Process for making a display box starting from a die-cut blank

Abstract

A die-cut blank (1) for making a display box (100) for containing, transporting and displaying products (P); the die-cut blank (1) comprises panels (2, 3, 4, 5, 6) separated by transverse fold lines (T1, T2, T3, T4), in such a way to wrap the products (P) around; the panels have side flaps that are glued to each other; the die-cut blank (1) comprises a tear line (9) disposed in an 5 intermediate position of the die-cut blank, in a substantially parallel direction to the transverse fold lines, in such a way to divide the die-cut blank in a first portion (1a) forming a tray (101) and in a second portion (1b) forming a lid (102) of the box.

Description

[0001] PROCESS FOR MAKING A DISPLAY BOX STARTING FROM A DIE-CUT BLANK

[0002] DESCRIPTION

[0003] The present invention relates to a die-cut blank and to a process for making a display box used to contain, transport and display products, such as food products.

[0004] Display boxes are known in the packaging sector, which comprise a tray whereon the products are disposed and a lid applied onto the tray to close the display box during transportation. Once the display box has reached its final destination, the lid is removed and the products are visible in the tray of the box, which also serves as a display.

[0005] Figs. 1 and 2 illustrate a display box according to the prior art that is comprehensively indicated with reference numeral 200. The display box (200) comprises a tray (201 ) suitable for containing and displaying products (P) and a lid (202) suitable for being removably applied onto the tray. These types of display boxes are widely used in supermarkets so that consumers can see and take the product (P) contained in the tray of the display box.

[0006] Generally speaking, the tray and lid are obtained from two cardboard die-cut blanks using two die-cutting machines that cut the two die-cut blanks in order to obtain the tray and lid.

[0007] Packaging machines are used to obtain a package in which the products (P) are packaged in the box (100). By way of example, such a type of packaging machine is described in EP3409598A1 , in the name of the same applicant.

[0008] Obviously, a packaging machine that handles two different die-cut blanks, respectively for the formation of the tray and of the lid, has a more complicated construction than a packaging machine that handles only one diecut blank.

[0009] US2021 / 0078760 discloses a method for forming a display ready case from a blank. Such a display ready case comprises a tray, in which various products are positioned, and a lid obtained from a portion of die-cut blank that is folded and applied to the tray to close the display ready caseduring transportation. Subsequently, the lid is removed from the tray by tearing along the tear lines of the die-cut blank. In this way, the products are visible in the tray of the box, which therefore acts as display. The process described in the previous document D1 provides for folding the flaps and side panels of the diecut blank so as to entirely form the tray of the display ready case in three- dimensional configuration. Once the tray of the display ready case has been made, such a process provide for positioning the products inside the tray and then folding the other panels of the die-cut blank to form the lid of the display ready case. Therefore, the process described in US2021 / 0078760 provides for completely pre-forming the tray of the display ready case, and then positioning the products inside the tray and finally forming the lid. Such a solution is impaired by some drawbacks due to the difficult folding operation of the walls of the tray, which is carried out without any reference means, and to the difficult positioning of the products inside the already formed tray.

[0010] EP1 177980 discloses a packaging method of products in boxes using a wrap-around packaging machine. Such a method provides for positioning products on a cardboard blank in flat configuration and then folding the panels of the cardboard blank around the products to form the tray and the lid of the box. Therefore, in the process implemented by the packaging machine described in EP1177980, each side panel of the blank is folded after the products have been positioned on the blank. Otherwise said, the side panels of the blank are folded around the products that are already positioned on the blank. Such a process is impaired by some drawbacks due to the fact that the products positioned on the flat blank inevitably tend to move during the transportation of the blank to the folding station, thus losing their correct packaging position.

[0011] The purpose of the present invention is to eliminate the drawbacks of the prior art by providing a process for making a display box that is capable of forming both a tray and a lid of the display box. Another purpose is to provide such a process for making a display box that is versatile so that the die-cut blank can be put into volume and filled by a single packaging machine to obtain a package comprising the box and the products to be displayed.

[0012] These purposes are achieved in accordance with the invention with the features of the attached independent claim 1 .

[0013] Advantageous embodiments of the invention are apparent from the dependent claims.

