Stacks of layered materials to form packaging and methods of use

Abstract

A stack of layered material, such as corrugated cardboard, for forming a package, the stack (S) comprising full panels (P) having a predetermined overall length (W), the full panels (P) folded into accordion-like pleats along transverse folds (C) formed in the full panels (P), the stack (S) comprising at least one longitudinal cut (T) on each full panel (P) to form at least two laterally adjacent stacks (S, S'') of partial panels (P', P'') having respective partial widths (W', W'') less than the overall width (W). At least one cut (T) is incomplete so that each partial panel (P') of each stack (S') and the partial panel (P") of the adjacent stack (S") have at least one joint (J) therebetween having a predetermined minimum length (H) for holding the partial panels (P', P") of adjacent stacks (S', S") together, thereby keeping adjacent stacks (S', S") substantially aligned while facilitating separation of each partial panel (P', P") when they are released by a pulling action from each adjacent stack (S', S"). Also provided is a method for using the stack (S) of layered material in a loading unit of a factory for manufacturing boxes for packaging.

Description

[Technical Field]

[0001] The present invention finds application in the packaging field generally, and in particular relates to stacks of layered materials for forming packages.

[0002] The present invention also relates to methods for using stacks of the above-described layered materials in automated or semi-automated machines and factories. [Background technology]

[0003] Layered materials, typically corrugated cardboard, have long been known to be used for the production of packaging boxes, and are intended to be loaded in the form of stacks of adjacent panels into automated or semi-automated machines or factory loading units to produce boxes of the desired size.

[0004] As used hereinafter, "laminate of layered material" refers to a stack of panels, for example made of corrugated cardboard or similar material, which have predetermined longitudinal and lateral dimensions, are folded into accordion- or concertina-like pleats, and are joined together along lateral fold lines.

[0005] Additionally, the term "continuous web" refers to a web of layered material having a predetermined overall width and formed from a plurality of individual panels that are joined together along corresponding fold lines and then folded into accordion- or bellows-like pleats.

[0006] Generally, an automated box making machine or factory comprises at least one processing unit with tools for cutting the panels and for scoring the panels.

[0007] Typically, at least one loading unit is located upstream from such a creasing and cutting unit and has a storage cartridge for one or more stacks of continuous web panels and means for driving one panel at a time towards the creasing and cutting unit.

[0008] In order to increase the operating speed of the factory and to facilitate the processing operations, multiple adjacent stacks of panels of equal or different widths are intended to be placed in a loading unit and continuously fed to the processing unit.

[0009] One drawback of this known system is that the panels of each stack tend to misalign and overlap along the edges, which affects their stability. Furthermore, due to this instability, the stacks must be limited in height or they will tend to bend or fall during shipping and handling.

[0010] To at least partially avoid these drawbacks, methods have been developed to avoid stack misalignment during shipping and to facilitate compaction.

[0011] One known method is to wrap a stretched film around the side edges of a single panel of each laminate or around the side end edges of multiple adjacent laminates of a single panel to compress each laminate or hold the end edges of the laminates adjacent to each other.

[0012] Nevertheless, the use of stretched film affects the edge integrity of each panel. Furthermore, when the stack of panels is used at the loading station, the film must be removed and discarded, which leads to lost productivity and increased processing waste, thus causing environmental impacts.

[0013] Further examples of methods involving the management of stacks of layered materials are known from DE 19711799 A1, US 3729367 A and WO 01 / 38215 A1.

[0014] In summary, known methods of manufacturing or using adjacent stacks of layered materials to form packaging suffer from reduced efficiency and cost-effectiveness, as well as high operating costs. Summary of the Invention [Problem to be solved by the invention]

[0015] In light of the prior art, the technical problem addressed by the present invention is to facilitate the handling of stacks of layered materials for producing packages, allowing them to be more easily unwound from continuous webs. [Means for solving the problem]

[0016] It is an object of the present invention to avoid the above drawbacks by providing a stack of layered materials and a method of using such a stack of layered materials to form packaging that is highly efficient and cost effective.

[0017] A particular object of the present invention is to provide a stack of layered materials that can form at least two adjacent stacks of layered materials, and that avoids misalignment of adjacent stacks with respect to one another.

[0018] Another object of the present invention is to provide a method that utilizes an adjacent stack of layered materials that can be easily unwound from a continuous web by a simple pulling action.

[0019] It is a further object of the present invention to provide a stack of layered materials that allows for the formation of adjacent stacks that have high stability, even when they have a considerable height.

[0020] Another object of the present invention is to provide a method for using adjacent stacks of layered materials that can limit processing waste and therefore has a low impact on the environment.

[0021] It is a further object of the present invention to provide a stack of layered materials that is easy to handle.

