously along the horizontal direction H.

[0175] In one example, in the step of placing the fingers 502A in the box, the pair of fingers are moved from the raised configuration to the lowered configuration with the fingers located close to each other at the central portion of the corresponding side wall of the box. Furthermore, in the lowered configuration, the fingers 502A are moved away from each other alternately along the second horizontal axis H2. Preferably, the fingers are moved from the lowered configuration to the raised configuration when they are spaced apart, and the fingers are moved toward each other when they are in the raised configuration. In one example, the fingers are moved by an actuator connected to a control unit. The control unit is configured to receive input data and to derive settings of the device 1 based on the input data. The input data may represent the size of each box 2 to be packed. Thus, the mutual movement of the fingers 502A toward and away from each other is performed by the actuator between a first position where the fingers 502A are located at a minimum distance from each other and a second position where the fingers 502A are located at a maximum distance from each other (maximum distance), the second position being set according to the settings of the device 1.

[0176] In one example, the plurality of folding heads 5 includes a plurality of pairs of folding heads. Preferably, for each pair of folding heads 5, the folding head acts on a corresponding pair of sides of the box 2 simultaneously.

[0177] In another example, the method may include folding the flaps from a horizontal position into the box such that the flaps fit tightly against the inner surfaces of the box side walls 202, 203, 204, 205. This is done by a horizontal rotating blade 502C configured to move horizontally parallel to the bottom wall 201 of the box 2 and configured to rotate about an axis of rotation from a first position where it is parallel to the bottom wall of the box to a second position where it is perpendicular to the bottom wall 201 of the box.

[0178] The method may also include supporting the inner surface of the side wall 202, 203, 204, 205 of the box with the arm 6 while the flaps 302, 303, 304, 305 are folded. Preferably, the arm 6 moves from a first position where it is spaced from the side wall 202, 203, 204, 205 of the box to a second position where it contacts the inner surface of the inner wall of the box.

[0179] In one example, the method also includes folding the four side flaps 306, 307, 308, 309 of the blank 3 such that they are tightly attached to portions of the inner surfaces of the long side walls 204, 205 of the box 2 by a plurality of hands 502E. Preferably, the hands 502E are configured to be horizontally and vertically movable to fit the size of the box to be packaged.

[0180] Preferably, the folding heads 5 constituting each pair of folding heads are spaced apart from one another along their working direction W. The support structure 4 may comprise a number of pairs of support bars 401, which may correspond to a number of pairs of folding heads 5. Preferably, for each pair of support bars 401, the bar is oriented transversely to the working direction W of the corresponding pair of folding heads 5. The support bars 401 are movable towards or away from one another in order to support corresponding edges of the bottom wall of the box. Preferably, the support bars 401 are moved by a number of actuators, depending on the setting of the device 1.

[0181] According to one aspect of the disclosure, the method includes providing a plurality of columns 7. The method also includes providing a horizontal tray 8 and connecting the plurality of columns 7 to the tray 8. In one example, the method includes horizontally moving the plurality of columns 7 such that at least each apex of the box 2 is vertically aligned with a corresponding column of the plurality of columns 7.

[0182] In one example, during the step of horizontally moving the plurality of columns 7, the plurality of columns are slidably connected to the tray 8. Alternatively, the step of horizontally moving the plurality of columns 7 may include removing the plurality of columns from the tray 8 and horizontally moving the plurality of columns relative to the tray 8.

[0183] Preferably, the step of horizontally moving the plurality of columns 7 is performed by a control unit depending on the settings of the device 1 .

[0184] The method may also include moving the tray 8 in a vertical direction V. The method includes moving the plurality of columns 7b vertically relative to the support structure 4. In moving the plurality of columns 7 vertically, the plurality of columns remain in contact with an inner surface of the bottom wall 201 of the box 2 while the flaps are folded from a horizontal position to a vertical position, such that the bottom wall 201 of the box is located between the support structure 4 and the plurality of columns at least at all vertices of the box.

