Method and system for creating custom-sized packaging boxes and for automatically packaging items

Abstract

Method and system for making custom-sized open packaging boxes from cardboard having a width W.sub.CBB and corresponding separate closing lids from cardboard having a width W.sub.CBL, the cardboard being continuously supplied to a system comprising structure for cutting, creasing and folding the cardboard to form custom-sized boxes and corresponding lids such that each box comprises a rectangular bottom panel having four edges, a first and a second rectangular end panel joined via respective crease lines to opposite edges of said bottom panel, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said bottom panel, two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel, and the second corner panels joined via respective crease lines to opposite edges of the second end panel, each lid comprises a rectangular top panel having four edges, a first and a second rectangular end panel joined via respective crease lines to opposite edges of said top panel, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said top panel, optionally two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel and the second corner panels joined via respective crease lines to opposite edges of the second end panel, said method comprising: a step of obtaining information on the desired minimum inner dimensions length L.sub.D, height H.sub.D and width W.sub.D of a box to be created, a calculating step of calculating the dimensions of the panels of a box and of the panels of a lid on the basis of the desired minimum dimensions taking into account predetermined optimization criteria, and a step of creating the box and the lid, wherein said calculating step comprises allowing the inner height of the side panels of the box to be smaller than the desired inner height of the box if (W.sub.D+2 T.sub.CBB+2H.sub.D)>(W.sub.CBB−M.sub.B), wherein MB denotes an optional minimum margin that is cut off at the sides of the cardboard supplied and wherein T.sub.CBB denotes a material dependent correction factor generally corresponding to the thickness of the cardboard used for the box, and/or if 2H.sub.D>L.sub.D and choosing the inner height of the side panels of the lid template so that the inner height of the side panels of the box plus the inner height of the side panels of the lid equals at least the desired height.

Claims

1. A method for making custom-sized open packaging boxes from cardboard having a width W.sub.CBB and corresponding separate closing lids from cardboard having a width W.sub.CBL, the cardboard being continuously supplied to a system comprising structure for cutting, creasing and folding the cardboard to form custom-sized boxes and corresponding lids such that each box comprises a rectangular bottom panel having four edges, a first and a second rectangular end panel joined via respective crease lines to opposite edges of said bottom panel, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said bottom panel, two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel, and the second corner panels joined via respective crease lines to opposite edges of the second end panel, each lid comprises a rectangular top panel having four edges, a first and a second rectangular end panel joined via respective crease lines to opposite edges of said top panel, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said top panel, optionally two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel and the second corner panels joined via respective crease lines to opposite edges of the second end panel, said method comprising: obtaining information that specifies a set of minimum inner dimensions of a box to be created, the set of minimum inner dimensions including a length L.sub.D, a height H.sub.D and a width W.sub.D of the box to be created, calculating a set of dimensions of the panels of the box to be created and of the panels of a lid to be created based on the set of minimum inner dimensions taking into account defined optimization criteria, and creating the box and the lid based on the set of dimensions of the panels of the box to be created and of the panels of the lid to be created, wherein said calculating comprises allowing an inner height H.sub.SPB of the side panels of the box to be smaller than the inner height H.sub.D of the box if (W.sub.D+2 T.sub.CBB2H.sub.D)>(W.sub.CBB−M.sub.B), wherein M.sub.B denotes an optional minimum margin that is cut off at the sides of the cardboard supplied and wherein T.sub.CBB denotes a material dependent correction factor that at least approximately corresponds to a thickness of the cardboard used to form the box, and/or if 2H.sub.D>L.sub.D and choosing an inner height H.sub.SPL of the side panels of a lid template so that the inner height H.sub.SPB of the side panels of the box plus the inner height H.sub.SPL of the side panels of the lid equals at least the height specified by the set of minimum inner dimensions of the box to be created.

