Packaging box, packaging box assembly sheet, and method for manufacturing packaging box

Abstract

Provided is a packaging box in which an object to be packaged can be packaged more easily than in conventional packaging boxes.　A packaging box (1) comprises an inner box (10) and an outer box (20). The inner box (10) has an outer flap (15) provided at a peripheral edge portion of an opening (14) of the inner box. The outer box (20) has an inner flap (25) provided at a peripheral edge portion of an opening (24) of the outer box. The inner flap (25) is switched between a first state in which a storage container (2) (object to be packaged) can be gripped and a second state in which the inner flap can be fitted to the outer flap (15) of the inner box (10). In a state in which the outer box (20) covers the storage container (2), the inner flap (25) in the first state contacts the peripheral edge portion of the storage container to hold the storage container. In a state in which the outer box (20) covers the inner box (10), the inner flap (25) in the second state is positioned closer to the bottom wall part side of the inner box than the outer flap (15), and the inner flap and the outer flap abut on each other, thereby fitting the outer box to the inner box.

Description

Packaging box, packaging box assembly sheet, and packaging box manufacturing method

[0001] The present invention relates to a packaging box, a packaging box assembly sheet, and a packaging method for packaging into a packaging box, and more particularly to a packaging box, a packaging box assembly sheet, and a packaging method for packaging into a packaging box used for packaging an item to be packaged.

[0002] Conventionally, pharmaceutical packaging boxes used to package pharmaceutical storage containers (e.g., pharmaceutical vials) in which pharmaceuticals are stored have been known. For example, Patent Document 1 discloses a pharmaceutical packaging container consisting of a lid (outer box) and a main body (inner box). In this packaging container, when the lid (outer box) is placed over the main body (inner box), a first protruding piece (outer flap) at the upper end of the main body and a second protruding piece (inner flap) at the lower end of the lid fit together vertically (sealing function). This allows the lid to be assembled to the main body with a simple operation, enabling the packaging container to be manufactured. Patent Document 2 also discloses a packaging container having a fitting structure similar to that of Patent Document 1, consisting of a lid (outer box) and a main body (inner box).

[0003] JP 2018-12528 A JP 2001-341735 A

[0004] Meanwhile, there has been a demand for a technology that enables packaging of packaged items more easily than before in packaging boxes consisting of a lid portion (outer box) and a main body portion (inner box) as in Patent Documents 1 and 2. In particular, in packaging boxes for packaging pharmaceutical storage containers, there has been a demand for a system that enables workers to complete the packaging work without touching the pharmaceutical storage containers as much as possible, or a system that enables a packaging machine (e.g., a packaging robot) to complete the packaging work quickly and reliably.

[0005] Additionally, when packaging pharmaceutical storage containers containing frozen preparations (frozen liquid preparations), they are shipped in packaging boxes at low temperatures of -30°C to -190°C for stability reasons. In such low-temperature environments, general-purpose adhesives and sealants freeze and cannot be used. Furthermore, low-temperature environments make it difficult to install conventional packaging machines due to factors such as the difficulty in securing a large space, the difficulty in conducting electricity, and / or the tendency of grease to solidify. In other words, packaging work is often performed manually, which poses a risk of frostbite for workers. Therefore, when packaging pharmaceutical storage containers for frozen preparations, there is a need for a system that can be easily completed by workers or small packaging machines.

[0006] An object of the present invention is to provide a packaging box, a packaging box assembling sheet, and a manufacturing method for a packaging box that enable packaging of packaged items more easily than before. Another object of the present invention is to provide a packaging box, a packaging box assembling sheet, and a manufacturing method for a packaging box that enable packaging of pharmaceutical storage containers by workers with minimal contact with the containers, or by packaging machines with simple operations.

[0007] The above problem is solved by a packaging box of the present invention, which is a packaging box used for packaging an item to be packaged, comprising: an inner box that accommodates the item to be packaged; and an outer box that is attached to the inner box so as to cover an opening of the inner box, wherein the inner box has an outer protrusion that is provided on a peripheral portion of the opening of the inner box or on a side wall portion of the inner box and protrudes outward from the side wall portion, and the outer box has an inner protrusion that is provided on a peripheral portion of the opening of the outer box or on a side wall portion of the outer box and protrudes inward from the side wall portion, and the inner protrusion has a first state in which the item to be packaged can be grasped, and a second state in which the item to be packaged can be fitted into the inner box. The problem is solved by the following configuration: the outer box is configured to switch between a first state and a second state, and when placed over the packaged item, the inner protrusion in the first state abuts against the peripheral edge of the packaged item, thereby gripping the packaged item; when placed over the inner box, the inner protrusion in the second state is located closer to the bottom wall of the inner box than the outer protrusion, and the outer protrusion is located closer to the top wall of the outer box than the inner protrusion, and the inner protrusion and the outer protrusion abut in the attachment direction of the outer box, thereby fitting into the inner box. With the above configuration, a packaging box that can package packaged items more easily than conventional can be realized. In more detail, the packaging box has both a "gripping function" and a "sealing function" by having an outer protrusion of the inner box and an inner protrusion of the outer box. Specifically, the inner protrusions are configured to switch between a first state in which they can grip the packaged item and a second state in which they can fit into the inner box. As a "gripping function," when the outer box is placed over the packaged item, the inner protrusions in the first state abut against the peripheral edge of the packaged item, allowing the packaged item to be gripped. As a "sealing function," when the outer box gripping the packaged item is placed over the inner box, the inner protrusions and outer protrusions in the second state abut in the direction in which the outer box is attached, allowing the outer box to be assembled to the inner box.

[0008] In this case, the packaging box is preferably a pharmaceutical packaging box used to package pharmaceutical storage containers in which pharmaceuticals are stored, and the inner box and the outer box are each formed from a single blank sheet. With the above configuration, the packaging box for packaging pharmaceutical storage containers can package the packaged items more easily than before. In particular, the packaging work can be completed with workers touching the pharmaceutical storage containers as little as possible. Furthermore, the packaging machine can complete the packaging work with simple operations. Furthermore, by forming the packaging box from a single blank sheet as described above, a packaging box that is suitable from the perspective of manufacturability (mass production) can be realized.