[0022] These and other objects are achieved, as will be more clearly shown below, by a stack of layered material, such as corrugated cardboard, to form a package, such stack having full panels of a predetermined length and formed with transverse folds along which the full panels are folded into accordion-like pleats.

[0023] In a particular aspect of the invention, the laminate comprises at least one longitudinal cut on each full panel to form at least two laterally adjacent laminates of partial panels having respective partial widths less than the full width.

[0024] According to the present invention, at least one cut is incomplete so that each partial panel of each laminate and the partial panels of the adjacent laminates have at least one connection therebetween having a predetermined minimum length for holding the partial panels of the adjacent laminates together, thereby facilitating separation of each partial panel when they are released by a pulling action from each adjacent laminate, while keeping the adjacent laminates substantially aligned.

[0025] The invention further relates to a method of using an adjacent stack of layered materials as claimed in claim 8.

[0026] Advantageous embodiments of the invention are obtained according to the dependent claims. Further features and advantages of the present invention will become more apparent from the detailed description of a stack of layered materials for forming packaging and a method of using such a stack, given by way of non-limiting example with reference to the accompanying drawings, namely: [Brief explanation of the drawings]

[0027] [Figure 1] 1 and 2 are front and rear perspective views, respectively, of a stack of layered materials of the present invention, according to a first embodiment. [Figure 2]1 and 2 are front and rear perspective views, respectively, of a stack of layered materials of the present invention, according to a first embodiment. [Figure 3] FIG. 3 is an enlarged perspective view of a stack of layered materials of the present invention according to a second embodiment. [Figure 4] FIG. 4 is a perspective view of the laminate of FIG. [Figure 5] 5 to 8 are top views of partial panels of laminates in different embodiments of the present invention. [Figure 6] 5 to 8 are top views of partial panels of laminates in different embodiments of the present invention. [Figure 7] 5 to 8 are top views of partial panels of laminates in different embodiments of the present invention. [Figure 8] 5 to 8 are top views of partial panels of laminates in different embodiments of the present invention. [Figure 9] 9 to 12 are perspective views of the laminate of FIG. 3 in steps a) to d) of the method of use of the present invention. [Figure 10] 9 to 12 are perspective views of the laminate of FIG. 3 in steps a) to d) of the method of use of the present invention. [Figure 11] 9 to 12 are perspective views of the laminate of FIG. 3 in steps a) to d) of the method of use of the present invention. [Figure 12] 9 to 12 are perspective views of the laminate of FIG. 3 in steps a) to d) of the method of use of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0028] With particular reference to the drawings, a stack of layered materials for forming packaging such as corrugated cardboard is shown and is generally designated S.

[0029] As best shown in FIG. 1, the laminate S has a predetermined overall length W and includes a full panel P having a transverse fold C formed therein along which the full panel P is folded into accordion-like pleats.

[0030] The stack S rests on a support surface G which defines a longitudinal direction L and a lateral direction V.

[0031] The initial stack S of full panel P may be made from a continuous web (not shown) of layered material that is substantially longitudinal and has a predetermined overall width W, on which a plurality of transverse fold lines C are formed that are substantially equally spaced apart by lengths K.

[0032] As best shown in Figures 1 and 2, the full panel P is then folded along fold lines C into accordion-like pleats to form an initial laminate S having a front A, a back B, and two sides D, E.

[0033] By way of non-limiting example, the overall width W may range from 400 mm to 3000 mm, while the length K may range from about 600 mm to 2500 mm.

[0034] The layered material must be sufficiently rigid to prevent deformation of the full panel P when folded into accordion-like pleats, and may have a thickness in the range of, for example, 2 mm to 8 mm.

[0035] According to a specific aspect of the invention, the laminate S comprises, on each full panel P of the initial laminate S, at least one longitudinal cut T substantially perpendicular to the transverse fold C, forming at least two laterally adjacent laminates S', S'' formed by partial panels P', P'' each having a partial width W', W'' smaller than the total width W of the full panel P.

[0036] Advantageously, as best shown in FIG. 2, at least one cut T is incomplete so that each partial panel P' of each laminate S' and partial panel P'' of its adjacent laminate S'' can have at least one joint J therebetween having a predetermined minimum length H to hold the partial panels P', P'' of adjacent laminates S', S'' together.

[0037] Thus, as best shown in FIG. 4, adjacent laminates S', S'' are held in substantial alignment while facilitating separation of each of the partial panels P', P'' when the partial panels P', P'' are released by a pulling action from each adjacent laminate S', S''.

[0038] In the illustrated embodiment, each full panel P of the laminate S has several longitudinal cuts T', T'', T''', ... made on the full panel P spaced apart from one another, as shown in Figure 2, to form a plurality of adjacent laminates S', S'', S''', ... of respective widths W', W'', W''', ....

[0039] This arrangement allows the panels P', P'', P''', ... of adjacent stacks S', S'', S''', ... to be perfectly aligned and rest stably on the support surface G during the use process described below.

