Method and installation for producing a pack

Abstract

The invention relates to a method for producing a packaging and a system for such. The method includes the following steps: providing a precut blank (1) consisting of a foldable material having a bottom (3) and hinged to it, lateral panels (4), a rear panel (6) and a front panel (5), fastening of an unstressed elastic element (15) to the front panel (5) or to connecting flaps (7) that are hinged to the front panel (5), erecting the lateral panels (4), the rear panel (6) and the front panel (5) out of a flat transport condition into an unfolded usable condition and connecting the lateral walls (4) with the rear panel (6) and the front panel (5) and tensioning the elastic element (15).

Claims

1. A method for producing a packaging, the method comprising: a) providing a precut blank consisting of a foldable material that has a bottom and, hinged to the bottom, two lateral panels, a rear panel, and a front panel, b) subsequently fastening an unstressed elastic element having two free ends pointing away from each other to connecting flaps that are hinged to the front panel, c) subsequently erecting the lateral panels, the rear panel and the front panel out of a flat transport condition into an unfolded usable condition and connecting the lateral panels with the rear panel and the front panel, d) subsequently tensioning the elastic element.

2. The method as recited in claim 1, wherein the elastic element in step d) has a tensioned condition such that the elastic element extends on an inside of the packaging parallel to the lateral panels and the rear panel.

3. The method as recited in claim 1, wherein the elastic element is locked in tensioned condition after step d).

4. The method as recited in claim 3, wherein a detaining flap is hinged to the rear panel, whereby the elastic element is locked in the tensioned condition by being fixed between the rear panel and the detaining flap that is folded unto the rear panel after the elastic element has been tensioned.

5. The method as recited in claim 4, a locking flap is formed in the bottom by cuts or cutouts and is hinged unilaterally to the bottom, whereby the detaining flap is locked in a position folded onto the rear panel by deflecting the locking flap out of a plane of the bottom.

6. The method as recited in claim 4, wherein fold-over flaps are hinged to the detaining flap at opposite edges, whereby the fold-over flaps are folded onto the detaining flap and connected with such prior to step d), in particular prior to step c).

7. A system for producing a packaging, in particular a tray, out of a flat precut blank that has a bottom and, hinged to the bottom, two lateral panels, a rear panel, and a front panel, wherein a first two connecting flaps are hinged to the front panel and a second two connecting flaps are hinged to the rear panel for connecting the lateral panels with the front panel and the rear panel, the precut blank further comprising an elastic element fastened to the first two connecting flaps of the precut blank at two ends, the system comprising: a first station for erecting and connecting the lateral panels, the rear panel and the front panel, and a second station downstream of the first station for tensioning the elastic element.

8. The system as recited in claim 7, wherein the first station has an additional station for fastening two ends of an unstressed, strip-shaped elastic element on the flat precut blank.

9. The system as recited in claim 7, wherein the second station has at least two manipulators movable relative to the packaging erected in the first station, that are respectively equipped to capture the elastic element away from the two ends that are fastened to the first two connecting flaps of the precut blank and move the elastic element along a track that has a directional component parallel to the lateral panels and a directional component parallel to the rear panel.

10. The system as recited in claim 9, wherein each manipulator has a plate that is driven and movable guided by a guide plate.

11. The system as recited in claim 7, wherein the second station or an additional station downstream of the second station has a first unit for folding a detaining flap of the precut blank onto the rear panel and the tensioned elastic element and a second unit for deflecting a locking flap of the precut blank relative to the bottom.

12. The system as recited in claim 7, wherein the second station has a filling station for filling the erected packaging with products, wherein in the filling station a further unit is provided for deflecting a locking flap of the precut blank relative to bottom.

Description

(1) In the following, the invention will be described in further detail with the aid of exemplary embodiments and by referring to the drawing. Schematically shown are:

(2) FIG. 1 shows a precut blank according to a first embodiment of the invention.

(3) FIG. 2 shows a packaging erected from a precut blank according to FIG. 1 with an unstressed elastic element.

(4) FIG. 3 shows the packaging according to FIG. 2 with a tensioned elastic element.

(5) FIG. 4 shows the packaging according to FIG. 2 with a tensioned and locked elastic element.

(6) FIG. 5 shows a station for tensioning the elastic element in a lateral view.

(7) FIG. 6 shows a front view of the station according to FIG. 5.

(8) FIG. 7 shows a top view of the station according to FIG. 5.

(9) FIG. 8 shows a perspective view of the station according to FIG. 5.