[0185] The method may include the step of providing a tray 8 having a central through hole 801. The method also includes the steps of providing a rod 9 that is inserted through the central hole 801 of the tray, and providing a disk 10 and connecting it to a lower end of the rod 9. The rod 9 may be movable relative to the support structure 4 along a vertical direction V.

[0186] The method may also include inserting the disk 10 into the box 2 against a central portion of the inner surface of the bottom wall 201 of the box 2. The method also preferably includes moving the rod 9 vertically independent of the vertical movement of the tray 8.

[0187] In one example, the method comprises the step of moving the support structure 4 together with the packaging blank 3 and the box 2 joined thereto along the vertical direction V to different heights.

[0188] In one example, the method includes inserting a plurality of columns 7 into the box 2 such that the plurality of columns 7 contact an inner surface of the bottom wall 201 of the box 2 .

[0189] The method may also include moving the plurality of columns 7 downwardly into an active configuration in which the plurality of columns contact an inner surface of the box's bottom wall 201. Preferably, the plurality of columns are configured to operate in conjunction with the support structure 4 to press against the box's bottom wall 201 disposed therebetween in the active configuration.

[0190] The method may also include moving the columns 7 upwardly into an inactive configuration in which the columns are spaced from the inner surface of the box 2 .

[0191] The method may also include holding the disk 10 inside the box 2 in contact with a central portion of the inner surface of the bottom wall 201 of the box while the plurality of columns 7 are moved upward (to the inactive configuration).

[0192] In one example, the method includes vertically moving the box 2 and packaging blank 3 between a first stop at a first height and a second stop at a second height that is lower than the first height.

[0193] Preferably, the step of folding the flaps 302, 302, 304, 305 from a horizontal position to a vertical position is performed at a first stop and the step of folding the outer portions 302b, 302b, 304b, 305b of the flaps into the box is performed at a second stop.

[0194] More specifically, the box 2 and the blank 3 coupled thereto are received at the infeed I at a first height. Preferably, the tray 8, the rod 9, the disk 10 and the column 7 are arranged above the box 2. The columns 7 can be moved horizontally depending on the setting of the device 1, and they are arranged inside the box 2 such that they contact the inner surface of the bottom wall 201 of the box at least at all vertices of the box, and the bottom wall 201 of the box 2 is arranged between the support structure 4 and the columns at at least at all vertices of the box 2. Also, the rods and disks are arranged inside the box so as to press a central portion of the inner surface of the bottom wall 201 of the box. In one example, the columns 7 and the support structure are then moved along a vertical direction V, moving the box 2 from the first height to the second height. During the downward movement of the box, the flaps 302, 303, 304, 305 of the blank are folded from a horizontal position to a vertical position by the tilters 501. Alternatively, the support structure 4 may remain stationary and the tilters 501 move upwards to fold the flaps 302, 303, 304, 305 of the blank from a horizontal position to a vertical position. When the flaps are folded from a horizontal position to a vertical position, the columns are spaced apart from the inner surface of the box 2, but the disks 10 are still in contact with the inner surface of the box 2. The support structure 4 and the rods 9 may perform another downward movement along the vertical direction V, such that the outer portions 302b, 303b, 304b, 305b are folded into the box 2 by the wrapping device 502. Alternatively, the support structure 4 may remain stationary while the wrapping device 502 of the folding head 5 moves upwards to fold the flaps into the box 2. The support structure 4 may then be moved upwards together with the rods 9 and the disks 10 to bring the box 2 to a first height.

[0195] According to one aspect of the disclosure, the method may include providing an apparatus 1 comprising a first packaging station S1 and a second packaging station S2. In one example, the packaging stations are spaced apart from one another along a horizontal direction H orthogonal to a vertical direction V. More specifically, the method may include performing a first subset of the plurality of folding operations at the first packaging station S1 and performing a second subset of the plurality of folding operations at the second packaging station S2.

