WO2016202402A1

WO2016202402A1 - Packaging box, blank, method and machine for forming the same

Info

Publication number: WO2016202402A1
Application number: PCT/EP2015/063827
Authority: WO
Inventors: Magnus VISTRÖM; Rickard HÄGGLUND; Mattias BODELL
Original assignee: Sca Forest Products Ab
Priority date: 2015-06-19
Filing date: 2015-06-19
Publication date: 2016-12-22
Also published as: EP3310672A1; CN107848658A; JP2018521910A

Abstract

A packaging box is provided. The box has a base and sidewalls. The base and sidewalls together define a space for accommodating a product. At least one of the sidewalls has an extension portion. The extension portion extends from an edge of the respective sidewall. The extension portion is curved into a closed loop. The extension portion therefore forms a support. The support extends from the base. The support extends to the top of the space. The extension portion is differentiated from another part of the sidewall by-treatment. The treatment is such as to cause the extension portion to more smoothly curve when bent than the other part of the sidewall. A blank for forming the box, a method for forming the blank into the box, and a machine for implementing the method are also provided.

Description

PACKAGING BOX, BLANK, METHOD AMD MACHINE FOR FORMING THE SAME

Technical Field The present invention relates to a packaging box, and particularly to a packaging box which provides improved strength when stacked. The present invention also relates to a contiguous blank for forming the packaging box, a method for forming the blank into the packaging box, and a machine for forming the packaging box from the blank.

Background

Conventional packaging boxes, for example corrugated boxes or cardboard boxes, are typically in the form of a rectangular prism, sometimes termed "brick shape", having six rectangular or square faces, respectively two pairs of opposing side walls and each of a top and bottom wall, defining an internal void for containing the articles to be packaged.

Such packaging boxes rely for their strength against external deformation on the inherent strength of the walls of the box against applied forces, as well as, in some circumstances, on the ability of the objects to be packaged to support the walls of the box from the inside. Where the articles to be packaged are themselves prone to damage, it is known to provide spacing material inside the box to provide internal support to the walls of the box, and also to inhibit the packaged articles from moving around inside the box.

It has previously been proposed to provide internal supporting structures inside such a box to strengthen the box against internal deformation. Such structures may take the form of struts placed between opposing walls of the box. However, such a configuration is typically difficult to assemble and also can restrict the volume of the box available for packaging articles. Accordingly, there is need for an improved packaging box which has improved strength against external deformation. There is also a need for improved blanks from which the box can be formed, together with improved methods and machines for assembling the blanks into boxes.

Sumnary of the Disclosure

According to a first aspect there is provided a packaging box. The box has a base and sidewalls. The base and sidewalls together define a space for accommodating a product. At least one of the sidewalls has an extension portion. The extension portion extends from an edge of the respective sidewall. The extension portion is curved into a closed loop. The extension portion therefore forms a support. The support extends from the base. The support extends to the top of the space. The extension portion is differentiated from another part of the sidewall by treatment. The treatment is such as to cause the extension portion to more smoothly curve when bent than the other part of the sidewall.

In one embodiment, the box is formed from a single contiguous blank. In one embodiment, the box has a lid portion. The lid portion extends from at least one of the sidewalls. The lid portion is such as to at least partially cover the space. The lid portion contacts the extension portion. In one embodiment, the box is formed of double-faced corrugated board. In one embodiment, the treatment comprises slitting one face of the double-faced corrugated board with slits. The slits run between neighbouring corrugations of the corrugated board.

In one embodiment, the number of slits is at least 4.

In one embodiment, the treatment comprises liquid applied to the extension portion.

In one embodiment, the liquid comprises water, glycerol, or another softening agent.

In one embodiment, the closed loop forms at least a double layer of the extension portion at at least a portion of the loop.

In one embodiment, an adjacent sidewall other than the at least one sidewall has a curved portion. The curved portion is curved to lie against an exterior of the curved extension portion. The curved portion follows the exterior of the curved extension portion.

According to a second aspect, there is provided a contiguous blank. The blank is for forming a packaging box. The box has a base and sidewalls. The base and sidewalls together define a space for accommodating a product. The blank has a base portion. The blank has sidewall portions. The sidewall portions are connected to the base portion along fold lines. At least one of the sidewall portions has an extension portion. The extension portion extends from an edge of the respective sidewall portion. The extension portion extends beyond a neighbouring edge of the base portion. The extension portion is of sufficient length as to be curvable into a closed loop to form a support extending a length of the sidewall portion beyond the fold line between the sidewall portion and the base portion. The extension portion is differentiated from another part of the sidewall portion by treatment. The treatment is so as to cause the extension portion to more smoothly curve when bent than the other part of the sidewall.

In one embodiment, there is no fold line between the at least one sidewall and the extension portion.

In one embodiment, the blank has a lid portion. The lid portion extends from one of the sidewall portions. The lid portion is connected to the respective sidewall portion by a fold line. The fold line is at an edge of the sidewall portion opposite to the edge of the sidewall portion connected to the base portion.

In one embodiment, the blank is formed of double-faced corrugated board.

In one embodiment, the treatment comprises slitting one face of the double-faced corrugated board. The slits are parallel slits. The slits run between corrugations of the corrugated board.

