Method for manufacturing containers

Abstract

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

Description

Description Title: Container Manufacturing Process technical field

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

[0002] In a logistics system for order preparation, such as an ASRS (Automatic Storage and Retrieval System), it is common practice to assemble orders into boxes whose size is appropriate for the order—neither too small nor too large. For example, it is common to manufacture cartons of the "American-style box" or RSC (Regular Slotted Container) type, whose width, length, and height are each independently adjusted to properly accommodate the various items that make up an order. Other types of containers are also used, such as Fefco 0406, 0452, or 0453 containers. As an illustration, US document 2020 / 0307140 A1 proposes a method for creating boxes and associated lids, according to the Fefco 0300 standard, with customized lengths, widths, and heights.This packaging philosophy is sometimes called "3D Packing" because the three dimensions of the container can be adjusted as needed. This principle requires the use of complex machines, such as the CVP Impack® or CVP Everest® machines from Sparck Technologies®, the X7, M1, or EM7 machines from Packsize LLC®, the Opera machine from Panotec®, or the CartonWrap® machine from CMC®. US patent documents 2024 / 0092514 A1 and WO patent documents 2020 / 146334 A1 show examples of such machines.

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

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

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

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

[0007] This disclosure improves the situation.

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

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

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

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

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

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

[0014] In this application, height is the vertical dimension of a box in its normal orientation, that is, when the bottom of the box is at the bottom and the opening for filling is at the top. Similarly, for a lid, height is the vertical dimension when the lid is in its normal orientation, for example, covering the box. Width and length are two transverse dimensions of the box or lid; they are perpendicular to the height. The length is longer than the width. In this document, height, width, and length are understood to be the usable dimensions, that is, the internal dimensions of the box or lid, disregarding the material thickness, which is often negligible. It goes without saying that two boxes with the same usable width will also have the same external (overall) width when made from a sheet of the same thickness.The common dimension of the boxes can therefore also be considered as the external width or length of the lid or box.

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

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

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

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

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

[0020] It follows from the above that, for example, if a predetermined dimension of 40 cm is agreed upon for a can production line and a paired lid production line, then each can has either a width or a length (or both) of 40 cm, and each lid has either a width or a length (or both) between 40 cm and 48 cm. If the material thickness is 5 mm and a 1 mm clearance is chosen for the lid mounting on the can, then the common dimension of the lids (usable width or length) can be 40 + 0.5 * 2 + 0.1 * 2 = 41.2 cm. A thicker material and / or a larger clearance will result in a larger common dimension for the lids. In another respect, at the end of the box manufacturing stage, all boxes have the same height. This strategy promotes simplicity in the machines and processes because it eliminates the need to adjust the box size to meet demand, even if it means suboptimizing the container volume.

[0021] Alternatively, at the end of the box manufacturing stage, each box has a height adjusted according to its order. Here, the scale promotes a compact container without unduly complicating the manufacturing process.

[0022] According to another aspect, the box manufacturing stage includes the steps of: feeding a first production line with a sheet; for each box, forming on the sheet two first parallel fold lines, spaced apart by the first dimension common to all boxes, and positioned at equal distances respectively from a first and a second edge of the sheet; for each box, forming on the sheet two second parallel fold lines, spaced apart by the second dimension of the box, the second fold lines being perpendicular to the first fold lines; optionally for each box, cutting the sheet parallel to the second fold lines, so as to obtain a third and a fourth edge such that the second lines are positioned at equal distances respectively from the third and fourth edge;For each box, cut the sheet along four cutting lines that join the intersections of the first and second lines at the first and second edges, or alternately at the third and fourth edges; and for each box, fold the sheet along the first and second fold lines. This technique allows you to obtain boxes of the desired size from simple folding and cutting steps. These "equal distances" form the height of the box.

[0023] In another respect, no cuts are made parallel to the first fold lines. Therefore, the sheet's dimensions perpendicular to the second fold lines remain unchanged for the box pattern, simplifying manufacturing.

