WO2013098682A1

WO2013098682A1 - Method and apparatus for covering a box

Info

Publication number: WO2013098682A1
Application number: PCT/IB2012/057126
Authority: WO
Inventors: Mauro Mazzinghi; Marco MENICHETTI
Original assignee: Emmeci S.P.A.
Priority date: 2011-12-29
Filing date: 2012-12-10
Publication date: 2013-07-04
Also published as: JP6250550B2; ITBO20110770A1; JP2015507561A

Abstract

A method for covering a box (100) with a flat covering blank (200) comprises the steps of coupling the blank (200) to the bottom wall (101) of the box (100), folding lateral wings (201) of the blank (200) on the lateral panels (103) of the box (100) to form flaps (202) projecting from the lateral panels (103), folding the projecting flaps (202) towards the inside of the box (100) to render them parallel with the bottom wall (101) of the box (100) by advancing folder elements (21) towards the box (100), and further folding the projecting flaps (202) towards the inside of the box (100), in such a way that they adhere to respective inner faces of the lateral panels (103). There is also a step of moving the box (100) towards the folder elements (21) along a line transversal to the bottom wall (101) of the box (100) for pressing the projecting flaps (202) against the end edges (104) of the lateral panels (103).

Description

DESCRIPTION

METHOD AND APPARATUS FOR COVERING A BOX

Technical field

The present invention relates to a method and an apparatus for covering a box.

Background art

The technical field of this invention is that of industrial processing for covering boxes having a bottom wall and a lateral wall with at least three sides, but more particularly four sides.

The boxes in question are made from shaped sheets of paper or paperboard, known as forming blanks.

In particular, the boxes are formed from flat blanks consisting of a base and a plurality of faces connected to the base and which can be folded relative to the base to constitute a lateral wall of the box.

As regards the industrial process which produces the finished box, it should noticed that said process comprises two separate steps: a step of forming the box and a subsequent step of covering the box by applying a covering sheet (that is to say, a cover) on it.

This invention specifically concerns the box covering step.

In particular, within the scope of this invention, and as mentioned above, the box to be covered is a box with a bottom wall having a number of sides which, in general, is equal to or greater than three, but in particular is equal to four. Moreover, the box has a lateral wall with as many faces. The covering sheets are in turn shaped sheets, which constitute covering blanks.

The covering blank is a flat blank with a base shaped like the bottom wall of the box and segments (that is to say, lateral portions) connected to the base and designed to be folded to cover the lateral wall of the box.

As regards the configuration of the covering blank, it generally has a number of segments equal to the number of sides of the base and each segment is connected to a corresponding side of the base. This type of blank is generally known as the "petal-type".

However, it should be noticed that blanks with other shapes are also used. For example, it is possible that the number of segments is equal to (or greater than) the number of sides of the base, but that the number of segments directly connected to the base is less than the number of sides of the base, since some segments are connected to other segments.

In such a case, the blank is usually called "H-type" or "T-type" or "cross- type", depending on the configuration of the blank when it is extended on a surface.

If the number of segments is greater than the number of sides of the base, there are segments associated with other segments and which can be folded laterally to cover the same face of the lateral wall of the box, each encompassing its own vertical edge of said face.

It should be noticed that this invention is not applied irrespective of the type of blank used.

A prior art process for covering the box is described in Italian patent application No. BO2010A000325 by the same Applicant as this invention. That method is divided into the following steps.

Firstly, a layer of glue is applied to the covering blank.

The box to be covered is then rested on the covering blank previously glued (that is to say, pre-glued), in such a way that the bottom wall of the box adheres to the base of the covering blank.

The segments of the covering blank are then folded (from a horizontal position coplanar with the base to a vertical position) to cover corresponding faces of the lateral wall of the box.

That folding occurs by moving the box vertically downwards, through an opening formed by contact elements. The folding is caused by the interaction between the moving box and the fixed contact elements.

For moving the box there is a mould, which consists in a body whose purpose is to form a constraining element operatively fitted to size in a space inside the box.

The mould is connected to a rod for moving the mould and the box coupled to it.

It should be noticed that the covering blank is shaped so that the lateral segments have a length, along the line orthogonal to the side which joins them to the base, greater than the length of the corresponding faces of the lateral wall of the box.

That way, when the segments of the covering blank are folded and adhering to the lateral wall of the box, each segment comprises a portion (hereinafter referred to as flap, or fold over flap) which protrudes, in an upwards direction, above the corresponding face of the lateral wall of the box.

The purpose of these upper flaps of the covering blank is to cover the upper free edge of the box and at least a portion of the inner surface of the lateral wall of the box.

Thus, after folding the segments of the covering blank, the flap of each segment of the covering blank projects vertically upwards (that is to say, from the part opposite the bottom wall).

It should be noticed that, according to the prior art, flaps projecting laterally from the segments of the covering blank are also folded; this operation is called lateral fold over.

As regards the upper flaps, these are all folded simultaneously inside the box, to cover the upper free edge and a portion of the lateral wall of the box.