[0014] Further features of the invention will become clearer from the detailed description below, which refers to a purely exemplary and therefore non-limiting embodiment illustrated in the accompanying drawings, wherein:

[0015] Fig. 1 is an exploded perspective view of a display box according to the prior art;

[0016] Fig. 2 is a perspective view of the display box of Fig. 1 , in assembled condition;

[0017] Fig. 3 is a top view of a die-cut blank used for making a display box with the process according to the invention;

[0018] Fig. 4 is the same view as Fig. 3, after making a tear line in the diecut blank;

[0019] Fig. 4A is an enlarged detail of Fig. 4;

[0020] Fig. 5 is a perspective view illustrating a display box that is put in volume starting from the die-cut blank of Fig. 4;

[0021] Fig. 6 is a perspective view illustrating the display box of Fig. 5 after removing the lid;

[0022] Fig. 7 is a diagrammatic perspective view illustrating a loading process of a display box according to the invention with products stacked one on top of the other;

[0023] Fig. 8 is a perspective view illustrating in greater detail a part of the packaging machine for the implementation of the process of Fig. 7;

[0024] Fig. 9 is a diagrammatic perspective view illustrating a loading process of a display box according to the invention with products in vertical position one next to the other; Fig. 10 is a perspective view illustrating in greater detail a part of the packaging machine for the implementation of the process of Fig. 9.

[0025] Figs. 5 and 6 illustrate a display box obtained with the process according to the invention and comprehensively indicated with reference numeral 100. The box (100) comprises a tray (101 ) suitable for containing products (P) and a lid (102) that covers the products (P).

[0026] The box (100) is obtained starting from a die-cut blank (1 ), for example a cardboard die-cut blank, shown in Figs. 3 and 4.

[0027] Hereinafter, the term “fold line” refers to a pre-crease or cut made on the die-cut blank that allows the die-cut blank to be folded.

[0028] With reference to Fig. 3, the die-cut blank (1 ) has a substantially rectangular shape, with a longitudinal extension greater than a transverse extension.

[0029] The die-cut blank (1 ) comprises:

[0030] - a bottom panel (2),

[0031] - a first side panel (3) and a second side panel (4) connected to the bottom panel (2) by a first transverse fold line (T1 ) and a second transverse fold line (T2), respectively, and

[0032] - at least one top panel (5, 6) connected to the first side panel (3) or to the second side panel (4) by means of at least one transverse fold line (T3, T4).

[0033] In the embodiment shown in Fig. 3, a first top panel (5) and a second top panel (6) are provided and respectively connected to the first side panel (3) and to the second side panel (4) by means of at least a third transverse fold line (T3) and a fourth transverse fold line (T4).

[0034] At least two among the bottom panel (2), the two side panels (3, 4) and the two top panels (5, 6) have side flaps connected to opposite sides of the panel by means of longitudinal fold lines.

[0035] In the embodiment illustrated in Fig. 3, each panel (2, 3, 4, 5, 6) has two side flaps.

[0036] A first and a second side flap (20, 21 ) are connected to the bottom panel (2) by means of respective longitudinal fold lines (L1 , L2). A first and a second side flap (30, 31 ) are connected to the first side panel (3) by means of respective longitudinal fold lines (L3, L4).

[0037] A first and a second side flap (40, 41 ) are connected to the second side panel (4) by means of respective longitudinal fold lines (L5, L6).

[0038] A first and a second side flap (50, 51 ) are connected to the first top panel (5) by means of respective longitudinal fold lines (L7, L8).

[0039] A first and a second side flap (60, 61 ) are connected to the second top panel (6) by means of respective longitudinal fold lines (L9, L10).

[0040] The bottom panel (2), the first side panel (3), and the second side panel (4) have a rectangular shape and are of equal dimensions.

[0041] The first top panel (5) has a substantially square shape. The second top panel (6) has a U-shape.

[0042] The side flaps (20, 21 , 30, 31 ) of the bottom panel (2) and of the first side panel (3) have a rectangular shape and are identical to each other.

[0043] The side flaps (40, 41 ) of the second side panel (4) have a rectangular trapezoidal shape.

[0044] The side flaps (50, 51 ) of the first top panel (5) have a rectangular shape and have a lower transverse extension than the side flaps (20, 21 , 30, 31 ) of the bottom panel and of the first side panel.

[0045] The side flaps (60, 61 ) of the second top panel (6) have a rectangular shape and the same transverse extension as the side flaps (50, 51 ) of the first top panel (5).