[0024] Alternatively, the box manufacturing process includes, for each box, a step of cutting the sheet parallel to the first fold lines and at a distance from the first lines corresponding to the box height, adjusted according to the order for which it is intended. This method minimizes the volume of the containers.

[0025] According to another aspect, the lid manufacturing stage includes the steps of: feeding a second manufacturing line with a sheet; for each lid, forming on the sheet two first parallel fold lines, spaced apart by the first common dimension of the lids, and positioned at equal distances respectively from a first and a second edge of the sheet; for each lid, forming on the sheet two second parallel fold lines, spaced apart by the second dimension of the lid, the second fold lines being perpendicular to the first fold lines; for each lid, cutting the sheet parallel to the second fold lines, so as to obtain a third and a fourth edge such that the second lines are positioned at equal distances respectively from the third and fourth edge;Optionally, for each lid, cut four rectangular notches in the sheet whose sides are parallel to the four edges and whose two vertices, respectively, at each rectangular notch are formed by a point of intersection of the first and second lines and a vertex of the four edges; and; For each lid, fold the sheet along the first and second fold lines. These "equal distances" form the height of the lid.

[0026] It should be noted that the cuts made on the sheet of the box or lid are given above as an example and that other cuts can be considered to allow easy folding of the sheet.

[0027] In another respect, the sheet feeding the first and / or second production line is a continuous sheet wound onto a reel or arranged in accordion-folded panels. This type of feeding allows for optimal adjustment of the box and lid dimensions without the machine needing a complicated device to transfer the sheet to the folding or cutting station.

[0028] In another respect, the sheet feeding the first and / or second production line is a sheet of constant width, measured perpendicular to the first fold lines. This type of raw material conveniently simplifies obtaining patterns of constant width since it is not necessary to cut parallel to the first fold lines. This feeding method is particularly advantageous for the lid, whose height can always be the same regardless of the box height, or for a series of boxes of the same height.

[0029] In an alternative that requires a slightly more complex machine, the sheet feeding the first and / or second production line comes from multiple sources of sheets of identical or different widths, measured perpendicular to the first fold lines. Feeding sheets of different widths optimizes the amount of material used, produces offcuts of useful dimensions for secondary use, or creates flaps, after folding, that give the box / lid varying degrees of rigidity.

[0030] From another perspective, between two successive manufacturing steps, the sheet advances along the first and / or second production line in a direction parallel to the first fold lines of the box and / or lid. Forming folds parallel to the direction of travel, using relatively simple machine components (for example, side guides), ensures that the fold lines are straight and parallel to the edges of the sheet.

[0031] The invention also relates to a method of preparing orders comprising the steps of, for any order: determining the dimensions of a container intended to receive all or part of the order, one of the dimensions of the container being fixed in a predefined manner and independently of the order; manufacturing the container comprising a box and a lid in accordance with one of the methods described above; placing in the box the items comprising all or part of the order; and covering the box with the lid.

[0032] In another aspect, the height of the boxes is adjusted by cutting or folding after the items have been placed in the box.

[0033] In another respect, plans include at least one third production line operating similarly to the first production line and / or at least one fourth production line operating similarly to the second production line. This makes it possible to increase productivity and maximize the technical advantages of compactness with simpler machines.

[0034] In another respect, the process involves using at least one additional production line manufacturing boxes, each additional production line being associated with a common box size. Several of these additional production lines may share the same common box size; or each additional production line may be associated with its own specific size. Thus, it is possible to produce several series of boxes, each series forming a group of boxes sharing a common size. Therefore, the expression "all boxes" can be understood in relation to all the boxes in a series. The series can be evenly distributed over a range of sizes: for example, one production line with a common box size of 5 cm, another with 10 cm, and so on up to 100 cm.Alternatively, the distribution of the number of production lines can be correlated with the demand for boxes of certain dimensions. A bell curve can be used for this: several production lines may have similar values ​​between 20 and 60 cm, while a very small number of production lines may offer boxes with a common dimension below or above this range.