2. The method according to claim 1 for making custom-sized open packaging boxes from cardboard having the width W.sub.CBB and corresponding separate closing lids from cardboard having the width W.sub.CBL, the cardboard being continuously supplied to a system comprising structure for cutting, creasing and folding the cardboard to form custom-sized boxes and corresponding lids such that each box comprises: a rectangular bottom panel having four edges, an inner length L.sub.BPB and an inner width W.sub.BPB, a first and a second rectangular end panel joined via respective crease lines to opposite edges of said bottom panel, each end panel having an inner width W.sub.EPB and an inner height H.sub.EPB, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said bottom panel, each side panel having a length L.sub.SPB and the inner height H.sub.SPB, two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel, and the second corner panels joined via respective crease lines to opposite edges of the second end panel, each corner panel having an inner length L.sub.CPB and a height H.sub.CPB, each lid comprises: a rectangular top panel having four edges and a length L.sub.TPL and a width W.sub.TPL, a first and a second rectangular end panel, joined via respective crease lines to opposite edges of said top panel, each end panel having a width W.sub.EPL and an inner height H.sub.EPL, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said top panel, each side panel having a length L.sub.SPL and the inner height H.sub.SPL, optionally two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel and the second corner panels joined via respective crease lines to opposite edges of the second end panel, each corner panel having an inner length L.sub.CPL and a height H.sub.CPL, wherein calculating comprises setting, if (W.sub.D+2 T.sub.CBB+2H.sub.D)>(W.sub.CBB−M.sub.B), wherein M.sub.B denotes an optional minimum margin that is cut off at the sides of the cardboard supplied for creating the box and wherein T.sub.CBB denotes a material dependent correction factor generally corresponding to the thickness of the cardboard used for the box, and/or if 2H.sub.D>L.sub.D H.sub.SPB to fulfil (2H.sub.SPB+2 T.sub.CBB+W.sub.BPB)≤(W.sub.CBB−M.sub.B) and 2H.sub.SPB≤L.sub.D and H.sub.SPL to fulfil H.sub.SPL+H.sub.SPB≥H.sub.D.

3. The method according to claim 1, wherein the bottom panel of each box has an inner width W.sub.BPB, and if (W.sub.D+2 T.sub.CBB+2H.sub.D)>(W.sub.CBB−M.sub.B) and/or if 2H.sub.D>L.sub.D, H.sub.SPB is set to, within the typical material-caused tolerances, (2H.sub.SPB+2T.sub.CBB+W.sub.BPB)=(W.sub.CBB−M.sub.B) if (W.sub.D+2 T.sub.CBB+2H.sub.D)>(W.sub.CBB−M.sub.B) and if 2H.sub.D≤L.sub.D, (1H.sub.SPB+1 T.sub.CBB)=½L.sub.D if (W.sub.D+2 T.sub.CBB+2H.sub.D)≤(W.sub.CBB−M.sub.B) and if 2H.sub.D>L.sub.D; and to the minimum of the above if (W.sub.D+2 T.sub.CBB+2H.sub.D)>(W.sub.CBB−M.sub.B) and if 2H.sub.D>L.sub.D.

4. The method according to claim 1, wherein the top panel of each lid has an inner length L.sub.TPL and an inner width W.sub.TPL, and each end panel of each lid has an inner height H.sub.EPL, and H.sub.SPL and H.sub.EPL are set to be equal if either (L.sub.TPL+2 T.sub.CBL+2H.sub.EPL)≤(W.sub.CBL−M.sub.L) or (W.sub.TPL+2 T.sub.CBL+2H.sub.SPL)≤(W.sub.CBL−M.sub.L), wherein M.sub.L denotes an optional minimum margin that is cut off at the sides of the cardboard supplied for creating the lid and wherein T.sub.CBL denotes a material dependent correction factor generally corresponding to the thickness of the cardboard used for the lid.

5. The method according to claim 4, wherein if both, (L.sub.TPL+2 T.sub.CBL+2H.sub.EPL)≤(W.sub.CBL−M.sub.L) and (W.sub.TPL+2 T.sub.CBL+2H.sub.SPL)≤(W.sub.CBL−M.sub.L), the lid is cut such that the side panels of the lid are in front and behind the top panel and the end panels of the lid are to the left and the right of the top panel seen in the transport direction of the cardboard supplied for making the lid, if (L.sub.TPL+2H.sub.EPL)>(W.sub.TPL+2H.sub.SPL), and such that the end panels of the lid are in front and behind the top panel and the side panels of the lid are to the left and the right of the top panel seen in the transport direction of the cardboard supplied for making the lid if (L.sub.TPL+2H.sub.EPL)<(W.sub.TPL+2H.sub.SPL).

6. The method according to claim 1, wherein the box and the lid are made in series from the same cardboard.

7. The method according to claim 1, wherein each side panel of each box has an inner height H.sub.SPB, and each end panel of each lid has an inner height H.sub.EPL, and if H.sub.SPB<H.sub.D, H.sub.SPL is set to fulfil, within the typical material-caused tolerances, H.sub.SPL+H.sub.SPB=H.sub.D, and/or wherein if H.sub.EPB<H.sub.D, H.sub.EPL is set to fulfil, within the typical material-caused tolerances, H.sub.EPL+H.sub.EPB=H.sub.D.