[0009] In this case, the outer protrusion is an outer flap that is provided on the peripheral portion of the opening of the inner box and is folded back so as to face the outer surface of the side wall of the inner box, and the inner protrusion is an inner flap that is provided on the peripheral portion of the opening of the outer box and is folded back so as to face the inner surface of the side wall of the outer box, and when the outer box is placed over the inner box, the tip of the inner flap in the second state and the tip of the outer flap abut in the attachment direction of the outer box, so that the inner flap abuts or is able to abut against the side wall of the inner box, and the outer flap abuts or is able to abut against the side wall of the outer box. As described above, when the outer box is placed over the inner box, the tip of the inner flap in the second state and the tip of the outer flap abut in the installation direction of the outer box, the inner flap abuts the side wall portion of the inner box, and the outer flap abuts the side wall portion of the outer box, allowing the outer box and inner box to be firmly fitted together with a simple configuration.

[0010] In this case, it is preferable that a plurality of the outer protrusions are formed along the circumferential direction of the inner box, and a plurality of the inner protrusions are formed along the circumferential direction of the outer box, and that the inner protrusions are arranged such that their tips are brought closer to the side wall of the outer box when switched from the first state to the second state. With the above configuration, it is possible to easily switch the inner protrusions when performing the work of placing the outer box over the packaged item and gripping the packaged item, and the work of placing the outer box gripping the packaged item over the inner box and assembling the outer box.

[0011] In this case, when the outer box is placed over the inner box, the inner protrusion abuts against the outer protrusion in the installation direction of the outer box, switching from the first state to the second state, and the inner protrusion in the second state is preferably located closer to the bottom wall of the inner box than the outer protrusion and abuts against an end face or back face of the outer protrusion. This configuration allows smooth operations of gripping the packaged item with the outer box and assembling the outer box with the packaged item gripped to the inner box. In other words, the inner protrusion can be switched (switched from the first state to the second state) during a series of operations.

[0012] In this case, a first cut line for opening the packaging box may be formed in the edge of the side wall of the outer box that is closer to the top wall of the outer box, and a second cut line for opening the packaging box may be formed in the edge of the side wall of the outer box that is closer to the opening of the outer box, the second cut line extending from the peripheral edge of the opening of the outer box along the side wall. With the above configuration, the outer box can be broken using the first or second cut line to remove the packaged item from the inner box. Note that if an attempt is made to remove the packaged item without using the cut line, the inner box will break. This provides a structure that allows visual confirmation of unintentional breaking (has a tamper-evident function).

[0013] Furthermore, the above-mentioned problem can also be solved by the packaging box assembly sheet of the present invention, which is a packaging box assembly sheet that can be assembled into the shape of the above-mentioned packaging box, and which comprises an inner box assembly sheet formed from one blank sheet and that can be assembled into the shape of the inner box, and an outer box assembly sheet formed from one blank sheet and that can be assembled into the shape of the outer box.

[0014] Furthermore, the above-mentioned problem is also solved by a manufacturing method for a packaging box of the present invention, which is a manufacturing method for manufacturing the above-mentioned packaging box, including: a preparation step of preparing the inner box and the outer box; a gripping step of placing the outer box over the packaged item and gripping the packaged item with the outer box; and an assembly step of placing the outer box, with the packaged item gripped, over the inner box, to contain the packaged item in the inner box, and assembling the outer box to the inner box so as to cover an opening of the inner box, wherein in the gripping step, the inner protrusion in the first state abuts against a peripheral portion of the packaged item, thereby gripping the packaged item with the outer box, and in the assembling step, the inner protrusion and the outer protrusion in the second state abut against each other in an attachment direction of the outer box, thereby assembling the outer box to the inner box.

[0015] The packaging box, packaging box assembly sheet, and packaging box manufacturing method of the present invention make it possible to package items more easily than before. Also, it allows workers to package pharmaceutical storage containers with minimal contact, and enables packaging machines to package with simple operations.

[0016] 1 is an exploded perspective view of a packaging box according to the present embodiment;

[0023] FIG. 1 is a view showing the opening of the inner box, outer flaps, the opening of the outer box, and inner flaps;

[0024] FIG. 2 is a view showing a manufacturing method for a first packaging box, showing a state before the outer box is placed over a storage container;

[0025] FIG. 3 is a view showing a state after the outer box has been placed over a storage container;

[0026] FIG. 4 is a view showing a state before the outer box, holding a storage container, is placed over the inner box;

[0027] FIG. 5 is a view showing a state after the outer box has been placed over the inner box;

[0028] FIG. 6 is a view showing a state in which the outer flaps of the inner box and the inner flaps of the outer box are fitted together;

[0029] FIG. 7 is a plan view of an inner box assembling sheet;

[0029] FIG. 8 is a view showing a manufacturing method for a second packaging box, showing a state in which the outer box has been temporarily assembled to the inner box;

[0029] FIG. 9 is a view showing a state in which a storage container is placed in the inner box;

[0029] FIG. 10 is a view showing a state in which the storage container placed in the inner box is covered with the outer box;

[0029] FIG. 11 is a view showing a state in which the outer box has been placed over the inner box, and the outer flaps of the inner box and the inner flaps of the outer box are fitted together;

[0029] FIG. 12 is a perspective view of a packaging box according to a second embodiment;

[0029] FIG. 13 is a plan view of an inner box assembling sheet according to the second embodiment; 10A and 10B are plan views of an outer box assembly sheet according to a second embodiment, an inner box assembly sheet according to a third embodiment, and an outer box assembly sheet according to a third embodiment.

