METHOD FOR MANUFACTURING OF CARTONS

Abstract

A method to accomplish manufacturing of cartons, that supports the objective to decrease relatively large volumes of unnecessary air shipped, and to standardise size aspects of raw material so that logistics of raw material use for cartons and carton manufacturing process can be optimized. The method comprise steps from the retrieval of measurements for intended content to be closed, to calculating required width and length of standardized sized carton pieces having width dimensions based on geometrical series 2, 4, 8, 16, 32, 64, and then cutting and re-join cardboard pieces edge to edge by an adhesive, to assemble a carton piece that matches a calculated required cardboard size for further forming and folding of a cardboard box, as described by the method, with minimal loss of carton material.

Claims

1-12. (canceled)

13. A method for manufacturing of cartons performed by a carton manufacturing system comprising a piece assembly unit and a piece attaching unit, wherein the method comprises steps: A) retrieving a set of measurements of an intended content to be enclosed in a final carton; B) calculating a required width X1 and a required length Y1 of a first carton piece, and a required width X2 and a required length Y2 of a second carton piece for enabling the intended content to be enclosed in the final carton assembled by the first and the second carton piece, wherein the width X1 of the first carton piece is equal to 2, 4, 8, 16, 32 or 64 times the width X2 of the second carton piece; C) providing the first carton piece with the width X1 and the length Y1, and a second carton piece with the width X2 and the length Y2; D) assembling the first and the second carton piece into a detachable carton piece assembly by using the piece assembly unit for the detachable carton piece assembly to match the set of measurements of the intended content; and E) attaching the first and the second carton piece by using the piece attaching unit to form a carton assembly, wherein a first edge of the first carton piece is placed against or onto a second edge of the second carton piece for an adhesive agent to take effect for attaching of the first and the second piece to form the carton assembly.

14. The method for manufacturing of cartons of claim 13 wherein: the carton manufacturing system further comprises a control unit; the control unit is arranged to communicate with a database; in the step A, the set of measurements of an intended content is retrieved from the database by the control unit; and in the step B, the calculations are performed by the control unit.

15. The method for manufacturing of cartons of claim 13 wherein the carton manufacturing system further comprises a slit generating unit and a folding unit, and wherein the method further comprises steps: F) forming a plurality of slits in the carton assembly by using the slit generating unit; and G) folding the carton assembly and folding in a plurality of flaps formed by the plurality of slits by using the folding unit to form the final carton for the purpose of accommodation of the intended content.

16. The method for manufacturing of cartons of claim 13 wherein the step C comprises: C1) retrieving a raw piece of carton; C2) cutting the first carton piece in the width of X1 out of the raw piece of carton and cutting the second carton piece in the width of X2 out of the raw piece of carton by using a width cutting unit; and C3) cutting the first carton piece in the length of Y1 out of the raw piece of carton and cutting the second carton piece in the length of Y2 out of the raw piece of carton by using a length cutting unit.

17. The method for manufacturing of cartons of claim 13 wherein the step E comprises attaching the first and the second carton piece by using the piece attaching unit by: E1) using an adhesive agent on a first edge of the first carton piece and/or on a second edge of the second carton piece, wherein the attaching includes use of at least one of a glue, an adhesive tape, and staples; and E2) placing said first edge of the first carton piece against or onto said second edge of the second carton piece for the adhesive agent to take effect for attaching of the first and the second piece to form the carton assembly.

18. The method for manufacturing cartons of claim 15 wherein the carton manufacturing system further comprises a point of production, and wherein the steps F and G are performed at the point of production.

19. The method for manufacturing of cartons of claim 15 wherein the carton manufacturing system further comprises a main feeding unit and a point of production, and wherein the method further comprises steps: D1) feeding the detachable carton piece assembly from the piece assembly unit to the piece attaching unit by using the main feeding unit, wherein the piece attaching unit is arranged at a distance from the piece assembly unit, and wherein the point of production is moved from the piece assembly unit to the piece attaching unit; E1) feeding the carton assembly from the piece attaching unit to the slit generating unit by using the main feeding unit, wherein the slit generating unit is arranged at a distance from the piece attaching unit, and wherein the point of production is moved from the piece attaching unit to the slit generating unit; and F1) feeding the carton assembly from the slit generating unit to the folding unit by using the main feeding unit, wherein the folding unit is arranged at a distance from the slit generating unit, and wherein the point of production in this step is moved from the slit generating unit to the folding unit.

