FOLDING SPOON, METHOD AND APPARATUS FOR MANUFACTURING SUCH FOLDING SPOON

Abstract

Various embodiments of the present disclosure are directed to a folding spoon apparatus and a method of manufacturing a folding spoon. In one example embodiment, a folding spoon is disclosed including a planar blank and a plurality of scores disposed on said planar blank. The planar blank has along a longitudinal axis a handle portion with a front lateral edge and a bowl portion with a rear lateral edge. The plurality of scores including a longitudinal handle folding line extending from said front lateral edge, along said longitudinal axis, towards a rear lateral edge opposite said front lateral edge and terminating in the bowl portion, or two longitudinal handle folding lines provided on said planar blank symmetrically in relation to the longitudinal axis. The handle portion includes a first lateral folding line, and a cut out forming a retainer flap.

Claims

1. A folding spoon comprising: a planar blank having along a longitudinal axis, a handle portion with a front lateral edge, and a bowl portion with a rear lateral edge; and a plurality of scores disposed on said planar blank including a longitudinal handle folding line extending from said front lateral edge along said longitudinal axis towards a rear lateral edge opposite said front lateral edge and terminating in the bowl portion, or two longitudinal handle folding lines provided on said planar blank symmetrically in relation to the longitudinal axis; wherein the handle portion includes a first lateral folding line in a position closer to said rear lateral edge than to said front lateral edge and extending transverse to said longitudinal axis, and further including a cut out forming a retainer flap arranged to be placed behind an edge area at said rear lateral edge when the spoon is in folded condition, being folded along said first lateral folding line.

2. The folding spoon of claim 1, wherein the folding spoon further includes a second lateral folding line arranged in said handle portion between said first lateral folding line and said front lateral edge in a distance from said first lateral folding line corresponding to the distance between said first lateral folding line and said rear lateral edge and extending transversal to said longitudinal axis.

3. The folding spoon of claim 2, wherein the cut out extends from said second lateral folding line towards said rear lateral edge and back to said second lateral folding line.

4. The folding spoon of claim 1, wherein that the at least one longitudinal handle folding line extends to a bowl folding line, the bowl folding line extending towards the rear lateral edge and ends at the side edge of the bowl portion.

5. The folding spoon of claim 1, wherein said handle portion has a width which is smaller than the width of the bowl portion and that the bowl portion is connected to the handle portion via a connecting portion having double curvatured side edges connecting outer side edges of the handle portion and the bowl portion.

6. The folding spoon of claim 5, wherein said vertex is positioned in the connecting portion.

7. The folding spoon of claim 1, wherein said planar blank consists essentially of paperboard sheet.

8. The folding spoon of claim 1, wherein said planar blank consists essentially of cardboard or plastic.

9. The folding spoon of claim 1, wherein said planar blank consists essentially of paperboard or cardboard, and wherein the thickness of the planar blank is greater than 300 μm.

10. The folding spoon of claim 1, wherein the cut out is a slit.

11. A method for manufacturing a folding spoon in a folded state, the method comprises the steps of: punching and embossing a sheet for establishing a number of said planar blanks which are arranged side by side and are connected through a first retaining strip and a second retaining strip at the front lateral edge and the rear lateral edge, transferring said punched sheet to a conveyor, conveying, in the conveyor, the punched sheet in a state being pinched in a transport plane between upper and lower pinching means to a first cutting station, cutting off, in the first cutting station, the first retaining strip thereby leaving the planar blank only connected through the second retaining strip, conveying, in the conveyor, the connected planar blank in the pinched state to a folding station while removing the first retaining strip, folding, in the folding station, the planar blank along a first lateral score while pinching a part of the planar blank thereby bringing a handle portion and a bowl portion in superimposed position being squeezed against each other in the transport plane, folding, in the folding station, the superimposed portions of the now folded blank along a second lateral score thereby a retainer flap in the transport plane as the edge area between the second lateral score and the front lateral edge, folding, in the folding station, a portion of the superimposed portions of the now folded blank along the second lateral score back to the transport plane and thereby placing the retainer flap behind the edge area at said rear lateral edge when the spoon is in folded condition, conveying, in the conveyor, the spoon in folded and retained state to a second cutting station, and cutting off, in the second cutting station, the second retaining strip thereby providing folded spoons in the folded and retained state.