[0017] Hereinafter, an embodiment of the present invention will be described with reference to Figures 1 to 18. This embodiment relates to a "packaging box" that enables a worker to package items (medicine storage containers) without touching them as much as possible and that enables a packaging machine (e.g., a packaging robot) to package them with simple operations. The embodiment also relates to a "packaging box assembly sheet" and a "packaging box manufacturing method."

[0018] <Overview of Packaging Box> As shown in FIGS. 1 to 7 , the packaging box 1 of this embodiment is used to package a storage container 2. It is a roughly rectangular box (a pharmaceutical packaging box) for housing the storage container 2 and is formed from a single blank sheet. Specifically, the packaging box 1 is a two-piece pharmaceutical packaging box composed of an inner box 10 and an outer box 20. The packaging box 1 is formed into the shape shown in FIGS. 1 and 2 by folding and assembling a "box assembly sheet 101" formed by punching out a single blank sheet. More specifically, the packaging box 1 is formed by assembling an "inner box assembly sheet 110" shown in FIG. 8 and an "outer box assembly sheet 120" shown in FIG. 9 to form a "two-piece packaging box primary assembly" shown in FIG. 1 . The storage container 2 is then housed in this primary assembly, and the primary assembly (inner box, outer box) is assembled to complete the box. The "primary assembly of the packaging box" shown in FIG. 1 may also be referred to as a "packaging box before assembly (before assembly is completed)."

[0019] The term "packaging box" includes not only "packaging box after assembly (after assembly is completed)" but also "packaging box before assembly (before assembly is completed)" shown in Fig. 1. The "packaging box before assembly" shown in Fig. 1 can be folded into a substantially flat shape as a primary assembly of the packaging box for transport or storage, and the user (for example, a pharmaceutical manufacturer or seller) can perform final assembly to complete the packaging box.

[0020] The packaging box 1 is designed to allow for easy packaging of the storage containers 2, and is a two-piece packaging box that combines a "grasping function" and a "sealing function." As shown in FIGS. 3 to 7 , the packaging box 1 has a "grasping function" in which the storage containers 2 can be gripped by placing the outer box 20 over the storage containers 2. Furthermore, the packaging box 1 has a "sealing function" in which the outer box 20 gripping the storage containers 2 is placed over the inner box 10, allowing the outer box 20 to be assembled to the inner box 10. This allows for packaging of the storage containers 2 without the worker having to touch them, or allows packaging machines to package them with a simple operation. Details will be described later.

[0021] The storage container 2 is a pharmaceutical storage container in which a pharmaceutical is stored. Examples include pharmaceutical vials and pharmaceutical ampoules. When packaging pharmaceutical storage containers, particularly pharmaceutical storage containers that store frozen preparations, packaging is performed in a low-temperature environment from the perspective of stability. In low-temperature environments, work is often performed in a small space, making it difficult to install conventional packaging machines. For this reason, the packaging box 1, which allows packaging with simple operations, is suitable for packaging pharmaceutical storage containers, particularly those that store frozen preparations. Of course, the storage container 2 is not particularly limited to pharmaceutical storage containers, and may be a storage container for food or beverages, or may be any other storage container.

[0022] <Details of Packaging Box> As shown in Figures 1 to 7, the packaging box 1 is a two-piece packaging box and includes an inner box 10 that houses the storage container 2, and an outer box 20 that is attached to the inner box 10 so as to cover the opening of the inner box 10. A storage space capable of housing the storage container 2 is formed in the inner box 10. A storage space capable of housing (covering) the storage container 2 and the inner box 10 is formed in the outer box 20. The inner box 10 may be referred to as the "main body" and the outer box 20 as the "lid".

[0023] As shown in Figures 1 and 2, the inner box 10 is a box having an opening 11 at its top. The inner box 10 has side walls 12 (12a to 12d) formed in a rectangular cylindrical shape, a bottom wall 13 and a lower flap 14 provided at the lower end of the side wall 12 and formed by folding inward the boundary line between the side wall 12 and the bottom wall 13, and an outer flap 15 provided at the upper end of the side wall 12 and formed by folding outward the boundary line between the side wall 12 and the bottom wall 13. The side walls 12a, 12b, 12c, and 12d correspond to the "box body."

[0024] The outer flaps 15 are provided around the periphery of the opening 11 of the inner box 10. They are folded back flaps that face the outer surfaces of the side walls 12 and protrude outward from the side walls 12. The outer flaps 15 are also referred to as "outer protrusions." A plurality of outer flaps 15 are formed along the circumferential direction (outer peripheral direction) of the inner box 10. More specifically, the outer flaps 15 include a first outer flap 15a connected to the end of the first side wall 12a, a second outer flap 15b connected to the end of the second side wall 12b, and a third outer flap 15c connected to the end of the third side wall 12c. The first outer flap 15a, the second outer flap 15b, and the third outer flap 15c are integrally connected.

[0025] A dashed cut line 16 is formed at the boundary between the side wall portion 12 and the outer flap 15 to make it easier to fold the outer flap 15. Furthermore, substantially triangular notches 17 are formed at both longitudinal ends of the boundary line (see FIG. 8 for details). Furthermore, a substantially circular (or diamond-shaped) fold hole 18 is formed at the boundary between each of the outer flaps 15a, 15b, and 15c. This makes it easier to fold each of the outer flaps 15a, 15b, and 15c and to overlap them on the outer surfaces of the side wall portions 12a, 12b, and 12c.

[0026] A flap insertion opening 19 extending in the width direction of the side wall portion 12 is formed on the side surface of the outer flap 15 (first outer flap 15a). As shown in Figures 10 and 11, the flap insertion opening 19 allows the inner flap 25 of the outer box 20 to be inserted into it using a second assembly method (manufacturing method). More specifically, the flap insertion opening 19 has a first cut line 19a extending linearly, a pair of second cut lines 19b extending in a direction intersecting each other from both ends of the first cut line 19a, and a guide hole 19c formed adjacent to the first cut line 19a. The guide hole 19c is a substantially semicircular through-hole that facilitates insertion of the inner flap 25 of the outer box 20.