[0035] Similarly, the process may include the use of additional production lines to produce series of lids, all the lids in the same series having a common dimension.

[0036] It is understood that the various examples listed above are conceivable alone or in any combination. Brief description of the drawings

[0037] Other features, details, and advantages will become apparent upon reading the detailed description below and analyzing the attached drawings, on which:

[0038] [Fig. 1] shows a container.

[0039] [Fig. 2] represents a group of containers sharing the same dimension.

[0040] [Fig. 3] describes the successive steps in a box manufacturing process.

[0041] [Fig. 4] illustrates the successive stages of a lid manufacturing process.

[0042] [Fig. 5] details a diagram of a manufacturing process.

[0043] [Fig. 6] shows a diagram of an order preparation process. Description of the implementation methods

[0044] Figure 1 shows a box 10 and a lid 20, together forming a container 30. The box 10 is essentially a parallelepiped, formed of five faces: a base 11 and four walls side walls 12, 13, 14, 15. The lid 20 is parallelepiped and has a ceiling 21 and four side walls 22, 23, 24, 25. The side walls 12-15, 22-25 are flat and parallel in pairs.

[0045] Box 10 has a width of 110, a length of L10 and a height of H10. Lid 20 has a width of I20, a length of L20 and a height of H20.

[0046] The height H20 of the lid 20 may be less than the height H10 of the box 20. For example, the height H20 is less than 30% of H10, or even less than 10% of H10.

[0047] The width I20 and length L20 of lid 20 are slightly greater than the width 110 and length L10 of box 10. For a tight fit, the width I20 (or length L20) will be equal to 110 (or L10) plus twice the material thickness of the lid. The material thickness is the distance between an inner surface and an outer surface of a side wall of the lid. For a fit with some clearance, the width I20 (or L20) will be greater than 110 (or L10) plus twice the material thickness of the lid.

[0048] Box 10 and lid 20 have a rectangular cross-section (in a horizontal plane of cut when the box and lid are in their normal orientation). Other cross-sections can be considered, notably polygonal (triangular, hexagonal, etc.) or rounded (elliptical, circular, etc.). The advantages of compactness and ease of manufacturing obtained with a container of rectangular cross-section can be applied to a container with a different cross-section.

[0049] The box 10 and the lid 20 can be made of the same material. Alternatively, the box 10 and the lid 20 can be made of different materials; for example, the box could be made of a more robust, more rigid material than the lid.

[0050] The box 10 and / or the lid 20 can be obtained by folding and cutting from a continuous feed of a sheet that is either wound or accordion-folded. The sheet can be made of cardboard or other flexible materials, such as synthetic fiber felts (e.g., recycled PET) or natural materials (particleboard or laminated wood, compressed paper, corn starch, animal leather, etc.).

[0051] In one variant, the box 10 and / or the lid 20 can be obtained by assembling panels. In this case, the panels can be made of a rigid (non-flexible) material such as plastics, plywood, or metal. The assembly technique will be adapted to the material in question; for example, assembling wooden panels using nails or staples, assembling metal parts using screws or welding, etc. Indeed, although this application focuses on bending and cutting processes, the benefits described herein (compact container and simplified manufacturing machinery) are also achieved with other materials and manufacturing technologies.

[0052] Figure 2 shows a series of three 30, 30', 30" containers produced by the manufacturing process described above. In this series of containers, all the 10, 10', 10" boxes share A common dimension A exists between the 10 and 10' boxes (and the 20 and 20' lids, respectively), and the 10 and 10' boxes share a common dimension B. This common dimension A (or B) is the width, while each of the 10 and 10' boxes has its own unique length. The 10" box (or the 20" lid) has a length equal to A (or B). The 10" box is also taller than the other 10 and 10' boxes, while the 20, 20', and 20" lids all have the same height.