The partial inner covering (known also as "inner fold over" or "upper fold over") may be more or less "deep", according also to the type, the geometrical shape and the planned use of the box. In particular, the depth of the fold over is determined by the length of the fold over flaps, compared with the height of the respective face of the lateral wall of the box to be covered. This invention relates, in particular, to this step of folding or fold over of the upper flaps of the segments of the covering blank on the corresponding inner surface of the faces of the lateral wall of the box.

The internal fold over step is performed in two sub-steps, as follows.

Starting from a configuration in which the mould is removed from the box, in a first sub-step the projecting flaps are folded at a right angle, towards the inside of the box, by a plurality of folder elements, each associated with a respective projecting flap and able to move towards and away from the box to intercept the corresponding flap and cause the flap to be folded from a vertical position to a horizontal position in which it is parallel with the bottom wall of the box.

In a subsequent second sub-step, the flaps which are horizontal are further folded through another right angle, to make them adhere to the inner face of the wall of the box. That is done by moving the mould vertically downwards, in such a way that it is synchronised with activation of the folder elements, to prevent it from interfering with them.

In short, the mould is raised and then lowered again towards the inside of the box for allowing further folding of the flaps previously folded into the horizontal position by the folder elements.

The Applicant found that an apparatus of the type described in the above- mentioned Italian patent application No. BO2010A000325 can be improved with reference to the production of the upper edges of the box. It was noticed that boxes made using such an apparatus do not demonstrate correct adhesion of the covering sheet at the upper edges, that is to say, the edges extending substantially parallel with the bottom wall and which are therefore located between the inner face and the outer face of the lateral walls of the box.

In particular, it was noticed that at said upper edges the covering sheet remains detached from the edge of the box and adopts an arched shape rather than adhering perfectly to the edge and adopting a straight horizontal configuration. Therefore, the boxes have to be subjected to a subsequent, usually manual, smoothing down treatment for the covering sheet at the upper edges of the box in order to produce perfect tracing of the edges.

However, said operation may involve a predetermined delay after the folding down by the apparatus described above, therefore the smoothing down of the edges may be carried out when the adhesive applied to the covering sheet is at least partly dry and has lost the necessary properties for adhering to the box beneath it.

US21241962A and US2713813A disclose box wrapping machines comprising fingers adapted to fold the upper flaps of the wrapping sheet inside the machine; said fingers can be forced down into contact with the upper edges of the box.

Disclosure of the invention

The aim of this invention is, therefore, to provide a method and an apparatus which overcome the above-mentioned disadvantages of the prior art.

In particular, the aim of this invention is to provide a method and an apparatus for automatically covering a box using a pre-glued covering blank, allowing boxes to be obtained which are particularly well-finished and free from aesthetic defects at the covered upper edges.

Another aim of this invention is to provide a method and an apparatus for automatically covering a box using a pre-glued covering blank, allowing rapid execution and therefore high productivity.

These aims are fulfilled by the method and the apparatus according to this invention, as described in the appended claims.

In particular, the method according to the invention is characterised in that it comprises a step of moving the folder elements and the box towards each other along a line transversal to the bottom wall of the box so as to press (smooth down), against the end edges of the box lateral panels, the fold over flaps projecting from the end edges. The step of moving towards each other is carried out before the folding of the flaps which causes the flaps to move from a configuration parallel with the bottom wall of the box to a configuration adhering to the inner faces of the lateral panels of the box.

Moreover, preferably, the step of moving towards each other is carried out by moving the box towards the folder elements.

Preferably, the flaps are still kept pressed against the end edges of the box lateral panels during insertion of the mould needed to make the flaps adhere to the inner faces of the lateral panels. That is made possible by the specific shape of the folder elements which do not require any backward movement away from the lateral panels.

Indeed, the shape of the folder elements is such that they do not interfere with insertion of the mould even when the folder elements are in the configuration closest to the box.

The configuration in which the folder elements are closest to the box is preferably defined by contact between a contact portion of each folder element and an outer face of the corresponding lateral panel.

The apparatus according to the invention is characterised in that it comprises a control unit programmed to move the plate and the folder elements towards each other, when the folder elements are positioned in contact with the end edges of corresponding lateral panels of the box, with the projecting flaps arranged in the rotated configuration in which they are parallel with the bottom wall of the box.

In particular, the control unit is operatively connected to the box supporting plate and to the folder elements and is programmed to move the plate and the folder elements towards each other when at least some of the folder elements have reached a configuration of maximum advancement towards the box, corresponding to folding of the projecting flaps so that they lie parallel with the bottom wall of the box, in such a way as to press the projecting flaps against corresponding end edges of the lateral panels.

Preferably, the movement of the plate and folder elements towards each other is defined by a translation of the plate only.

In other words, preferably, the control unit is operatively connected to the box supporting plate (and is programmed) to move the plate towards the folder elements (and not vice versa), once at least some of the folder elements have reached said configuration of maximum advancement towards the box (in such a way as to generate a pressure on the edges of the lateral panels in contact with the corresponding projecting flaps.

