Patent Publication Number: US-2023158767-A1

Title: Carton production method

Description:
TECHNICAL FIELD 
     The present invention relates to a carton production method. 
     BACKGROUND ART 
     Conventionally, there has been known a carton including a box body having an upper surface that is opened, a suspension piece extending upward from an upper end of one side surface of the box body, and a lid body that closes the upper surface of the box body, and provided with an inserting flap that is directed toward the one side surface of the box body to be inserted in the inner side of the box body. 
     There is a situation where such a carton is subjected to a process of applying an adhesive, such as a hot melt adhesive, to the inserting flap to seal the opening of the box body using the inserting flap in order to prevent “falsification”, that is, an act of opening the lid body, replacing or picking out a product stored in the box body or putting a foreign object in the box body, for example, and then closing the lid body. 
     However, for a carton including a suspension piece for suspending the carton, the suspension piece intervenes between a nozzle for discharging the adhesive and the inserting flap and hinders application of the adhesive to the inserting flap. This makes is difficult to apply the adhesive to the inserting flap. 
     In this regard, for such a carton including a suspension piece, Patent Literature 1 discloses a technique of using a suspension hole created in a suspension piece to apply an adhesive to an inserting flap via a nozzle in a relatively easy manner. 
     CITATION LIST 
     Patent Literature 
     Patent Literature 1: JP-U 3072763 Gazette 
     SUMMARY OF INVENTION 
     Technical Problems 
     A packing box described in Patent Literature 1 includes side plates (second side surface and third side surface) provided at both edges of a front plate (one side surface of a box body), a back plate (another side surface of the box body) provided at one side edge of one of the side plates, an upper lid piece (lid body) connected to an upper end of the back plate, and an insertion piece (inserting flap) connected to the upper lid piece. A hanging piece (suspension piece) extends from an upper end of the front plate, and an opening (suspension hole) is created in a lower end portion of the hanging piece so as to touch a boundary between the hanging piece and the front plate. 
     In the packing box, the insertion piece is mountain-folded at a folding line (line for folding), and the insertion piece is inserted in the inner side of the front plate. 
     In the process of inserting the insertion piece in the inner side of the front plate, a glue (adhesive) is applied to the insertion piece through the opening. Then, the insertion piece is further inserted, and the insertion piece and the inner side of the front plate are bonded and sealed. 
     However, in the packing box described in Patent Literature 1, the adhesive applied to the inserting flap may adhere to the suspension piece and one side surface of the box body when the inserting flap is inserted, which may deteriorate the quality of the carton. 
     In addition, when applying the adhesive through the suspension hole, the adhesive may adhere to the suspension piece due to an erroneous timing of discharging the adhesive or stringing of the applied adhesive, which may deteriorate the quality of the carton. 
     The present invention has been made in view of such problem. An object of the present invention is to provide a carton production method that can provide sealing to a carton having a suspension piece with an effect of preventing falsification, and at the same time prevent quality deterioration which may happen during the sealing due to adhesion of an adhesive to the suspension piece and one side surface of the box body. 
     Solutions to Problems 
     The problem to be solved by the present invention is as described above, and means for solving the problem will be described below. 
     That is, one aspect of the present invention is a carton production method for a carton including a box body having an upper surface that is opened, a suspension piece extending upward from an upper end of one side surface of the box body, a lid body that is provided so as to be rotatable about an upper end of another side surface of the box body and closes the upper surface of the box body, an inserting flap provided to the lid body and on an opposite side of the upper end of the another side surface of the box body, so as to be inserted in an inner side of the one side surface of the box body, and a suspension hole penetrating the suspension piece, the method including a first insertion step of rotating the lid body toward the one side surface of the box body to a position where the inserting flap overlaps the suspension hole, an application step of applying an adhesive to the inserting flap through the suspension hole, a second insertion step of curving the one side surface of the box body so as to protrude away from the inserting flap, inserting the insertion flap, and closing the upper surface of the box body with the lid body, and an adhesion step of bonding the inserting flap, to which the adhesive is applied, to the inside of the one side surface of the box body. 
     In this carton production method according to one aspect of the present invention, the adhesive applied to the inserting flap will not adhere to the suspension piece and the inside of the one side surface of the box body when the inserting flap is inserted. This prevents quality deterioration due to adhesion of the adhesive to the suspension piece and the one side surface of the box body. 