[0053] According to one variation of the manufacturing process described in this disclosure, the height H10 of each box can be intentionally adjusted. According to a second variation, all boxes share the same height H10.

[0054] Figure 3 illustrates the successive steps in an example of manufacturing a box 10.

[0055] A sheet of 100 (rolled or accordion-folded) feeds into the production line. The sheet is placed on a conveyor (for example, a conveyor belt) which moves it along the X direction. The sheet thus passes through several successive production stations; the numbers 100, 106, 114, 118, 124, and 126 designate the sheet in its successive states.

[0056] The sheet 100 is substantially flat in a plane (X, Y), with two edges 102, 104 parallel to the X axis. It has a width in the Y direction, perpendicular to X, which is denoted Y100.

[0057] In the illustrated example, the sheet has a constant width in the Y direction. Alternatively, in an example not shown but mentioned above, more complex feeding configurations with several types of sheets of varying widths are possible. In one scenario, the boxes have varying heights. Height changes from one box to another can be achieved by folding a flap and / or cutting the box after it has been folded. Alternatively, box height changes can be achieved by feeding the machine with sheets of varying widths (sheet width = box width + 2x height). In a second scenario, all the boxes have the same height. Feeding sheets of the same width is preferred. However, variable sheet widths are possible by folding a flap and / or cutting the box after it has been folded.In both cases, situations not requiring flap folding or cutting allow for the simplest possible machine. Situations requiring flap folding or cutting result in a slightly more complex machine, but not as complex as when all three dimensions of the box are variable.

[0058] Sheet 106 reaches a station where the first two fold lines, 108 and 110, are formed. These lines, 108 and 110, are spaced a distance A apart, which is the common dimension for all boxes. Lines 108 and 110 are equidistant from their respective edges, 102 and 104. This distance can be H10, the height of box 10, or a greater distance than H10. In this case, a height adjustment step can be performed, either by cutting the pattern (before or after folding the box) or by folding the sheet again.

[0059] The 108 and 110 bend lines can be made by punches whose X and Y positions are fixed, which simplifies the machine compared to a machine with punches that must be adjustable to obtain boxes of different dimensions as opposed to the boxes in this disclosure sharing a common dimension A.

[0060] At the next station, two second fold lines, 114 and 116, are formed in sheet 112. These lines, 114 and 116, are parallel to each other and perpendicular to the first lines, 108 and 110. In the illustrated case, these two fold lines are separated by a length L10. In other cases, this distance may be the width 110, with distance A then being the length of the box.

[0061] The intersections of the first and second lines, which will form the corners of the base of the box, are marked C, D, E and F.

[0062] At the next station, sheet 118 is cut parallel to Y, so as to form two edges 120, 122. The edges 120, 122 are spaced from the second rows 114, 116 by the same distance, which can be the height H10 of the box, or another distance which (as for the first rows) will be rectified by cutting or folding.

[0063] In some cases, edge 122 may have been formed by a previous cut. Indeed, edge 122 of sheet 118 may coincide with edge 120 of the immediately preceding sheet 118. If this is the case, in the previous step, the two second fold lines 114, 116 are positioned relative to this edge cut during the passage of the previous sheet 118.

[0064] The intersections of the fold lines with the edges 102, 104, 120, 122 are noted G, H, I, J, K, L, M and N. Figure 3D identifies the elements that will form the base 11, and the side walls 12-15 of the box.

[0065] In order to fold sheet 124 in on itself to form the box, cuts are necessary. In one variation, lines CN, DI, EJ, and FM will be cut as shown in Figure 3E. In a second variation, not shown, lines CG, DH, EK, and FL will be cut.

[0066] In a third variant, the cutouts can be rectangles as shown in connection with the manufacture of the lid in figure 4E.

