IE84616B1 - A method of forming packaging board - Google Patents

Description

A METHOD OF FORMING PACKAGING BOARD Introduction The invention relates to a method of forming packaging board with cut-outs, especially a plurality of circular cut-outs to receive pharmaceutical pills. The invention also relates to die-cutting and stripping apparatus used in forming the packing board.

There are considerable problems in producing a packaging board with a large number of individual cut-outs per unit area. Each cut-out requires a die cutting tool and each tool must make essentially a perfect cut in order to form a clean cut-out of required quality while maintaining the integrity of the main body of the board.

This invention is directed towards providing a method and apparatus which will overcome at least some of these problems.

Statement of Invention According to the invention there is provided a method of forming packaging board with cut-outs comprising the steps of:- die cutting a packaging board to provide a plurality of cut—outs in the board, the cut-outs being attached to the board by connecting webs formed by a blunted region of a die cutting edge, the blunted region having a width of less than 0.2 mm; and stripping the cut-outs from the board by engaging a male cut-out member against each cut—out and ejecting the cut-out into a female waste-receiving hole.

In one embodiment of the invention the cut-outs are of curved shape and there are at least two connecting webs between the cut-outs and the main body of the board.

Most preferably the cut-outs are of generally circular shape.

In a preferred embodiment of the invention the method includes the step, prior to die cutting, of blunting a portion ofa cut-out forming tool to provide, on die-cutting, the connection webs. Preferably a region of the cut-out forming tool is blunted by engaging the cutting edge with a cutting blade to cut through the cutting edge of the forming tool. ln one embodiment of the invention the cut-outs are stripped by engaging a male cut- out member having a number of cut-out engaging projections against each cut-out for ejection of the cut-out into a female waste receiving hole.

Preferably the male member has four equi-spaced-apart projections for engaging a cut-out. ldeally the male stripping members project from a male stripping board into corresponding recesses in a female stripping board having a coating or facing of anti- static material, especially a formica material.

The invention also provides die cutting apparatus for die cutting cut-outs in a packaging board comprising a die cutting form having a plurality of cut-out forming tools, each having a cutting edge, the cutting edge ofthe tool having blunted regions to form, on die cutting, connecting webs between the cut-out and the board.

Preferably each blunted region has a width of less than 0.2 mm.

The invention further provides an apparatus for forming packaging board with cut- outs comprising a die cutting apparatus of the invention and cut-out stripping apparatus for stripping cut-outs from a die cut board, the stripping apparatus comprising a male stripping board having a plurality of male projections extending therefrom to engage with the cut-outs and eject them into a female waste-recovery hole of a female stripping board. Preferably female stripping board has a facing or covering layer of anti-static material. Most preferably the anti-static layer is of formica material.

In a preferred embodiment of the invention each male projection includes a number of spaced-apart cut—out engaging prongs to simultaneously engage the cut-out in point contact at a number of regions on the surface thereof to strip the cut-out from the board.

The invention also provides packaging board with cut-outs wherever formed by a method and/or using an apparatus as hereinbefore described.

In a particularly preferred aspect the packaging board is a pill packaging board having a plurality of pill-receiving recesses.

Brief Description of the Drawimgs The invention will be more clearly understood from the following description thereof given by way of example only, in which:- Fig. l is a plan view of a blank for a package formed using the method and apparatus of the invention; Fig.2 is a side elevational view of the blank of Fig. l; Figs. 3 and 4 are perspective views ofthe blank being folded to form a package; Figs. 5 and 6 are plan and side views of another package blank; Fig. 7 is a plan view of a die cutting tool used for forming the blanks of Figs. and 2; Fig. 8 is a perspective view of part of the tool of Fig. 7; Figs. 9a and 9b are enlarged views of one ofthe cut-out tools being locally blunted; Fig. 10 is a cross sectional view illustrating the blunting operation; Fig. l 1 is an elevational view of the die cutting apparatus used in the method of the invention; Figs. l2 and 13 are cross sectional views illustrating the operation of the die cutting apparatus; Fig. 14 is an enlarged cut-away view illustrating one cut-out in position; Fig. 15 is a perspective view of a male stripping board used in the method of the invention; Fig. 16 is an enlarged view of one ofthe male stripping elements of Fig. l5; Fig. l7 is an exploded perspective view of male and female stripping boards; Fig. 18 is a side view of the stripping boards, assembled; Fig. l9 is a cross section view illustrating the stripping operation; Fig. 20 is a plan view illustrating the stripping operation; and Fig. 21 is a perspective view of one element of a package with a cut-out removed.

Detailed Description Referring to the drawings there is illustrated a method and apparatus according to the invention for forming a packaging board l with cut-outs 2. In this case the packaging board 1 is for housing a plurality of pharmaceutical tablets which are arranged in a particular pattern to encourage patient compliance in taking medication. Score or fold lines 5 are made to facilitate folding of the package as illustrated in Figs. 3 and 4.

Another package 10 ofthis type is illustrated in Figs. 5 and 6 which is similar to the package I but with a different arrangement of cut-outs 2.