Each of these folder elements comprises a surface parallel to the end edge of the corresponding lateral panel (and opposite and above thereto, when the folder elements have reached said configuration of maximum advancement towards the box), i.e. parallel to the direction of advancement of the folder element towards the box; said pressure is established between said surface of the folder element and the upper edge of the box, when the bow is pushed upward against the folder element.

The fact that the plate (and therefore the box) is moved (upwardly) to force the upper edges of the box against said surfaces of the folder elements in contact therewith is advantageous because it allows the machine (and in particular the folding elements) to be of particularly simple construction. Each folder element comprises a contact portion facing towards a line of folder element advancement towards the box and designed to make contact with the outer face of a corresponding lateral panel of the box in order to determine the configuration in which the folder element is closest to the box.

Preferably, the front end of each folder element is equipped with a step formed by a pair of surfaces which are perpendicular to each other, a first of which can be positioned opposite the outer face of a corresponding lateral panel of the box to form the above-mentioned contact portion, and the second of which can be positioned opposite the end edge of the corresponding lateral panel.

Preferably, the second surface of the step has a size, measured along the line of translation of the folder element towards the box, which is less than or equal to the thickness of the corresponding lateral panel on which the folder element acts.

Preferably, that size is less than 10 millimetres and even more preferably it is less than 5 millimetres.

Preferably, the apparatus comprises a first and a second drive unit which are independent of each other, the first drive unit being connected to the mould and the second drive unit being connected to the plate. The second drive unit pushes the box upwards against the folders, while the first drive unit moves the mould along the vertical movement axis of the box.

Brief description of drawings

The technical features of the invention, with reference to the above aims, are clearly described in the claims below and its advantages are more apparent from the detailed description which follows, with reference to the accompanying drawings which illustrate a preferred non-limiting example embodiment of the invention and in which:

Figure 1 is a partly simplified perspective view of an apparatus for covering boxes made of paperboard of the known type;

Figure 2 shows an enlarged detail of the apparatus of Figure 1 ; Figures 3 to 8 are all schematic perspective views of a series of steps of the method for covering boxes, in accordance with this invention; - Figure 9 is a schematic cross-section of a detail of the apparatus of Figure 2.

Detailed description of preferred embodiments of the invention

With reference to the accompanying drawings, in particular with reference to figure 1 , the apparatus, labelled 1 in its entirety, and the related method according to the invention are intended for covering boxes 100 having a lateral wall formed by at least three lateral panels, but more particularly four lateral panels (obviously, for a simple description and by way of non- limiting example, hereinafter reference will be made to this type of box having the shape of a cube or parallelepiped with a square or rectangular base, without thereby restricting the scope of the inventive concept).

Preferably, the apparatus 1 is a machine having a system for electronic control of the movements of the moving parts of the machine. Alternatively, these movements are controlled by mechanical systems (for example, cams).

The boxes 100 are made from shaped sheets of paper or paperboard, known as forming blanks having a bottom wall 101 and a lateral wall 102 comprising a predetermined number of lateral panels 103 which, in the specific non-limiting embodiment described, are four in number and have the shape of a rectangle or a square.

The box 1 is covered using a flat covering blank 200 (made from paper material) with a base (not visible in the accompanying drawings) shaped like the bottom wall 101 of the box 100.

The blank 200 has a plurality of segments 201 equal in number to the number of lateral panels 103 of the box 100 to be covered. These segments 201 are connected to the base and can be folded to cover the entire lateral wall 102 of the box 1 (the initial coupling configuration between box 100 and blank 200 is visible in Figure 3).

The sequence of folding steps to which the blank 200 must be subjected in order to obtain the covered box 1 is illustrated in Figures 3 to 7. Said steps may be summarised as follows, in the specific sequence indicated:

- coupling of the covering blank 200 and the box 100 in such a way that the bottom wall 101 of the box 100 is superposed on the base of the covering blank 200;

- folding of the segments 201 of the covering blank 200, from a configuration in which they are aligned (coplanar) with the base (Figure 3) to a rotated configuration (through 90° in this embodiment, as shown in Figure 4) in which the segments 201 are in contact with the outer faces of the corresponding lateral panels 103 of the box, each segment 201 being shaped in such a way as to form a projecting flap 202, aligned (that is to say, parallel) with the respective lateral panel 103 of the box 100 with which it is in contact and projecting beyond an end edge 104 of the lateral panel 103 itself;

- first folding, towards the inside of the box 100, of the projecting flaps 202 to bring the flaps 202 into a configuration in which they are parallel with the bottom wall 101 of the box 100 (by advancing towards the box the folder elements which are described below), as shown in Figure 5 or 6;

- second folding, towards the inside of the box 100 of the flaps 202 previously folded, to bring each flap 202 into a configuration in which it is in contact with the inner face of a respective lateral panel 103 (by inserting at least part of a supporting mould in the box, as described below), as shown in Figure 7 or 8.