[0027] 1 and 2, the outer box 20 is a box having an opening 21 at its bottom. The outer box 20 has side walls 22 (22a to 22d) formed in a rectangular cylindrical shape, a top wall 23 and an upper flap 24 provided at the upper end of the side wall 22 and formed by folding inward the boundary line between the side wall 22, and an inner flap 25 provided at the lower end of the side wall 22 and formed by folding inward the boundary line between the side wall 22. The side walls 22a, 22b, 22c, and 22d correspond to the "box body."

[0028] The top wall 23 corresponds to the lid of the outer box 20 and is connected to the end of the first side wall 22a. A convex insertion protrusion 23a is formed at the extended end of the top wall 23. Of the multiple upper flaps 24, an insertion groove 24a is formed on the side of the upper flap connected to the end of the fourth side wall 22d (see FIG. 9 for details). When sealing the outer box 20, the insertion protrusion 23a is inserted into the insertion groove 24a. Strictly speaking, the insertion protrusion 23a is inserted into the insertion groove 24a by folding the insertion protrusion 23a inward relative to the top wall 23. The insertion protrusion 23a is then sealed as necessary. Note that when sealing the outer box 20, instead of inserting the insertion protrusion 23a into the insertion groove 24a, the top wall 23 and the upper flaps 24 may simply be bonded together with an adhesive (adhesive). In this case, the insertion protrusion 23a may or may not be inserted into the insertion groove 24a. If the top wall 23 and the upper flap 24 are attached with an adhesive (pressure-sensitive adhesive), the insertion protrusion 23a and the insertion groove 24a may not be necessary. For example, if the work is done mechanically rather than manually, they may simply be attached with an adhesive (pressure-sensitive adhesive).

[0029] The inner flaps 25 are provided around the periphery of the opening 21 of the outer box 20. They are folded back flaps that face the inner surfaces of the side walls 22 and protrude inward from the side walls 22. The inner flaps 25 are also referred to as "inner protrusions." A plurality of inner flaps 25 are formed along the circumferential direction (inner circumferential direction) of the outer box 20. Specifically, the inner flaps 25 include a first inner flap 25a connected to the end of the first side wall 22a, a second inner flap 25b connected to the end of the second side wall 22b, a third inner flap 25c connected to the end of the third side wall 22c, and a fourth inner flap 25d connected to the end of the fourth side wall 22d. The first inner flap 25a, the second inner flap 25b, the third inner flap 25c, and the fourth inner flap 25d are spaced apart from one another.

[0030] A first incision line 26 for opening the packaging box 1 (outer box 20) is formed in an end portion of the side wall portion 22 (first side wall portion 22a) on the top wall portion 23 side. Second incision lines 27, 28 for opening the packaging box 1 are formed in end portions of the side wall portion 22 (first side wall portion 22a, third side wall portion 22c) on the opening 21 side. The first incision line 26 is a substantially semicircular (semi-elliptical) breaking line that extends along the side wall portion 22 from the boundary line between the side wall portion 22 and the top wall portion 23. The second incision lines 27, 28 are also substantially semicircular (semi-elliptical) breaking lines that extend along the side wall portion 22 from the boundary line between the side wall portion 22 and the inner flap 25 (the peripheral edge of the opening 21). The cut lines 26, 27, and 28 may be substantially triangular or substantially rectangular.

[0031] In the packaging box 1, the top wall 23 (lid) can be easily opened by pressing a finger along the first cut line 26 to form an opening, and the storage container 2 can be removed from the opened top wall 23. In addition, in the packaging box 1, the inner box 10 and the outer box 20 can be disassembled and opened by pressing a finger along the second cut lines 27, 28 to form an opening, and the storage container 2 can be removed from the opening 11 of the inner box 10. Note that while it is preferable to open the packaging box 1 using the first cut line 26, it is also possible to open the packaging box 1 by disassembling the inner box 10 and the outer box 20 using the second cut lines 27, 28.

[0032] In the above configuration, as shown in FIGS. 3 to 6 , the inner flaps 25 are configured to switch between a "first state (grasping state)" in which the storage container 2 can be grasped and a "second state (fitting state)" in which the storage container 2 can be fitted into the inner box 10. When the inner flaps 25 (25a to 25d) switch from the "first state" shown in FIG. 5 to the "second state" shown in FIG. 6 , the leading ends of the inner flaps 25 are positioned in a state where they are close to the side wall 22 of the outer box 20. More specifically, the inner flaps 25 are folded back so as to overlap the side wall 22. In other words, the inner flaps 25 are in a state where they cannot grasp the storage container 2 in the "second state." Note that FIG. 2 is a diagram showing the opening 21 of the outer box 20, as viewed from below. 2, the inner flaps 25a to 25d are arranged to partially overlap one another in the "first state," i.e., before being placed on the storage container 2 or the inner box 10. An opening 21 is formed in the center of the bottom of the outer box 20.

[0033] <Manufacturing Method 1 for Packaging Box> Next, a specific manufacturing method for the packaging box 1 using the inner flap 25 and the outer flap 15 will be described with reference to FIGS. 3 to 7. This method includes at least a "preparation step" of preparing the inner box 10 and the outer box 20, a "holding step" of holding the storage container 2 with the outer box 20, and an "assembly step" of covering the inner box 10 with the outer box 20 holding the storage container 2, and assembling the outer box 20 to the inner box 10. A detailed description will be given below. Details other than those described above regarding packaging the storage container 2 using the packaging box 1 will not be described here. Furthermore, although the work is described as being performed by a worker, the work may also be performed by a packaging machine (e.g., a packaging robot).

[0034] In the "preparation step," first, a worker prepares the inner box 10, the outer box 20, and the storage container 2. Specifically, the worker prepares the inner box 10 assembled from the inner box assembly sheet 110 shown in Fig. 8, and the outer box 20 assembled from the outer box assembly sheet 120 shown in Fig. 9. The worker also prepares the storage container 2 in which medicines and the like are stored.