[0046] The bottom panel (2) has a hole (22). The side panels (3, 4) and the first top panel (5) have respective slots (32, 42, 52). The second side panel (4) has a notch (43) shaped like a rectangular slot that is disposed at the fourth transverse fold line (T4) that connects the second side panel (4) to the second top panel (6).

[0047] With reference to Fig. 4, the die-cut blank (1 ) comprises a tear line (9) disposed in an intermediate position of the die-cut blank, so as to divide the die-cut blank into a first portion (1 a) and a second portion (1 b). The tear line (9) passes through the bottom panel (2) and the side flaps (20, 21 ), remaining substantially parallel to the first and second transverse fold lines (T1 , T2). The first portion (1 a) of the die-cut blank forms the tray (101 ) of the box suitable for containing the products (P), and the second portion (1 b) of the die-cut blank forms the lid (102) of the box suitable for covering the products (P)-

[0048] Once the die-cut blank has been put in volume, the tear line (9) is suitable for being broken to remove the lid (102) from the tray (101 ).

[0049] The tear line (9) comprises:

[0050] - two side portions (90, 91 ) disposed in an intermediate position along the longitudinal extension of the first and second side flaps (20, 21 ) of the bottom panel (2), and

[0051] - two central portions (92, 93) that converge towards the hole (22) in the bottom panel (2).

[0052] The two side portions (90, 91 ) of the tear line extend parallel to the transverse fold lines (T1 , T2).

[0053] With reference to Fig. 4A, the two central portions (92, 93) of the tear line are inclined by an angle (a) of approximately 2°-10° with respect to the side portions (90, 91 ) of the tear line.

[0054] Hereinafter, a box obtained starting from the die-cut blank (1 ) with the process according to the invention is described.

[0055] The products (P) are arranged in a row on the bottom panel (2) of the die-cut blank (1 ).

[0056] The first side panel (3) is folded along the first transverse fold line (T1 ) in such a way to be positioned anteriorly with respect to the products (P). The second side panel (4) is folded along the second transverse fold line (T2) in such a way to be positioned posteriorly with respect to the products (P). Now the side flaps (30, 31 , 40, 41 ) of the two side panels (3, 4) are folded along respective longitudinal fold lines (L3, L4, L5, L6) in such a way to abut against the products (P) and to be positioned laterally with respect to the products (P). Then, the first top panel (5) is folded along the third transverse fold line (T3) in such a way to be positioned superiorly with respect to the products (P), and the second top panel (6) is folded along the fourth transverse fold line (T4) in such a way to be positioned superiorly with respect to the products (P). In view of the above, the products are wrapped around by the panels (2, 3, 4, 5, 6).

[0057] Now, an adhesive is applied to the side flaps (20, 21 ) of the bottom panel and to the side flaps (50, 51 , 60, 61 ) of the top panels. Finally, the side flaps (20, 21 ) of the bottom panel are glued to the side flaps (30, 31 , 40, 41 ) of the two side panels and the side flaps (50, 51 , 60, 61 ) of the top panels are glued to the side flaps (30, 31 , 40, 41 ) of the two side panels.

[0058] As shown in Fig. 5, the package comprising the box (100) and the products (P) can be transported, preventing the products (P) from falling out of the box (100). It should be noted that, in order to be disposed in vertical position, the box (100) must be rotated by 90° with respect to the loading configuration. In such a case, the bottom wall of the box (100) corresponds to the second side panel (4) of the die-cut blank and the top wall of the box corresponds to the first side panel (3) of the die-cut blank.

[0059] Once the package has reached its final destination, the user can insert his / her hand into the slot (52) of the first top panel and pull the first top panel upwards. As a result, the tear line (9) is broken and the lid (102) consisting of the second portion (1 b) of the die-cut blank is removed from the tray (101 ) consisting of the first portion (1 a) of the die-cut blank, as shown in Fig. 6. In view of the above, the products (P) are contained and displayed in the tray (101 ) consisting of the first portion (1 a) of the die-cut blank, and a user can take a product (P) from the tray (101 ).

[0060] With reference to Fig. 7, a packaging machine (300) used to implement the process according to the invention and make a package containing products (P) is shown schematically. The packaging machine (300) is a monoblock packaging machine, comprising only one machine module, i.e. , a single main frame machine.

[0061] The packaging machine (300) comprises a die-cut blank magazine, a die-cut blank feeding station (301 ), a product feeding station (302), a product positioning station (303), a loading station (304), a gluing station (305), and an unloading station (306). The die-cut blanks (1 ) in flat configuration are stacked one on top of the other in the die-cut blank magazine.