Figures 5 and 7 relate to partial covering of the inner faces of the lateral panels 103, while Figures 6 and 8 relate to an embodiment in which covering blanks 200 are prepared of a size such that the projecting flaps 202, after the second folding, substantially entirely cover the inner faces of the lateral panels 103 of the box 100.

Figure 1 shows an apparatus 1 for covering the box 100 with the covering blank 200.

The apparatus 1 comprises a folding station 10, for initial folding of the segments 201 , beneath which there is a folding station 20 for folding the projecting flaps 202.

In more detail, the folding station 2 comprises a plurality of contact elements 1 1 shaped in such a way as to interact with the covering blank 200 during a translation movement of the box 100 from the folding station 10 to the fold over station 20, to allow folding of the segments 201 from a configuration in which they are aligned with the base of the covering blank 200 (Figure 3) to a configuration in which they are aligned with the outer faces of the lateral panels 103 of the box 104 (Figure 4). Each contact element 1 1 preferably comprises an elongate body, associated with a frame of the apparatus 1 (not shown in the accompanying drawings, but of a known type) and positioned in a fixed position relative to the box 100, that is to say, relative to the mould 2.

Preferably, the contact elements 1 1 are cylindrical bodies (brushes) or idle rollers.

The number of contact elements 1 1 is preferably equal to the number of segments 201 of the covering blank 200. For the sake of clarity, Figure 1 only shows two of the four rollers 1 1 present.

Figure 4 shows how, after folding, each segment 201 is shaped in such a way that it forms the above-mentioned flap 202 projecting beyond the end edge 104 of the corresponding lateral panel 103. Therefore, in the embodiment illustrated, each flap 202 projects vertically above the end edge 104 of the corresponding lateral panel 103.

In that configuration, the rollers 1 1 intercept the segments 201 as the box 100 passes through the folding station 10, causing the segments to be folded and positioned in contact with the outer faces of the box 100 lateral panels 103.

In the embodiment illustrated, the apparatus 1 causes the box 100 to make a vertical movement between the folding station 10 and the fold over station 20. However, that line could also be different to the vertical, without altering the inventive concept.

To support and move the box 100, the apparatus 1 comprises a mould 2 which can be moved, preferably by translation (in a vertical direction in the specific embodiment illustrated, although said line is not limiting), and which can be operatively fitted to size in the box 100 so as to support and move the box 100 at least between the folding station 10 and the fold over station 20.

More generically, the mould 2 is designed to move the box 100 from a box 100 forming station (not illustrated), in which the box is obtained by folding a paperboard blank, to the folding station 10, then to the fold over station 20 and from there to an outfeed station (not illustrated) for the finished box 100.

The mould 2 is moved by means of a suitable drive unit, preferably comprising a cylinder 3 connected to the mould 2. This cylinder 3 allows the mould 2 to be raised and lowered according to the operating cycle for covering the box 100.

The apparatus 1 also comprises a supporting plate 4, designed to sustain the box 100 from below and therefore to form a support on which the bottom wall 101 can rest. The plate 3 opposes the mould 2 to hold the bottom wall 101 between the mould 2 and the plate 4. Therefore, the mould 2 can be moved vertically (integrally with the box 100 and the covering blank 200 applied to it) to move the box 100 from the folding station 10 to the fold over station 20.

Preferably, the mould 2 and the plate 4 have the same surface extension, thus avoiding a situation in which there are portions of the bottom wall 101 of the box 100 which are not supported on both sides.

Preferably, the plate 4 can also be moved and, in particular, it can be moved along the line of translation of the mould 2, therefore vertically in the embodiment illustrated.

For example, the plate 4 is moved by means of a rack-style movement system 5.

It should be noticed that the box 1 , when it is in the folding station 10, is positioned on the pre-glued covering blank 200 and positioned on the supporting plate 4. In particular, the box 100 is positioned on the covering blank 200 with the bottom wall 101 in contact with (that is, glued to) the base of the blank 200.

As is known, the mould 2 forms a constraining element operatively fitted to size in a space inside the box 1 , and forms contact surfaces operatively in contact with the inner surfaces (faces) of the lateral panels 103.

As shown in Figure 1 and in more detail in the enlarged detail in Figure 2, the fold over station 20 comprises a plurality of folder elements 21 for the projecting flaps 202.

The number of folder elements 21 is preferably equal to the number of segments 101 of the covering blank 200.

Each folder element 21 can be moved by translation towards and away from the box 100 to intercept the corresponding projecting flap 202, causing the flap to be folded from a configuration in which it is aligned with the respective lateral panel 103 to a rotated configuration (through 90°) in which the flap 202 is parallel with the bottom wall 101 of the box 100.

The fold over station 20 also comprises a plurality of actuators 26 each of which is connected to a corresponding folder element 21 for moving it by translation away from and towards the box 100.

Preferably, these actuators 26 comprise cams for moving the corresponding folder element 21 in both directions.

