Patent Description:
A pack with a sliding opening comprises a tray which is open at the top (namely, is devoid of upper wall) and contains a group of products and a case which is open on at least one side and houses, on the inside, the tray so that the tray can slide relative to the case between a closed position in which the tray is fully inserted into the case and an open position in which the tray is at least partially extracted from the case.

Some examples of a pack with a sliding opening are provided in patent applications <CIT>, <CIT> and <CIT>.

A further example of a pack with a sliding opening is provided by patent application <CIT>.

Generally, two separate packer machines arranged in series are used to manufacture a pack with a sliding opening: a first packer machine manufactures the trays containing the respective groups of products while a second packer machine manufactures (wraps) the cases around the trays received from the first packer machine. Consequently, the production of a pack with a sliding opening has very high fixed costs (namely, equipment expenses) as it requires the use of two different packer machines.

The object of the present invention is to provide a wrapping method and a packer machine to manufacture a pack with a sliding opening without the drawbacks described above and therefore allowing to reduce fixed costs (namely, equipment expenses).

According to the present invention, a wrapping method and a packer machine are provided to manufacture a pack with a sliding opening, according to what is claimed in the appended claims.

The present invention will now be described with reference to the attached drawings, which illustrate some non-limiting embodiments thereof, wherein:.

In <FIG>, number <NUM> denotes, as a whole, a pack with a sliding opening comprising a case <NUM> which is open on at least one side and houses, on the inside, a tray <NUM> which is open at the top (namely, is devoid of upper wall) and contains a group of products <NUM> (schematically illustrated in <FIG>). By way of example, the products <NUM> can be food products such as capsules containing a powder for the production of beverages (typically coffee capsules) or the products <NUM> can be tobacco industry articles such as single doses of molasses.

The case <NUM> houses, on the inside, the tray <NUM> so that the tray can slide (lengthwise) relative to the case <NUM> between a closed position (illustrated in <FIG>) in which the tray <NUM> is completely inserted into the case <NUM> and an open position (not illustrated) in which the tray <NUM> is at least partially extracted from the case <NUM> to allow the products <NUM> contained in the tray <NUM> to be removed.

As illustrated in <FIG>, the case <NUM> has a rectangular parallelepiped shape and has a lower wall <NUM> and an upper wall <NUM> parallel and opposite to one another, two larger side walls <NUM> and <NUM> parallel and opposite to one another, and a single smaller side wall <NUM>; on the opposite side of the smaller side wall <NUM>, the case <NUM> has a through opening through which the tray <NUM> can be extracted. The upper wall <NUM> has a recess, which by way of example can have the shape of a semicircle, which is arranged in the area of the through opening and facilitates the gripping of the tray <NUM> contained inside the case <NUM>.

<FIG> illustrates a blank <NUM> used to manufacture the case <NUM>; namely, the case <NUM> is formed by folding and gluing the blank <NUM>.

The blank <NUM> sequentially comprises a panel <NUM>' which forms the outer portion of the larger side wall <NUM>, the upper wall <NUM>, which is connected to the upper panel <NUM>' along a pre-weakened longitudinal folding line, the larger side wall <NUM>, which is connected to the upper wall <NUM> along a pre-weakened longitudinal folding line, the lower wall <NUM>, which is connected to the larger side wall <NUM> along a pre-weakened longitudinal folding line, and a panel <NUM>", which forms the inner part of the larger side wall <NUM>, overlaps and is glued to the panel <NUM>', and is connected to the lower wall <NUM> along a pre-weakened longitudinal folding line.

The blank <NUM> comprises a panel <NUM>' which forms the outer part of the smaller side wall <NUM> and is connected to the upper wall <NUM> along a pre-weakened transverse folding line; the blank <NUM> comprises, furthermore, a panel <NUM>" which forms the inner part of the smaller side wall <NUM>, overlaps and is glued to the panel <NUM>', and is connected to the lower wall <NUM> along a pre-weakened transverse folding line.

The blank <NUM> comprises two tabs <NUM> which are connected along respective pre-weakened transverse folding lines to the larger side wall <NUM> and to the panel <NUM>", are folded by <NUM>° relative to the larger side wall <NUM> and to the panel <NUM>", and rest, from the inside, against the panel <NUM>".

As illustrated in <FIG>, the tray <NUM> has a rectangular parallelepiped shape and has a lower wall <NUM>, two larger side walls <NUM> and <NUM> parallel and opposite to one another, and two smaller side walls <NUM> and <NUM>; on the opposite side of the lower wall <NUM>, the tray <NUM> is open (that is, devoid of upper wall) and therefore has a through opening through which the products <NUM> contained in the tray <NUM> can be removed.

The smaller side wall <NUM> is arranged in the area of the through opening of the case <NUM>, is box-shaped (namely, is formed by an internally hollow structure), and is elastically deformable to be gripped and pulled more easily when it is necessary to extract the tray <NUM> out of the case <NUM>.

