GB2393431A

GB2393431A - A partially erected package and an automated method of packaging

Info

Publication number: GB2393431A
Application number: GB0319390A
Authority: GB
Inventors: Mark Moore; Philip F O'neill
Original assignee: Amcor Pty Ltd
Current assignee: Amcor Pty Ltd
Priority date: 2002-08-19
Filing date: 2003-08-18
Publication date: 2004-03-31
Also published as: AU2002950861A0; NZ527668A; GB0319390D0

Abstract

An automated method of packaging a product using a partially erected package comprises comprising the steps of a) providing a partially erected package which has external side walls 22 that define a cavity and at least one retaining assembly 23 in a collapsed position b) placing the product in the cavity and c) moving the retaining assembly 23 from the collapsed position to an erected position, whereby the retaining assembly 23engages the product. Step a) preferably includes conveying a blank to a folding station, the blank having a series of folding lines, that define panels which form the side walls 22 and the retaining assembly 23, and folding the blank to form the partially erected package. Apparatus for carrying out the method includes means for receiving a partially erected package, means for placing the product in the cavity, preferably a mechanical hand 29, and means 30 for moving the retaining assembly 23 into the erected position.

Description

- 1 - A PACKAGE

FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to a package, method 5 and apparatus for packaging a product.

The task of packaging products has historically been labour intensive. In essence, the task has typically involved manually positioning each product into a package such as a carton and in the case of fragile 10 products, ensuring each product is adequately protected against breakage.

In the case of packaging chocolate eggs into cartons, each egg is usually manually placed into a clear thermoformed plastic insert that houses the egg. Once 15 placed in the insert, the insert is then manually positioned inside one or more decorated outer cartons having a window through which the eggs can be viewed by the consumer. As many tens of thousands of eggs are packaged in this manner annually, there is a vast amount 20 of plastic material that is discarded when the package is opened. The use of plastic inserts is also common for packaging other products including novelty items and small toys. 25 It is therefore an object of the present invention to provide an alternative package, method and apparatus for packaging products.

SUMMARY OF THE INVENTION

30 According to the present invention is provided by an automated method of packaging a product, the method including the steps of: a) providing a partially erected package having side walls that define a cavity and at least one retaining 35 assembly in a collapsed loading position; b) placing the product in the cavity; and

- 2 - c) moving the retaining assembly from the collapsed loading position to an erected retaining position, whereby the retaining assembly engages the product and substantially prevents the product from moving within the 5 package.

It is preferred that step a) includes: conveying a flat blank to a folding station, the blank having a series of fold lines that define panels that define the side walls and the retaining assembly of 10 the packager and folding the blank to form the side walls and the retaining assembly in a collapsed loading position.

It is also preferred that the blank include a base from which the side walls extend upwardly therefrom.

15 It is preferred that the retaining assembly includes 3 interconnected walls, namely upper and lower walls pivotally connected to one of the side walls and an internal side wall for engaging the product, whereby (a) when the retaining assembly is in the collapsed position, 20 the upper, lower and internal side walls lie substantially flat on the side wall, and (b) when the retaining assembly is in the erected position, the upper and lower walls are disposed laterally to the side wall and the internal side wall is disposed parallel to and inwardly of the side 25 wall.

It is preferred that at least a portion of the upper wall projects above the side walls while in the collapsed position and is located substantially level with the opening of the cavity when the erected position. This 30 preferred feature enables the retaining assembly to be conveniently moved from the collapsed loading state to an erected retaining state by pressing the upper wall projecting above the side wall.

In addition, it also preferred that the lower wall 35 be disposed adjacent to the base of the package when in the erected position.

- 3 - It is preferred that the retaining assembly have one or more openings which receive segments of the product when the retaining assembly is located in the erected retaining position.

5 Although it is possible that the package may include any number of retaining assemblies, it is preferred that the package include two retaining assemblies, each one on opposite sides of the cavity.

It is preferred that the method also includes a 10 step of applying an adhesive to the package such that the retaining assembly can be fastened in the erected retaining position. It is even more preferred that the method include applying adhesive to a region of the base contacted by the lower wall of the retaining assembly when 15 in the erected position.

Any suitable adhesive may be used such as hot melt adhesive, cold glue or double sided tape.

It is also preferred that step c) of moving the retaining assembly from the collapsed loading position to 20 the erected retaining position includes contacting the retaining assembly with an arm and moving the retaining assembly downwardly.

Although it is possible that the step b) may be carried out using air suction cups or other suitable 25 means, it is preferred that the step be carried out by a mechanical means.