     Another aspect of the present invention is a carton production method in which, in the application step, the adhesive is discharged from a tip of a nozzle positioned on a side opposite to the inserting flap with respect to the suspension piece toward the inserting flap through the suspension hole, and a separation distance between the tip of the nozzle and the inserting flap is 5 mm or less. 
     In this carton production method according to another aspect of the present invention, the adhesive can be easily applied to the inserting flap without causing a contact of the adhesive with an edge of the suspension hole. This prevents quality deterioration due to adhesion of the adhesive to the suspension piece. 
     Advantageous Effects of Invention 
     The present invention described above can provide a carton production method that can provide sealing to a carton having a suspension piece with an effect of preventing falsification, and at the same time prevent quality deterioration which may happen when creating the sealing due to adhesion of an adhesive to the suspension piece and one side surface of a box body. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
         FIG.  1    is a perspective view illustrating an overall configuration of a carton according to an embodiment of the present invention. 
         FIG.  2    is an exploded view illustrating the overall configuration of the carton according to an embodiment of the present invention. 
         FIG.  3    is a flowchart illustrating a carton production method according to an embodiment of the present invention. 
         FIG.  4    is a perspective view illustrating the carton before performing a first insertion step. 
         FIG.  5 A  is a perspective view illustrating the carton in the first insertion step. 
         FIG.  5 B  is a plan view illustrating the carton in the first insertion step. 
         FIG.  5 C  is a side view illustrating the carton in the first insertion step. 
         FIG.  6 A  is a perspective view illustrating the carton in an application step. 
         FIG.  6 B  is a plan view illustrating the carton in the application step. 
         FIG.  6 C  is a side view illustrating the carton in the application step. 
         FIG.  7 A  is a perspective view illustrating the carton in a second insertion step. 
         FIG.  7 B  is a plan view illustrating the carton in the second insertion step. 
         FIG.  7 C  is a view illustrating the carton in the second insertion step, the view being a cross-sectional view as viewed in a direction indicated by arrows X in  FIG.  7 B . 
         FIG.  8    is a perspective view illustrating the carton in an adhesion step. 
         FIG.  9    is a schematic plan view illustrating the carton production method. 
     
    
    
     DESCRIPTION OF EMBODIMENT 
     An embodiment of the present invention will be described below with reference to the drawings. 
     In the following description, for convenience, the direction indicated by arrow A in  FIG.  9    is defined as a conveyance direction of a carton  1 . 
     As illustrated in  FIG.  9   , in the present embodiment, a carton conveyance unit  2  that conveys the carton  1  is provided, and along a conveyance path  3 , a first pushing member  4 , an adhesive applicator  5 , a second pushing member  6 , a claw member  7 , and a pusher  8  are provided in this order. 
     The carton  1  is expanded from a folded flat form (carton blank) into a box shape, and is then conveyed in such an orientation that a first side surface  14  is an upper surface. The conveyed carton  1  is fixed by a plurality of fixing members  9 . How the carton  1  is fixed is not particularly limited, and any appropriate fixing method can be used. The carton  1  is conveyed continuously by continuous conveyance. How the carton  1  is conveyed is not particularly limited. The carton  1  may be conveyed intermittently by pitch conveyance. 
     The first pushing member  4  pushes a lid body  20  (see  FIG.  1   ) of the carton  1  to a position where an adhesive  10  can be applied. The first pushing member  4  is linked to a first driving device  11 . The first driving device  11  operates to move the first pushing member  4  toward or away from the conveyance path  3 . The first pushing member  4  is driven to move toward the conveyance path  3  when the conveyed carton  1  passes, whereby the lid body  20  is pushed in. 
     The adhesive applicator  5  applies the adhesive  10  to an inserting flap  21  of the carton  1 . The adhesive applicator  5  is, for example, a hot melt applicator, and discharges a hot melt adhesive from a nozzle  28  (see  FIG.  6 A ). A sensor (not illustrated) or the like detects presence or absence of the conveyed carton  1 . When presence of the conveyed carton  1  is detected, the nozzle  28  discharges the adhesive  10  toward the inserting flap  21 . 