[0062] The die-cut blank feeding station (301 ) has a system of mechanical arms suitable for taking a die-cut blank (1 ) from the die-cut blank magazine and positioning said die-cut blank (1 ) in the loading station (304).

[0063] The product feeding station (302) comprises a conveyor that transports the products (P) in a row to the product positioning station (303) that takes the products (P) and positions them on the die-cut blank (1 ) in the loading station (304).

[0064] In the example shown in Fig. 7, the product positioning station (303) comprises a manipulator (330) suitable for stacking the products (P) one on top of the other to form a stack (S) of products which is positioned on the bottom panel (2) of the die-cut blank (1 ) disposed in the loading station (304).

[0065] With reference also to Fig. 8, the die-cut blank (1 ) in the loading station (304) is partially put in volume by forming means (340, 341 ) that fold at least partially the first side panel (3) and the second side panel (4) along the first transverse fold line (T1 ) and the second transverse fold line (T2).

[0066] Therefore, during the positioning of the products (P) on the bottom panel (2) of the die-cut blank, the two side panels (3, 4) are folded into a three- dimensional configuration with respect to the bottom panel (2). Due to the fact that, during the positioning of the products (P) on the bottom panel (2), the diecut blank is partially put in volume, the products can be held in position on the bottom panel (2) by the side panels (3, 4). Unlike the solution described in EP1177980, such a solution allows for transporting the die-cut blank with the products to the next gluing station (305), thus preventing the products from losing their position, as they abut against the side panels (3, 4) disposed in vertical position of the die-cut blank that act as retaining edges for the products.

[0067] The products (P) can be positioned on the bottom panel (2) of the die-cut blank in vertical position or lying on the side, next to each other, in flat configuration and stacked vertically.

[0068] The partially formed die-cut blank (1 ) with the products (P) disposed on the bottom panel (2), is moved forward on a conveyor (308) towards the gluing station (305). During such a transportation, some side flaps of the panels are folded by means of second forming means, so that they abut against the products (P). Unlike the one described in US2021 / 0078760, because of such a solution, the products (P) act as stop for the side flaps of the panels, thus allowing the side flaps of the panels to be folded correctly, wrapping the products around as in a wrap-around machine.

[0069] In the gluing station (305), glue is applied to preset areas of some side flaps that have not yet been folded, and then the side flaps provided with glue are folded on the side flaps that have already been folded in order to be firmly glued.

[0070] The gluing station (305) comprises guns (350) for applying the glue and clamps (351 ) for holding the side flaps of the die-cut blank in place during gluing.

[0071] Fig. 8 shows a first gluing step in which the side flaps of the bottom panel are glued to the side flaps of the side panels.

[0072] Successively, the first top panel (5) and the second top panel (6) are folded. In such a case, the first top panel (5) has no side flaps. In fact, the side flaps (30, 31 ) of the first side panel (3) have side edges (30', 31 ') that are glued to the first top panel (5). The side flaps (60, 61 ) of the second top panel are glued to the side flaps (40, 41 ) of the second side panel.

[0073] Going back to Fig. 7, finally, the box (100), which is now formed, closed, glued, and filled with products (P), is unloaded from the machine at the unloading station (306). In such a case, the box (100) is turned over so that the second side panel (4) corresponds to the bottom panel (2) of the die-cut blank and the two top panels (5, 6) of the box correspond to the first side panel (3) of the die-cut blank.

[0074] Alternatively, the box (100) may travel forward in the same position in which it exits the packaging machine (300).

[0075] Figs. 9 and 10 illustrate an embodiment in which the manipulator (330) of the positioning station (303) comprises a mechanical arm suitable for taking the products (P) one at a time and positioning them in vertical position side by side on the bottom panel (2) of the die-cut blank (1 ), whose side panels (3, 4) are partially folded. The manipulator (330) may also dispose the products (P) in the die-cut blank in a flat position.

[0076] It should be noted that the steps of forming the die-cut blank, loading the products into the die-cut blank, gluing the die-cut blank, and closing the box obtained from the die-cut blank are all performed in a single monoblock module. Conversely, the packaging machines of the prior art use several separate modules connected to each other by conveyor belts to perform the individual steps of the process.