[0035] In the "gripping step," as shown in FIGS. 3 and 4 , a worker places the outer box 20 over the storage container 2 from above and grips the storage container 2 with the outer box 20. Specifically, when the outer box 20 is placed over the storage container 2, the inner flaps 25 in the "first state" abut from the sides against the neck portion 2a (peripheral portion) of the storage container 2, thereby gripping the storage container 2. More specifically, the leading ends of the first inner flap 25a, the second inner flap 25b, the third inner flap 25c, and the fourth inner flap 25d protrude inward from the side wall portion 22 and hook onto the neck portion 2a of the storage container 2. It is preferable to fold the outer box 20 at the boundary (boundary line) between the side wall portion 22 and the inner flaps 25 so that the inner flaps 25 are maintained (retained) in the "first state." That is, it is preferable to assemble the inner flaps 25 so that they protrude inward from the side wall portions 22, or to fold the inner flaps.

[0036] In the "assembly process," as shown in Figures 5 and 6 , a worker places the outer box 20, holding the storage container 2, over the inner box 10, accommodates the storage container 2 in the inner box 10, and assembles the outer box 20 to the inner box 10. When the outer box 20 is placed over the inner box 10, the inner flaps 25 abut against the outer flaps 15 in the attachment direction of the outer box 20, thereby switching from the "first state" to the "second state." In the "second state," the inner flaps 25 are positioned closer to the bottom wall 13 of the inner box 10 than the outer flaps 15 and abut against the end faces of the outer flaps 15. In other words, the outer flaps 15 are positioned closer to the top wall 23 of the outer box 20 than the inner flaps 25 and abut against the end faces of the inner flaps 25.

[0037] 7 , when the outer box 20 is placed over the inner box 10, the leading edge of the inner flap 25 in the "second state" abuts against the leading edge of the outer flap 15 in the vertical direction. The inner flap 25 abuts against the side wall 12 of the inner box 10, and the outer flap 15 abuts against the side wall 22 of the outer box 20. The above-described fitting structure allows the outer box 20 to be stably assembled to the inner box 10.

[0038] 2 and 6, the three outer flaps 15a, 15b, and 15c are fitted to the three inner flaps 25a, 25b, and 25c. By fitting the multiple inner flaps 25 and outer flaps 15 together in this manner, the outer box 20 can be stably assembled to the inner box 10.

[0039] The above manufacturing method makes it possible to manufacture a packaging box that allows a worker to pack the storage container 2 with minimal contact, or that allows a packaging machine to pack with a simple operation.

[0040] <Packaging Box Assembly Sheet> Next, the box assembling sheet 101 (packaging box assembling sheet) will be described with reference to Figures 8 and 9. The box assembling sheet 101 is made up of an "inner box assembling sheet 110" shown in Figure 8 and an "outer box assembling sheet 120" shown in Figure 9. By assembling the inner box assembling sheet 110 and the outer box assembling sheet 120, respectively, a "primary assembly of the packaging box 1 (inner box 10, outer box 20)" is formed. Then, by placing a storage container 2 in this primary assembly, a "finished product of the packaging box 1" is manufactured.

[0041] When assembling the inner box 10, the lower flaps 14 and bottom wall 13 of the inner box assembly sheet 110 are folded inward in that order, and the outer flaps 15 are also folded outward, completing the inner box 10 shown in FIG. 1 . At this time, the outer flaps 15 of the inner box 10 are in the state shown in FIG. 2 . The lower flaps 14 and bottom wall 13 may be bonded together, or the side walls 12 and outer flaps 15 may be bonded together. The same applies to the outer box 20. The upper flaps 24 and top wall 23 of the outer box assembly sheet 120 are folded inward in that order, and the inner flaps 25 are also folded inward, completing the outer box 20 shown in FIG. 1 . At this time, the inner flaps 25 of the outer box 20 are in the state shown in FIG. 2 (first state). The upper flaps 24 and top wall 23 may be bonded together.

[0042] Specifically, the inner box assembly sheet 110 includes side walls 12a to 12d that form a cylindrical box body, a bottom wall 13 that extends continuously from one longitudinal end of the box body and is folded against the box body to form a lid, a lower flap 14, and outer flaps 15a to 15c that extend continuously from the other longitudinal end of the box body and are folded against the box body. In addition, a dashed cut line 16 is formed in the inner box assembly sheet 110 along the boundary between the side walls 12 and the outer flaps 15, and approximately triangular cutouts 17 are formed at both longitudinal ends of the boundary. Furthermore, fold holes 18 are formed along the boundary between each of the outer flaps 15a, 15b, and 15c, and a flap insertion opening 19 is formed on the side of the first outer flap 15a.

[0043] The outer box assembly sheet 120 includes side walls 22a-22d that form a cylindrical box body, a top wall 23 and upper flaps 24 that extend continuously from one longitudinal end of the box body and form a lid by being folded against the box body, and inner flaps 25a-25d that extend continuously from the other longitudinal end of the box body and are folded against the box body. A convex insertion protrusion 23a is formed at the extending end of the top wall 23, and an insertion groove 24a is formed on the side of a predetermined upper flap 24. In addition, a first cut line 26 for opening is formed at one end of the side wall 22 (first side wall 22a) of the outer box assembly sheet 120, and second cut lines 27 and 28 for opening are formed at the other end of the side wall 22 (first side wall 22a, third side wall 22c).

[0044] The inner box 10 and outer box 20 shown in Fig. 1 can be manufactured by folding the inner box assembly sheet 110 and the outer box assembly sheet 120 and assembling them by bonding predetermined locations with an adhesive. Then, the packaging box 1 can be manufactured by assembling the inner box 10 and the outer box 20.