12. The method according to claim 11, characterised in that in said punching step the number of said planar blanks is connected through a first retaining strip at the rear lateral edge and through the second retaining strip at the front lateral edge.

13. The method according to claim 11, further including choosing said sheet either as a roll or as sheets from a stack of sheets which are continuously conveyed by the conveyor.

14. Apparatus for manufacturing a folding spoon comprising: a punching station configured for punching and embossing planer blanks out from a sheet, at least one cutting station configured for cutting the planar blanks free from retaining strips connecting the planar blanks, a conveyor configured for conveying the planar blanks through the different stations, and a folding station configured for folding the planar blanks into the folded spoons in a folded and retained state.

15. The apparatus according to claim 14, further including a first and a second cutting station and that the folding station is arranged between said first and second cutting station.

16. The apparatus according to claim 14, characterised in that said conveyor comprises endless belts configured to convey, the planar blanks in a squeezed state between opposite arranged endless belts and support element for supporting the planar blanks and the retaining strips in the folding and cutting stations.

17. The folding spoon of claim 9, wherein the thickness of the planar blank is in the range of 500-600 μm.

18. The folding spoon of claim 7, wherein the planar blank further includes a moisture barrier coating.

19. The folding spoon of claim 1, wherein the spoon further including a second cut out forming a second retainer flap arranged to be placed behind an edge area at said rear lateral edge when the spoon is in folded condition, being folded along said first lateral folding line.

20. The folding spoon of claim 18, wherein the cut outs are arranged at each side of the handle portion and extend to the side edges of the handle portion.

21. The method of claim 12, further including choosing said sheet either as a roll or as sheets from a stack of sheets which are continuously conveyed by the conveyor.

22. The apparatus of claim 15, characterised in that said conveyor comprises endless belts configured to convey the planar blanks in a squeezed state between opposite arranged endless belts and support element for supporting the planar blanks and the retaining strips in the folding and cutting stations.

Description

DESCRIPTION OF THE DRAWING

[0119] The invention will be described with reference to the accompanying drawing, where each reference number refers to identical or functionally-similar elements throughout separate figures and where

[0120] FIG. 1 illustrates different views of a first embodiment for a folding spoon according to the present invention,

[0121] FIG. 2 illustrates views corresponding to FIG. 1 of a further embodiment for a folding spoon according to the present invention,

[0122] FIG. 3 illustrates views corresponding to FIG. 1 of a further embodiment for a folding spoon according to the present invention,

[0123] FIG. 4 illustrates views corresponding to FIG. 1 of a further embodiment for a folding spoon according to the present invention,

[0124] FIG. 5 illustrates views corresponding to FIG. 1 of a further embodiment for a folding spoon according to the present invention,

[0125] FIG. 6 illustrates a further embodiment of a folding spoon provided with slits in order to have a fork-like cutlery,

[0126] FIG. 7 illustrates different steps in the method of manufacturing the folding spoon,

[0127] FIG. 8 illustrates a partial view of a part of an apparatus according to the present invention,

[0128] FIG. 9 illustrates a partial view of a first cutting station of an apparatus according to the present invention,

[0129] FIG. 10 illustrates a partial view of a first part of a folding station in an apparatus according to the present invention,

[0130] FIG. 11 illustrates a partial view of a further part of the folding station in an apparatus according to the present invention, and

[0131] FIG. 12 illustrates a partial view of a second cutting station in an apparatus according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

[0132] In the following text, the invention will be described in connection with the figures. Different parts and positions seen in the figures will be numbered with the same number in the different figures. Not all parts and positions indicated at a specific figure will necessarily be discussed together with such figure.

[0133] In FIG. 1-5, different views of a folded spoon 1 are illustrated.

[0134] View A illustrates a planar blank 2. View B illustrates a top view of the folding spoon in folded condition. View C illustrates a side view of the folding spoon in folded position. View D illustrates the folding spoon in unfolded state, ready to be used.

[0135] The planar blank comprises a handle portion 3 and a bowl portion 4 and a connecting portion 5 arranged between the handle portion 3 and the bowl portion 4. The planar blank has a front lateral edge 6 and a rear lateral edge 7. At the rear lateral edge 7, an edge area 8 is provided. The planar blank comprises a longitudinal handle score 9 extending from the front lateral edge 6 towards the rear lateral edge 7.