[0040] This offers the advantage that factories for producing packaging boxes from partial panels P', P'', P''', ... lifted from adjacent stacks S', S'', S''', ... and formed in the above-mentioned way can avoid using multiple stacks of completely cut panels arranged side by side, thereby providing a more stable and reliable production process.

[0041] As an example, as shown in the figure, on a full panel P having an overall width W of 2400 mm, three longitudinal cuts T', T'', T''' can be made at 600 mm intervals to provide four adjacent laminates of equal width.

[0042] As an example, all the links J may have the same minimum length H in the range of 5 mm to 20 mm, and the part widths W', W'', W''', . . . may range from 200 mm to 1500 mm.

[0043] In a first embodiment, as shown in Figures 1, 2, and 5, at least one connector J is located adjacent to at least one of the transverse fold lines C of each full panel P, and each longitudinal cut T abuts another transverse fold line C. Alternatively, as best shown in Figure 6, the longitudinal cuts T and connectors J alternate along each fold line C.

[0044] In the second embodiment, as shown in FIGS. 3, 4 and 7, all of the connectors J are located adjacent to both of the lateral folds C of each full panel P.

[0045] Thus, each longitudinal cut T may be at least as long as the difference between the length K between the transverse folds C and twice the minimum length H, as best shown in FIG.

[0046] In an alternative embodiment, as shown in FIG. 8, at least one longitudinal cut T is discontinuous and is formed by a plurality of longitudinally aligned connectors J for more firmly joining the partial panels P', P'' of adjacent laminates S', S''.

[0047] Of course, this does not exclude that the arrangement of the at least one longitudinal cut T and the at least one joint J in each full panel P may be other than that described or shown here.

[0048] It will be appreciated that the stacks S of layered material described herein can reduce processing waste because the joints J to promote adhesion between one stack S' and the next adjacent stack S'' are used later during processing of the layered material.

[0049] Furthermore, each connection J allows a number of adjacent stacks S', S'', S''', ... to be of smaller dimensions, allowing them to be handled in a very simple way without the risk of falling or shifting.

[0050] In operation, a series arrangement of a creasing machine for forming folds C and an automatic folding machine for processing the creasing layered material may be provided to form joints J in the full laminate P to obtain adjacent laminates S', S'', S''', ...

[0051] An automatic machine can then be provided which includes a series of cutting tools of known type for making at least one longitudinal cut T and joint J on each full panel P.

[0052] Alternatively, the longitudinal cuts T and joints J can be made before the full panel P is folded.

[0053] The latter configuration may provide a sequential arrangement of a creasing machine for forming folds C, a cutting machine for forming at least one longitudinal cut T, and a folding machine for processing the fold-lined layered material formed by the longitudinal cut T.

[0054] In a further aspect, the present invention relates to a method for using a stack S of layered material as described hereinabove, and thus adjacent stacks S', S'', S''', ... in a layered material loading unit in a factory for producing custom boxes for packaging, as shown schematically in Figures 9-12.

[0055] The method of use of the present invention comprises the steps of: a) placing a stack S on a support surface G, as shown in Figure 9; and b) providing a holding means U acting on adjacent stacks S'', S''', ... except for the initial stack S', to hold together all partial panels P'', P''', ... of adjacent stacks S'', S''', ..., as shown in Figure 10.

[0056] For simplicity, the holding means U is shown as a plate located on top of adjacent stacks S'', S''', ..., but such holding means U may also comprise rollers or other devices for holding the partial panels P'', P''', ... of adjacent stacks S'', S''', ... on top of surface G.

[0057] This is followed by step c) pulling by the loading unit the partial panels P' of the initial stack S' that are not held by the holding means, breaking at least one connection J and unwinding the panels P' of the initial stack S', leaving the panels P'', P''',... of the adjacent stacks S'', S''',... held on the support surface G and perfectly aligned, as shown in Figure 11.

[0058] Of course, the pulling step c) will be repeated for all the base panels P' of the stack S' in order to feed them to a loading unit for producing packages using the panels P'.

[0059] As best shown in Figure 12, once all panels P' have been released from stack S' in step c), the next step involves d) laterally displacing support surface G, as well as retaining means U, in lateral direction V so that step c) can be repeated on the next adjacent stack S''.

[0060] Of course, in step d) above, the support surface G is displaced in direction V in a corresponding direction opposite to the lateral displacement of the holding means U.

[0061] Alternatively to what is described herein, step d) may comprise providing holding means U'', U''', ... acting on all adjacent stacks S'', S''', ... except for the initial stack S', and once step c) has been completed on the initial stack S', there may also be provided step d') of laterally displacing the support surface G to remove one of the holding means U'' from the next adjacent stack S'', and repeating step c) with the next adjacent stack S''.