20. The method for manufacturing of cartons of claim 16 wherein the carton manufacturing system further comprises a point of production, and wherein the step C3 is performed at the point of production.

21. The method for manufacturing of cartons of claim 16 wherein the carton manufacturing system further comprises a point of production, and wherein the steps C1-C3 are performed at the point of production.

22. The method for manufacturing of cartons of claim 16 wherein the carton manufacturing system further comprises a carton piece feeding unit and a point of production, and wherein the method further comprises, after the step C3, the step: C4) feeding the first and the second carton piece from the length cutting unit to the piece assembly unit by using the carton piece feeding unit, wherein the piece assembly unit is arranged at a distance from the length cutting unit, and wherein the point of production is moved from the length cutting unit to the piece assembly unit.

23. A computer program product comprising: a non-transitory, computer-readable medium comprising instructions that, when executed by a processor of a computing device, cause the computing device to control a carton manufacturing system that comprises a piece assembly unit and a piece attaching unit by causing the carton manufacturing system to perform steps: A) retrieving a set of measurements of an intended content to be enclosed in a final carton; B) calculating a required width X1 and a required length Y1 of a first carton piece, and a required width X2 and a required length Y2 of a second carton piece for enabling the intended content to be enclosed in the final carton assembled by the first and the second carton piece, wherein the width X1 of the first carton piece is equal to 2, 4, 8, 16, 32 or 64 times the width X2 of the second carton piece; C) providing the first carton piece with the width X1 and the length Y1, and a second carton piece with the width X2 and the length Y2; D) assembling the first and the second carton piece into a detachable carton piece assembly by using the piece assembly unit for the detachable carton piece assembly to match the set of measurements of the intended content; and E) attaching the first and the second carton piece by using the piece attaching unit to form a carton assembly, wherein a first edge of the first carton piece is placed against or onto a second edge of the second carton piece for an adhesive agent to take effect for attaching of the first and the second piece to form the carton assembly.

24. The computer program product of claim 23 wherein: the carton manufacturing system further comprises a control unit; the control unit is arranged to communicate with a database; in the step A, the set of measurements of an intended content is retrieved from the database by the control unit; and in the step B, the calculations are performed by the control unit.

25. A carton manufacturing system comprising a piece assembly unit and a piece attaching unit, wherein the carton manufacturing system is operable to perform steps: A) retrieving a set of measurements of an intended content to be enclosed in a final carton; B) calculating a required width X1 and a required length Y1 of a first carton piece, and a required width X2 and a required length Y2 of a second carton piece, wherein the width X1 of the first carton piece is equal to 2, 4, 8, 16, 32, or 64 times the width X2 of the second carton piece for enabling the intended content to be enclosed in the final carton assembled by the first and the second carton piece; C) providing the first carton piece with the width of X1 and the length of Y1, and a second carton piece with the width of X2 and the length of Y2; D) assembling the first and the second carton piece into a detachable carton piece assembly by using the piece assembly unit for the detachable carton piece assembly to match the set of measurements of the intended content; and E) attaching the first and the second carton piece by using the piece attaching unit to form a carton assembly, wherein a first edge of the first carton piece is placed against or onto a second edge of the second carton piece for an adhesive agent to take effect for attaching of the first and the second piece to form the carton assembly.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0062] The invention is now described, by way of example, with reference to the accompanying drawings, in which:

[0063] FIG. 1 is a flow chart of a procedure according to an embodiment, and

[0064] FIG. 2 is a flow chart of a procedure according to an embodiment, and

[0065] FIG. 3 is a flow chart of a procedure according to an embodiment, and

[0066] FIGS. 4a and 4b are flow charts of procedures according to different embodiments, and

[0067] FIGS. 5a and 5b are flow charts of procedures according to different embodiments, and

[0068] FIGS. 6a, 6b and 6c are flow charts of procedures according to different embodiments, and