Preferably, as shown in Figures 1 and 2, each of these folder elements 21 comprises an elongate flat body 22 having a front end equipped with a step 23 formed by a pair of surfaces 24, 25 which are perpendicular to each other. A first 24 of said surfaces is opposite the outer face of a corresponding lateral panel 103 of the box 100 and forms the contact portion, while the other surface 25 is opposite the end edge 104 of the corresponding lateral panel 103, in particular above it.

Preferably, the second surface 25 has a size "L", measured along the line of translation of the folder element, which is less than or equal to the thickness "s" of the corresponding lateral panel 103 on which the folder element 21 acts.

Preferably, that size "L" of the second surface 25 is less than 10 millimetres and even more preferably it is less than 5 millimetres.

The distance "L" preferably coincides with the distance between the second surface 25 and the front end of the folder element 21 , for reasons explained in more detail below.

The first surface 24 of the step 23 is designed to make contact with the outer face of the corresponding lateral panel 103 of the box 100 during translation of the folder element 21 towards the box 100, producing a position in which the folder element is closest to the box. Therefore, the first surface 24 forms a contact portion facing towards the line of advancement of the folder element 21 towards the box 100 in order to reach the above-mentioned closest position.

Advantageously, the apparatus 1 comprises a control unit (not illustrated) operatively connected at least to the plate 4 and to the folder elements 21 and programmed to move the plate 4 and the folder elements 21 towards each other when at least some of the folder elements 21 have reached a configuration of maximum advancement towards the box 100, corresponding to folding of the projecting flaps 202 into the rotated configuration shown in Figure 5, so that the projecting flaps 202 are pressed against the corresponding end edges 104 of the lateral panels 103 of the box 100.

Preferably, the movement of the plate 4 and folder elements 21 towards each other is defined by a translation of the plate 4 only. In other words, in that situation the folder elements 21 can move exclusively with a (horizontal) translation movement away from and towards the box 100, for positioning the projecting flaps 202 parallel with the bottom wall 101 of the box 100, while the plate 4 can move (vertically) perpendicularly to the line of translation of the folder elements 21 for producing reciprocal compression between the above-mentioned end edges 104 of the lateral panels 103 and the stretches of the projecting flaps 202 superposed on said end edges 104.

The above-mentioned folding of the projecting flaps 202 into the position in which they are parallel with the bottom wall 101 of the box 100 is a first folding operation performed by the fold over station 20.

That first folding operation requires that, during the time needed for its completion, the mould 2 is at least partly removed from the box 100 in such a way that the mould 2 does not interfere with the rotation of the above-mentioned projecting flaps 202. Therefore, the apparatus 1 also preferably comprises means for retaining the box 100 in the fold over station 20, said means operating in conjunction with the drive unit of the mould 2 for holding the box 100 in position while at least part of the mould 2 is removed from the box 100 and placed in a position further away from the box 100 relative to the end edges 203 of the projecting flaps 202 (that is to say, in the embodiment described and illustrated, a position raised above the end edges 203 of the projecting flaps 202).

In a first embodiment, the mould 2 comprises a single-piece body connected to the above-mentioned drive unit of the mould 2. Since complete removal of the mould 2 from the box 100 means that the box 100 is no longer internally supported, in this embodiment the means for retaining the box 100 in the fold over station 20 may comprise a pusher element (not illustrated) operating on the inner surface (that is to say the upper one) of the bottom wall 101 of the box 100, during removal of the mould 2, to prevent the box 100 from being dragged on the mould 2 during removal of the mould 2 from the box 100.

The structure and operation of the pusher element are described in detail in Italian patent application No. BO2010A000325 by the same Applicant, which is incorporated herein in its entirety in terms of the aspects relating to the pusher element. Therefore, the pusher element is not described here in further detail.

Alternatively or in addition to the pusher element, the retaining means comprise suction units which are associated with the supporting plate 4 for applying a suction action on the bottom wall 101 of the box 100 (the bottom wall 101 is already covered with the covering blank 200) so as to stably hold the bottom wall 101 on the plate 4.

Preferably, the suction units comprise a suction opening positioned on an upper surface of the plate 4, in fluid communication with a vacuum pump (or any means designed to generate a vacuum).

Preferably, the suction units comprise a suction plane comprising an upper perforated contact surface of the plate 4.

This perforated surface is connected, in a sealed fashion, to a unit for generating a vacuum so as to obtain a suction cup effect on the bottom wall 101 of the box 100.

The structure and operation of the suction units are described in detail in Italian patent application No. BO2010A000325 by the same Applicant, which is incorporated herein in its entirety in terms of the aspects relating to the suction units, which are therefore not described here in further detail.

In a different embodiment, the mould 2 is divided into two parts, a first part which is stably inserted in the box and rests against the (upper) inner face of the bottom wall 101 for stably supporting the box 100 against the plate 4, and a second part which can be raised relative to the first part and removed from the box 100. This embodiment is particularly suitable, since the covering blank 200 is designed to only partly cover the inner faces of the lateral panels 103 of the box 100, without reaching the bottom wall 101 and therefore without requiring the entire mould 2 to be removed from the space inside the box 100.