[0196] Preferably, the method includes a step of supporting the base 301 of the blank 3 and the box 2 coupled thereto by a respective support structure 4, 4' at each packaging station. The support structures 4, 4' are according to the present disclosure. In one example, the packaging stations S1, S2 each comprise a plurality of folding heads 5 according to the present disclosure. The plurality of folding heads 5 may comprise a first pair of folding heads 5 and a second pair of folding heads 5'. The folding heads constituting the first pair of folding heads 5 are spaced apart from one another along a first working direction W, and the folding heads constituting the second pair of folding heads 5' are spaced apart from one another along a second working direction W' perpendicular to the first working direction W. The first working direction W may be perpendicular to the second working direction W'. In one example, the first pair of folding heads 5 forms part of the first packaging station S1 and the second pair of folding heads 5' forms part of the second packaging station S2. Furthermore, for each pair of folding heads 5, 5', the pair of folding heads may simultaneously act on a respective pair of side surfaces (i.e. side walls 202, 203, 204, 205) of the box 2. At the first packaging station S1, the support structure 4 may comprise a first pair of support bars 401 oriented transversely to the first working direction W, and at the second packaging station S2, the support structure 4' may comprise a second pair of support bars 401' oriented transversely to the second working direction W'. Preferably, for each of the first and second pairs of support bars, the bars are movable towards or away from each other such that the bars are displaceable depending on the setting of the apparatus to support corresponding ends of the bottom wall 201 of the box 2.

[0197] In one example, the method may include providing each of the packaging stations S1, S2 with a plurality of columns 7 according to the present disclosure. In one example, the plurality of columns 7 includes a first group of columns 7 and a second group of columns 7'.

[0198] The first and second packaging stations S1, S2 may respectively comprise first and second groups of columns 7, 7'. In each packaging station S1, S2 a plurality of columns 7, 7' are oriented perpendicular to the working direction W, W' of the respective pair of folding heads 5, 5'.

[0199] In one example, the first packaging station S1 is located upstream of the second packaging station S2 with respect to the forward path of the boxes 2 from the infeed I to the outfeed O of the apparatus 1. Preferably, a first subset of folding operations is performed at the first packaging station and a second subset of folding operations is performed at the second packaging station.

[0200] The method may comprise the step of transporting the box 2 and the blanks 3 connected thereto in a forward direction by a transport device 11 which is movable relative to each of the support structures 4, 4'. Preferably, the box 2 is transported from the first packaging station S1 to the second packaging station S2 by a translational movement without a rotational movement of the box.

[0201] In one example, the boxes 2 are transferred from a first packaging station S1 to a second packaging station S2 by a translational movement of the boxes 2 aligned in the infeed I with the forward direction F of the boxes.

[0202] More specifically, the method may include receiving the box and blank 3 by an alignment device 12. The box is aligned with a conveyor belt 13 extending along a horizontal direction H and transferred to an infeed of a first packaging station S1. The method includes receiving the box 2 and the blank 3 coupled thereto at the infeed I at a first height of the first packaging station S1.

[0203] The method may include folding a first pair of flaps, for example flaps 304, 305, of a packaging blank 3 from a horizontal position to a vertical position at a first packaging station S1.

[0204] The method may include moving the box 2 and the blank 3 coupled thereto, together with its support structure 4, along the first vertical axis V at a second height in the first packaging station S1. The second height is lower than the first height. The method may include folding the outer portions 302b, 303b, 304b, 305b of the first pair of flaps from a vertical position to a horizontal position and from a horizontal position to a vertical position towards the inside of the box 2, so that they fit tightly against the inner surfaces of the side walls 202, 203, 204, 205 of the box 2.

[0205] The method may include the step of moving the box 2 to a first height at a first packaging station S1.

[0206] The method may comprise a step of transferring the boxes 2 to a first height of a second packaging station by a transfer device 11. The transfer device may simultaneously receive two successive boxes of the series of boxes and move them along a forward movement path without rotating the boxes 2, so that the forward movement path is aligned with the forward movement direction F of the boxes 2 at the infeed. To move the boxes between various positions between the infeed I, the packaging stations S1, S2 and the outfeed O, the device is moved back and forth.