(10) FIG. 9 shows a precut blank according to a second embodiment of the invention.

(11) FIG. 10 shows an erected packaging from the precut blank according to FIG. 9, and

(12) FIG. 11 shows a precut blank according to a third embodiment of the invention.

(13) FIG. 1 shows a precut blank 1 in its flat transport condition. Precut blank 1 is provided with several groove or bending lines 2a, 2b, 2c, 2d, 2e, 2f, 2g by means of which a bottom 3, lateral panels 4, a front panel 5, a rear panel 6, connecting flaps 7 and 8, a detaining flap 9 and fold-over flaps 10 are defined.

(14) As shown in FIG. 1, bottom 3 has a rectangular design in the embodiment shown in which groove or bending lines 2a, 2b, 2c that delineate bottom 3 extend perpendicular to each other. On the right and left side of bottom 3 in FIG. 1, the essentially rectangular lateral panels 4 are hingedly deflectable. Therefore, the lateral panels 4 are integrally connected with bottom 3. Front panel 5 is hinged to the lower side of bottom 3 in FIG. 1, the lateral edges of which are also defined by groove or bending lines 2d that hinge connecting flaps 7 to front panel 5. Even front panel 5 with connecting flaps 7 is thus integrally connected with bottom 3. On the upper side of bottom 3 in FIG. 1, the rear panel is hinged by a groove or bending line. The lateral edges of rear panel 6 are in turn defined by groove or bending lines 2e that hinge connecting flaps 8 to rear panel 6. On the upper side of rear panel 6 in FIG. 1, a double groove or bending line 2 f hinges detaining flap 9, that is in turn connected with fold-over flaps 10 by lateral groove or bending lines 2g. Thereby, rear panel 6, connecting flaps 8, detaining flap 9 and fold-over flap 10 are likewise integrally connected with bottom 3.

(15) In the embodiment shown in FIG. 1, groove or bending lines 2d, 2e that connect connecting flaps 7 and 8 with front panel 5 or rear panel 6 are located offset outwardopposite to groove or bending lines 2a that connect bottom 3 with lateral panels 4by approximately one material thickness. This has the effect that when precut blank 1 is erected into a packaging, connecting flaps 7 can be fastened on the outside of lateral panels 4 without any warping of the packaging.

(16) In bottom 3 of the embodiment shown, a locking flap 11 is formed by providing a recess 12 in the area of the groove or bending line 2c that connects bottom 3 with rear panel 6, and for such, cuts 13 that extend essentially rectangular are formed in bottom 3. By means of an additional groove or bending line 2h, locking flap 11 is connected deflectable with bottom 3.

(17) In the embodiment shown, in front panel 5, a removal opening 14 is provided that extends slightly beyond groove and bending line 2b that connects bottom 3 with the front panel into the area of bottom 3. In the embodiment shown, removal opening 14 is provided in the middle of front panel 5 so that crosspieces of front panel 5 extend on both sides of removal opening 14.

(18) Precut blank 1 according to the invention is provided with an elastic element 15 that is a strip or a band consisting of latex in the embodiment shown. Elastic band 15 has essentially the width of front panel 5, including connecting flaps 7, so that elastic band 15 can be placed onto connecting flaps 7 and front panel 5, whereby the free ends of elastic band 5 come to lie approximately near the free lateral edges of connecting flaps 7. In the embodiment shown, elastic band 15 is glued to the two connecting flaps 7 so that a middle section of elastic band 15 that covers the front panel of removal opening 14 in sections, lies loosely on precut blank 1 and is fastened only at the two ends.

(19) In the following, the erection of a packaging according to the invention from a precut blank according to FIG. 1 will be described in further detail. For this, first lateral panels 4 and front panel 5 and rear panel 6 are deflected by approximately 90 relative to bottom 3. Subsequently, connecting flaps 7 and 8 are likewise deflected by approximately 90 and fastened on the erected lateral panels 4 from the outside. Advantageously, this can be accomplished by adhesion. Alternatively, this can be accomplished by using clamps, for example. In this way, the lateral ends of elastic band 15 are clamped between connecting flap 7 and the outside of lateral panels 4 and connected with the respective connecting flap 7 as well as also the respective lateral panel 4. Thus, elastic band 15 extends in sections along the erected lateral panels 4 and lies inside parallel to front panel 5 without, however, being firmly connected to it. This condition is shown in FIG. 2.