In one embodiment, the number of slits is at least 4.

In one embodiment, the treatment comprises applying a liquid to the extension portion.

In one embodiment, the extension portion is of sufficient length to form at least a double layer of the extension portion at (at least) a portion of the loop.

In one embodiment, an adjacent sidewall portion to the at least one sidewall is bendable so as to form a curved portion to lie against and follow an exterior of the curved extension portion.

According to a third aspect, there is provided a method of forming a packaging box from a contiguous blank. The packaging box has a base and sidewalls. The base and sidewalls together define a space for accommodating a product. The blank has a base portion and sidewall portions. The sidewalls portions are connected to the base portion along fold lines. At least one of the sidewall portions has an extension portion. The extension portion extends from an edge of the respective sidewall portion. The extension portion extends beyond a neighbouring edge of the base portion. The extension portion is of sufficient length as to be curvable into a closed loop to form a support. The support is such as to extend a length of the sidewall portion away from the fold line between the sidewall portion and the base portion. The method comprises differentiating the extension portion from another part of the sidewall portion by treatment. The treatment is such as to cause the extension portion to more smoothly curve when bent than the other part of the sidewall. The method comprises winding the extension portion into a closed loop. The method comprises securing the closed loop. The method comprises erecting the sidewall portions to form the sidewalls. The method comprises securing the sidewalls relative to the base portion to define the space.

In one implementation, there is no fold formed between the at least one sidewall and the extension portion.

In one implementation, the blank has a lid portion. The lid portion extends from one of the sidewall portions. The lid portion is connected to the respective sidewall portion by a fold line. The fold line is at an edge of the sidewall portion opposite to the edge of the sidewall portion connected to the base portion. The method comprises folding the lid portion relative to the sidewall portion to at least partially enclose the space.

In one implementation, the blank is formed of double-faced corrugated board.

In one implementation, the treatment comprises slitting one face of the double-faced corrugated board with slits running between neighbouring corrugations of the corrugated board.

In one implementation, the number of slits is at least 4.

In one implementation, the treatment comprises applying a liquid to the extension portion.

In one implementation, the liquid comprises water, glycerol, or another softening agent.

In one implementation, the extension portion forms at least a double layer of the extension portion at (at least) a portion of the loop.

In one implementation, an adjacent sidewall portion to the at least one sidewall is bent so as to form a curved portion. The curved portion is such as to lie against an exterior of the curved extension portion. The curved portion is such as to follow against an exterior of the curved extension portion. The method comprises securing the curved portion to the exterior of the curved extension portion.

According to a third aspect, there is provided a machine for forming a packaging box from a contiguous blank. The packaging box has a base and sidewalls together defining a space for accommodating a product. The blank has a base portion and sidewall portions connected to the base portion along fold lines. At least one of the sidewall portions has an extension portion extending from an edge of the respective sidewall portion. The extension portion extends beyond a neighbouring edge of the base portion. The extension portion is of sufficient length as to be curvable into a closed loop to form a support. The support extends a length of the sidewall portion away from the fold line between the sidewall portion and the base portion. The extension portion is differentiated from another part of the sidewall portion by treatment. The treatment is such as to cause the extension portion to more smoothly curve when bent than the other part of the sidewall. The machine comprises translation means. The translation means are for translating the base portion of the blank from an initial position. The initial position is planar. The translation means are for translating the base portion of the blank in a machine direction. The translation means are for translating the base portion of the blank into a folding zone. The machine comprises winding means. The winding means are arranged at the planar initial position. The winding means are arranged for winding the at least one extension portion into a closed loop. The machine comprises securing means. The securing means are arranged to apply a securing medium to the extension portion. The securing means are applied such that, when wound, the extension portion is secured in the closed loop. The apparatus comprises folding guides. The folding guides surround the folding zone. The folding guides are configured to fold the sidewalls relative to the base portion to define the space as the base portion translates in the machine direction.

In one embodiment, the translation means comprises at least one gripper.

One embodiment further comprises folding means arranged above the folding zone. The folding means are for folding a lid portion relative to the sidewall portion to at least partially enclose the space. The lid portion extends from one of the sidewall portions. The lid portion is connected to the respective sidewall portion by a fold line. The fold line is at an edge of the sidewall portion opposite to the edge of the sidewall portion connected to the base portion.

In one embodiment, the winding means comprises a fork. The fork is arranged in the plane of the initial position. The fork is arranged to engage with the extension portion in the initial position. The fork is arranged to translate from a first position to a second position. The fork is arranged simultaneously with the translation to rotate. The fork is arranged thereby to wind the extension portion into a closed loop.

In one embodiment, the securing means comprises an adhesive dispenser. The adhesive dispenser is for dispensing adhesive onto the extension portion.

In one embodiment, the adhesive dispenser is arranged to translate with the winding means. The adhesive dispenser is thereby arranged to apply adhesive at a series of different positions on the extension portion.

In one embodiment, the winding means comprises a rack and pinion. The fork is connected to the pinion. The pinion is translatable along the rack. The pinion thereby simultaneously translates and rotates the fork.