[0207] The method may include folding a second pair of flaps of the packaging blank 3, e.g., flaps 302, 303, from a horizontal position to a vertical position at a second packaging station S2. The method may also include moving the box 2 and the blank coupled thereto, together with its support structure 4', along a second vertical axis at a second height at the second packaging station. The second height is lower than the first height, and the first and second vertical axes are horizontally spaced apart from one another.

[0208] The method may also include folding the outer portions 302b, 303b, 304b, 305b of the second pair of flaps toward the inside of the box 2 from a vertical position to a horizontal position and from a horizontal position to a vertical position so that they fit tightly against the inner surfaces of the side walls 202, 203, 204, 205 of the box.

[0209] Preferably, the method includes the step of moving the box to a first height of a second wrapping station S2. The method includes the step of releasing the wrapped box 2 at an outfeed O of the device 1.

[0210] Alternatively, the method may comprise a step of folding the flaps 302, 302, 304, 305 of the blank from a horizontal position to a vertical position at the first packaging station. In this solution, the box with the inner parts 302A, 303A, 304A, 305A attached to the side walls 202, 203, 204, 205 of the box 2 and with the tops of the flaps 302b, 303b, 304b, 305b in a vertical position is transported by the transfer device 11 to the second packaging station S2. The method comprises a step of folding the outer flaps of the blank into the box 2 at the second packaging station. Furthermore, at each station the box 2 can be moved along the vertical direction between different heights.

[0211] In another example, the method may comprise the steps of arranging the packaging stations S1, S2 such that they are spaced apart from one another along the vertical direction V. In this solution, the method may comprise the steps of folding a pair of flaps of the packaging blank 3, e.g. flaps 304, 305, from a horizontal position to a vertical position, whereby an inner part of each flap adheres to the outer surface of a side wall of the box, e.g. walls 204, 205, and an outer part of each flap protrudes vertically from the box 2, and folding the outer parts of the pair of flaps from a vertical position to a horizontal position and further folding the outer parts of the pair of flaps from a horizontal position to a vertical position towards the inside of the box, whereby they adhere to the inner surface of the side wall of the box.

[0212] The method may include the steps of moving the box along the vertical direction V to a second packaging station. The method may also include the steps of folding another pair of flaps of the packaging blank 3, e.g., flaps 302, 303, from a horizontal position to a vertical position, whereby an inner portion of each flap adheres to the outer surface of a side wall of the box, e.g., walls 204, 205, and an outer portion of each flap protrudes vertically from the box 2, and folding the outer portions of the pair of flaps from a vertical position to a vertical position and further folding the outer portions of the pair of flaps from a horizontal position to a vertical position towards the inside of the box 2, whereby they adhere to the inner surface of the side wall of the box. In other words, a pair of side walls of the box 2, e.g., long walls 204, 205, are wrapped at a first packaging station and another pair of side walls, e.g., short walls 202, 203, are wrapped at a second packaging station and vice versa. [Prior art documents] [Patent documents]

[0213] [Patent Document 1] WO2015 / 079342A1 [Patent Document 2] BO2010A000658 [Patent Document 3] CN111516295A

Claims

1. 1. An apparatus for automatically wrapping a packaging blank onto a side wall of a corrugated box, the packaging blank having a base and a plurality of flaps connected thereto, the box being coupled to the base of the packaging blank, the apparatus comprising: a support structure configured to support the base of the packaging blank, whereby the packaging blank and the box coupled thereto are vertically movable; and a plurality of folding heads configured to fold the flaps of the packaging blank from a horizontal position to a vertical position, whereby an inner portion of each flap is in intimate contact with the outer surface of the side wall of the box and an outer portion of each flap protrudes vertically from the box, the plurality of folding heads configured to fold the outer portions of the flaps from a vertical position to a horizontal position and further fold the outer portions of the flaps from the horizontal position to the vertical position toward the inside of the box so that they are in intimate contact with the inner surface of the side wall of the box, Each folding head includes a pair of fingers that are movable toward and away from each other, and the pair of fingers are displaceable within the box so that the pair of fingers are movable relative to each other in sliding contact with the packaging blank on the inner surface of the side wall of the box.