(20) Now, elastic band 15 can be tensioned. Hereby, it is advantageous if the packaging has already been erected completely and the lateral panels are connected with front panel 5 and rear panel 6 so that the packaging has sufficient stability. As will be explained in further detail below, the elastic band is tensioned in such a way that it extends, as shown in FIG. 3, lying on the inside approximately parallel to the lateral panels and parallel to rear panel 6. In this condition, detaining flap 9 can be deflected inward by 180 so that it clamps elastic band 15 between itself and rear panel 6. Previously, fold-over flaps 10 have been folded onto detaining flap 9 so that fold-over flaps 10 abut at elastic band 15.

(21) In this position, detaining flap 9 can be locked against the tension of elastic band 15 by slightly deflecting locking flap 11 upward out of the plane of bottom 3. Hereby, the free edge of locking flap 11 that is facing rear panel 6 pushes at almost a right angle against the lower side of detaining flap 9 in FIG. 4 and thus prevents that detaining flap 9 is deflected forward or upward by the reset force of elastic band 15in FIG. 4.

(22) In the condition of the packaging shown in FIG. 4, it can be filled. As the result of filling the packaging, the products exert pressure onto locking flap 11, so that it is pushed back into its initial position in which it extends in a plane with bottom 3. Thus, by means of the filling process, the lock of detaining flap 9 by locking flap 11 is released again. Elastic band 15 thus pushes the products contained in the packaging toward the front panel and removal opening 14 via detaining flap 9.

(23) If individual products are now removed through the removal opening or removed upward, elastic band 15 first pushes the products remaining in the packaging further toward front panel 5 via detaining flap 9. After a few products have been removed from the packaging, detaining flap 9 is deflected to such a degree by the reset force of elastic band 15 that it extends approximately parallel to the bottom, for example. Shortly before reaching this condition already, elastic band 15 slides off detaining flap 9 and exerts a tensile force toward front panel 5 directly upon the products remaining in the packaging. Thus elastic band 15 surrounds the products remaining in the packaging laterally and from the rear. This prevents that products, for example bar-like products fall over in the packaging and are thereby not as easily identifiable or removable by the consumer through removal opening 14.

(24) FIG. 2 through 4 shows a packaging erected from precut blank 1 in the form of an open tray (chute). After filling, the tray can be closed with a cover that has a cover surface opposite to bottom 3 and circumferential walls hinged to it. The circumferential walls can, for example, abut on the outside on the lateral panels 4 and the rear panel 6. A further circumferential wall can be inserted into the packaging so that it abuts inside at the front panel and thus closes the removal opening 14. Alternatively, it is also possible to locate this additional circumferential wall on the outside on the front panel. Preferably, at least one area of the cover surface and/or the front panel associated with the circumferential wall of the cover is designed to be ripped open or torn off, so that the packaging that is provided with a covering can be opened easily.

(25) In the following, the process of tensioning elastic band 15 and the locking of elastic band 15 by means of detaining flap 9 and locking flap 11 will be described in further detail by referring to FIG. 5 through 8. These Figures show a station into which the erected packaging as shown in FIG. 2 is inserted and converted into the condition shown in FIG. 4.

(26) For this, as shown in FIG. 5, station 20 has an adapter for the packaging. The adapter is formed by a bottom 21, lateral walls 22 and a rear wall 23. The adapter is thus open on the right side in FIG. 5, so that the packaging can be inserted into the adapter. In the embodiment shown, four openings are provided in bottom 21 by means of which suction elements 24 can retain bottom 3 of the packaging within the adapter.

(27) A plate 25 is mounted above the adapter in which two guide plates 26 are provided. Guide plates 26 are formed as an approximately S-shaped opening or slot in the embodiment shown, in which respectively one plate 27 is guided displaceable. Plates 27 can be displaced by a drivenot shown in further detailfrom the position on the right shown in FIG. 5 as dotted lineinto the position on the left shown with solid lines. In FIG. 7, the two bearings of plates 27 are also shown by two dotted lines respectively, and/or two solid circles in the different positions of the plates.

(28) Guide plates 26 in plate 25 are designed in such a way that plates 27 can enter through removal opening 14 in front panel 5 into the packaging. Hereby, when the packaging is inserted into the station, the elastic band 15 can come to abut with the left edge of the respective plates 27 (although this abutment is not shown in FIG. 5). Plates 27 thus serve as manipulators that push the elastic band 15 into the corners of lateral panels 4 with rear panel 6 by moving plates 27 along guide plate 26 to the left in FIG. 5. In this way, elastic band 15 is tensioned. Plates 27 are preferably comparatively thin so that plates 27 abut as tightly as possible to lateral panels 4 in their position on the left in FIG. 5, without impeding the folding over of detaining flap 9.