After the first folding operation on the projecting flaps 202 into the position in which they are aligned with the bottom wall 101 , a second folding operation is carried out on said flaps 202, to bring each of them into a configuration in contact with the inner face of the respective lateral panel 202.

The second folding operation is performed by re-inserting the mould 2 (or the part of it previously removed) in the box 100, according to substantially known methods.

In practice, to perform a complete fold over for a box 100 with four lateral panels 103, from a minimum of two sub-sets of folding operations (opposite pairs of flaps 202) to a maximum of four sub-sets of folding operations (one single flap 202 at a time) may be carried out. Each sub-set comprises the raising of at least a part of the mould 2, activation of the one or more corresponding folder elements 21 , the relative lowering of the mould 2 or part of it, and the activation of any pressing units (not illustrated) designed for pressing, from the outside, against the mould 2 already inserted in the box, so as to aid adhesion of the flaps 202 to the inner faces of the lateral panels 103 of the box 100. Similarly to the pusher element, the structure and operation of the pressing units are described in detail in Italian patent application No. BO2010A000325 by the same Applicant, which is incorporated herein in its entirety in terms of the aspects relating to them. Therefore, the pressing units are not described here in further detail.

Again according to this invention, the apparatus 100 comprises a control unit (not illustrated) connected at least to the actuators 26 of the folder elements 21 , for activating a sub-set of the plurality of folder elements 21 consisting of one or more folder elements 21 which are not consecutive with each other, for folding a corresponding sub-set of flaps 202 (see for example Figure 5 or 6).

Preferably, the control unit is programmed to activate the sub-set of folder elements 21 depending on the height of the projecting flap 202, measured from the end edge 104 of a lateral panel 103 to the end edge 203 of the respective projecting flap 202 to be folded, and the distance between the lateral panel 103 and the lateral panel 103 opposite it. That allows the control unit to automatically assess whether or not the two projecting flaps 202 associated with two opposite lateral panels 103 may be folded simultaneously without interfering with each other (Figure 5) or if they must be folded one at a time (Figure 6).

In light of this, the control unit 15 is programmed to operate a pair of folder elements 21 along the same longitudinal line, in opposite directions of movement towards the box 100, while the remaining folder elements 21 remain stationary, for folding towards the inside of the box 100 a corresponding pair of flaps 202 lying in parallel planes at right angles to said longitudinal line (see Figure 5). In an alternative programming, the control unit 15 operates one single folder element 21 , while the remaining folder elements 21 remain stationary, for folding one flap 202 at a time towards the inside of the box 100.

Preferably, the vacuum unit is also connected to the control unit, so that it can be activated in such a way that it is synchronised with the mould 2, when it starts the movement step for removal from the box 100.

Advantageously, the control unit is also operatively connected to the plate 4 and is programmed to move the plate 4, supporting the box 100, and the folder elements 21 towards each other when at least some of the folder elements 21 have reached a configuration of maximum advancement towards the box 100, corresponding to folding of the projecting flaps 202 into the rotated configuration and parallel with the bottom wall 101 of the box 100. As already described, said movement of the plate and folder elements towards each other in that specific configuration allows the projecting flaps 202 to be pressed against the corresponding end edges 103 (below) of the lateral panels 103 of the box 100.

In more detail, the control unit is preferably connected to the plate 4 (and in particular to the movement system 5) for moving the plate 4, raising it, in such a way that this is synchronised with completion of the first folding of the projecting flaps 202.

Preferably, the control unit is programmed for advancing towards the box (100) a corresponding sub-set of a plurality of folder elements (21 ) not consecutive with each other, for folding (in a first folding step) a sub-set of flaps (202) consisting of one or more flaps (202) not consecutive with each other, bringing said flaps (202) parallel with the bottom wall (101 ) of the box (100).

In addition, the control unit is programmed to lower said at least one part of the mould (2), for folding (in a second folding step) said sub-set of folded flaps (202) bring said flaps (202) into a position in which they are in contact with the inner faces of the lateral panels (103). The control unit is programmed to perform in sequence the steps of advancing the sub-set of a plurality of folder elements and subsequent lowering of the mould, until all folder elements have been advanced, i.e. until all of the flaps (202) are in the position in contact with the inner faces of the corresponding lateral panels (103).

This invention also provides a method for covering the box 100.

This method comprises the following steps:

a) positioning the box 100 in the folding station 10, with the bottom wall 101 superposed on the base of the covering blank 200 which is positioned on the supporting plate 4;

b) folding the segments 201 of the covering blank 200, from a configuration in which they are aligned with the base of the blank 200, to a rotated configuration in which the segments 201 are in contact with corresponding outer faces of the lateral panels 103 of the box 100, in such a way that each segment 201 comprises a projecting flap 202, aligned with the respective lateral panel 103 and projecting beyond an end edge 104 of the lateral panel;

c) first folding, towards the inside of the box 100, of the projecting flaps 202 to bring said flaps into a configuration in which they are parallel with the bottom wall 101 of the box 100, by advancing towards the box the folder elements 21 which are described above;

d) second folding, towards the inside of the box 100 of the flaps 202 previously folded, to bring each flap 202 into a configuration in which it is in contact with the inner face of the respective lateral panel 103, by inserting the supporting mould 2 or part of it in the box 100.