[0069] FIG. 7 is a flow chart of a procedure according to an embodiment, and

[0070] FIG. 8 shows a carton manufacturing system, from above, comprising four different method steps, according to an embodiment of the invention, and

[0071] FIG. 9 shows a carton manufacturing system, in a perspective view, comprising one method step, according to an embodiment of the invention, and

[0072] FIGS. 10a, 10b and 10c show a carton manufacturing system, in a perspective view, according to an embodiment of the invention, and

[0073] FIGS. 11a, 11 b and 11c show three different examples of adding carton strips in order to achieve a required width and length, and

[0074] FIG. 12 is a block diagram illustrating a control unit, according to a possible embodiment.

DESCRIPTION OF EMBODIMENTS

[0075] In the following, a detailed description of a method for manufacturing of cartons and a carton manufacturing system, is provided.

[0076] FIG. 1 shows a flow chart illustrating a procedure in a computer program product. The various actions may come in different orders than presented in this description, or in a different order than shown in this or other flowcharts related to this description, or some steps may be performed in parallel.

[0077] In a step S100 a set of measurements 5 of an intended content 6 to be enclosed in a final carton 7 is retrieved. In a step S110 the required width X1=x.sub.1*(y1{circumflex over ()}n) and the required length Y1 of a first carton piece 8, and the required width X2=x.sub.2*(y2{circumflex over ()}n) and the required length Y2 of a second carton piece 9 is calculated, wherein x.sub.1, x.sub.2>0, n=0, 1, 2, 3 . . . , and y1, y2>0, for enabling the intended content 6 to be enclosed in the final carton 7 assembled by the first 8 and the second carton piece 9. In a step S120 the first carton piece 8 with a width of X1=x.sub.1*(y1{circumflex over ()}n) and a length of Y1, and the second carton piece 9 with a width of X2=x.sub.2*(y2{circumflex over ()}n) and a length of Y2 is provided, wherein x.sub.1, x.sub.2>0, n=0, 1, 2, 3 . . . , and y1, y2>0, for the first 8 and the second carton piece 9 to match the calculated required widths X1, X2 and lengths Y1, Y2. In a step S130 the first 8 and the second carton piece 9 are assembled into a detachable carton piece assembly 10 by using the piece assembly unit 3 for the detachable carton piece assembly 10 to match the set of measurements of the intended content 6. In a step S140 the first 8 and the second carton piece 9 are attached by using the piece attaching unit 4 for creation of a carton assembly 11.

[0078] FIG. 2 shows a flow chart illustrating a procedure in a computer program product. The various actions may come in different orders than presented in this description, or in a different order than shown in this or other flowcharts related to this description, or some steps may be performed in parallel.

[0079] In a step S200 a plurality of slits 14a . . . 14z in the carton assembly 11 are formed by using the slit generating unit 12. In a step S210 the carton assembly 11 is folded, and a plurality of flaps 15a . . . 15z formed by the plurality of slits 14a . . . 14z are folded in, by using the folding unit 13, to form the final carton 7 for the purpose of accommodation of the intended content 6.

[0080] FIG. 3 shows a flow chart illustrating a procedure in a computer program product. The various actions may come in different orders than presented in this description, or in a different order than shown in this or other flowcharts related to this description, or some steps may be performed in parallel.

[0081] In a step S300 a raw piece of carton 16 is retrieved. In a step S310 the first carton piece 8 is cut in a width of X1=x.sub.1*(y1{circumflex over ()}n) out of the raw piece of carton 16 and the second carton piece 9 is cut in a width of X2=x.sub.2*(y2{circumflex over ()}n) out of the raw piece of carton 16 by using a width cutting unit 17. In a step S320 the first carton piece 8 is cut in a length of Y1 out of the raw piece of carton 16 and the second carton piece 9 is cut in a length of Y2 out of the raw piece of carton 16 by using a length cutting unit 18, for the first 8 and the second carton piece 9 to match the calculated required sizes.

[0082] FIGS. 4a and 4b show flow charts illustrating procedures in a computer program product. The various actions may come in different orders than presented in this description, or in a different order than shown in these or other flowcharts related to this description, or some steps may be performed in parallel.