(29) For this, an angle 28 is provided in station 20 that has a width as shown in FIG. 8 corresponding approximately to that of detaining flap 9. Angle 28 can be deflected clockwise from its position shown in FIG. 5 by means of a drive that is not shown in further detail, so that the longer perpendicular leg of angle 28 in FIG. 5 contacts detaining flap 9 and folds it onto rear panel 6.

(30) In other words, angle 28 in operation brings detaining flap 9 out of the position shown in FIG. 3 into the position shown in FIG. 4.

(31) Further, a cylinder unit 29 is provided in station 20, whose plunger can act upon locking flap 11 of the packaging through an additional opening in bottom 21. After the folding over of detaining flap 9, cylinder unit 29 is actuated and thereby slightly deflecting locking flap 11 out of its position lying in the plane of bottom 3 into the interior of the packaging so that the free edge of locking flap 11 comes in contact with the lower side of detaining flap 9. This prevents that detaining flap 9 is deflected back due to the force of elastic band 15 when angle 28 returns into its initial positionshown in FIG. 5and plates 27 are moved back again into the position on the right in FIG. 5. The packaging is thus in a condition according to FIG. 4 in which the packaging can be filled.

(32) Deviating from the embodiment of precut blank 1 and station 20 described above, it is alternatively also possible to dispense with detaining flap 9, fold-over flaps 10 and/or locking flap 11. In this case, elastic band 15 is tensioned by plates 27 as described above and the packaging must then be filled while plates 27 hold elastic band 15 tensioned. Thereby, elastic band 15 acts directly upon the products after filling as soon as plates 27 are disengaged from band 15.

(33) Station 20 can have a further station upstreamnot shown in the Figuresin which the packaging is erected from precut blank 1 and glued. For example, this upstream station can be designed as described in the as of yet unpublished, international patent application PCT/GB2013/051755.

(34) Elastic band 15 can be applied to precut blank 1 in a unit upstream of station 20. For example, this can be accomplished thereby that from a roll that has a width corresponding approximately to the distance of the free lateral edges of connecting flaps 7, elastic band is uncoiled and applied to a substrate. This substrate is preferably connected with a suction unit so that the uncoiled material is retained on the substrate. On this substrate, the uncoiled material can then be cut into strips that have a suitable height for advancing the products in the packaging. This custom-cut strip can then be fed to precut blank 1 and glued together with it to connecting strip 7.

(35) FIGS. 9 and 10 shows a second embodiment that has a fundamentally similar structure to the first embodiment. On the upper side of detaining flap 9 in FIG. 9, however, cutouts 30a are provided. Corresponding cutouts 30b are also provided at the free edge of locking flap 11 that faces rear panel 6. As in FIG. 10in which elastic band 15 was omitted for reasons of clarityshows, these cut-outs 30a, 30b have the effect of a serration that preventsin erected condition of locking flap 11that it can be pushed out of the position that locks detaining flap 9 due to the force of elastic band 15. In other words, locking flap 11 and detaining flap 9 snap into each other to secure elastic element 15 via detaining flap 9.

(36) A modification of this embodiment is shown in FIG. 11. Hereby, first of all, the groove or bending line 2h, by means of which locking flap 11 is connected with bottom 3, has a curved design. This increases the reset force. Additionally, cuts 13 are slanted. Regardless of that, rear panel 6 has a shorter design than in the other embodiments. Correspondingly, the height of the fold-over flaps 10 is also shorter. To avoid a sharp edge with connecting flap 8, the double groove of bending line 2f therefore does not extend over the entire width of rear panel 6 andstarting from the ends of the double groove or bending line 2fslanted cuts extend to the respective corners of connecting flaps 8.

REFERENCE NUMBERS

(37) 1 Precut 2a-h Groove or bending line 3 Bottom 4 Lateral wall 5 Front panel 6 Rear panel 7 Connecting flap 8 Connecting flap 9 Detaining flap 10 Fold-over flap 11 Locking flap 12 Recess 13 Cut 14 Removal opening 15 Elastic element (band) 20 Station 21 Bottom 22 Lateral wall 23 Rear wall 24 Suction element 25 Plate 26 Guide plate 27 Plate (manipulator) 28 Angle 29 Cylinder 30a, b Cutout