     Note that the adhesive  10  is not limited to a hot melt adhesive, and can be appropriately selected according to, for example, the material of the carton  1 . 
     The second pushing member  6  pushes the lid body  20  to a position where the lid body  20  closes the upper surface of the box body  13  (see  FIG.  1   ) of the carton  1 . The second pushing member  6  is linked to a second driving device  12 . The second driving device  12  operates to move the second pushing member  6  toward or away from the conveyance path  3 . The second pushing member  6  is driven to move toward the conveyance path  3  when the conveyed carton  1  passes, whereby the lid body  20  is pushed in. 
     A claw member  7  curves the first side surface  14  to protrude away from the inserting flap  21 . The claw member  7  is fixed to the second pushing member  6 . Two claw members  7  are provided so as to point their tips between the inserting flap  21  and the first side surface  14 . Like the second driving device  12 , the claw members  7  move toward or away from the conveyance path  3 , operated by the second driving device  12 . In addition, the claw members  7  are configured to move, after being inserted in the carton  1  from between the inserting flap  21  and the first side surface  14 , away from the inserting flap  21 . With this movement, the claw members  7  curve the first side surface  14  to protrude away from the inserting flap  21 . 
     After the claw members  7  that have curved the first side surface  14  to protrude away from the inserting flap  21  are removed, the pusher  8  presses the first side surface  14  toward the inserting flap  21 . When the carton  1  passes, the pusher  8  presses a portion of the first side surface  14  toward the inserting flap  21 , in which the portion is overlapping the surface, to which the adhesive  10  has been applied, of the inserting flap  21 . This reliably bond the inserting flap  21  to the inside of the first side surface  14 . 
     Next, the carton  1  will be described with reference to  FIG.  1    and  FIG.  2   . The carton  1  accommodates a product or the like which is an object to be packed. The carton  1  of the present embodiment is made of paper, for example. 
     As illustrated in  FIG.  1    and  FIG.  2   , the carton  1  includes a quadrangular sleeve-shaped box body  13  whose upper surface and lower surface are opened. The box body  13  includes the first side surface  14  which is one side surface of the box body  13 , a second side surface  15  and a third side surface  16  positioned on both sides of the first side surface  14  to oppose each other, and a fourth side surface  17  which is the other side surface of the box body  13  and faces the first side surface  14 . The fourth side surface  17 , the second side surface  15 , the first side surface  14 , and the third side surface  16  are provided in series with fold lines each between adjacent ones of the surfaces. The fourth side surface  17  and the third side surface  16  are joined via a gluing piece  18  extending from the fourth side surface  17  via a fold line. 
     On the upper end of the box body  13 , a side flap  19   a  connected to the upper end of the second side surface  15  via a fold line and a side flap  19   b  connected to the upper end of the third side surface  16  via a fold line are provided. Also provided are a lid body  20  connected to the upper end of the fourth side surface  17  via a fold line, and the inserting flap  21  connected, via a fold line, to the lid body  20  on a side opposite to the upper end of the fourth side surface  17  of the box body  13 . 
     The side flap  19   a  is rotated toward the inside of the box body  13  about the fold line at the upper end of the second side surface  15 . The side flap  19   b  is rotated toward the inside of the box body  13  about the fold line at the upper end of the third side surface  16 . 
     Then, the lid body  20  is rotated toward the first side surface  14  about the fold line at the upper end of the fourth side surface  17  to close the upper surface of the box body  13 . In this action, the inserting flap  21  is rotated toward the first side surface  14  about the fold line between the lid body  20  and the insertion flap  21 , and is inserted in the inner side of the first side surface  14 . 
     A suspension piece  22  extending upward from the upper end of the first side surface  14  is provided at the upper end of the box body  13 . A suspension hole  23  penetrating the suspension piece  22  is provided at the center of the lower end portion of the suspension piece  22 . 
     The carton  1  can be used in a suspended state by putting a hook or the like through the suspension hole  23 . The suspension hole  23  has such a shape that is a combination of a long hole  24  extending in a width direction of the suspension piece  22  and a semicircular hole  25  provided at the upper center of the long hole  24  to allow the semicircular hole  25  to engage with a hook or the like. 