According to the present invention there is provided an apparatus for packaging a product, the apparatus including: 30 means for receiving a partially erected package having side walls that define a cavity and at least one retaining assembly in a collapsed loading position; means for placing the product in the cavity; and means for moving said retaining assembly from a 35 collapsed loading position to an erected retaining position, whereby the retaining assembly is adapted to engage the product and substantially prevent the product

- 4 - from moving within the package when located in the erected retaining position.

It is preferred that the means for placing the product in the cavity be a mechanical hand.

5 It is also preferred that the means for moving the retaining assembly from the collapsed loading position to the erected retaining position be a mechanical means.

According to the present invention there is provided a partially erected package for packaging a 10 product, the package including: side walls that define a cavity for receiving the product; and an retaining assembly in a collapsed loading position that is moveable into an erected retaining position; 15 whereby in use, the product can be placed in the cavity and the retaining assembly can be moved to an erect retaining position, such that the retaining assembly, adapted to engage the product, can substantially prevent the product from moving within the cavity.

20 It is preferred that an adhesive, such as hot melt, cold glue or double sided tape be provided to fasten the retaining assembly in the erected retaining state.

Alternatively, or in addition, the package may include a mechanical means, such as a tab to engage and fasten the 25 retaining assembly in the erected retaining position.

It is preferred that the carton include a closure flap for covering the cavity.

BRIEF DESCRIPTION OF THE DRAWINGS

30 Preferred embodiments of the present invention will now be described with reference to the accompanying Figures, of which: Figures la to to illustrate a side view of a blank in the process of being partially erected; 35 Figures 2 to 4 illustrate perspective views of a first embodiment of a package;

- 5 - Figures 5 and 6 schematically illustrate a method and apparatus for packaging a product; Figures 7 to 12 illustrate perspective views of six 5 alternative embodiments of a package; and Figures 13a and 13b illustrates a cross sectional side view of a package containing a product.

DETAILED DESCRIPTION

10 The same reference numerals have been used to identify similar and substantially identical features of the various embodiments throughout the Figures.

Figures la through to lo illustrate a packaging carton being partially erected in a folding station. In 15 general terms a carton blank 20 in a flat orientation is conveyed to the folding station and a plunger head 21 is positioned on a central region of the blank 20 to form the base of the carton. Side walls 22 extending from the base of the carton are folded upwardly around the plunger head 20 21 as shown in figures lb and lo. Creases may be pre-

formed at the junction of the base and the side walls 22 and any suitable means may be employed for folding the side walls 22 upwardly.

Although not illustrated in the Figures, the side 25 walls 22 may include flaps that overlap adjacent side walls so that pre-applied glue, or any other adhesive, may secure the flaps, and thus the side walls 22 in an erected position. The carton exits the folding station in a 30 partially erected state which is shown in greater detail in Figure 2.

The partially erected carton is essentially an open box and includes four side walls 22 that define a cavity and two retaining assemblies in the form of false 35 block walls 23 that extend from the side walls 22 and are folded inside the cavity. The block walls 23 each

- 6 - comprise an upper wall 24, a lower wall 26 and an internal side wall 25 connected by perforated fold lines 27.

The block walls 23 are adapted to engage and prevent the product moving within the package. More 5 particularly, as can be seen in Figures 2 to 4, the block walls 23 include an opening 28 that is intended to receive the product.

Figures 2 to 4 shows the block walls 28 in various positions namely; a collapsed loading position shown in 10 Figure 2, an intermediate position shown in Figure 3, and finally an erected retaining position shown in Figure 4.

The upper, lower and internal side walls, 24, 26 and 25 respectively, lye substantially flat against the 15 side walls when in the collapsed loading position. In the erected position, the upper and lower walls 24 and 26 extend laterally of the side walls 22 and the internal side wall 25 is disposed inwardly of the side walls 22, thereby reducing the size of the cavity.

20 Figure 5 schematically illustrates a process and apparatus for packing a product in the form of a chocolate egg in the carton shown in Figures 1 to 4. The first stage illustrated at left side of Figure 5 represents the partially erected carton exiting the folding station 25 described above with reference to Figure la to lo.

The second stage illustrated immediately to the right of the first stage represents hot-melt glue being applied to the inside face of the base of the carton for fixing the lower wall in position.

30 The third stage illustrated immediately to the right of the second stage represents an automated mechanism for loading a chocolate egg in the cavity of the carton and moving the blocked walls 23 from the collapsed loading position to an erected retaining position.