According to the invention described above, after the first folding of the projecting flaps 200, there is the step of moving the folder elements 21 and the box 100 towards each other along a line transversal to the bottom wall 101 of the box 100, for pressing the projecting flaps 202 against the end edges 104 of the lateral panels 103 of the box 100.

Preferably, said moving step is performed by moving the box (100) towards the folder elements (21 ), wherein the folder elements (21 ) are preferably not moved in the direction of movement of the mould (that is, the direction of movement of the box).

Preferably, said moving step is performed by moving the box (100) upwards (vertically) towards the folder elements (21 ).

Preferably, the step of moving the folder elements and the box towards each other is carried out before the start of the second folding of the flaps 202 and, as described above, is performed by moving the box 100 towards the folder elements 21 .

Preferably, the second folding operation is carried out while the flaps 202 are still held pressed against the end edges 104 of the lateral panels 103 of the box 100.

Advantageously, the folder elements 21 may remain in the position closest to the box 100 during the second folding operation, therefore during insertion of the mould 2, or part of it, in the box 100. This is made possible by the specific longitudinal size (that is to say, along the line of advancement towards the box 100) of the folder elements 21 , and specifically by the dimension "L" of the first surface 24, which allows the folder elements 21 not to interfere with the movement for mould 2 insertion in the box 100.

In other words, the dimension "L" is such that it allows each folder element 21 to substantially press along the entire thickness "s" of the respective lateral wall 103 without extending into the area of movement of the mould 2, or part of it.

Therefore, the second folding operation does not require any backward movement of the folder elements 21 away from the lateral panels 103 of the box 100.

Moreover, the configuration in which the folder elements 21 are closest to the box 100 is defined by contact between the above-mentioned contact portion (second surface 25 of the step 23) of each folder element 21 and the outer face of the corresponding lateral panel 103. It should be noticed that the aspects of this invention relating to the relative movement of the plate and the folder elements, and in particular relating to the movement of the plate towards the folder elements, allow the projecting flaps of the covering blank and the end edges of the lateral panels of the box to perfectly adhere to each other, along the entire reciprocal contact surface (preventing deformations, detachments or unwanted curvatures).

During the step of pressing together the projecting flaps of the covering blank and the end edges of the lateral panels, the folder elements are preferably kept stationary.

Moreover, it should be noticed that the aspects of this invention relating to the particular shape of the folder elements allow said elements to be kept in the operating position even during insertion of the mould needed for the second folding operation. That prevents the second folding operation carried out on the end flaps from compromising the previous adhesion to the above-mentioned end edges of the lateral panels.

The invention described above is susceptible of industrial application and may be modified and adapted in several ways without departing from the scope of the inventive concept. Moreover, all the details of the invention may be substituted by technically equivalent elements.

Claims

1 . A method for covering a box (100) which has a bottom wall (101 ) and a lateral wall (102) formed by a plurality of lateral panels (103), using a flat covering blank (200) having a base shaped like the bottom wall (101 ) of the box (100) and a plurality of segments (201 ) which are connected to the base and which can be folded in such a way as to cover the lateral panels (103), characterised in that it comprises the following steps:

a) preparing a box (100) and a covering blank (200);

b) coupling the covering blank (200) to the box (100) in such a way that the bottom wall (101 ) of the box (100) is superposed on the base of the covering blank (200);

c) folding the segments (201 ) of the covering blank (200) from a configuration in which they are aligned with the base to a rotated configuration in which the segments (201 ) are in contact with corresponding lateral panels (103) of the box (100), each segment (201 ) being shaped in such a way as to form a projecting flap (202), aligned with the respective lateral panel (103) of the box (100) with which it is in contact and projecting beyond an end edge (104) of the lateral panel (103) itself; d) first folding, towards the inside of the box (100), of the projecting flaps (202) to bring said flaps (202) into a configuration in which they are parallel with the bottom wall (101 ) of the box (100), by advancing folder elements (21 ) towards the box (100);

e) second folding, towards the inside of the box (100) of the folded flaps (202), to bring each flap (202) into a configuration in which it is in contact with an inner face of a respective lateral panel (103), by inserting at least part of a supporting mould (2) in the box (100),

the method being characterised in that it also comprises, after the first folding of the projecting flaps (202), a step of moving the folder elements (21 ) and the box (100) towards each other along a line transversal to the bottom wall (101 ) of the box (100), for pressing the projecting flaps (202) against the end edges (104) of the lateral panels (103) of the box (100).

2. The method according to claim 1 , wherein the step of moving the folder elements and the box towards each other is carried out before the second folding of the flaps.

3. The method according to claim 1 or 2, wherein the step of moving the folder elements and the box towards each other is carried out by moving the box (100) towards the folder elements (21 ).