     On the lower end portion of the box body  13 , a bottom flap  26   a  connected to the lower end of the second side surface  15  via a fold line and a bottom flap  26   b  connected to the lower end of the third side surface  16  via a fold line are provided. Also provided are a bottom part  27   a  connected to the lower end of the first side surface  14  via a fold line, and a bottom part  27   b  connected to the lower end of the fourth side surface  17  via a fold line. 
     The bottom flap  26   a  is rotated toward the inside of the box body  13  about the fold line at the lower end of the second side surface  15 . The bottom flap  26   b  is rotated toward the inside of the box body  13  about the fold line at the lower end of the third side surface  16 . 
     Then, the bottom part  27   a  is rotated toward the bottom flaps  26   a  and  26   b  about the fold line at the lower end of the first side surface  14 . The bottom part  27   b  is rotated toward the bottom part  27   a  about the fold line at the lower end of the fourth side surface  17 . The bottom part  27   a  and the bottom part  27   b  are bonded to each other with an adhesive, whereby the opening of the lower end portion of the box body  13  is sealed. 
     Next, a method for producing the carton  1  will be described with reference to  FIGS.  3    to  FIG.  8   . 
     Note that illustration of the conveyance path  3  is omitted in  FIGS.  4    to  FIG.  8   , illustration of the nozzle  28  is omitted in  FIG.  6 B , and illustration of the pusher  8  is omitted in  FIG.  8   . 
     As illustrated in  FIG.  3   , the method for producing the carton  1  includes a first insertion step K 1 , an application step K 2 , a second insertion step K 3 , and an adhesion step K 4 . 
     As illustrated in  FIG.  4   , the carton  1  is expanded from a folded flat form (carton blank) into a box shape before the first insertion step K 1  is performed. While the carton  1  is conveyed by the carton conveyance unit  2  (see  FIG.  9   ), an object to be packed is put into the carton  1 , and the side flaps  19   a  and  19   b  are rotated toward the inside of the box body  13 . 
     In the first insertion step K 1  as illustrated in  FIGS.  5 A ,  FIG.  5 B , and  FIG.  5 C , the lid body  20  is rotated toward the first side surface  14  to a position where the inserting flap  21  overlaps the suspension hole  23 . The inserting flap  21  (see  FIG.  4   ) horizontally projecting from the lid body  20  is rotated toward the first side surface  14  by a guide (not illustrated). In a similar manner, the lid body  20  horizontally projecting from the fourth side surface  17  is rotated toward the first side surface  14  by a guide (not illustrated). Then, the first pushing member  4  pushes the lid body  20  to the inside of the box body  13 , whereby the inserting flap  21  slides against the suspension piece  22  and the first side surface  14  to be inserted. 
     For example, the first pushing member  4  pushes the lid body  20  until a position P on the surface to which the adhesive  10  is applied comes to the central portion of the suspension hole  23  in a plan view. 
     In the application step K 2  as illustrated in  FIGS.  6 A ,  FIG.  6 B , and  FIG.  6 C , the adhesive  10  is applied to the inserting flap  21  through the suspension hole  23 . The nozzle  28  is positioned on the side opposite to the inserting flap  21  with respect to the suspension piece  22 , and discharges the adhesive  10  from the tip of the nozzle  28  toward the insertion flap  21  through the suspension hole  23 . The nozzle  28  discharges the adhesive  10  through, for example, the central portion of the suspension piece  22 . The nozzle  28  preferably has a separation distance D of 5 mm or less between the tip of the nozzle  28  and the inserting flap  21 . This is based on the idea derived through extensive studies by the inventor of the present application that an excessively large separation between the nozzle  28  and the inserting flap  21  (an excessively large separation distance D) may cause a defect due to stringing of the adhesive  10  discharged from the nozzle  28 , that is, a string of adhesive adhering to the suspension piece, in particular, to the edge of the suspension hole, where application of the adhesive is not necessary, whereas a separation distance D of 5 mm or less greatly reduces such a defect. 
     Note that the carton conveyance unit  2  (see  FIG.  9   ) recognizes the position of the conveyed carton  1 , and based on the position, the adhesive  10  is discharged toward the inserting flap  21  of the passing carton  1 . However, the present invention is not limited to this configuration, and for example, the suspension hole  23  may be recognized using image recognition, and the adhesive  10  may be discharged toward the central portion of the recognized suspension hole  23 . 