<FIG> illustrates a blank <NUM> used to manufacture the tray <NUM>; namely, tray <NUM> is formed by folding and gluing the blank <NUM>.

The blank <NUM> sequentially comprises the larger sidewall <NUM>, the bottom wall <NUM> that is connected to the larger sidewall <NUM> along a pre-weakened longitudinal folding line, and the larger sidewall <NUM> that is connected to the bottom wall <NUM> along a pre-weakened longitudinal folding line.

The blank <NUM> comprises a panel <NUM>' which forms the outer portion of the smaller side wall <NUM> and is connected to the bottom wall <NUM> along a pre-weakened transverse folding line; the blank <NUM> further comprises a panel <NUM>" which forms the inner part of the smaller side wall <NUM>, overlaps (by means of a <NUM>° fold) the panel <NUM>', and is connected to the panel <NUM>' along a pre-weakened transverse folding line. According to a preferred embodiment, the panel <NUM>" has an appendage <NUM> which enters (fits) into a through slot <NUM> formed through the lower wall <NUM> (in the area of the transverse folding line provided between the panel <NUM>' and the lower wall <NUM>); the function of the appendage <NUM> is to mechanically lock the panel <NUM>" to the lower wall <NUM> so as to keep the panel <NUM>" folded against the panel <NUM>'.

The blank <NUM> comprises two tabs <NUM> which are connected along respective pre-weakened transverse folding lines to the larger side walls <NUM> and <NUM>, are folded by <NUM>° relative to the larger side walls <NUM> and <NUM>, and are arranged between the two panels <NUM>' and <NUM>" (namely, they are enclosed between the two panels <NUM>' and <NUM>").

The blank <NUM> comprises a panel <NUM>' which forms the outer part of the smaller side wall <NUM> and is connected to the bottom wall <NUM> along a pre-weakened transverse folding line. The blank <NUM> comprises a panel <NUM>" which forms an upper portion of the smaller side wall <NUM>, is folded by <NUM>° relative to the panel <NUM>', and is connected to the panel <NUM>' along a pre-weakened transverse folding line. The blank <NUM> further comprises a panel <NUM>'", which forms the outer part of the smaller side wall <NUM>, is folded by <NUM>° relative to the panel <NUM>", and is connected to the panel <NUM>" along a pre-weakened transverse folding line. Finally, the blank <NUM> comprises a panel <NUM>"", which rests against and is glued to the lower wall <NUM>, is folded by <NUM>° relative to the panel <NUM>'", and is connected to the panel <NUM>'" along a pre-weakened transverse folding line. In the tray <NUM>, the panels <NUM>', <NUM>" e <NUM>'" have a "U"-shaped conformation (namely, a portal-like shape) and are elastically deformable. In particular, the four panels <NUM>', <NUM>", <NUM>'" and <NUM>"" form an articulated quadrilateral (namely, a kinematic chain made up of four rigid members connected in pairs by means of articulation hinges) which is deformable: the panel <NUM>" forms the connecting rod, the panel <NUM>"" (glued to the lower wall <NUM>) forms the frame, and the panels <NUM>' and <NUM>'" form the two handles.

According to an alternative embodiment of the blank <NUM> of <FIG>, the blank <NUM> is devoid of the appendage <NUM> (and of the slot <NUM>) and provides for the gluing of the panel <NUM>" to the two tabs <NUM> folded (and possibly glued) against panel <NUM>'.

According to a further alternative embodiment of the blank <NUM> of <FIG>, the blank <NUM> is devoid of the appendage <NUM>, the slot <NUM> and the panel <NUM>"; it also provides for the gluing of the tabs <NUM> to the panel <NUM>'.

Number <NUM> in <FIG> illustrates, as a whole, a packer machine which produces the pack <NUM> with a sliding opening.

The packer machine <NUM> comprises a conveyor <NUM> which moves with a law of intermittent motion (namely, in a step-like manner by cyclically alternating motion steps and stop steps) a plurality of pockets <NUM> along a linear wrapping path; typically, the conveyor <NUM> is of the belt (chain) type and therefore comprises (at least) a belt (chain) closed in a loop and to which the pockets <NUM> are fixed.

Each pocket <NUM> is stopped at a feeding station S1 in which a feeding device <NUM> inserts a corresponding blank <NUM> into the pocket <NUM>, and is subsequently stopped at a feeding station S2 in which a feeding device <NUM> inserts into the pocket <NUM> (or rather in the case <NUM> partially formed and contained inside the pocket <NUM>) a corresponding blank <NUM> which has been glued and partially pre-folded beforehand, a feeding station S3 in which a feeding device <NUM> inserts into the pocket <NUM> (or rather into the tray <NUM> inserted into the case <NUM> contained in the pocket <NUM>) the group <NUM> of products, and a folding station S4 in which the folding of the blank <NUM> is completed (namely, the forming of the case <NUM> is completed) around the tray <NUM> containing the products <NUM>.