35 Specifically, a mechanical hand 29 for holding a chocolate egg can be raised and lowered in the direction of arrow A and two side levers 30 can be pivoted downwardly and

- 7 - upwardly in the direction of arrows B to engage the block walls projecting above the side walls.

The fourth stage represents the chocolate egg retained in the carton by the block walls 23 located in 5 the erected retained position which substantially prevents the egg from moving within the carton.

The third stage of Figure 5 can be readily broken down into three or more sub-stages A, B and C; each of which are schematically illustrated in Figure 6.

10 Sub-stage A represents a partially erected carton exiting a glue applying station. Hot-melt adhesive glue 31 has been applied on the inside face of the base of the carton at a location for adhering the lower wall 26 of the block walls 23. The mechanical hand 29 holding an egg to 15 be packaged is provided above the partially erected carton. As can be seen in sub-stage B. the mechanical hand 29 places the egg in a pre-selected position within the cavity of the carton and the two side levers 30, pivotally 20 mounted to a base plate attached to the mechanical hand 29, move downwardly and move the block walls 23 from the collapsed loading position.

Sub-stage C represents the levers 30 moving the blocked walls 23 into a fully erected position so that the 25 openings 28 of the block walls 23 retain the egg within the carton. In addition, the adhesive glue 31 fastens lower wall 26 to the base of the carton to secure the blocked wall 23 in the erected retaining position.

Although not illustrated, the mechanical hand 29 30 subsequently releases the egg so that the side levers 30 and hand 29 lift upwardly away from the carton. The hand can then be reloaded with another egg.

It will be readily appreciated that the process and apparatus illustrated in Figures 5 and 6 can be fully 35 automated.

- 8 - Figures 7 through to 12 illustrate several alternative cartons for packaging. A brief description of

each carton follows.

Figure 7 illustrates a hexagonal carton having a 5 base, four side walls and two block walls on opposite hexagonal side walls 32. The block walls are shown in an erected retaining position.

Figure 8 illustrates a rectangular carton, similar to that shown in Figures 1 to 4. However in this 10 instance, the carton includes four false block walls 23, one on each side wall. The block walls are shown in an erected retaining position.

Figure 9 illustrates a further modification to the carton shown in Figures 1 to 4. In this instance, the 15 carton also includes a closure flap 33 provided with two side tabs 34 and a window 35, the closure flap 33 extends from one of the side walls 23. A perforated fold line between the segment 24 of the block wall 23 and the side walls 22 includes a retaining slit 36 of receiving the 20 tabs.

Figure 1O illustrates a modification of the carton shown in Figure 6. Specifically, the modification is constituted by two pairs of recesses 37 provided in the upper region of the block walls 23. Each pair of the 25 recesses 37 accommodates additional products across the carton, such as a chocolate bar (not shown in the Figure).

Additional windows 35 are also provided in the closure flap 33 for viewing the product supported in the recesses 37. 30 Figure 11 illustrates yet another modification of the carton shown in Figure 6. Specifically, the modification is represented by additional dotted lines 38 in the form of an arc at opposite ends of the closure flap 33. The dotted lines indicate an outward fold such that 35 the central region of the closure flap 33 forms an outwardly curved face.

- 9 - Figure 12 illustrates a carton in which at least one of the side walls 23 is sloped outwardly and the closure flap 33 is larger than the base such that the overall visual impression of the carton is that it has 5 trough shape.

Figure 13a illustrates a cross sectional side view of a carton rotate 90 degrees so as to stand on an end.

The upper end of the carton is configured to decline from the back to the front.

10 Figure 13b illustrates the carton of Figure 13a as an inner carton that is placed inside an outer carton.

Specifically, the outer carton is essential a box sized to snuggly receive the inner carton save for upper cavity 39 formed above the inner carton. As can be seen, the upper 15 cavity 39 is intended to receive several smaller egg.

that, due to the declined top of the inner carton, rest against the right side of the upper cavity and can be seen through a window 40 in the outer carton.

It will be understood by a person skilled in the 20 art of the present invention that modifications may be made to the invention without departing from the spirit and scope of the present invention.