In one embodiment, the fork is displaceable in a direction parallel to the translation direction of the winding means. The fork is thereby arranged so as to be successively placed into and from engagement with the extension portion.

In one embodiment, the winding fork is arranged to make more than one complete rotation when translating from the first position to the second position.

In one embodiment, the translation means is configured to translate further the base portion of the blank from the folding zone in a machine direction into a removal zone. Conveying means are provided at the removal zone. The assembled box may be conveyed away from the removal zone by the conveying means.

Brief Description of the Drawings

For a better understanding of the present invention and to show how the same may be carried into effect, reference will be made, by way of example only, to the accompanying drawings, in which:

Figs. 1 to 6 show an implementation of a method of assembling a packaging box being an embodiment of the present invention from a blank being an embodiment of the present invention;

Figs. 7A, 7B and 7C show the effect of treating double-faced corrugated board with parallel slits; Fig. 8 shows a machine for assembling a packaging box from a blank, being an embodiment of the present invention;

Figs. 9 to 15 show an alternative implementation of a method of assembling a packaging box being an embodiment of the present invention from a packaging blank also being an embodiment of the present invention, via an automated process implemented by the machine of Fig. 8; and

Fig. 16 shows a variant packaging box being an alternative embodiment of the present invention.

Description

Fig. 1 shows a packaging blank 100 being an embodiment of the present invention suitable for folding into packaging box 200 also being an embodiment of the present invention. Packaging box 200 is shown in Fig. 6, while Figs. 2 to 5 show intermediate stages in the process of assembling blank 100 into box 200.

Packaging blank 100 has a generally planar form, and is formed of a single, continuous sheet of packaging material. Here, blank 100 is formed of double-faced corrugated board. As shown in Fig. 7A, double-faced corrugated board 9 comprises two outer layers 9a, 9c of sheet material, such as paper or card, having a corrugated inner layer 9b of sheet material arranged between the two layers, such that opposite- side peaks of the corrugated material contact respective opposite layers of the sheet material. The sheet material can be the same in all three layers, can be the same as between the exterior layers but having a different material for the corrugated layer, or can have a different material for all three layers. Further layers and/or coatings can be applied to each external layer, and each of the external layers and the corrugated layer can itself be formed of several sheets of material laminated together.

The packaging blank 100 of Fig. 1 has several principal portions .

Base portion 101 is provided, having a generally rectangular shape with rounded corners. Base portion 101 has two pairs of opposite straight edges 101a, 101b, and 101c, lOld, each of which is connected to another portion via a fold line. Connecting adjacent straight edges are curved edges lOle, lOlf, lOlg, and lOlh which provide the mentioned rounded corners.

One pair of opposite end edges 101a, 101b are connected to a respective pair of first side wall portions 102 and 103 via fold lines at edges 101a, 101b. First side wall portions 102 and 103 have width in a direction parallel to edges 10la, 101b which corresponds to the width in the same direction of respective edges 10la, 101b, that is, not including the rounded corners.

Second wall portions 104 and 105 extend from base portion 101 at opposite edges 101c and lOld which are arranged opposite each other in a direction perpendicular to opposite edges 101a and 101b in the plane of base portion 101. Second wall portions 104 and 105 are joined to base portion 101 by respective fold line.

Each of first side wall portions 102 and 103 and second side wall portions 104 and 105 extends away from the respective edge at which it is connected to base portion 101 by the same distance. Thus, when all side wall portions are folded to be perpendicular to base portion 101, the top of each side wall portion is at the same height relative to the base portion.

As shown in Fig. 1, each of second side wall portions 104 and 105 are provided with extension portions 104a, 104b and 105a, 105b. Each of extension portions 104a, 104b, 105a, 105b extends from the respective second side wall portion 104, 105 at a distance along the respective second side wall portion 104 and 105 at which respective edges 101c and lOld of base portion 101 no longer connect to the side wall portion. In other words, extension portions 104a, 104b, 105a, 105b each extend from second side wall portions 104, 105 so as to be disconnected, at least in a direct sense, from base 101.

Each of extension portions 104a, 104b, 105a, 105b is sufficiently long such that, when it is wound or rolled to form a closed loop, the radius of curvature of the closed loop corresponds to the radius of curvature of curved edges lOle, lOlf, lOlh, lOlg. Here, for the avoidance of doubt, the term "wound" means that the end of each extension portion 104a, 104b, 105a, 105b which is furthest from the base portion 102, in other words, the free end of each extension portion 104a, 104b, 105a, 105b, is lifted out of the plane of blank 100 and rolled back on Itself to form a tube-like structure.

The process of winding the extension portions 104a, 104b, 105a, and 105b results in the structure shown in Fig. 2, in which the wound or rolled extension portions 104a, 104b, 105a, 105b now form closed loops arranged at each end of second side wall portions 104, 105. The closed loops project above the plane of the base portion 101 and run in a height direction of the side wall portions 104, 105, that is, the direction from the edges 101c, lOld at which the respective side wall portions 104 and 105 connect to base portions 101.

In the transition from Fig. 1 to Fig. 2, adhesive is provided on a face of each extension portion 104a, 104b, 105a, 105b at positions which will contact another face of each respective extension portion 104a, 104b, 105a, 105b when the extension portion is wound into a closed loop. Thereby, each extension portion 104a, 104b, 105a, 105b is secured in the closed loop state into which it has been wound.