[0067] Figure 3F shows a sheet 126 being folded along the fold lines to form a box 10. The base 11 and two side walls 12, 13 of the box are annotated for reference.

[0068] The production line uses standard means to apply bend lines (e.g. linear punches) and cuts (cutting rollers, knives, etc.) which do not need to be described in further detail.

[0069] The steps described in figures 3A to 3F are repeated to obtain several boxes sharing the same dimension A along the Y direction, and for which the dimension in X is specific to each box.

[0070] Figure 4 illustrates the successive steps in an example of manufacturing a lid 20.

[0071] A 200-gauge sheet (rolled or accordion-folded) feeds into the production line. The 200-gauge sheet is placed on a conveyor (for example, a conveyor belt) which moves it forward in the direction X. Sheet 200 thus goes through several successive manufacturing stations; the numbers 200, 206, 214, 218, 224 and 226 designate the sheet in its successive states.

[0072] The sheet 200 is substantially flat in a plane (X, Y), with two edges 202, 204 parallel to the X axis. It has a width in the Y direction, perpendicular to X, which is denoted Y200.

[0073] Sheet 206 reaches a station where the first two fold lines, 208 and 210, are formed. These lines, 208 and 210, are spaced a distance B apart, which is the common dimension for all lids. Lines 208 and 210 are equidistant from their respective edges, 202 and 204. This distance can be H20, the height of the lid 20, or a greater distance than H20. In this case, a height adjustment step can be performed, either by cutting the pattern (before or after folding the lid) or by folding the sheet.

[0074] The 208, 210 fold lines can be made by punches whose X and Y position is fixed, which simplifies the machine compared to a machine with punches that must be adjustable to obtain lids of different dimensions as opposed to the lids of this disclosure sharing a common dimension B.

[0075] At the next station, two second fold lines, 214 and 216, are formed in sheet 212. These lines are parallel to each other and perpendicular to the first lines, 208 and 210. In the illustrated case, these two fold lines are separated by a length L20. In other cases, this distance may be the width I20, with distance B then being the length of the lid.

[0076] The intersections of the first and second lines, which will form the corners of the lid's ceiling, are marked C, D, E and F.

[0077] At the next station, sheet 218 is cut parallel to Y, so as to form two edges 220, 222. The edges 220, 222 are spaced from the second rows 214, 216 by the same distance, which can be the height H20 of the lid, or another distance which (as for the first rows) will be rectified by cutting or folding.

[0078] In some cases, edge 222 may have been formed by a previous cut. Indeed, edge 222 of sheet 218 may coincide with edge 220 of the immediately preceding sheet 218. If this is the case, in the previous step, the two second fold lines 214, 216 are positioned relative to this cut edge when the previous sheet 218 is passed through.

[0079] The intersections of the fold lines with the edges 202, 204, 220, 222 are marked G, H, I, J, K, L, M and N. Figure 4D identifies the elements that will form the ceiling 21, and the side walls 22-25 of the lid.

[0080] In order to fold sheet 224 over itself to form the lid, cutouts are necessary. In this example, rectangles CGON, DIPH, EKQJ and FMRL will be cut, where O, P, Q and R are the intersections of edges 202, 204, 220, and 222.

[0081] It is understood that the cutouts shown for the manufacture of the box in relation to figure 3E can be chosen alternatively.

[0082] Figure 4F shows a sheet 226 being folded along the fold lines to form a lid 20. The ceiling 21 and the side walls 22-25 of the lid are annotated for reference.

[0083] The production line uses standard means to apply bend lines (e.g. linear punches) and cuts (cutting rollers, knives, etc.) which do not need to be described in further detail.

[0084] The steps described in Figures 4A to 4F are repeated to obtain several lids sharing the same dimension B along the Y direction, and for which the dimension in X is specific to each lid, according to a corresponding box dedicated to receiving items from an order.

[0085] Figure 5 represents a process 1000 for manufacturing a box and a lid.