8. The method according to claim 1, wherein each side panel of each box has an inner height H.sub.SPB, and each end panel of each lid has an inner height H.sub.EPL, and H.sub.SPL is set to fulfil, within the typical material-caused tolerances, H.sub.SPB+H.sub.SPL=H.sub.D+M.sub.OSP, wherein M.sub.OSP denotes a desired overlap of the side panels of the lid with the side panels of the box, and/or wherein H.sub.EPL is set to fulfil, within the typical material-caused tolerances, H.sub.EPL+H.sub.EPB=H.sub.D+M.sub.OEP, wherein M.sub.OEP denotes a desired overlap of the end panels of the lid with the end panels of the box.

9. The method according to claim 1, further comprising: introducing two parallel perforation lines in at least some of the panels of the lid and optionally attaching a tear strip between the parallel perforation lines.

10. The method according to claim 1, further comprising: optimizing the dimensions of the panels of the box and the lid under at least one of the following criteria: minimum volume of the closed box, maximum strength of the closed box, minimum waste material, position of fold lines in zig-zag folded cardboard.

11. The method according to claim 1, further comprising: folding the corner panels of the box upwards with one or more items to be packaged on the bottom panel of the box, folding the end panels of the box upwards and the corner panels inwards, and folding the side panels upwards and placing the corresponding lid on top of the box.

12. The method according to claim 11, wherein placing the lid on the box comprises placing the top panel of the lid on the box and folding the end panels and the side panels of the lid downwards.

13. The method according to claim 11, wherein closing the box comprises holding the lid above the box and attaching the end panels of the lid to the end panels of the box and the side panels of the lid to the side panels of the box.

14. The method according to claim 11, wherein the corner panels and the side panels are glued to each other.

15. A system for making custom-sized open packaging boxes from cardboard having a width W.sub.CBB and corresponding separate closing lids from cardboard having a width W.sub.CBL, the cardboard being continuously supplied to the system, wherein: each box comprises: a rectangular bottom panel having four edges, an inner length L.sub.BPB and an inner width W.sub.BPB, a first and a second rectangular end panel joined via respective crease lines to opposite edges of said bottom panel, each end panel having an inner width W.sub.EPB and an inner height H.sub.EPB, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said bottom panel, each side panel having a length L.sub.SPB and an inner height H.sub.SPB, two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel, and the second corner panels joined via respective crease lines to opposite edges of the second end panel, each corner panel having an inner length L.sub.CPB and a height H.sub.CPB, each lid comprises: a rectangular top panel having four edges and a length L.sub.TPL and a width W.sub.TPL, a first and a second rectangular end panel, joined via respective crease lines to opposite edges of said top panel, each end panel having a width W.sub.EPL and an inner height H.sub.EPL, a first and a second rectangular side panel joined via respective crease lines to opposite edges of said top panel, each side panel having a length L.sub.SPL and an inner height H.sub.SPL, optionally two first and two second rectangular corner panels, the first corner panels joined via respective crease lines to opposite edges of the first end panel and the second corner panels joined via respective crease lines to opposite edges of the second end panel, each corner panel having an inner length L.sub.CPL and a height H.sub.CPL, said system comprising: at least one of a database and/or a non-contact dimensioner, to obtain information that specifies a set of minimum inner dimensions of a box to be created, the set of minimum inner dimensions including a length L.sub.D, a height H.sub.D and a width W.sub.D of the box to be created, a calculating unit operable to calculate a set of dimensions of the panels of the box and of the panels of the lid based on the set of minimum inner dimensions taking into account a set of defined optimization criteria, wherein said calculating unit is adapted to set, if (W.sub.D+2 T.sub.CBB+2H.sub.D)>(W.sub.CBB−M.sub.B), wherein M.sub.B denotes an optional minimum margin that is cut off at the sides of the cardboard supplied for creating the box and wherein T.sub.CBB denotes a material dependent correction factor generally corresponding to the thickness of the cardboard used for the box, and/or if 2H.sub.D>L.sub.D H.sub.SPB to fulfil (2H.sub.SPB+2 T.sub.CBB+W.sub.BPB)≤(W.sub.CBB−M.sub.B) and 2H.sub.SPB≤L.sub.D and H.sub.SPL to fulfil H.sub.SPL+H.sub.SPB≥H.sub.D.