2. 2. The apparatus of claim 1, wherein each pair of fingers is further movable along a first horizontal axis toward or away from a corresponding wall of the box, the relative movement of the pair of fingers is along a second horizontal axis perpendicular to the first horizontal axis, and the support structure and each pair of fingers are further movable vertically relative to one another from a raised configuration in which the pair of fingers are positioned above the box to a lowered configuration in which the pair of fingers are positioned inside the box.

3. For each folding head: the fingers of a corresponding pair of fingers are movable relative to one another between a first position in which they are positioned at a minimum distance from one another and a second position in which they are positioned at a maximum distance from one another; - said pair of fingers are displaceable within said box with said pair of fingers in said first position; The device of claim 2, wherein the folding head is configured to move the pair of fingers away from each other from the first position to the second position while the fingers are in the lowered configuration.

4. The apparatus of claim 3 , wherein each folding head is configured to move the pair of fingers closer together from the second position to the first position with the fingers in the raised configuration.

5. a control unit adapted to receive input data representative of the size of each box to be packed and programmed to derive settings for the machine based on said input data; a plurality of actuators connected to said control unit and configured to move said plurality of folding heads; 5. The apparatus of claim 1, wherein the plurality of actuators include slide actuators configured to move the fingers toward or away from one another between a first position in which the fingers are positioned at a minimum distance from one another and a second position in which the fingers are positioned at a maximum distance from one another, the second position being set according to a setting of the apparatus.

6. a control unit adapted to receive input data representative of the size of each box to be packed and programmed to derive settings for the machine based on said input data; a plurality of actuators connected to said control unit and configured to move said plurality of folding heads; The plurality of folding heads includes a plurality of pairs of folding heads, and for each pair of folding heads: - the folding heads act simultaneously on a corresponding pair of sides of the box; the pair of folding heads are spaced apart from each other along the working direction; The support structure includes a plurality of pairs of support bars corresponding to the plurality of pairs of folding heads, and for each pair of support bars:

5. The device according to claim 1, wherein the bars are oriented transversely to the working direction of the corresponding pair of folding heads and are movable towards or away from each other so that they can be displaced depending on the setting of the device to support corresponding edges of the bottom wall of the box.

7. a first packaging station and a second packaging station arranged at a distance from each other along a horizontal direction perpendicular to said vertical direction; - a transfer device configured to transfer the box from the first packaging station to the second packaging station by translational movement of the box along the horizontal direction without rotating the box.

8. 5. The apparatus of claim 1, further comprising a plurality of columns movable vertically and horizontally, said plurality of columns contacting the inner surface of the bottom wall of said box at least at all vertices of said box.

9. a rod movable along the vertical direction; 9. The device of claim 8, further comprising: a disk connected to the lower end of the rod and configured to contact a central portion of the inner surface of the bottom wall of the box.

10. the support structure is adapted to move along the vertical direction between a first stop at a first height and a second stop at a second height that is less than the first height; 5. The apparatus of claim 1, wherein the folding head is configured to fold the flaps of the packaging blank from the horizontal position to the vertical position when the support structure is positioned at the first stop, fold the outer portions of the flaps from the vertical position to the horizontal position, and further fold them from the horizontal position to the vertical position so that they are in close contact with the inner surface of the side wall of the box when the support structure is positioned at the second stop.

11. 5. The device of claim 1, wherein each folding head further includes a horizontal blade connected to an actuator for moving horizontally parallel to the bottom wall of the box and for moving toward and away from the corresponding wall of the box, the blade configured to fold the outer portion of the flap of the packaging blank from the vertical position to the horizontal position, the horizontal blade including a groove and a corresponding pair of fingers operably inserted inside the groove.