[0077] Furthermore, in the machines of the prior art, the products are inserted in a box that has already been formed and glued, which is then definitively closed. Conversely, in the present invention, the products are positioned in the semi-formed die-cut blank, without the die-cut blank being glued, i.e., when no part of the die-cut blank has yet been glued.

[0078] Numerous modifications can be made to the present embodiment of the invention, which are within the reach of an expert of the field and fall in any case within the scope of the invention as disclosed by the attached claims..

Claims

CLAIMS1. Process for making a display box for containing, transporting, and displaying products (P) starting from a die-cut blank (1 ); wherein said die-cut blank (1 ) comprises:- a bottom panel (2),- a first side panel (3) and a second side panel (4) connected to the bottom panel (2) respectively by means of a first transverse fold line (T1 ) and a second transverse fold line (T2),- at least one top panel (5, 6) connected to the first side panel (3) or to the second side panel (4) by means of at least one transverse fold line (T3, T4),- side flaps (20, 21 , 30, 31 , 40, 41 , 50, 51 , 60, 61 ) connected to opposite sides of at least two of said panels (2, 3, 4, 5, 6) by means of longitudinal fold lines (L1 , ..., L10), wherein said die-cut blank (1 ) comprises a tear line (9) disposed in an intermediate position of the die-cut blank, substantially parallel to the transverse fold lines, so as to divide the die-cut blank into a first portion (1 a) and a second portion (1 b); wherein the first portion (1 a) of the die-cut blank forms a tray (101 ) of the box suitable for containing the products and the second portion (1 b) of the die-cut blank forms a lid (102) of the box suitable for covering the products; said tear line (9) being suitable for being broken when the die-cut blank is put in volume in order to remove the lid (102) from the tray (101 ). said process comprising the following steps:- feeding a die-cut blank (1 ) in flat configuration from a die-cut blank magazine to a loading station (304) of a packaging machine,- feeding products (P) to a positioning station (303),- positioning the products on the bottom panel (2) of the die-cut blank,- folding the side panels (3, 4) of the die-cut blank along the transverse fold lines (T1 , T2),- folding first side flaps of the die-cut blank,- folding the at least one top panel (5, 6), and- folding and gluing second side flaps on the first side flaps of the die-cut blank in such a way to close the box, characterized in that said step of positioning the products on the bottom panel (2) of the diecut blank is performed between the step of folding the side panels (3, 4) of the die-cut blank along the transverse fold lines (T 1 , T2) and the step of folding the first side flaps of the die-cut blank.

2. The process according to claim 1 , wherein said step of positioning the products on the bottom panel (2) of the die-cut blank is performed when no part of the die-cut blank has yet been glued.

3. The process according to claim 1 or 2, wherein said step of positioning the products on the bottom panel (2) of the die-cut blank is performed by means of a manipulator suitable for stacking the products (P) in such a way to form a stack (S) which is positioned on the bottom panel (2) of the die-cut blank.

4. The process according to claim 1 or 2, wherein said step of positioning the products on the bottom panel (2) of the die-cut blank is performed by means of a mechanical arm that takes the products (P) one by one and positions said products (P) one by one on the bottom panel (2) of the die-cut blank.

5. The process according to any of the preceding claims, wherein the tear line (9) of the die-cut blank comprises:- two side portions (90, 91 ) disposed in an intermediate position along the longitudinal extension of the side flaps (20, 21 ) of the bottom panel and parallel to the transverse fold lines, and- two central portions (93, 94) converging towards the hole (22) of the bottom panel (2) and inclined by an angle (a) of approximately 2°-10° with respect to the side portions (90, 91 ) of the tear line.

6. The process according to any of the preceding claims, wherein said die-cut blank (1 ) comprises a first top panel (5) and a second top panel (6).

7. The process according to claim 6, wherein said bottom panel (2) and said side panels (3, 4) of the die-cut blank have the same rectangular shape and the same dimensions, and the first top panel (5) and the second top panel(6) have a lower longitudinal extension lower than the bottom panel (2), and said second top panel has a U-shape.

8. The process according to any of the preceding claims, wherein each of said panels (2, 3, 4, 5, 6) of the die-cut blank comprises two side flaps.

9. The process according to claim 8, wherein the side flaps (40, 41 ) of the second side panel (4) have a rectangular trapezoidal shape.

10. The process according to any of the preceding claims, wherein all the steps of the process are performed in a monoblock packaging machine comprising only one machine module, i.e., in a main frame machine.

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