16. The system according to claim 15, wherein the calculating unit is adapted to perform at least one of the following settings: if (W.sub.D+2 T.sub.CBB+2H.sub.D)>(W.sub.CBB−M.sub.B) and/or if 2H.sub.D>L.sub.D, setting H.sub.SPB to fulfil, within the typical material-caused tolerances, (2H.sub.SPB+2T.sub.CBB+W.sub.BPB)=(W.sub.CBB−M.sub.B), setting H.sub.SPL and H.sub.EPL to be equal if either (L.sub.TPL+2 T.sub.CBL+2H.sub.EPL)≤(W.sub.CBL−M.sub.L) or (W.sub.TPL+2 T.sub.CBL+2H.sub.SPL)≤(W.sub.CBL−M.sub.L), wherein M.sub.L denotes an optional minimum margin that is cut off at the sides of the cardboard supplied for creating the lid and wherein T.sub.CBL denotes a material dependent correction factor generally corresponding to the thickness of the cardboard used for the lid, setting H.sub.SPL to fulfil, within the typical material-caused tolerances, H.sub.SPL+H.sub.SPB=H.sub.D, and/or H.sub.EPL to fulfil, within the typical material-caused tolerances, H.sub.EPL+H.sub.EPB=H.sub.D, setting H.sub.SPL to fulfil, within the typical material-caused tolerances, H.sub.SPB+H.sub.SPL=H.sub.D+M.sub.OSP, wherein M.sub.OSP denotes a desired overlap of the side panels of the lid with the side panels of the box, and/or setting H.sub.EPL is set to fulfil, within the typical material-caused tolerances, H.sub.EPL+H.sub.EPB=H.sub.D.+M.sub.OEP, wherein M.sub.OEP denotes a desired overlap of the end panels of the lid with the end panels of the box.

17. The system according to claim 15, further comprising: structure for cutting, creasing, and folding the lid which structure is adapted to cut the lid, if both, (L.sub.TPL+2 T.sub.CBL+2H.sub.EPL)≤(W.sub.CBL−M.sub.L) and (W.sub.TPL+2 T.sub.CBL+2H.sub.SPL)≤(W.sub.CBL−M.sub.L), such that, if (L.sub.TPL+2H.sub.EPL)>(W.sub.TPL+2H.sub.SPL), the side panels of the lid are in front and behind the top panel and the end panels of the lid are to the left and the right of the top panel seen in the transport direction of the cardboard supplied for making the lid, and such that, if (L.sub.TPL+2H.sub.EPL)<(W.sub.TPL+2H.sub.SPL), the end panels of the lid are in front and behind the top panel and the side panels of the lid are to the left and the right of the top panel seen in the transport direction of the cardboard supplied for making the lid.

18. The system according to claim 15, further comprising structure for cutting, creasing, and folding to create the box and the lid in series from the same cardboard supplied to the system.

19. The system of claim 15, further comprising: a number of crease rollers or perforation rollers for introducing two parallel perforation lines in at least some of the panels of the lid and structure for attaching a tear strip between the parallel perforation lines.

Description

BRIEF DESCRIPTION OF THE DRAWING

(1) FIG. 1 is a perspective view of a blank for a type 0300 box.

(2) FIG. 2 is a perspective view of a box folded from the blank shown in FIG. 1.

(3) FIG. 3 is a schematic diagram explaining the difference between outer and inner dimensions.

(4) FIG. 4 shows a blank for a type 0302 lid.

(5) FIG. 5 is a perspective view of a lid folded from the blank according to FIG. 4.

(6) FIG. 6 is a perspective view of a box and a corresponding lid according to a first embodiment of the invention.

(7) FIGS. 7a, 7b and 7c form a schematic diagram showing how limits of the width of the cardboard supplied for making a lid can be overcome.

(8) FIG. 8 is a perspective view of a box and a corresponding lid according to a second embodiment of the invention.

(9) FIG. 9 shows the box and the lid of FIG. 8 in the closed state, wherein a part of the lid has been cut off to show certain details.

(10) FIG. 10 is a perspective view of a box and a corresponding lid according to a third embodiment of the invention.

(11) FIG. 11 shows the box and the lid of FIG. 10 in the closed state, wherein a part of the lid has been cut off to show certain details.

(12) FIG. 12 is a perspective view of a box and a corresponding lid according to a fourth embodiment of the invention.