12. 1. A method for packaging a corrugated box with a packaging blank, comprising: The packaging blank has a base and a plurality of flaps attached to a side wall of the box, and the method includes: receiving the box coupled to the base of the packaging blank; - placing the base of the packaging blank and the box connected thereto on a support structure movable along a vertical direction; - folding the flaps of the packaging blank from a horizontal position to a vertical position so that an inner portion of each flap fits tightly against the outer surface of the side wall of the box and an outer portion of each flap projects vertically from the box; - folding the outer portions of the flaps from the vertical position to a horizontal position; - further folding the outer portions of the flaps of the packaging blank towards the inside of the box from the horizontal position to a vertical position so that they fit tightly against the inner surfaces of the side walls of the box; - providing a plurality of folding heads, each of the folding heads including a pair of fingers movable relative to one another so as to move towards and away from one another; - positioning said fingers at least partially inside said box and moving said fingers relative to said packaging blanks in sliding contact with said inner surfaces of said side walls of said box.

13. - for each pair of fingers, moving the fingers along a first horizontal axis to said horizontal position parallel to the bottom wall of said box, so as to move them towards or away from the corresponding wall of said box; - for each pair of fingers, moving the support structure and each pair of fingers vertically relative to one another from a raised configuration in which the pair of fingers is positioned above the box to a lowered configuration in which the pair of fingers is positioned inside the box, in order to fold the outer portions of the flaps into the vertical position inside the box; 13. The method of claim 12, further comprising the step of: for each pair of fingers, in the lowered configuration, moving the fingers relative to one another in sliding contact with the inner surface of the side wall along a second horizontal axis perpendicular to the first horizontal axis.

14. 14. The method of claim 13, wherein in the step of placing the fingers within the box, the pair of fingers are moved from the raised configuration to the lowered configuration with the fingers positioned adjacent to each other at central portions of the corresponding side walls of the box, and in the lowered configuration, the fingers move away from each other along the second horizontal axis.

15. 15. The method of claim 14, wherein the fingers are moved from the lowered configuration to the raised configuration when they are spaced apart, and the fingers are moved toward each other when they are in the raised configuration.

16. - providing a first packaging station and a second packaging station spaced apart from each other along a horizontal direction perpendicular to said vertical direction, the plurality of folding heads include a first pair of folding heads spaced apart from one another along a first working direction and a second pair of folding heads spaced apart from one another along a second working direction perpendicular to the first working direction, the first pair of folding heads being part of the first packaging station and the second pair of folding heads being part of the second packaging station, and for each pair of folding heads, the pair of folding heads operatively act simultaneously on a respective pair of sides of the box; The support structure includes: a first pair of support bars oriented transversely to the first working direction at the first packaging station; a second pair of support bars oriented transversely to the second working direction at the second packaging station; and for each of the first and second pairs of support bars, the bars are movable toward and away from each other such that the bars are displaceable in response to settings of the apparatus derived by a control unit to support corresponding edges of a bottom wall of the box, the method further comprising:

15. A method according to any one of claims 12 to 14, comprising transferring the box from the first packaging station to the second packaging station by translational movement without rotational movement of the box.

17. - providing a plurality of columns; - moving the columns downwardly relative to the support structure and in contact with the inner surface of the bottom wall of the box at at least all vertices of the box, whereby the bottom wall of the box is positioned between the support structure and the columns at at least all vertices of the box; vertically moving the box and the packaging blank between a first stop at a first height and a second stop at a second height that is lower than the first height; folding of the flap from the horizontal position to the vertical position occurs at the first stop; 15. The method of any one of claims 12 to 14, wherein folding of the outer portion of the flap into the inside of the box occurs at the second stop.

18. 15. The method of any one of claims 12 to 14, wherein folding of the outer portions of the flaps from the vertical position to the horizontal position is performed by a horizontal blade moving horizontally against the corresponding side of the box and parallel to the bottom wall of the box, with each pair of fingers being operably inserted inside a groove provided in the corresponding blade.

Images