[0083] In a step S400 the first 8 and the second carton piece 9 are attached by means of attaching means 19 by using the piece attaching unit 4.

[0084] In a step S500 an adhesive agent 20 is used on a first edge 21 of the first carton piece 8 and/or on a second edge 22 of the second carton piece 9. In a step S510 said first edge 21 of the first carton piece 8 is placed against or on to said second edge 22 of the second carton piece 9 for the adhesive agent 20 to take effect for attaching of the first 8 and the second piece 9 for creation of a carton assembly 11.

[0085] FIGS. 5a and 5b show flow charts illustrating procedures in a computer program product. The various actions may come in different orders than presented in this description, or in a different order than shown in these or other flowcharts related to this description, or some steps may be performed in parallel.

[0086] In a step S600 the plurality of slits 14a . . . 14z in the carton assembly 11 are formed by using a slit cutting unit 23.

[0087] In a step S700 the first 8 and the second carton piece 9 are fed from the length cutting unit 18 to the piece assembly unit 3 by using the carton piece feeding unit 25, wherein the piece assembly unit 3 is arranged on a distance from the length cutting unit 18, wherein the point of production 24 in this step is moved from the length cutting unit 18 to the piece assembly unit 3.

[0088] FIGS. 6a, 6b and 6c show flow charts illustrating procedures in a computer program product. The various actions may come in different orders than presented in this description, or in a different order than shown in these or other flowcharts related to this description, or some steps may be performed in parallel.

[0089] In a step S800 the detachable carton piece assembly 10 is fed from the piece assembly unit 3 to the piece attaching unit 4 by using the main feeding unit 26, wherein the piece attaching unit 4 is arranged on a distance from the piece assembly unit 3, wherein the point of production 24 in this step is moved from the piece assembly unit 3 to the piece attaching unit 4.

[0090] In a step S900 the carton assembly 11 is fed from the piece attaching unit 4 to the slit generating unit 12 by using the main feeding unit 26, wherein the slit generating unit 12 is arranged on a distance from the piece attaching unit 4, wherein the point of production 24 in this step is moved from the piece attaching unit 4 to the slit generating unit 12.

[0091] In a step S1000 the carton assembly 11 is fed from the slit generating unit 12 to the folding unit 13 by using the main feeding unit 26, wherein the folding unit 13 is arranged on a distance from the slit generating unit 12, wherein the point of production 24 in this step is moved from the slit generating unit 12 to the folding unit 13.

[0092] FIG. 7 shows a flow chart illustrating a procedure in a computer program product. The various actions may come in different orders than presented in this description, or in a different order than shown in this or other flowcharts related to this description, or some steps may be performed in parallel.

[0093] In a step 7.1 a set of measurements 5 of an intended content 6 to be enclosed in a final carton 7 is retrieved from the database 27. In a step 7.2 the required width X1=x.sub.1*(y1{circumflex over ()}n) and the required length Y1 of a first carton piece 8, and the required width X2=x.sub.2*(y2{circumflex over ()}n) and the required length Y2 of a second carton piece 9 is calculated at the control unit 2 of the carton manufacturing unit 1, wherein x.sub.1, x.sub.2>0, n=0, 1, 2, 3 . . . , and y1, y2>0, for enabling the intended content 6 to be enclosed in the final carton 7 assembled by the first 8 and the second carton piece 9. In a step 7.3 the first carton piece 8 with a width of X1=x.sub.1*(y1{circumflex over ()}n) and a length of Y1, and the second carton piece 9 with a width of X2=x.sub.2*(y2{circumflex over ()}n) and a length of Y2 is provided at the carton manufacturing unit 1, wherein x.sub.1, x.sub.2>0, n=0, 1, 2, 3 . . . , and y1, y2>0, for the first 8 and the second carton piece 9 to match the calculated required widths X1, X2 and lengths Y1, Y2. In a step 7.4 the first 8 and the second carton piece 9 are assembled into a detachable carton piece assembly 10 at the carton manufacturing unit 1 by using the piece assembly unit 3 for the detachable carton piece assembly 10 to match the set of measurements 5 of the intended content 6. In a step 7.5 the first 8 and the second carton piece 9 are attached at the carton manufacturing unit 1 by using the piece attaching unit 4 for creation of a carton assembly 11.