(13) FIG. 13 shows the box and the lid of FIG. 12 in the closed state, wherein a part of the lid has been cut off to show certain details.

(14) FIG. 14 is a perspective view of a box and a corresponding lid according to a fifth embodiment of the invention.

(15) FIG. 15 shows a box according to the invention in a closed state, when the lid has been provided with perforated lines facilitating opening the lid.

(16) FIG. 16 is a schematic diagram of a system according to a first embodiment of the invention.

(17) FIG. 17 is a schematic diagram of a system according to a second embodiment of the invention.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

(18) FIG. 1 shows a blank 10 for a type 0300 box, having a bottom panel 12, a first end panel 14, a second end panel 16, a first side panel 18, a second side panel 20, two first corner panels 22 and 24 joined to opposite edges of the first end panel 14 and two second corner panels 26 and 28 joined to opposite edges of the second end panel 16. The panels are delimited against each other via eight crease lines 30-44 respectively four slots 46, 48, 50 and 52. The crease lines 38 and 44 are with respect to the crease line 36 slightly shifted, namely to an amount corresponding to the thickness of the cardboard towards the first end panel 14 respectively the second end panel 16. Likewise, the crease 40 and 42 are shifted in an amount corresponding to the thickness of the cardboard towards the first end panel 14 respectively towards the second end panel 16 with respect to the crease line 48. This allows that in the erected state as shown in FIG. 2, the corner panels 22 and 28 run perfectly parallel to the side panel 18 and the corner panels 24 and 26 run parallel to the side panel 20. The slots 46, 48, 50 and 52 are also dimensioned to take into account the thickness of the cardboard: the height H.sub.CPB of the corner panels has to be decreased by the thickness of the cardboard as in the erected state these corner panels abut against the bottom panel while the top side of the corner panels shall be level with the top end of the end panels. Due to the material inherent properties, the slots are typically not made such that only the height of the cornel panels is shortened, but also the length of the side panels, which facilitates erecting the box and ensures that the side panels not extend beyond the end panels in the erected state. Hence, the length of the side panels is typically a bit shorter than the length of the bottom panel.

(19) As can be seen in FIG. 2, in this type of box the side panels and the end panels have the same height, which defines the maximum height of this prior art box. This type of box has two limits: as the length L.sub.CPB basically (plus 1T.sub.CBB) corresponds to the height H.sub.SPB, which is the same as the height H.sub.EPB of the end panels, the height of the box is limited by the length L.sub.BPB of the bottom panel, as 2 L.sub.SPB has to be smaller than L.sub.BPB in order to avoid a collision of opposite first and second corner panels, i.e. a collision of corner panel 22 with corner panel 28 respectively of corner panel 24 with corner panel 26 upon erecting the box.

(20) The second limitation of this type of box is that if the blank is cut out from cardboard having a certain width W.sub.CBB such that the side panels run parallel to the edges of the cardboard, the width of the supplied cardboard limits the height of the box in that (W.sub.BPB+2T.sub.CBB+2 H.sub.SPB)≤W.sub.CBB has to be fulfilled.

(21) FIG. 3 is a very schematic diagram showing a part of bottom panel 12 and end panel 14 explaining the difference between outer and inner dimensions. In theory, the crease line 30 applied to the cardboard in the flat state (FIG. 3a) works like a mitre such that in the erected state (FIG. 3b), L.sub.BPB+1T.sub.CBB≈OL.sub.BPB and H.sub.EPB+1T.sub.CBB≈OH.sub.EPB, wherein OL.sub.BPB denotes the outer length of the bottom panel and and OH.sub.EPB denotes the outer height of the end panel. As explained above, in practice due to the folding behaviour of the cardboard and the inherent properties of the cardboard lead to deviations from theory, which however can easily be taken into account by regarding T.sub.CBB (and T.sub.CBL for the lid) as a kind of correction factor that can be chosen depending on the actual material used. As apparent from FIG. 3, when folding the side and end panels upwards from a bottom panel or downwards from a top panel, the transition between the panels is usually round and there is no clear end of either of the panels. Hence, if a dimension is not measured between two free ends of a panel, like the length of the side panels, the outer dimension is considered to relate to the dimension between a free end of the respective panel and the respective outer plane of an adjacent orthogonal panel.

(22) FIG. 4 shows a blank 62 for a type 030 lid, which comprises a bottom panel 64, a first end panel 66, a second end panel 68, a first side panel 70 and a second side panel 72. FIG. 5 shows a lid 74 formed from such blank.