[0086] Process 1000 includes a process 1100 for manufacturing the box and a process 1200 for manufacturing the lid.

[0087] As appears from the foregoing and in the attached claims, some steps of the illustrated process may be optional.

[0088] At step 1110, in connection with figure 3A, a sheet feeds a first production line, dedicated to boxes.

[0089] At step 1120, in relation to figure 3B, the first fold lines are made in the sheet. They are parallel and spaced apart by dimension A.

[0090] In step 1130, as shown in Figure 3C, second fold lines are created, parallel and spaced apart by the width or length of the box, depending on what A represents for that particular box. These second fold lines are perpendicular to the first fold lines. Alternatively, the second fold lines (parallel to Y) can be created before forming the first fold lines (parallel to X).

[0091] In step 1140, as shown in Figure 3D, the upstream and downstream edges of the sheet are cut parallel to the second fold lines. The edges and the second fold lines are equidistant from each other. In an alternative, the second fold lines are formed after cutting at least one, or even both, edges.

[0092] In step 1150, in relation to figure 3E, the cuts are made along the second or first fold lines, between the intersections of these lines and the edges.

[0093] At step 1160, in relation to figure 3F, each box is folded along the first and second fold lines.

[0094] Step 1170 is an optional step for leveling the box height. Depending on the sheet size (Y100 in Fig. 3A), it may be necessary to cut the sheet parallel to X to obtain a box height specific to each box. This step 1170 can can be carried out at any point in the process: for example, even before step 1120, or even after filling the box with the order items.

[0095] At step 2110, in connection with figure 4A, a sheet feeds a first production line, dedicated to lids.

[0096] At step 2120, in relation to figure 4B, the first fold lines are made in the sheet. They are parallel to each other and spaced apart by dimension B.

[0097] In step 2130, as shown in Figure 4C, second fold lines are created, parallel and spaced apart by the width or length of the lid, depending on what B represents for that specific lid. These second fold lines are perpendicular to the first fold lines. Alternatively, the second fold lines (parallel to Y) can be created before forming the first fold lines (parallel to X).

[0098] In step 2140, as shown in Figure 4D, the upstream and downstream edges of the sheet are cut parallel to the second fold lines. The edges and the second fold lines are equidistant from each other. In an alternative, the second fold lines are formed after cutting at least one, or even both, edges.

[0099] At step 2150, in connection with figure 4E, the rectangular cutouts are made.

[0100] At step 2160, in relation to figure 4F, each box is folded along the first and second fold lines.

[0101] Step 2170 is an optional step for leveling the lid height. In fact, except in specific cases where the box is very short, the lid height can be kept constant regardless of the box dimensions. If necessary, the lid height can be adjusted in the same way as the boxes in step 1170.

[0102] Figure 6 summarizes a 2000 order preparation process.

[0103] Process 2000 includes a step to determine the dimensions of box 2100. One of the box's dimensions is A (its length or width). The other dimensions (width or length, and possibly height if it is not fixed for all boxes) are calculated so that the box can accommodate the items in the order, possibly taking into account any shock-absorbing material that may be used to protect the items during transport.

[0104] Depending on certain parameters, such as supplier lead times, it may be necessary to fill the box with only part of the order. The lid's dimensions are determined based on those of the box: the width and length of the lid are slightly larger than the width and length of the box, as explained above. The height of the lid can be predetermined and independent of the box's dimensions.

[0105] In the next step (1000), in one variant, the box and its corresponding lid are manufactured, according to the process described above, after the box dimensions have been determined. In another variant, the box and lid are selected from a pool of boxes and lids previously manufactured according to the process described above.

[0106] The items are then placed in the box by an operator or an automated device such as a robotic gripper. A calculation unit (for example, the one that determined the dimensions required for the box) can be used to indicate to the operator the ideal arrangement of the items in the box.