From the configuration shown in Fig. 2, tab portions 104c and 105c provided to each of second side wall portions 104 and 105 are folded in. These tab portions allow the box to be formed as a pallet-type box, having cut-out areas at the top of each of second side wall portions 104 and 105 to enable the product more easily to be accessed from the outside of the box once placed in the box, as well as to act as a reinforcement to apertures providing as hand-holds for lifting. Of course, such a pallet configuration is only one possibility, and embodiments not having such tab portions are fully within scope of the present disclosure.

From the configuration shown in Fig. 3, second side wall portions 104 and 105 are elevated by folding about fold lines 101c and lOld such that second side wall portions 104 and 105 become perpendicular to base portion 101. In this configuration, an end of each of wound extension portions 104a, 104b, 105a, 105b which is closest to base portion 101 in the unfolded state rests against base portion 101 in the folded state. Wound extension portions 104a, 104b, 105a and 105b now extend upwards from base portion 101. By appropriate choice of the radius of curvature of each of wound extension portions 104a, 104b, 105a, 105b, the external form of each of extension portions 104a, 104b, 105a, 105b follows the form of curved edges lOle, lOlf, lOlh and lOlg of base portion 101.

From the configuration shown in Fig. 4, first side wall portions 102 and 103 are respectively folded about fold lines at edges 101a and 101b of base portion 101 so as to be perpendicular to base portion 101, each first side wall portion 102, 103 lying against a respective two of wound extension portions 104a, 105a, 104b, 105b. Between the states shown in Fig. 4 and Fig. 5, adhesive may be supplied to locations of each of respective first side wall portions 102 and 103 which are to contact respective wound extension portions 104a, 105a, 104b, 105b, such that when each first side wall portion 102, 103 is contacted to an external surface of each of respective wound extension portions 104a, 105a, 104b, 105b, each first side wall portion 102 and 103 is secured thereto.

From the configuration shown in Fig. 5, tab portions 102c and 103c are folded down so as to form cut-out portions in first side wall portions 102 and 103, also. The resulting box is shown in Fig. 6. Box 200 has a base 201 and two pairs of mutually opposing first side walls 202 and 203 and second side walls 204 and 205. Box 200 has wound extension portions 204a and 204b and 205a and 205b extending from edges of each second side wall 204, 205 so as to form supports extending from base 201 to the top of the space enclosed by side walls 202, 203, 204 and 205. The extension portions 204a, 204b, 205a and 205b thus act as pillars, such that when two or more boxes 200 are stacked one on the other, the box 200 has greater resistance to crushing forces than a box in which extension portions 204a, 204b, 205a and 205b were absent. In the configuration of Figs. 1 to 6, the column strength of each pillar formed by wound side wall portions 204a, 204b, 205a and 205b can be increased, at the expense of extra material usage, by winding more than one turn of the extension portion to form the pillar. For example, each portion may be formed from an extension portion which has been wound on itself twice, three times, or even more times, to provide respectively two, three or even more overlapping layers of material, each overlapping layer of material serving further to improve the column strength.

However, in the process of forming box 200 from blank 100, it is important that extension portions 104a, 104b, 105a, 105b are able to be smoothly curved while being wound from the essentially planar configuration shown in Fig. 1 to the columnar configuration shown in Fig. 6. However, it is also important for the overall strength and stability of the box that side wall portions 102, 103, 104 and 105 retain good structural integrity. Accordingly, each extension portion 104a, 104b, 105a and 105b is differentiated from another part of the side wall portion 104, 105 by treatment to cause the extension portion to more smoothly curve when bent than the other part of the side wall.

Several options are available for such treatment. One approach is shown in Fig. 7B, which shows a number of substantially parallel cuts being made in a top surface layer 9a of a conventional corrugated board 9 as shown in Fig. 7A so as to form slits 9d. The slits 9d extend from one edge to an opposing edge of the corrugated board, and are parallel to, and run between, the peaks of neighbouring corrugations of the inter corrugated layer 9b which contact that surface of the board. As shown in Fig. 7C, the slits 9d allow the material to bend, in either a direction toward the surface layer 9a having the cuts or away from the surface layer 9a having the slits, with only a small reduction in key mechanical properties such as buckle strength. By providing such slits, preferably perpendicular to the axis about which the extension portions are wound, the extension portions may be made more flexible without affecting the mechanical properties of the remaining portions of the blank and the corresponding parts of the box. In some cases, it is envisaged that as few as four or five slits around the circumference of a wound extension portion can permit adequately smooth curving. However, embodiments are envisaged in which every corrugation in the corrugated board is provided with a corresponding cut.