(23) In order to overcome the aforementioned limits of the known boxes, the invention allows that the first and second side panels have a height H.sub.SPB, which is less than the height H.sub.EPB of the first and the second end panel of the box and to compensate the limited height of the side panels of the box by increasing the height of the side panels of the lid. FIG. 6 shows a box 80 and a corresponding lid 82 according to a first embodiment of the invention. Again, the box comprises a bottom panel (not visible in this view), a first end panel 84, a second end panel 86, a first side panel 88, a second side panel (not visible in this view), two first corner panels 92 and 94 attached to the first end panel 84 and two second corner panels 96 and 98 attached to the second end panel 86. The lid 82 comprises a top panel 100, a first end panel (not visible in this view), a second end panel 104, a first side panel 106 and a second side panel 108. The dimensions of the side panels of the box and the side panels of the lid are chosen such that they correspond to the height of the box, i.e. that they abut against each other in the closed state.

(24) While FIG. 6 seems to imply that the lid 82 is put on the box 80 in the erected state, i.e. with the side panels and the end panels folded downwards, in an automatic implementation of the inventive method the lid blank with corresponding crease lines to define the respective end panels and side panels is placed on top of the erected box, glue is applied to either or both of the respective panels of the box and the lid, and the end panels and the side panels of the lid are folded downwards and pressed against the respective panels of the box. Of course, instead of glue, sealing the box could be done in other ways for example with adhesive tape.

(25) FIG. 7 is a schematic diagram to show how a limitation implied by a certain cardboard width of the cardboard supplied for making the lid 82 of FIG. 6 can be overcome. If cardboard 110 having a width W.sub.CBL is supplied for making the lid and the calculated layout of the lid 82 is such that the height of the side panels 106 and 108, which have been extended to compensate the “missing” height of the side panels 88 of the box 80 (FIG. 6), plus 2T.sub.CBL plus the width of the lid exceeds W.sub.CBL(FIG. 7c), the layout can simply be rotated as shown in FIG. 7b. Thus, the height of the side panels 106 and 108 is no longer limited by the width of the cardboard supplied for the lid. As explained above, depending on the general setup of a system for automatically erecting and placing the lids on a box, it may be necessary to rotate either the box or the lid such that the lid fits on top of the box.

(26) FIG. 8 and FIG. 9 show an embodiment of the invention, in which the end panels 104 and the side panels 106 of the lid 82 have the same height. Generally, this gives the box an appealing appearance. Also, it has turned out that due to the properties of the cardboard, it is generally advantageous when the panels have certain minimum dimensions to allow proper handling and folding the panels. For example, the side and end panels of the lid may advantageously have a minimum height of 40-60 mm, which also facilitates gripping and/or holding the panels that might be necessary during the process of creating the lid and the box. As shown in particular in FIG. 9, where the front corner of the lid has been cut away to show details of the box 80 closed with the lid 82, the side panel 106 of the lid overlaps the side panel 88 of the box (and on the opposite, not visible side, the corresponding panels overlap too). Accordingly, the inner width W.sub.TPL of the top panel of the lid has to be broader by at least twice the thickness of the cardboard used for the box with respect to the inner width W.sub.BPB of the bottom panel of the box to allow that the side panels of the lid run in a plane parallel to the plane of the side panels of the box.

(27) Allowing the side panels of the lid to overlap the side panels of the box has also the advantage, that there is no “hole” or “gap” between the facing edges of the side panels of the lid and the side panels of the box and the facing edges of the corner panels. In a situation like the one shown in FIG. 6, where the opposite first and second corner panels 92 and 98 respectively 94 and 96 abut like the side panel 88 of the box and the side panel 106 of the lid, at the point, where the abutting lines of the side panels and the corner panels meet, an infinitesimal hole is formed, which forms a weak point of the box. In a situation like the one shown in FIG. 11, where the opposite first and second corner panels 92 and 98 do not abut while the edges of the side panel 88 of the box and the side panel 106 of the lid 82 abut, an infinitesimal slot will be formed along the abutting line of the side panels between the corner panels.