[0045] <Manufacturing Method 2 for Packaging Box> The packaging box 1 can also be manufactured by a manufacturing method based on Figures 10 to 13. This method includes at least a "preparation step" of preparing the inner box 10 and the outer box 20, a "temporary assembly step" of temporarily assembling the outer box 20 to the inner box 10, a "storage step" of accommodating the storage container 2 in the inner box 10, and an "assembly step" of covering the outer box 20 on the inner box 10 and assembling the outer box 20 to the inner box 10. This will be described in detail below. Note that although the work is performed by a worker, the work may also be performed by a packaging machine (for example, a packaging robot).

[0046] In the "preparation step," first, a worker prepares the inner box 10, the outer box 20, and the storage container 2. Specifically, the worker prepares the inner box 10 assembled from the inner box assembly sheet 110 shown in Fig. 8, and prepares the outer box 20 assembled from the outer box assembly sheet 120 shown in Fig. 9.

[0047] In the "temporary assembly process," a worker temporarily assembles the outer box 20 to the inner box 10, as shown in FIG. 10 . Specifically, the worker vertically inserts the inner flap 25 (first inner flap 25a) of the outer box 20 into the flap insertion opening 19 formed in the outer flap 15 (first outer flap 15a) of the inner box 10. Then, the worker places the outer box 20 in a connected state on the side of the inner box 10. At this time, the worker inserts the inner flap 25 into the flap insertion opening 19 from below, and sandwiches the inner flap 25 of the outer box 20 between the side wall portion 12 and the outer flap 15 of the inner box 10. This allows the outer box 20 to be held with the opening 21 (bottom) of the outer box 20 facing the inner box 10.

[0048] In the "accommodation step," a worker accommodates the storage container 2 in the inner box 10, as shown in Figures 10 and 11. Specifically, the worker accommodates the storage container 2 inside the inner box 10 from above, with the outer box 20 temporarily assembled to the side of the inner box 10.

[0049] In the "assembly process," a worker places the outer box 20 over the inner box 10 and assembles the outer box 20 to the inner box 10, as shown in FIGS. 11 to 13 . Specifically, as shown in FIGS. 11 and 12 , the worker rotates the outer box 20 relative to the inner box 10 so that it stands upright, and places the outer box 20 over the inner box 10. In other words, with the outer box 20 temporarily assembled to the inner box 10, the worker moves the outer box 20 so as to draw the inner flaps 25 into the outer box 20 (so as to fold the inner flaps 25). When the outer box 20 is erected, the outer box 20 covers the inner box 10 and the storage container 2 from above, as shown in FIG. 12 .

[0050] Then, as shown in FIG. 13 , the worker assembles the outer box 20 to the inner box 10 by pushing the outer box 20 from above toward the inner box 10 (by moving the outer box 20 downward). When the outer box 20 is pushed in, as shown in FIG. 13 , the inner flaps 25 (strictly speaking, the inner flaps 25b and 25c) abut against the outer flaps 15 in the installation direction of the outer box 20, switching from the "first state" to the "second state." Note that the inner flap 25a has already switched to the "second state" when inserted into the flap insertion port 19. In the "second state," the inner flaps 25a, 25b, and 25c are positioned closer to the bottom of the inner box 10 than the outer flaps 15 and abut against the end faces of the outer flaps 15. In other words, the outer flaps 15 and the inner flaps 25 are fitted together in the vertical direction. This allows the outer box 20 to be assembled to the inner box 10.

[0051] The manufacturing method 2 also makes it possible to manufacture a packaging box 1 that can easily package the storage containers 2. In the case of the manufacturing method 2, it is preferable to use a packaging machine to manufacture the packaging box 1. That is, it is preferable for the packaging machine (e.g., a packaging robot) to grasp the storage containers 2 and place them in the inner box 10.

[0052] <Second Embodiment of Packaging Box> Next, a second embodiment of the packaging box 1 will be described with reference to Figures 14 to 16. Note that descriptions of the contents that overlap with the packaging box 1 of the first embodiment described above will be omitted.

[0053] The packaging box 1S of the second embodiment is a packaging box for packaging a storage container 2S. The storage container 2S is a medicine storage container (medicinal vial) with a smaller capacity than the storage container 2. For example, the storage container 2 is a 10 mL pharmaceutical vial (e.g., 24 mm in diameter), and the storage container 2S is a 2 mL pharmaceutical vial (e.g., 14.75 mm in diameter).

[0054] The packaging box 1S includes an inner box 10S and an outer box 20S. The inner box 10S has an opening 11S, side walls 12S, a bottom wall 13S, a lower flap 14S, an outer flap 15S, and a grip flap 30S. The outer box 20S has an opening 21S, side walls 22S, a top wall 23S, an upper flap 24S, and an inner flap 25S.

[0055] As shown in FIG. 14 , the gripping flap 30S grips the neck portion 2Sa of the storage container 2S. It extends from the upper end of the side wall 12S (fourth side wall 12Sd) and is formed by folding back the boundary line between the side wall 12S and the gripping flap 30S inward. The gripping flap 30S extends inward from the upper end of the side wall 12S and can grip the storage container 2S contained inside the inner box 10S. A notch is formed on the extended end of the gripping flap 30S near the base end of the gripping flap 30S, forming a recessed portion 31S that can hold the storage container 2S. In addition, a dashed cut line 32S is formed at the boundary line between the side wall 22S and the gripping flap 30S. This makes the gripping flap 30S easier to fold and allows it to bend easily.

[0056] The gripping flaps 30S are arranged to bend vertically relative to the side wall portions 12S. Therefore, when the outer box 20S holding the storage container 2S is placed over the inner box 10S from above, the gripping flaps 30S are initially pressed down by the bottom of the storage container 2S, but then rise again to grip the neck portion 2Sa of the storage container 2S, as shown in Fig. 14. This makes it possible to manufacture the packaging box 1S in the same manner as manufacturing method 1 shown in Figs. 3 to 7 described above.