[0062] It will be appreciated from the above that the stack of layered materials and method of use of the present invention achieves its intended purpose, i.e., to facilitate handling of the stack of layered materials to make packages and to facilitate unwinding from a continuous web.

[0063] The laminate and method of use according to the present invention are susceptible to numerous modifications and variations within the scope of the inventive concept disclosed in the appended claims.

[0064] Although the laminate and method of use have been described with particular reference to the accompanying drawings, the numerals referred to in the disclosure and claims are used merely for a better understanding of the invention and are not intended to limit the scope of the claims in any way.

[0065] References herein to "one embodiment" or "embodiments" or "some embodiments" indicate that the particular feature, structure, or element being described is included in at least one embodiment of the inventive subject matter.

[0066] Furthermore, the particular features, structures, or elements may be combined together in any suitable manner to provide one or more embodiments. [Industrial Applicability]

[0067] The invention has potential industrial applications as it can be manufactured on an industrial scale in factories for converting layered materials into packaging.

Claims

1. A laminate of layered material in the form of cardboard for producing a packaging box, the laminate (S) comprising full panels (P) having a predetermined overall width (W), the full panels (P) folded into accordion-like pleats along transverse folds (C) made in the full panels (P), each transverse fold (C) being continuous and without holes, the laminate (S) comprising at least one longitudinal cut (T) on each full panel (P) to form at least two transversely adjacent laminates (S', S'') of partial panels (P', P'') having respective partial widths (W', W'') smaller than the overall width (W), the partial panels (P') of each laminate (S') and the adjacent laminates (S'') a laminate in which the partial panels (P'') of the laminate (S', S'') have at least one connecting portion (J) therebetween having a predetermined minimum length (H) for holding the partial panels (P', P'') of the adjacent laminates (S', S'') together, and the at least one longitudinal cut (T) is incomplete such that, due to the at least one connecting portion (J), when the partial panels (P', P'') are released by a pulling action from each adjacent laminate (S', S''), the partial panels (P', P'') are easily separated from each other along the at least one connecting portion (J) while keeping the adjacent laminates (S', S'') aligned, thereby preventing separation along each fold line (C) of the partial panels (P', P'').

2. A laminate as described in claim 1, characterized in that at least one of the connecting portions (J) is positioned in close proximity to at least one of the horizontal folds (C) of each full panel (P).

3. 2. The laminate according to claim 1, characterized in that said at least one longitudinal cut (T) is discontinuous and is formed by a plurality of longitudinally aligned joints (J) for firmly joining said partial panels (P', P'') of said adjacent laminates (S', S'').

4. A laminate as described in claim 1, characterized in that at least one of the connecting portions (J) has a predetermined minimum length (H) in the range of 5 to 20 mm.

5. 2. A laminate according to claim 1, characterized in that it comprises a plurality of longitudinal cuts (T, T', T'', ...) parallel to one another and spaced apart from one another to form respective panels (P', P'', P''', ...) having respective partial widths (W', W'', W''', ...).

6. 2. The laminate according to claim 1, characterized in that the total width (W) is in the range of 400 mm to 3000 mm and the partial widths (W', W'', W''', ...) are in the range of 200 mm to 1500 mm.

7. 10. A method of using a stack (S) of layered materials according to claim 1 in a layered material loading unit of a factory for producing boxes for packaging, said method of using comprising: Step a) placing the laminate (S) on a support surface (G); step b) providing holding means (U) acting on the adjacent stacks (S'', S''', ...) except for the initial stack (S') to hold together all the partial panels (P'', P''', ...) of the adjacent stacks (S'', S''', ...); step c) pulling a first partial panel (P') of the initial stack (S') and breaking at least one of the connections (J) to allow the partial panel (P') of the initial stack (S') to unravel, leaving the partial panels (P'', P''', ...) of the adjacent stacks (S'', S''', ...) held on the support surface (G) and perfectly aligned; A method comprising:

8. Once step c) has been completed on the initial stack (S') and all partial panels (P') of the unsupported stack (S') have been unwound, 8. The method according to claim 7, characterized in that it comprises a step d) of laterally displacing the support surface (G) and the holding means (U) and repeating step c) with the next adjacent stack (S'').

9. 9. The method according to claim 8, characterized in that in step d), the lateral displacement of the support surface (G) occurs in an opposite relative direction to the lateral displacement of the holding means (U).

10. 9. A method according to claim 8, characterized in that step d) comprises providing retaining means (U'', U''', ...) acting on all adjacent stacks (S'', S''', ...) except for the initial stack (S'), and when step c) has been completed on the initial stack (S') and all the partial panels (P') of the unretained stack (S') have been unwound, step d') comprises displacing the support surface (G) laterally to remove one of the retaining means (U'') from the adjacent stack (S'') and repeating step c) on the next adjacent stack (S'').

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