(28) FIG. 12 and FIG. 13 show a situation, where the opposite first and second corner panels 92 and 98 do not abut, but as the side panels of the lid 82, of which only side panel 106 is visible, overlap the respective side panels 88 and 90 of the box, no infinitesimal slot or “hole” is formed and the box can be securely closed at all sides for example by simply gluing the side panels of the lid to the respective side panels of the box. However, in a situation like the one shown in FIGS. 12 and 13, where the side panels of the lid overlap the side panels of the box a gap of the thickness of the cardboard used for the box, is formed between the corner panels of the box and the side panels of the lid. This has generally no effect, but makes the lid slightly depressible at the edges of the side panels, which have no support by the side panels of the box. If either for reasons of stability or high-value boxes this is not wanted, the invention allows that lids are created having the layout of the box, i.e. where the corners between adjacent side and end panels are not cut away and instead four corner panels, of which one corner panel 112 is visible in FIG. 14, are formed. If the thickness of the cardboard used for the lid is the same as the thickness of the cardboard used for the box, the corner panels will fill the gap between the side panels of the lid and the corner panels of the box such that a high-value and very stable box is formed. However, according to the invention it is generally preferred to use lids without corner panels, as these lids are easier and hence faster to automatically fold on a respective box, allowing a high throughput for automatically packaging items in a box.

(29) FIG. 15 shows a box 80 with a lid 82 placed on top of it. Some of the panels of the lid, in this embodiment both end panels (only one end panel 104 is visible in this view) and one side panel 106 have been provided with parallel perforated lines 114, 116, which allow that the cardboard 118 between the perforated lines can easily be torn off to open the box. This tearing of can be enhanced by placing a tear off strip of tear-resistant material between the parallel lines, but in most cases providing the perforated lines is perfectly sufficient.

(30) While in the embodiments shown in the figures the lid is generally placed on top of the end panels and the corner panels of the box, it is also possible to hold the lid above the box and to adhere the side and end panels of the lid to the respective side and end panels of the box such that the upper edges of the end panels and the corner panels of the box do not abut against the top panel of the lid, such that the total height of the box is greater than the height of the end panels of the box.

(31) The boxes according to the invention shown in the drawings are simple and fast to be formed automatically. The dimensions of a corresponding blank can easily be calculated either from dimensions of the items to be packaged known from a database or by simply putting the items to be shipped on a conveyor belt, transporting the item(s) through a laser scanner, which determines the width, height and length respectively the arrangement of items and calculates the desired minimum dimensions of a box. These dimensions can be optimized taking into account numerous optimisation criteria like for example minimum volume of the closed box, maximum strength of the closed box, minimum waste material, position of fold lines from zig-zag folded cardboard. If the cardboard is supplied from a stack of zig-zag folded cardboard, the cardboard comprises fold lines where the cardboard is zig-zag folded. These fold lines can be adverse for folding a box or a lid when the present fold lines are close to a crease line that has to be formed for defining respective panels of the lid or the box. A control unit can easily obtain information about the position of such “unwanted crease lines” (the fold lines present due to zig-zag folding), and can adapt the dimensions of a box or a lid so that a certain minimum distance, which depends on the properties of the cardboard, is kept between unwanted and wanted crease lines.

(32) The dimensions of the box will typically be calculated based on the desired minimum dimensions such that: the inner length of the bottom panel corresponds to the desired length plus some tolerance value, the inner width of the bottom panel corresponds to the desired width plus some tolerance, the inner height of the end panels may correspond to the desired height plus some tolerance or may, if the lid shall not abut against the end panels, may be less that the desired height. All other dimensions follow from this automatically.

(33) A respective system for folding and cutting the cardboard to create lids and boxes comprises structure for cutting (which may also include die cutting), like rotating or reciprocating knifes, lasers, die cutters etc., structure for creasing, like crease rollers or moving stamps, and structure for folding the cardboard, like moveable grippers and flaps, and preferably structure for attaching the respective panels to each other, like a glue unit for applying hot melt glue to one or both of overlapping panels, and/or an adhesive strip application unit. In a preferred embodiment, only hot melt glue is used for attaching the panel of the box to each other and for closing the box by attaching the end and side panels of the lid to the respective panels of the box. The slots mentioned above between the corner panels and the side panels can be cut out or punched out and accordingly structure for cutting includes structure for so called die cutting i.e. punching. Likewise, the corners of the lid between adjacent side and end panels, which are generally not wanted unless the lid shall comprise corner panels as described above, can either be cut or punched away.