     To apply the adhesive  10  by an amount that manifests a sufficient bond strength, the discharge amount of the adhesive  10  is determined in advance according to the material of the carton  1 , the viscosity of the adhesive  10 , the discharge velocity from the nozzle  28 , and the like. 
     In the second insertion step K 3  as illustrated in  FIGS.  7 A ,  FIG.  7 B , and  FIG.  7 C , the first side surface  14  is curved to protrude away from the inserting flap  21  to insert the inserting flap  21 , and the upper surface of the box body  13  is closed with the lid body  20 . The two claw members  7  opposing each other with the suspension hole  23  therebetween are inserted along the inside of the first side surface  14  in the carton  1 . The claw members  7  are moved away from the inserting flap  21  to curve the first side surface  14  to such an extent that the adhesive  10  will not touch the first side surface  14 . In this action, the suspension piece  22  is also curved with the first side surface  14 . While the first side surface  14  and the suspension piece  22  are curved to such an extent that the adhesive  10  will not touch the first side surface  14  and the suspension piece  22 , the second pushing member  6  pushes the lid body  20  to a position where the lid body  20  closes the upper surface of the box body  13 . 
     The number, arrangement, and shape of the claw members  7  are not limited to those illustrated in the drawings. The claw members  7  may be configured in an appropriate number, arrangement, and shape. For example, the number, arrangement, and shape of the claw members  7  may be changed according to the material and dimension of the carton  1  so as not to leave a mark made by curving on the first side surface  14 . A suction member (not illustrated) that sucks the outer side of the first side surface  14  may be provided to pull the first side surface  14  by the suction member so as to protrude away from the inserting flap  21 , thereby curving the first side surface  14 . 
     In the adhesion step K 4  as illustrated in  FIG.  8   , the inserting flap  21  to which the adhesive  10  is applied is bonded to the inside of the first side surface  14 . The pusher  8  (see  FIG.  9   ) presses a portion of the first side surface  14  toward the inserting flap  21 , in which the portion is overlapping the surface, to which the adhesive  10  has been applied, of the inserting flap  21 . 
     In the method for producing the carton  1  according to the present invention, the adhesive  10  applied to the inserting flap  21  will not adhere to the suspension piece  22  nor to the first side surface  14  when the inserting flap  21  is inserted. This prevents quality deterioration due to adhesion of the adhesive  10  to the suspension piece  22  and the first side surface  14 . 
     Furthermore, since the adhesive  10  is applied to the inserting flap  21  through the suspension hole  23 , the inserting flap  21  can be bonded to the inside of the first side surface  14  by simply further inserting the lid body  20  that has already been inserted halfway. This allows, when the adhesive  10  is a hot melt adhesive, immediately performing bonding before the adhesive  10  solidifies. Furthermore, in a case where the carton  1  is continuously conveyed, the inserting flap  21  to which the adhesive  10  is applied can be easily inserted even when the carton  1  is moving. 
     According to the method of producing the carton  1  and the carton  1  according to the present invention, the adhesive  10  can be easily applied to the inserting flap  21  without the adhesive  10  touching an edge of the suspension hole  23 . This prevents quality deterioration due to adhesion of the adhesive  10  to the suspension piece  22 . 
     Lastly, the carton  1  of the present invention is not limited to the embodiment described above, and the material, and the shape, arrangement, and the like of the members (inserting flap  21 , suspension piece  22 , suspension hole  23 , and the like) may be appropriately changed. 
     INDUSTRIAL APPLICABILITY 
     The present invention can be used for a carton including a box body having an upper surface that is opened, a suspension piece extending upward from an upper end of one side surface of the box body, and a lid body that closes the upper surface of the box body, and provided with an inserting flap that is directed toward the one side surface of the box body to be inserted in the inner side of the box body. 
     REFERENCE SIGNS LIST 
       1  carton 
       10  adhesive 
       13  box body 
       14  first side surface (one side surface of box body) 
       17  fourth side surface (another side surface of box body) 
       20  lid body 
       21  inserting flap 
       22  suspension piece 
       23  suspension hole 
       28  nozzle 
     D separation distance 
     K 1  first insertion step 
     K 2  application step 
     K 3  second insertion step 
     K 4  adhesion step