Claims

- 10 THE CLAIMS DEFINING THE INVENTION ARE AS FOLLOWS:

1. An automated method of packaging a product, the method including the steps of: 5 a) providing a partially erected package having external side walls that define a cavity and at least one retaining assembly in a collapsed loading position; b) placing the product in the cavity; and c) moving the retaining assembly from the collapsed 10 loading position to an erected retaining position, whereby the retaining assembly engages the product and substantially prevents the product from moving within the package. 15

2. The method according to claim 1, wherein step a) includes: conveying a flat blank to a folding station, the blank having a series of fold lines that define panels that define the side walls and the retaining assembly of 20 the package; and folding the blank to form the side walls and the retaining assembly in a collapsed loading position.

3. The method according to claim 1 or 2, wherein the 25 blank includes a base from which the external side walls extend upwardly therefrom.

4. The method according to any one of the preceding claims, wherein the retaining assembly includes 3 30 interconnected walls, namely an upper wall and a lower wall that is pivotally connected to one of the side walls and an internal wall for engaging the product, whereby (i) when the retaining assembly is in the collapsed position, the upper, lower and internal walls lie 35 substantially flat on the side wall, and (ii) when the retaining assembly is in the erected position, the upper and lower walls are disposed laterally

- 11 to the side wall and the internal wall is disposed inwardly of the side wall.

5. The method according to claim 4, wherein at least 5 a portion of the upper wall projects above the side walls when in the collapsed position and is moved downwardly to locate the retaining assembly in the erected retaining position. 10

6. The method according to claim 4 or 5, wherein the lower wall be disposed adjacent to the base of the package when in the erected position.

7. The method according to any one of the preceding 15 claims, wherein the retaining assembly has one or more openings which receive segments of the product when the retaining assembly is located in the erected retaining position. 20

8. The method according to any one of the preceding claims, wherein the package includes two retaining assemblies, each one on opposite sides of the cavity.

9. The method according to any one of the preceding 25 claims including a step of applying an adhesive to the package such that the retaining assembly can be fastened in the erected retaining position by adhesive.

10. The method according to claim 9 when dependent on 30 claim 3, wherein the step of applying adhesive includes applying adhesive to the base for fastening the retaining assembly in the erected position.

11. The method according to any one of the preceding 35 claims, wherein step c) of moving the retaining assembly from the collapsed loading position to the erected retaining position includes contacting the retaining

-

12 assembly with an arm and moving the retaining assembly downwardly. 12. The method according to any one of the preceding 5 claims, wherein step b) is carried out by a mechanical means.

13. An apparatus for packaging a product, the apparatus including: 10 means for receiving a partially erected package having side walls that define a cavity and at least one retaining assembly in a collapsed loading position; means for placing the product in the cavity; and means for moving said retaining assembly from a 15 collapsed loading position to an erected retaining position, whereby the retaining assembly is adapted to engage the product and substantially prevent the product from moving within the package when located in the erected retaining position.

14. The apparatus according to claim 13, wherein the means for placing the product in the cavity be a mechanical hand having opposed moving members.

25

15. The apparatus according to claim 13 or 14, wherein the means for moving the retaining assembly from the collapsed loading position to the erected retaining position be a mechanical means.

30

16. A partially erected package for packaging a product, the package including: side walls that define a cavity for receiving the product; and a retaining assembly in a collapsed loading position 35 that is moveable into an erected retaining position; whereby in use, the product can be placed in the cavity and the retaining assembly can be moved to an erect

- 13 retaining position, such that the retaining assembly, adapted to engage the product, can substantially prevent the product from moving within the cavity.

5

17. The package according to claim 16 including a base from which the side walls extend upwardly therefrom.

18. The package according to claim 17, wherein the retaining assembly includes 3 interconnected walls, namely 10 an upper wall and a lower wall that is pivotally connected to one of the side walls and an internal wall for engaging the product, whereby (i) when the retaining assembly is in the collapsed position, the upper, lower and internal walls lie 15 substantially flat on the side wall, and (ii) when the retaining assembly is in the erected position, the upper and lower walls are disposed laterally to the external side wall and the internal wall is disposed inwardly of the side wall.

19. The package according to claim 18, wherein at least a portion of the upper wall projects above the side walls when in the collapsed position and is moved downwardly to locate the retaining assembly in the erected 25 retaining position.

20. The package according to claim 19, wherein the lower wall is disposed adjacent to the base of the package when in the erected position.

21. The package according to any one of claims 16 to 20, wherein the retaining assembly has one or more openings which receive segments of the product when the retaining assembly is located in the erected retaining 35 position.

- 14

22. The package according to any one of claims 16 to 21, wherein the package includes two of said retaining assemblies, each one on opposite sides of the cavity.

5

23. The package according to any one of claims 16 to 22 including a closure flap for closing the cavity defined by the side walls.