(34) FIG. 16 is a schematic diagram showing a system according to the invention. Cardboard 120 is supplied from a stack 122 of zig-zag folded cardboard to a station 124 for cutting the cardboard, punching out slots between the corner panels and the side panels and introducing crease lines to delimit the respective panels from each other and to thus produce a blank for a custom-sized box. The respective dimensions of the panels are calculated as set forth above, and the system comprises for this purpose a calculating unit, which can form part of a control unit for controlling the complete system and which may for example be integrated in a receiving unit 126, where items like the items 128, 130 and 132, which shall be packaged, are placed either automatically or manually. The items to be packaged are transported via conveyor belts through a laser scanning unit 134, which measures the outer dimensions of the items passing through the unit in order to obtain information on the desired inner dimensions length L.sub.D, width W.sub.D and height H.sub.D a box needs to have in order to receive the items or the arrangement of items as they are, i.e. without re-arranging the items. Of course, the system could also be provided with structure for arranging the items in a certain manner for example to reduce the volume needed. However, in this schematic drawing a simple and fast working embodiment is shown. The cardboard blank is transported from the cutting and creasing station 124 to a folding station 136, where the item or the items to be packaged are put on top of the bottom panel of the respective blank cut and creased in the cutting and creasing station. Respective grippers and folders like the gripping and folding units 138 and 140 fold the box around the item(s) to be packaged as described above, i.e. erect all four corner panels, of which two, namely corner panels 92 and 98, are visible in this view upwards, then fold the end panels inwards thus folding also the corner panels inwards and finally the side panels, of which side panel 88 is visible in this view, upwards.

(35) When the respective blank is transported from the station 124 to the station 136, it passes a glue application unit 142, which applies hot melt glue to the parts of the side panels, which are to be brought into contact with the corner panels.

(36) To close the box, in this embodiment a lid placing station 144 is provided, which as indicated by the double-sided arrows is moveable upwards and downwards, forwards and rewards in the transport direction of the items respectively the boxes. Similar to the blanks for the box, based on the calculated dimensions a blank for the lid is produced and picked up by the lid placing station 144 for example with suction grippers that can be integrated in respective folding units 146 and 148 of the lid placing station. A gluing unit 150 applies hot-melt glue to the end panels and the side panels of the lid, which is placed on top of the box that just has been erected, upon which the end panels and the side panels of the lid are folded downwards. The thus closed boxes 152, 154 are then transported via respective conveyor belts to a label printing and application unit 156, which puts a label including for example address of the recipient and postage on the boxes, which then can be picked up and further transported. The lid can be created from the same cardboard supplied as the box, in case of which the cutting and creasing station may be set up to produce not only a blank for the box, but also a blank for the lid, which may then be transported via respective conveyor belts to the lid placing station, which picks up the lid and puts it on top of the box.

(37) FIG. 17 schematically shows an embodiment of a system according to the invention, which comprises separate production lines for producing the boxes and the lids, which could increase the through-put of the system. As in FIG. 16, items 128, 130 132 are scanned, blanks are produced from cardboard 120 and boxes are folded around the items via respective stations 124, 126, 136 as shown in FIG. 16. However, the boxes are then transported as indicated by arrow 138 to a lid creation and placing line, in which lids are produced more or less parallel to producing the boxes. Like the box creation line, the lid production line comprises a station for cutting and creasing the cardboard 160 supplied from a stack 162 of cardboard 164, which may correspond to the cardboard used for producing the boxes or which may have different properties, in particular different widths, strengths, branding etc. It is also possible to provide the lid production line with different cardboard supplies so that depending for example on the dimensions needed for a respective lid, a cardboard can be chosen that allows to reduce the amount of waste produced upon producing the lid. As described above, it may be that the lid is cut out from the cardboard supplied in a “rotated” manner, i.e. such that seen in the transport direction of the cardboard the side panels are in front and in the rear of the top panel of the lid, whereas the end panels are to the left and the right of the top panel. In order to properly align the box and the lid, the system may comprise a box rotating unit, in which during transporting the box from the box line to the lid production and placing line the box is rotated, if necessary, by 90° in order to align the lid and the box. As is apparent from the present application, of course instead of rotating the box, if is necessary at all, the lid may be rotated by 90°.

(38) Both production lines comprise glue application units 142, 166, 168 and 170. In this embodiment, the lid placing station 144 comprises a separate glue unit 166 for applying hot-melt glue to the side panels in the transport direction of the cardboard of the lid 172 to be placed on a box, and two glue units 168 and 170 for applying holt-melt glue to the end panels of the box where the end panels of the lid have to be attached to the box.