Another approach involves the treatment of the extension portions 104a, 104b, 105a and 105b in a selective manner with a softening agent. The softening agent can be water, or can be glycerol or another suitable softening agent. The softening agent may be mixed with or dissolved in a carrier liquid such as water for easy application. If the softening agent is applied suitably prior to the winding of the extension portions 104a, 104b, 105a, 105b to the closed loop configuration, these portions may more easily be wound into a smoothly curved configuration. Allowing the softening agent then to dry before the box is used allows much of the original mechanical properties of the extension portion to be restored. Meanwhile, the side wall portions, not having been treated with the softening agent, retain their mechanical properties unaltered. One approach to selectively applying a softening agent is to apply, for example by printing, regions on the extension portions or on nearby portions which either attract or repel the softening agent. For example, hydrophobic stripes could be printed at areas where the softening agent should not spread, or should not spread beyond, to limit the spread of a water-based softening agent, or a softening agent using water as a carrier liquid. The process depicted in Figs. 1 to 6 may be carried out manually. Alternatively, the process can be carried out in an automated fashion by a machine 400 as shown in Fig. 8.

Machine 400 will be described with reference to an imaginary plane P, which is a plane defined as the intended plane for the base wall of the packaging box. With reference to this plane, three orthogonal axes are considered, perpendicular X and Y direction axes, which together define plane P, and direction axis Z perpendicular to each of X and Y axes, defining a normal to the plane P.

In the configuration of Fig. 8, the Z-axis extends in the opposite direction of the elevation of the side walls of the finished box, in a direction perpendicularly bound from the base surface. The Z-axis defines a machine direction of the machine in which base portion 101 travels through the machine during the folding process.

Machine 400 comprises five principal working parts. Gripping means 410 function to grip base surface 101 of blank 100 and draw it from an initial position through a folding zone to a final position. Side wall folding guides 420 and 430 function to guide the side walls from a planar configuration to a vertical, folded configuration as base portion 101 passes through the folding zone. Winding units 440 function to grasp the extension portions 104a, 104b, 105a and 105b in the planar configuration and to wind them into the wound configuration prior to folding. Adhesive application units 450 function to apply adhesive to various surface portions of the blank 100 during the folding, and especially to provide adhesive to extension portions 104a, 104b, 105a and 105b and first side wall portions 102 and 103.

The operation of this machine 400 will now be described in detail, with reference to Figs. 9 to 15. In Fig. 9, blank loo is arranged at an initial position, resting on an upper, planar surface of each of second side wall folding guides 420. The second side wall folding guides 420 have the general shape shown in the inset diagram in Fig. 8, and have a folding surface in cross-section which extends from an upper planar surface 420a through a curved portion 420b to a vertical section 420c. Folding guides 420 are opposed across a folding zone, the folding zone having a width corresponding to the width of base portion 101 measured between opposing edges 101c and lOld. Vertical surfaces 420c of folding guides 420 arranged on opposite sides of the folding zone each other and are spaced by a width of the folding zone. Here, there are three folding guides provided on each side of the folding zone, each folding guide 420 having its vertical surface 420c facing a vertical surface 420c of another folding guide 420. However, more or fewer such folding guides may be provided. In the configuration shown in Fig. 9, four winding units 440 are provided, one to correspond to each extension portion 104a, 104b, 105a, 105b. Bach winding unit is arranged at a position to correspond to each free end of the respective extension portion 104a, 104b, 105a, 105b.

Each winding means includes a winding fork 440c, which is extendable and retractable to engage with and correspondingly to release the respective extension portion from between the tines of fork 440c. Fork 440c may, for example, be extendable and retractable by means of a cooperating solenoid and a spring, the solenoid acting to displace the fork to engage the extension portion, the spring serving to retract the fork from engagement with the extension portion when the fork is to be disengaged from the respective extension portion. The fork may be retractable, for example, in the Y direction. Each fork is coupled to the pinion 440a of a rack-and-pinion drive, the rack 440b of the rack-and-pinion drive being arranged in plane P along an extension direction of the corresponding extension portion. By means of the rack-and- pinion drive, as fork 440c translates in the extension direction of the corresponding extension portion, for example in Fig. 8 the X direction, the fork will correspondingly and simultaneously rotate, the rotation being synchronized with the translation by means of the rack-and-pinion drive. The translation may, in Figure 8, be in the X direction. Each pinion is driven in an appropriate translation direction by, for example, piston 44Od.

The winding units 440 are provided in two pairs, one pair on one side of the plane P in the Y-direction and cooperating with extension portions 104a and 104b of side wall portion 104, and the other pair on another side of the plane F in the Y-direction operating on extension portions 105a and 105b of side wall portion 105. Of each pair, the winding means are arranged to translate toward each other in the X-direction during a winding operation as will be explained with reference to Fig. 10.

In Fig. 10, each fork 440c has been extended in the Y- direction inwardly into the plane of the blank 100, specifically toward the respective extension portion 104a, 104b, 105a, 105b. During the extension, the tines of each form 440c are arranged to sandwich the plane of the blank 100 such that, after the extension each free end of each extension portion is located between the tines of a respective fork 440c of winding unit 440.