[0057] Fig. 15 is a plan view of the inner box assembly sheet 110S. Fig. 16 is a plan view of the outer box assembly sheet 120S. The box assembling sheet 101S is composed of the "inner box assembling sheet 110S" shown in Fig. 15 and the "outer box assembling sheet 120S" shown in Fig. 16. As described above, the inner box 10S and outer box 20S shown in Fig. 14 can be manufactured by folding the inner box assembling sheet 110S and the outer box assembling sheet 120S and bonding them at predetermined locations with adhesive. Then, the inner box 10S and the outer box 20S can be assembled to manufacture the packaging box 1S.

[0058] <Third embodiment of packaging box> Next, a third embodiment of the packaging box 1 will be described with reference to Fig. 17 and Fig. 18. Note that descriptions of the contents that overlap with the packaging boxes 1 and 1S of the first and second embodiments described above will be omitted.

[0059] The packaging box 1V of the third embodiment is a packaging box for packaging, for example, a 2 mL capacity pharmaceutical vial (storage container 2V). The packaging box 1V has a shape similar to that of the packaging box 1S of the second embodiment shown in Fig. 15 and includes an inner box 10V and an outer box 20V.

[0060] 17, the inner box 10V has an opening, side walls 12V, a bottom wall 13V, a lower flap 14V, an outer flap 15V, and a gripping flap 30V. The inner box 10V also has an engagement groove 15Va formed on the side edge of the outer flap 15V, and an engagement flap 13Va (engagement protrusion 13Vb) provided at the tip of the bottom wall 13V. Note that the inner box 10V does not necessarily have to have the gripping flap 30V.

[0061] When the inner box 10V is assembled, the outer flap 15V is folded outward along the boundary line between it and the side wall 12V, contacting the outer surface of the side wall 12V. The engaging flap 13Va is folded inward along the boundary line between it and the bottom wall 13V, contacting the outer surface of the side wall 12V. In this state, the engaging protrusion 13Vb (engaging portion) and the engaging groove 15Va (engaged portion) are located on the outer surface of the same side wall 12V and engage with each other on the outer surface of the side wall 12V. Engaging the engaging protrusion 13Vb and the engaging groove 15Va makes it easier to assemble the inner box 10V and increases the strength of the inner box 10V. Furthermore, the outer flap 15V of the inner box 10V and the inner flap 25V of the outer box 20V can be more appropriately fitted together (improving the sealing function).

[0062] 18, the outer box 20V has an opening, side walls 22V, a top wall 23V, an upper flap 24V, and an inner flap 25V. The outer box 20V also has an insertion protrusion 23Va (insertion portion) provided at the tip of the top wall 23V, and an insertion groove 22Va (inserted portion) formed in the side wall 22V (22VA).

[0063] When the outer box 20V is assembled, the insertion protrusion 23Va is inserted into the insertion groove 22Va. This makes it easier to assemble the outer box 20V and increases its strength. When the inner flap 25VA connected to the side wall 22VA having the insertion groove 22Va is folded inward along the boundary line between the side wall 22VA and the inner flap 25VA, the insertion protrusion 23Va is also folded inward at the same time. That is, since the inner flap 25Va and the insertion protrusion 23Va are positioned in an overlapping position, when the inner flap 25Va is folded inward, the insertion protrusion 23Va is also folded inward accordingly. By combining the inner box 10V and the outer box 20V in this state, the outer flap 15V of the inner box 10V and the inner flap 25V (25Va) of the outer box 20V can be more appropriately fitted together (enhancing the sealing function).

[0064] The box assembling sheet 101V is composed of an "inner box assembling sheet 110V" shown in Fig. 17 and an "outer box assembling sheet 120V" shown in Fig. 18. As described above, the inner box 10V and outer box 20V can be manufactured by folding the inner box assembling sheet 110V and outer box assembling sheet 120V and bonding them at predetermined locations with adhesive. Then, the inner box 10V and outer box 20V can be assembled to manufacture the packaging box 1V.

[0065] 1 and 2, the packaging box 1 (inner box 10, outer box 20) is a rectangular parallelepiped box, but this is not particularly limited and can be changed, and may be, for example, a substantially cylindrical shape or a substantially triangular prism shape (substantially polygonal shape), etc. In other words, the box bodies of the inner box 10 and the outer box 20 may be cylindrical (hollow circular) or other cylindrical (hollow) shapes instead of square tubular (hollow rectangular) shapes.

[0066] In the above embodiment, as shown in Figures 5 to 7, the outer flaps 15 protrude inward from the peripheral portion of the opening 11 of the inner box 10, but they may also protrude inward from the side wall 12 of the inner box 10. That is, they may be formed as outer protrusions rather than outer flaps. Also, the inner flaps 25 protrude inward from the peripheral portion of the opening 21 of the outer box 20, but they may also protrude inward from the side wall 22 of the outer box 20. That is, they may be formed as inner protrusions rather than inner flaps.

[0067] In the above embodiment, as shown in Figures 6 and 7, the outer flaps 15 abut against the side wall portions 22 of the outer box 20, but this is not limited to abutting against the side wall portions 22 of the outer box 20 and may be in a state where they can abut against the side wall portions 22 of the outer box 20. Alternatively, they may not abut against the side wall portions 12 of the inner box 10. Similarly, the inner flaps 25 abut against the side wall portions 12 of the inner box 10, but this is not limited to abutting against the side wall portions 12 of the inner box 10 and may be in a state where they can abut against the side wall portions 12 of the inner box 10. Alternatively, they may not abut against the side wall portions 12 of the inner box 10.

[0068] 6 and 7, in the above embodiment, the outer flap 15 abuts against the end surface of the inner flap 25, but it may also abut against the back surface of the inner flap 25. Similarly, the inner flap 25 abuts against the end surface of the outer flap 15, but it may also abut against the back surface of the outer flap 15.

[0069] 1 and 2, in the above embodiment, a plurality of outer flaps 15 are formed along the outer periphery of the inner box 10, but there may be only one outer flap 15. Similarly, a plurality of inner flaps 25 are formed along the outer periphery of the outer box 20, but there may be only one inner flap 25.