[0107] Optionally, the box can be set to a height of 1170 after the box has been filled.

[0108] Finally, the box is covered with the lid. Fastening methods (hot melt adhesive, staples, etc.) can be used to secure the lid to the box.

[0109] The process may include preliminary steps, namely one or more of the following: making a product catalogue available to a user; the user selecting one or more products to form an order; the user paying for the order; the acquisition and / or transport and / or storage of the items in the order from a supplier; and the confirmation by an operator of the validity of the order.

[0110] The process may also include subsequent steps, such as transporting, storing and / or delivering the container to a user.

[0111] This disclosure has focused on order preparation, but those skilled in the art will understand that the technical advantages described here for manufacturing series of containers extend beyond this single application.

Claims

Demands

1. A method (1000) for manufacturing a plurality of containers (30) each intended to receive all or part of an order of items, each container (30) consisting of a box (10) with a rectangular cross-section and a lid (20) with a rectangular cross-section, the method comprising: - the manufacture of boxes (1,100), such that all boxes (10) have: - a first dimension (110, L10, A) common to all boxes (10) and which constitutes for each box (10) its width (110) or its length (L10), and - a second dimension (110, L10) which constitutes the width or length of each box (10), the second dimension being adjusted for each box (10) according to the order intended for it; and - the manufacture of lids (1200), all lids having: - a first dimension (I20, L20, B) common to all the lids (20) and which constitutes for each lid (20) its width (I20) or its length (L20), and - a second dimension (I20, L20) which constitutes for each lid (20) its width or its length, the second dimension being adjusted for each lid (20), so that each lid (20) can be paired with one of the boxes (10).

2. Method (1000) according to claim 1, wherein at the end of the box manufacturing step (1100), all the boxes (10) have the same height (H10). [Claims] Method (1000) according to claim 1, wherein at the end of the box manufacturing step (1100), each box (10) has a height (H10) adjusted according to the order intended for it.

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

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

6. A method (1000) according to claim 4 in combination with claim 3, wherein the box manufacturing step (1100) comprises, for each box, a step consisting of cutting (1170) the sheet (100, 106, 112, 124) parallel to the first fold lines (108, 110) and at a distance from the first lines (H10) corresponding to the height of the box (H10) adjusted according to the order intended for it.

7. A method according to any one of claims 1 to 6, wherein the lid manufacturing step (1200) comprises the steps of: feeding (1210) a second manufacturing line with a sheet (200); for each lid, forming (1220) on the sheet (206) two first fold lines (208, 210) parallel to each other, spaced apart by the first common dimension of the lids (B), and arranged at equal distances respectively from a first and a second edge of the sheet (202, 204); for each lid, form (1230) on the sheet (212) two second fold lines (214, 216) parallel to each other and spaced apart by the second dimension of the lid (I20, L20), the second fold lines (214, 216) being perpendicular to the first fold lines (208, 210);for each lid, cut (1240) the sheet (218) parallel to the second fold lines (214, 216), so as to obtain a third and a fourth edge (220, 222) such that the second lines (214, 216) are positioned at equal distances (H20) respectively from the third and fourth edge (220, 222); optionally, for each lid, cut (1250) in the sheet (224) four rectangular notches whose sides are parallel to the four edges (202, 204, 220, 222) and whose two respective vertices at each rectangular notch are formed by a point of intersection (C, D, E, F) of the first and second lines and a vertex (O, P, Q, R) of the four edges (202, 204, 220, 222); and; For each lid, fold (1260) the sheet (226) along the first and second fold lines.

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

9. A method (1000) according to any one of claims 4 to 8, wherein the sheet (100, 200) feeding the first and / or second production line is a sheet of constant width (Y100, Y200), measured perpendicular to the first fold lines (108, 110, 208, 210).

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

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

12. Method (1000) according to claim 11, wherein the height (H10) of the box (10) is adjusted by cutting or folding after arranging the articles in the box (10).

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