In each case it will be noted that there are a large number of cut-outs 2 per unit area of the printing board. These cut-outs 2 are difficult to form at a high level of quality to uniform shape and with sharp edges. The invention provides a method and apparatus for forming such a package in a highly efficient manner to a high level of quality.

Referring to Figs. 7 to 13 there is illustrated die cutting apparatus used in the method of the invention. The die cutting apparatus comprises a die cutting form 20 having a number of straight blades or rules 2| to form fold/score lines in a printing board.

The form 20 also includes a plurality of cut-out posts 30 having an upper cutting edge 3l for cutting the board to form a cut-out '2. As illustrated in Figs. 9a, 9b and l0 the cutting edge 3l of each post 30 is blunted by a sharp edge 41 ofa blade which is driven into the cutting edge 3] of the post 30 to form diametrically apposed nicks 35 in the cut-out forming post 30. The nicks 35 have a width less than 0.2 mm. preferably 0.] to 0.2 mm to form on die cutting, thin connecting webs 29 between the cut-out 2 and the main body of the surrounding board. We have found that this is optimum to form an effective die cut in which the cut-out are retaining partially to the board for subsequent waste removal.

The cut-outs 2 are stripped from the board I by placing the board between a male stripping board 50 and a female stripping board 51. The male stripping board 50 has a plurality of posts 52 with upstanding corner prongs 55 which engage the cut-outs 2 as illustrated in Fig. 20. The posts 52 are driven through corresponding holes 58 in the female stripping board 51 to knock-out the cut-outs 2, leaving a clean inner edge defining each hole in the board.

To optimise the stripping operation the female board 51 includes an anti-static board engaging layer 60 and is reinforced by reinforcing bars 6] to withstand the force generated, on stripping.

In use, a printed board to be scored and die cut is placed on a platen of a die cutting machine. The form of the die cutter is then operated to cut through the cut-outs 2, except for the fine webs which retain the cut-outs 2 attached to the board. The die cut board is then transferred onto a female stripping board and the corresponding male stripping board is projected downwardly to strip the cut-outs from the board.

The board is then ready for further processing.

The invention is not limited to the embodiments hereinbefore described which may be varied in detail.

Claims (1)

Claims

1.A method of forming packaging board with cut-outs comprising the steps of:- die cutting a packaging board to provide a plurality of cut-outs in the board, the cut-outs being attached to the board by connecting webs formed by a blunted region of a die cutting edge, the blunted region having a width ofless than 0.2 mm; and stripping the cut-outs from the board by engaging a male cut- out member against each cut-out and ejecting the cut-out into a female waste-receiving hole. A method as claimed in claim I wherein the cut-outs are of curved shape and there are at least two connecting webs between the cut-outs and the main body of the board. A method as claimed in claim 1 or 2 wherein the cut-outs are of generally circular shape. A method as claimed in any preceding claim including the step, prior to die cutting, ofblunting a portion ofa cut-out forming tool to provide, on die—cutting, the connecting webs. A method as claimed in claim 4 wherein a region of the cut-out forming tool is blunted by engaging the cutting edge with a cutting blade to cut through the cutting edge of the forming tool. A method as claimed in any preceding claim wherein the cut-outs are stripped by engaging a male stripping member having a number ofcut- out engaging projections against each cut-out for ejection ofthe cut-out into a female waste receiving hole. A method as claimed in claim 6 wherein the male member has four equi- spaced-apart projections for engaging a cut-out. A method as claimed in any preceding claim wherein the male stripping members project from a male stripping board into corresponding recesses in a female stripping board having a coating or facing of anti-static material, especially a formica material. A method of forming packaging board with cut-outs substantially as hereinbefore described with reference to the accompanying drawings. Die cutting apparatus for die cutting cut-outs in a packaging board comprising a die cutting form having a plurality ofcut-out forming tools, each having a cutting edge, the cutting edge of the tool having blunted regions to form, on die cutting, connecting webs between the cut-out and the board. Die cutting apparatus as claimed in claim I0 wherein each blunted region has a width of less than 0.2 mm. Apparatus for forming packaging board with cut-outs comprising a die cutting apparatus as claimed in claim 10 or I l and cut-out stripping apparatus for stripping cut-outs from a die cut board, the stripping apparatus comprising a male stripping board having a plurality of male projections extending therefrom to engage with the cut-outs and eject them into a female waste-recovery hole of a female stripping board. Apparatus as claimed in claim 12 wherein the female stripping board has a facing or covering layer of anti-static material. Apparatus as claimed in claim I3 wherein the anti-static layer is of formica material. Apparatus as claimed in any of claims 12 to 14 wherein each male projection includes a number of spaced-apart cut-out engaging prongs to simultaneously engage the cut-out in point contact at a number of regions on the surface thereof to strip the cut-out from the board. Die cutting apparatus substantially as hereinbefore described with reference to the accompanying drawings. Packaging board with cut-outs whenever formed by a method as claimed in any of claims I to 9 and/or using an apparatus as claimed in any of claims 10 to 16. Packaging board as claimed in claim 17 comprising a pill packaging board having a plurality of pill-receiving recesses.