[0070] In this embodiment, the packaging box, packaging box assembly sheet, and packaging method for packaging boxes according to the present invention have been mainly described. However, the above embodiment is merely an example for facilitating understanding of the present invention and does not limit the present invention. The present invention may be modified or improved without departing from the spirit thereof, and of course, the present invention includes equivalents thereof.

[0071] 1, 1S, 1V Packaging box (medicine packaging box) 2, 2S, 2V Storage container (medicine storage container, packaged item) 2a, 2Sa Neck portion 10, 10S, 10V Inner box 11, 11S Opening 12, 12S, 12V Side wall portion 12a First side wall portion 12b Second side wall portion 12c Third side wall portion 12d, 12Sd Fourth side wall portion 13, 13S, 13V Bottom wall portion 13Va Engagement flap 13Vb Engagement protrusion portion 14, 14S, 14V Lower flap 15, 15S, 15V Outer flap (outer protrusion portion) 15a First outer flap 15b Second outer flap 15c Third outer flap 15Va Engagement groove 16, 16S Score line 17, 17S Cutout 18, 18S Fold hole 19, 19S Flap insertion opening 19a First cut line 19b Second cut line 19c Guide hole 20, 20S, 20V Outer box 21, 21S Opening 22, 22S, 22V, 22VA Side wall 22a First side wall 22b Second side wall 22c Third side wall 22d, 22Sd Fourth side wall 22Va Insertion groove 23, 23S, 23V Top wall 23a Insertion protrusion (insertion portion) 23Va Insertion protrusion 24, 24S, 24V Upper flap 24a Insertion groove (inserted portion) 25, 25S, 25V, 25VA Inner flap (inner protrusion) 25a First inner flap 25b Second inner flap 25c Third inner flap 25d Fourth inner flap 26, 26S First cut line 27, 28, 27S, 28S Second cut line 30S, 30V Gripping flap 31S Depression 32S Cut line 101, 101S, 101V Box assembly sheet (packaging box assembly sheet) 110, 110S, 110V Inner box assembly sheet 120, 120S, 120V Outer box assembly sheet

Claims

1. A packaging box used to package an item to be packaged, comprising: an inner box that contains the item to be packaged; and an outer box that is attached to the inner box so as to cover the opening of the inner box, wherein the inner box has an outer protrusion that is provided on the peripheral portion of the opening of the inner box or on a side wall of the inner box and protrudes outward from the side wall, and the outer box has an inner protrusion that is provided on the peripheral portion of the opening of the outer box or on a side wall of the outer box and protrudes inward from the side wall, and the inner protrusion is configured to switch between a first state in which it can grasp the item to be packaged and a second state in which it can fit into the inner box, and the outer box is configured to grasp the item to be packaged when the inner protrusion in the first state abuts on the peripheral portion of the item to be packaged when placed over the item, The outer box is configured to fit into the inner box when placed over the inner box, such that the inner protrusion in the second state is positioned closer to the bottom wall of the inner box than the outer protrusion, and the outer protrusion is positioned closer to the top wall of the outer box than the inner protrusion, and the inner protrusion and the outer protrusion abut in the installation direction of the outer box.

2. The packaging box according to claim 1 is a pharmaceutical packaging box used to package pharmaceutical storage containers in which pharmaceuticals are stored, and the inner box and the outer box are each formed from a single blank sheet.

3. The packaging box according to claim 1, characterized in that the outer protrusion is an outer flap that is provided on the periphery of the opening of the inner box and is folded back so as to face the outer surface of the side wall of the inner box, and the inner protrusion is an inner flap that is provided on the periphery of the opening of the outer box and is folded back so as to face the inner surface of the side wall of the outer box, and when the outer box is placed over the inner box, the tip of the inner flap in the second state and the tip of the outer flap abut in the attachment direction of the outer box, so that the inner flap abuts or is able to abut against the side wall of the inner box, and the outer flap abuts or is able to abut against the side wall of the outer box.

4. The packaging box according to claim 1, characterized in that the outer protrusions are formed in a plurality along the circumferential direction of the inner box, the inner protrusions are formed in a plurality along the circumferential direction of the outer box, and the inner protrusions are arranged such that, when switched from the first state to the second state, the tip ends of the inner protrusions are positioned toward the side wall of the outer box.

5. A packaging box as described in any one of claims 1 to 4, characterized in that when the outer box is placed over the inner box, the inner protrusion switches from the first state to the second state by abutting against the outer protrusion in the installation direction of the outer box, and the inner protrusion in the second state is located closer to the bottom wall of the inner box than the outer protrusion and abuts against the end face or back surface of the outer protrusion.

6. A packaging box according to any one of claims 1 to 4, characterized in that a first cut line for opening the packaging box is formed in the end portion of the side wall of the outer box that is on the top wall side of the outer box, and a second cut line for opening the packaging box is formed in the end portion of the side wall of the outer box that is on the opening side of the outer box, and the second cut line extends from the peripheral portion of the opening of the outer box along the side wall.

7. A packaging box assembly sheet that can be assembled into the shape of the packaging box described in claim 1, comprising: an inner box assembly sheet formed from one blank sheet and that can be assembled into the shape of the inner box; and an outer box assembly sheet formed from one blank sheet and that can be assembled into the shape of the outer box.

8. A method for manufacturing a packaging box as defined in claim 1, comprising: a preparation step of preparing the inner box and the outer box; a gripping step of placing the outer box over the item to be packaged and gripping the item with the outer box; and an assembly step of placing the outer box, with the item to be packaged gripped, over the inner box, causing the item to be contained in the inner box and assembling the outer box to cover the opening of the inner box, wherein in the gripping step, the inner protrusion in the first state abuts against the peripheral portion of the item to be packaged, thereby gripping the item with the outer box; and in the assembling step, the inner protrusion and the outer protrusion in the second state abut against each other in the installation direction of the outer box, thereby assembling the outer box to the inner box.

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