4. The method according to claim 2, wherein the second folding operation is carried out by inserting said at least part of the mould (2) in the box (100) while the flaps (202) are still held pressed against the end edges (104) of the lateral panels (103) of the box (100).

5. The method according to any of the foregoing claims, wherein the folder elements (21 ) remain in an advanced position during the second folding operation, without moving backwards away from the box.

6. The method according to any of the foregoing claims, wherein the first folding operation is carried out by advancing the folder elements (21 ) towards corresponding lateral panels (103) of the box (100) until a configuration closest to the box (100) is reached, in which the folder elements (21 ) are superposed on the end edges (104) of the lateral panels (103) of the box (101 ), without interfering with an insertion movement of said at least part of the mould (2) in the box (100).

7. The method according to claim 6, wherein the configuration in which the folder elements (21 ) are closest to the box (100) is defined by contact between a contact portion (24) of each folder element (21 ) and an outer face of the corresponding lateral panel (103).

8. The method according to any of the foregoing claims, wherein:

- the first folding step (d) comprises folding from a position a sub-set of flaps (202) consisting of one or more flaps (202) not consecutive with each other, to bring said flaps (202) parallel with the bottom wall (101 ) of the box (100), by advancing towards the box (100) a corresponding sub-set of a plurality of folder elements (21 ); - the second folding step (e) comprises further folding of the sub-set of folded flaps (202), to bring said flaps (202) into a position in which they are in contact with the inner faces of the lateral panels (103), by lowering said at least one part of the mould (2);

the steps (d) and (e) being repeated one after another until all of the flaps (202) are in the position in contact with the inner faces of the corresponding lateral panels (103).

9. An apparatus for covering a box (100) which has a bottom wall (101 ) and a lateral wall (102) formed by a plurality of lateral panels (103), using a flat covering blank (200) having a base shaped like the bottom wall (101 ) of the box and a plurality of segments (201 ) which are connected to the base and which can be folded in such a way as to cover the lateral panels (103) of the box (100), comprising:

- a movable plate (4) for supporting the covering blank (202) and the box (100);

- a movable mould (2) which can be operatively fitted to size in the box (100) for moving the box (100);

- a folding station (10) for coupling the base of the covering blank (200) to the bottom wall (101 ) of the box (100) and for folding the segments (201 ) of the covering blank (200) from a configuration in which they are aligned with the base to a rotated configuration in which the segments (201 ) are in contact with an outer face of corresponding lateral panels (103) of the box (100), each segment (201 ) being shaped in such a way as to form a projecting flap (202), aligned with the respective lateral panel (103) with which it is in contact and projecting beyond an end edge (104) of the lateral panel (103);

- a fold over station (20) in which the projecting flaps (202) are folded onto the lateral panels (103) to at least partly cover inner faces of the lateral panels (103);

- a plurality of folder elements (21 ) positioned in the fold over station (21 ) and which can be moved towards and away from the box (100) for intercepting corresponding projecting flaps (202) causing the flaps to be folded from a configuration in which they are aligned with respective lateral panels (103) to a rotated configuration in which they are parallel with the bottom wall (101 ) of the box (100),

the apparatus being characterised in that it comprises a control unit programmed to move the plate (4) and the folder elements (21 ) towards each other, when the folder elements (21 ) are positioned in contact with the end edges (104) of corresponding lateral panels (103) of the box (101 ), with the projecting flaps (202) arranged in the rotated configuration in which they are parallel with the bottom wall (101 ) of the box (100).

10. The apparatus according to claim 9, comprising movement means which are connected to the plate (4) for pushing it against the folder elements (21 ).

1 1 . The apparatus according to claim 9 or 10, wherein each folder element (21 ) can move at least along a line towards and away from the box (100) and comprises a contact portion (24) positioned perpendicularly to the direction of advancement of the folder element (21 ) towards the box (100), the contact portion (24) being designed to make contact with the outer face of a corresponding lateral panel (103) of the box (100), the contact portion (24) determining the configuration in which the folder element (21 ) is closest to the box (100).

12. The apparatus according to any of the claims from 9 to 1 1 , wherein each folder element (21 ) comprises a front end equipped with a step (23) formed by a pair of surfaces (24, 25) which are perpendicular to each other, and wherein a first (24) of the surfaces can be positioned in contact with the outer face of a corresponding lateral panel (103) of the box (100) and forms a contact portion, and a second (25) of the surfaces can be positioned in contact with an end edge (104) of the corresponding lateral panel (103).

13. The apparatus according to claim 12, wherein the second surface (25) has a dimension (L), measured along the line of translation of the folder element (21 ) towards the box (100), which is less than 10 millimetres and even more preferably less than 5 millimetres.

14. The apparatus according to any of the claims from 10 to 13, wherein the mould (2) is a single-piece body.

15. The apparatus according to any of the claims from 9 to 13, comprising a first and a second drive unit which are independent of each other, the first drive unit being connected to the mould (2) and the second drive unit being connected to the plate (4).