From the configuration shown in Fig. 10, winding units 440 are translated by means of pistons 44Od toward the centre of each respective side wall 104 and 105. At the same time, adhesive deposition units 450 are simultaneously and synchronously translated above extension portions 104a, 104b, and 105a, 105b in front of the position of forks 440c so as to deposit adhesive as each extension portion 104a, 104b, 105a and 105b is wound into a closed loop configuration. Notably, adhesive deposition units 450 are, as indicated in Fig. 8, movable at least in paths defined in plane P, including in X direction and Y direction, such that they are able to apply adhesive to other portions also of the blank, as required. By this process, the configuration achieved in Fig. 11 is obtained, each extension portion 104a, 104b, 105a and 105b having been wound into a closed loop. From this configuration, forks 440c (not visible in Fig. 11) are withdrawn from engagement with extension portions 104a, 104b, 105a and 105b, such that the extension portions 104a, 104b, 105a, 105b are secured in place by means of the deposited adhesive from deposition units 450.

As shown in Fig. 12, winding units 440 are then retracted to their original positions. From this configuration, gripping units 410, which are provided with suction grippers at an end thereof which face base portion 101, engage with base surface 101 to allow base surface 101 to be drawn into the folding zone in the Z direction. Gripping units 410 may also have been engaged with base portion 101 previously, prior to the winding, for example, to stabilise blank 100 during the winding. Gripping units 410 are translatable in the machine direction, here the Z-direction, by pistons or other drive means, so as to draw the base surface 101, and consequently the blank 100, through the machine, and specifically through the folding zone.

As the base surface 101 is drawn by means of gripping units 410, each side wall portion 104 and 105 moves from resting against folding surface 420a of respective folding guides 420 and slides along folding surface 420b such that, as the base portion 101 reaches an end of vertical portion 420c, side walls 104 and 105 are arranged vertically to base portion 101. Similarly, as first side wall portions 102 and 103 slide along corresponding guide surfaces 430b and 430c of the first side wall folding guides 430, which are also arranged opposed to each other across the folding zone, the first side wall portions 102 and 103 are also elevated. By making the curve of folding surface 430b of each first side wall folding guide 430 shallower than the corresponding curve 420b of each second side wall folding guide 420, it can be ensured that the first side wall portions 102, 103 fold to the vertical slightly after second side wall portions 104, 105 fold to the vertical, such that it can be ensured that first side wall portions 102 and 103 overlie respective wound extension portions 104a, 104b, 105a, 105b.

The effect of this process is shown in Fig. 13. Between the configurations shown in Figs. 12 and 13, adhesive deposition units 450 have been moved and operated to apply adhesive to appropriate regions of first side wall portions 102 and 103 which are to contact wound extension portions 104a, 104b, 105a, 105b. Thereby, the configuration of Fig. 13 is secure and stable. From this configuration, folding arms 420d and 43Od, provided respectively to second side wall folding guides 420 and first side wall folding guides 430 swing over the top of the respective folding guides to fold inwardly tab portions 102c, 103c, 104c, 105c, to arrive at the configuration shown in Fig. 14.

In the configuration shown in Fig. 14, blank 100 has substantially been folded into box 200 by the action of machine 400. However, it remains to remove box 200 from machine 400, and this can be achieved by further displacing gripper means 410 in the Z axis direction to lower box 200 into a position beyond the folding zone such that box 400 may be removed from the machine by an appropriate conveyor means, not shown, such as a belt conveyor, as shown in Fig. 15. Although the above explanation is considered to fully clarify how the present invention may straightforwardly be put into effect by those skilled in the art, it is to be regarded as purely exemplary. In particular, there are a number of variations which are possible, as may be appreciated by those skilled in the art. For example, with reference to Fig. 16, it is possible also to provide a box which is not of the pallet-form shown in Fig. 6, but which has a lid L extending from one side wall of the box, supported optionally by lid support tabs T, which may rest on an upper surface of the wound extension portion 104a, 104b, 105a, 105b. Alternatively, the lid support tabs T may be absent, and lid L may rest directly on the wound extension portions 104a, 104b, 105a, 105b.

Further, it is not necessary that the box be provided with rounded corners. It is instead possible to have a box provided with angled corners, for example being formed by extension tabs extending from side walls 102 and 103 and folded at a corner of the box to run parallel to side walls 104 and 105. In such a configuration, wound pillars can be provided internally to support the structure of the box and/or to support or constrain any enclosed products. Further, rectangular boxes having four walls perpendicular to a base and forming two pairs of mutually parallel walls arranged perpendicular to the other pair of walls are only one possible configuration. Boxes having other numbers of sides, curved sides, indented sides, non-perpendicular sides with respect to a base, and non-perpendicular sides with respect to adjacent sides are all contemplated by the present disclosure .

Furthermore, when it is explained that the various portions of the box are relatively secured to another by means of adhesive, this is of course exemplary and any appropriate means for doing this as known in the art can be applied. For example, tapes, staples or rivets are also appropriate securing means in the context of the present disclosure.

With reference to the description of the machine for folding blank 100 into box 200, the operation of this means is again purely exemplary. The various moving parts of this machine may be driven by any appropriate means, such as pistons, worm drives, linear motors or other drive means such as are known in the art. The adhesive deposition units may, for example, be replaced by stapling or riveting units. The winding of the extension portions into the closed loop state may be performed, for example, by industrial robot arms having appropriately configured end effectors, such as pincers on rotary mountings. The suction grippers used to translate base surface from the initial position through the folding zone to the final position may equivalently be replaced by a plunger applied from above the machine to an upper surface of base surface 101 to push, rather than pull, base surface 101 through the machine.