[0136] The planar blank has a longitudinal axis 10 dividing said planar blank into two general, symmetric halves 11, 12. The longitudinal handle score 9 is coinciding with the longitudinal axis 10.

[0137] The planar blank comprises a first lateral score 13. The first lateral score 13 is arranged in the handle portion 2. It is placed closer to the rear lateral edge 7 than to the front lateral edge 6.

[0138] The planar blank comprises a second lateral score 14 arranged in the handle portion 2 in a distance 15 from the first lateral score 13. The distance 15 between the first lateral score 13 and the second lateral score 14 correspond to a distance 16 between the first lateral score 13 and the rear lateral edge 7.

[0139] A cut out 17 extends from said second lateral score 14 towards the rear lateral edge 7 and back to the second lateral score 14. In the illustrated form, the cut out is provided as two linear cuts ending in a common point at the longitudinal axis 10. The cut out defines a retainer flap 18.

[0140] As seen in the views B and C, the retainer flap 18 will be placed behind the edge area 8 adjacent to the rear lateral edge 7 when the spoon is in the folded condition folded along the first lateral score 13.

[0141] View D illustrates the spoon in unfolded state. The spoon has opposing side edges 19 at the handle portion 3 and opposing side edges 20 at the bowl portion 4. Opposing side edges 21 at the connection portion 5 connect the side edges 19 and 20.

[0142] In view D, arrows 22 indicate forces exerted on the side edges 19 of the handle portion 3. These forces are exerted by the user's fingers and will be sufficient for effecting a folding of the spoon along the longitudinal handle score 9 as illustrated. Hereby, the spoon is ready for use, and due to the folding, it will have a stable condition without risk that the bowl portion and handle portion will pivot in relation to each other during use.

[0143] FIG. 2 corresponds to FIG. 1. However, here it is seen that cut outs 17 are arranged at each side of the handle portion and extend to the side edges 21 of the handle portion 3. Hereby, two retainer flaps 18 are provided.

[0144] FIG. 3 illustrates a further embodiment in which two longitudinal handle scores 9 are provided. The two longitudinal handle scores 9 are provided symmetrically in relation to the longitudinal axis 10.

[0145] The longitudinal handle scores ends at point 23. From each point 23, a bowl score 24 extends towards the rear lateral edge 7 and ends at the side edges 20 of the bowl portion 4.

[0146] As seen in view D, the unfolded spoon will be provided with two side walls 25 connecting a bottom 26 in the handle portion 3. In order to fold up the wall parts 25, forces 22 are needed in the same way as the forces exerted in the above explained embodiments.

[0147] FIG. 4 illustrates a further embodiment corresponding to the embodiment illustrated in FIG. 1. View D illustrates the unfolded state of the spoon. Here it is seen that a folded portion 27 is provided as the edge area at the front lateral edge is folded along the second lateral handle score 14. Hereby the handle portion will maintain its V-shape, without the need of exerting forces on the side edges of the handle portion. The folded portion 27 may be provided with glue in order to keep the folded portion 27 attached to the remainder of the handle portion 3.

[0148] FIG. 5 illustrates a folding spoon in which the bowl portion 4 and handle portion 3 are thermoformed to a spatial form when providing the planar blank with score lines.

[0149] View C illustrates clearly that the bowl portion 4 and handle portion 3 have a curved form. A longitudinal handle score 9 is provided. However, this is provided in order to amend the mutual position of the two symmetrical halves of the handle portion, when the spoon is used. It might be possible to provide the spoon without the longitudinal handle score if the thermoformed handle in itself is sufficiently stiff for use.

[0150] FIG. 6 illustrates a further embodiment in which the bowl portion 4 is provided with slits 27. Hereby, fork branches 28 are formed. Hereby, a cutlery is established which could also be noted as fork.

[0151] FIG. 6 illustrates that the longitudinal handle score 9 ends in a vertex 29. From said vertex 29 two bowl scores 30 extend towards the rear lateral edge 7 and extend to the side edges 20 of the bowl portion.