[0094] FIG. 8 shows a carton manufacturing system. Activities related to step S120, step S130, step S140 and step S200 are shown in sequence. A first 8 and a second carton piece 9 are shown, originating from a raw piece of carton 16, and transported to the different points of production 24. A detachable carton piece assembly 10 is shown comprising a first edge 21 of the first carton piece 21 and second edge 22 of the second carton piece 9. A carton assembly 11 is shown, wherein attaching means 19 such as an adhesive agent 20 are applied to said edges 22, 22. A plurality of slits 14a . . . 14e are formed in the carton assembly 11.

[0095] FIG. 9 shows a carton manufacturing system. Activities related to step S210 are shown in sequence. A carton assembly 11 is shown and transported to the different points of production 24, until a final carton 7 is finalised. The carton assembly 11 is folded and the plurality of flaps 15a . . . 15h formed by the plurality of slits are folded in.

[0096] FIGS. 10a, 10b and 10c show a carton manufacturing system. In FIG. 10a a width cutting unit 17, a length cutting unit 18, a carton piece feeding unit 25 and a piece assembly unit 3 are shown. In FIG. 10b a main feeding unit 26, a piece attaching unit 4, a slit generating unit 12 and a slit cutting unit 23 are shown. In FIG. 10c a folding unit 13 and an intended content 6 are shown.

[0097] FIGS. 11a, 11b and 11c show three different examples of adding different carton pieces in order to achieve a carton assembly required widths X and required lengths Y. The arrow with reference number 1 illustrates the feeding direction of carton strips. The arrow 2 with reference number 2 illustrates the direction of adding carton strips. In FIG. 10a a first carton piece 8 with the width of X.sub.1 and the length of Y.sub.1 and a second carton piece 9 with the width of X.sub.2 and the length of Y.sub.2 are put together. Wherein the width X.sub.1 equals two times the width of X.sub.2. In FIG. 10b a first carton piece 8 with the width of X.sub.1 and the length of Y.sub.1 and a second carton piece 9 with the width of X.sub.2 and the length of Y.sub.2 are put together. Wherein the width X.sub.1 equals four times the width of X.sub.2. In FIG. 10c a first carton piece 8 with the width of X.sub.1 and the length of Y.sub.1, a second carton piece 9 with the width of X.sub.2 and the length of Y.sub.2, and a third carton piece 28 with the width of X.sub.3 and the length of Y.sub.3 are put together. Wherein the width X.sub.2 equals two times the width of X.sub.3, and wherein the width X.sub.1 equals four times the width of X.sub.3.

[0098] FIG. 12 shows a block diagram of a control unit 2, comprising a processor 2.a, a user interface 2.b, a memory 2.c, and communication gateways 2.d. Through the communication gateways the control unit can receive and send signals from/to other parts of the system. Through the user interface the control unit can communicate with the user, through for instance a viewing screen, keyboard, mouse, printer, loudspeaker, microphone or other type of peripheral. The computer program product can be stored in the memory and be executed in the processor.

LIST OF COMPONENTS

[0099] 1=carton manufacturing system [0100] 2=control unit [0101] 3=piece assembly unit [0102] 4=piece attaching unit [0103] 5=set of measurements of an intended content [0104] 6=intended content [0105] 7=final carton [0106] 8=first carton piece [0107] 9=second carton piece [0108] 10=detachable carton piece assembly [0109] 11=carton assembly [0110] 12=slit generating unit [0111] 13=folding unit [0112] 14a-14z=plurality of slits [0113] 15a-15z=plurality of flaps [0114] 16=raw piece of carton [0115] 17=width cutting unit [0116] 18=length cutting unit [0117] 19=attaching means [0118] 20=adhesive agent [0119] 21=first edge of the first carton piece [0120] 22=second edge of the second carton piece [0121] 23=slit cutting unit [0122] 24=point of production [0123] 25=carton piece feeding unit [0124] 26=main feeding unit [0125] 27=database [0126] 28=third carton piece