In some embodiments, the wound extension portions, instead of or in addition to functioning as support pillars, can be provided with slits or apertures running, for example, parallel to the base to act as a support for one or more products packaged in the box. In such a configuration, the wound extension portions can act to provide shock protection for products packaged in the box, by preventing them from loose movement within the box. In some embodiments, the closed loop of the extension portions can be extended to provide double or more thickness of the wound portions, in order to include as much material as needed to provide a certain desired column strength. Additionally, although the present invention is disclosed in the context of paper-type or card-type packaging materials such ae cardboard and corrugated board, it is also possible to apply the present disclosure to boxes made of plastic-type materials, the treatment in such a case to achieve a smoothly bendable state of the extension portions being effected, for example, by the application of softener chemicals, heat, or appropriate radiation to soften these portions relative to other portions of the blank.

Further, the material for forming the blank of Fig. 1 can also be manufactured from the bendable board disclosed in the co-pending International application published as WO2013/012362 Al, which allows even small-radius corners to be obtained reliably and without creasing.

Further to this, it is recognised that various aspects of the present disclosure will be understood by the skilled person as being optional, or as providing particular technical effects or advantages even absent other elements in the context of which they are also presented. Accordingly, one skilled in the art will be able to adapt the present disclosure to any particular circumstance or application requirement without undue burden, taking into account the concepts disclosed herein.

All the above are fully in scope of the present disclosure, and are considered to form the basis for alternative embodiments in which one or more combinations of the above- described features are applied, without limitation to the specific combinations disclosed above.

The box of the present disclosure is easy to assemble from a corresponding blank in both a manual, machine assisted, or automated fashion, and is economical in the use of materials. Furthermore, it provides enhanced strength when stacked with other boxes. In the light of this, there will be many alternatives which implement the teaching of the present disclosure. It is expected that one skilled in the art will be able to modify and adapt the above disclosure to suit its own circumstances and requirements within the scope of the present invention, while retaining some or all technical effects of the same, either disclosed or derivable from the above, in light of the common general knowledge in this art. All such equivalents, modifications or adaptions fall within the scope of the invention hereby defined and claimed.

Claims

1. A packaging box having a base and eidewalls, the base and eidewalls together defining a space for accommodating a product, wherein at least one of the eidewalls has an extension portion extending from an edge of the respective sidewall, the extension portion being curved into a closed loop so as to form a support extending from the base to the top of the space, the extension portion being differentiated from another part of the sidewall by treatment to cause the extension portion to more smoothly curve when bent than the other part of the sidewall.

2. The packaging box of claim 1, wherein the box is formed from a single contiguous blank.

3. The packaging box of claim 1 or 2, wherein the box has a lid portion extending from at least one of the eidewalls so as to at least partially cover the space and to contact the extension portion.

4. The packaging box of any one of claims 1 to 3, wherein the box is formed of double-faced corrugated board.

5. The packaging box of claim 4, wherein the treatment comprises slitting one face of the double-faced corrugated board with slits running between neighbouring corrugations of the corrugated board.

6. The packaging box of claim 5, wherein the number of slits is at least 4.

7. The packaging box of claim 1 to 3, wherein the treatment comprises applying a liquid to the extension portion.

8. The packaging box of claim 7, wherein the liquid comprises water, glycerol, or another softening agent.

9. The packaging box according to any one of claims 1 to 8, wherein the closed loop forms at least a double layer of the extension portion at at least a portion of the loop.

10. The packaging box according to any one of claims 1 to 9, wherein an adjacent sidewall other than the at least one sidewall has a curved portion which is curved to lie against and follow an exterior of the curved extension portion.

11. A contiguous blank for forming a packaging box having a base and sidewalls together defining a space for accommodating a product, the blank having a base portion and sidewall portions connected to the base portion along fold lines, wherein at least one of the sidewall portions has an extension portion extending from an edge of the respective sidewall portion beyond a neighbouring edge of the base portion, the extension portion being of sufficient length as to be curvable into a closed loop to form a support extending a length of the sidewall portion away from the fold line between the sidewall portion and the base portion, the extension portion being differentiated from another part of the sidewall portion by treatment to cause the extension portion to more smoothly curve when bent than the other part of the sidewall.

12. The contiguous blank of claim 11, wherein there is no fold line between the at least one sidewall and the extension portion.

13. The contiguous blank of claim 11 or 12, wherein the blank has a lid portion extending from one of the sidewall portions, the lid portion being connected to the respective sidewall portion by a fold line at an edge of the sidewall portion opposite to the edge of the sidewall portion connected to the base portion.

14. The contiguous blank of any one of claim 11 to 13, wherein the blank is formed of double-faced corrugated board.

15. The contiguous blank of claim 14, wherein the treatment comprises slitting one face of the double-faced corrugated board with slits running between neighbouring corrugations of the corrugated board.

16. The contiguous blank of claim 15, wherein the number of slits is at least 4.

17. The contiguous blank of claim 11 to 13, wherein the treatment comprises applying a liquid to the extension portion.

18. The contiguous blank of claim 17, wherein the liquid comprises water, glycerol, or another softening agent.

19. The contiguous blank according to any one of claims 11 to 18, wherein the extension portion is of sufficient length to form at least a double layer of the extension portion at at least a portion of the loop.