[0152] Even though the embodiment with the vertex 29 and the bowl scores 30 are only illustrated in connection with the embodiment of FIG. 6, then it is understood that a corresponding use of scores will also apply in embodiments according to FIGS. 1, 2 and 4.

[0153] The use of the vertex 29, at which the handle score 9 and the bowl scores 30 meets, will make it possible to provide a hollowed form of the bowl portion when applying the forces 22 on the side edges of the handle portion 3. The bowl portion 4 will be drawn upwardly in relation to a straight line containing the longitudinal handle score when the forces 22 are applied on the handle portion.

[0154] In FIG. 6 it is illustrated that the side edges 21 of the connecting portion 5 has a double curvatured form. A corresponding form of the side edges 21 of the connecting portion 5 may also be used in embodiments according to FIGS. 1, 2 and 4.

[0155] FIG. 7 illustrates the different steps of the method for manufacturing the folding spoon 1 in a folded state. In FIG. 7 is illustrated a stack 31 of paperboard sheets 32. After punching and embossing the sheets 32 they are provided as a stack 33 of the punched and embossed sheets 32. This stack 33 is transferred as indicated at 34 to conveying equipment which is illustrated in FIGS. 8-12. When conveying the sheets, they will be provided in a pinched condition between endless belts 35,36 (see FIG. 8).

[0156] In the sheets 32, the planar blanks 2 are connected through the first retaining strip 38 at the rear lateral edge 7 of the planar blanks 2 and a second retaining strip 39 at the front lateral edge 6 of the planar blanks 2.

[0157] In a first cutting station 37, the first retaining strip 38 is cut off, thereby leaving the rear lateral edge 7 free, whereas the front lateral edge 6 is still connected to the second retaining strip 39. The sheet is conveyed to a folding station. A folding of the bowl portion 4 in relation to the handle portion 3 is effected around a folding guide 40 by means of belts illustrated in FIGS. 10 and 11.

[0158] Hereafter, the bowl portion and the handle portion are provided in a superimposed state as illustrated at 41. Hereafter, further folding is effected, whereby the superimposed portions are folded downwardly as indicated by 42. A part of the handle portion and the second retaining strip 39 are maintained in the original plane, which could be denoted as a transport plane, and which will normally be horizontal. As indicated at 43, the superimposed portions are folded back to the transport plane. Hereby the retainer flap 18 is positioned behind the edge area 8. Hereafter, a further cutting station 44 is provided for cutting off the second retaining strip 39. Hereby, the folding spoons 1 are leaving the equipment as individually items in a folded and retained position.

[0159] In FIG. 7, arrow 45 indicates the transport direction of the sheets through the method steps and accordingly through the apparatus used for effecting the method.

[0160] FIG. 8 illustrates details of the apparatus according to the invention used for the manufacture of the folding spoon 1. Also here, the arrow 45 indicates the transport direction of the sheets through the apparatus.

[0161] FIG. 8 illustrates endless belts 35,36 which are used for pinching the sheet 32 and conveying the sheet 32 from the stack 33 through the apparatus. FIG. 8 illustrates a vacuum unit 46 used for transferring the uppermost sheet 32 in the stack 33 into a nip between the endless belts 35,36.

[0162] FIG. 9 illustrates the first cutting station 37 for cutting the first retaining strip 38 out of the sheets 32. A rotating knife 47 is used. The knife cooperates with fixed cutting bar (not illustrated).

[0163] FIG. 10 illustrates a folding station. A belt 48 is used for folding the bowl portion around a folding guide 40 when advancing the sheets according to the arrow 45. Instead of a belt 48, a guiding rail may be used. The bowl portion 4 is folded through 180 degrees to be placed upon the handle portion 3.

[0164] FIG. 11 illustrates a second part of the folding station, where the superimposed bowl portions and handle portions are folded 90° downwardly. As illustrated, the retainer flaps 18 remain in the transport plane. A further belt 50 is used for folding the superimposed portions upwardly back into the transport plane as illustrated at 51. Hereby, the retainer flaps 18 are placed behind the edge area 8 of the spoon portion 4.

[0165] FIG. 12 illustrates the second cutting station 44 in which a rotating knife 52 is used for cutting free the second retaining strip 39. Hereby, the folding spoons 1 can freely and individually be transferred to further prosecution in a folded and retained state.