20. The contiguous blank according to any one of claims 11 to 19, wherein an adjacent sidewall portion to the at least one sidewall is bendable so as to form a curved portion to lie against and follow an exterior of the curved extension portion.

21. A method of forming a packaging box from a contiguous blank, the packaging box having a base and sidewalls together defining a space for accommodating a product, the blank having a base portion and sidewall portions connected to the base portion along fold lines, wherein at least one of the sidewall portions has an extension portion extending from an edge of the respective sidewall portion beyond a neighbouring edge of the base portion, the extension portion being of sufficient length as to be curvable into a closed loop to form a support extending a length of the sidewall portion away from the fold line between the sidewall portion and the base portion, the method comprising:

differentiating the extension portion from another part of the sidewall portion by treatment to cause the extension portion to more smoothly curve when bent than the other part of the sidewall;

winding the extension portion into a closed loop;

securing the closed loop;

erecting the sidewall portions to form the sidewalls; securing the sidewalls relative to the base portion to define the space.

22. The method of claim 21, wherein there is no fold formed between the at least one sidewall and the extension portion.

23. The method of claim 21 or 22, wherein the blank has a lid portion extending from one of the sidewall portions, the lid portion being connected to the respective sidewall portion by a fold line at an edge of the sidewall portion opposite to the edge of the sidewall portion connected to the base portion, and wherein the method comprises folding the lid portion relative to the sidewall portion to at least partially enclose the space.

24. The method of any one of claims 21 to 23, wherein the blank is formed of double-faced corrugated board.

25. The method of claim 24, wherein the treatment comprises slitting one face of the double-faced corrugated board with slits running between neighbouring corrugations of the corrugated board.

26. The method of claim 25, wherein the number of slits is at least 4.

27. The method of any one of claim 21 to 23, wherein the treatment comprises applying a liquid to the extension portion.

28. The method of claim 27, wherein the liquid comprises water, glycerol, or another softening agent.

29. The method according to any one of claims 21 to 28, wherein the extension portion forms at least a double layer of the extension portion at at least a portion of the loop.

30. The method according to any one of claims 21 to 29, wherein an adjacent sidewall portion to the at least one sidewall is bent so as to form a curved portion to lie against and follow an exterior of the curved extension portion, wherein the method comprises securing the curved portion to the exterior of the curved extension portion.

31. A machine for forming a packaging box from a contiguous blank, the packaging box having a base and sidewalls together defining a space for accommodating a product, the blank having a base portion and sidewall portions connected to the base portion along fold lines, wherein at least one of the sidewall portions has an extension portion extending from an edge of the respective sidewall portion beyond a neighbouring edge of the base portion, the extension portion being of sufficient length as to be curvable into a closed loop to form a support extending a length of the sidewall portion away from the fold line between the sidewall portion, the extension portion being differentiated from another part of the sidewall portion by treatment to cause the extension portion to more smoothly curve when bent than the other part of the sidewall,

the apparatus comprising:

translation means for translating the base portion of the blank from a planar initial position in a machine direction into a folding zone; winding means arranged at the planar initial position the folding zone for winding the at least one extension portion into a closed loop;

securing means arranged to apply a securing medium to the extension portion such that, when wound, the extension portion is secured in the closed loop;

folding guides surrounding the folding zone configured to fold the sidewalls relative to the base portion to define the space as the base portion translates in the machine direction.

32. The machine of claim 31, wherein the translation means comprises at least one gripper.

33. The machine of claim 31 or 32, further comprising folding means arranged above the folding zone for folding a lid portion relative to the sidewall portion to at least partially enclose the space, the lid portion extending from one of the sidewall portions and being connected to the respective sidewall portion by a fold line at an edge of the sidewall portion opposite to the edge of the sidewall portion connected to the base portion.

34. The machine of any one of claims 31 to 33, wherein the winding means comprises a fork arranged in the plane of the initial position to engage with the extension portion in the initial position and to translate from a first position to a second position and simultaneously to rotate to wind the extension portion into a closed loop.

35. The machine of claim 34, wherein the securing means comprises an adhesive dispenser for dispensing adhesive onto the extension portion.

36. The machine of claim 35, wherein the adhesive dispenser is arranged to translate with the winding means so as to apply adhesive at a series of different positions on the extension portion.

37. The machine of any one of claims 34 to 36, wherein the winding means comprises a rack and pinion, wherein the fork is connected to the pinion, the pinion being translatable along the rack to simultaneously translate and rotate the fork.

38. The machine of claim 37, wherein the fork is displaceable in a direction parallel to the translation direction of the winding means so as to be successively placed into and from engagement with the extension portion.

39. The machine according to any one of claims 34 to 38, wherein the winding fork is arranged to make more than one complete rotation when translating from the first position to the second position.

40. The machine according to any one of claims 31 to 39, wherein the translation means is configured to translate further the base portion of the blank from the folding zone in a machine direction into a removal zone, conveying means being provided at the removal zone by which the assembled box may be conveyed away from the removal zone.