According to a different embodiment not illustrated, the feeding station S2 could be incorporated with the feeding station S1, namely, the feeding device <NUM> could alternatively feed the blanks <NUM> and the blanks <NUM>. According to a further embodiment not illustrated, the feeding station S2 could be incorporated with the feeding station S3, namely, the feeding device <NUM> could alternatively feed the blanks <NUM> and the groups of products <NUM>. According to another embodiment not illustrated, the feeding stations S2 and S3 could be incorporated with the feeding station S1, namely, the feeding device <NUM> could alternatively feed the blanks <NUM>, the blanks <NUM>, and the groups of products <NUM>.

The methods to manufacture a single pack <NUM> with a sliding opening are described in the following with reference to <FIG>.

Initially and as illustrated in <FIG>, in station S1 the blank <NUM> is folded into a "U"-shaped conformation by being inserted from above (namely, by being inserted with a movement from top to bottom and along a vertical downward path) into a corresponding pocket <NUM> by the feeding device <NUM>. In other words, the feeding device <NUM> picks up the blank <NUM> with a suction head, transports the same above the pocket <NUM> and then inserts the blank <NUM> into the pocket <NUM> from above, thus causing the side walls <NUM> and <NUM> to fold by <NUM>° relative to the lower wall <NUM> and also causing the <NUM>° folding of the smaller side wall <NUM> relative to the lower wall <NUM>. Preferably, during the transport of the blank <NUM> over the pocket <NUM>, glue is applied to the panel <NUM>" (at the areas of the panel <NUM>'' which will overlap the tabs <NUM>).

Beforehand, namely, before inserting the blank <NUM> into the pocket <NUM>, the tabs <NUM> are folded (by a special folding device <NUM> schematically illustrated in <FIG>) by (almost) <NUM>° relative to the larger side walls <NUM> and <NUM>, so that by folding the larger side walls <NUM> and <NUM> by <NUM>° relative to the lower wall <NUM>, the tabs <NUM> rest against the panel <NUM>" of the smaller side wall <NUM>.

As illustrated in <FIG>, once the blank <NUM> has been inserted into the pocket <NUM>, the case <NUM> is almost completely formed (made) lacking only the folding of the upper wall <NUM>; therefore, the insertion of the blank <NUM> into the pocket <NUM> in the feeding station S1 causes a folding of the blank <NUM> (designed to form the case <NUM>) so as to give the blank <NUM> a "U"-shaped conformation having an open upper end.

Once the "U"-shaped blank <NUM> has been inserted into the pocket <NUM> in the feeding station S1, the pocket <NUM> moves from the feeding station S1 to the feeding station S2 where the feeding device <NUM> feeds the blank <NUM>.

As illustrated in <FIG>, <FIG> and <FIG>, in the feeding station S2 the blank <NUM> (designed to form the tray <NUM>) is folded so as to manufacture the tray <NUM> which is inserted at least partially formed inside the "U"-shaped blank <NUM>. In particular, in the feeding station S2 the feeding device <NUM> feeds the blank <NUM> from top to bottom and along a vertical downward path into the "U"-shaped blank <NUM> (still contained in the pocket <NUM>); along this vertical downward path the blank <NUM> is folded to form (at least partially) the tray <NUM> before the blank <NUM> (namely, the at least partially formed tray <NUM>) enters the "U"-shaped blank <NUM>.

According to a preferred embodiment, the blank <NUM> is made to pass through a folding profile <NUM> (illustrated schematically in <FIG> and movable from and towards the feeding station S2) arranged along the vertical downward path so as to cause at least one "U"-fold of the blank <NUM>. In particular, the folding profile <NUM> has the shape of a rectangular frame and is crossed from side to side by the blank <NUM> to determine both the <NUM>° folding of the two larger side walls <NUM> and <NUM> of the tray <NUM> relative to the lower wall <NUM> of the tray <NUM>, and the <NUM>° folding of the two smaller side walls <NUM> and <NUM> of the tray <NUM> relative to the lower wall <NUM> of the tray <NUM> (as illustrated in <FIG>).

As previously stated, the smaller side wall <NUM> of the tray <NUM> is box-shaped, is elastically deformable, and is arranged in the area of an open end of the tray <NUM>; preferably, the smaller box-shaped side wall <NUM> is made in advance by folding and gluing the blank <NUM> before inserting the at least partially formed tray <NUM> into the "U"-shaped blank <NUM> and then the smaller box-shaped side wall <NUM> is flattened before inserting the tray <NUM> at least partially formed inside the "U"-shaped blank <NUM> so as to give the blank <NUM> a flat shape (illustrated in <FIG>).

As previously stated, the smaller side wall <NUM> of the tray <NUM> is formed by two panels <NUM>' and <NUM>" overlapping one another; preferably, the overlap of the two panels <NUM>' and <NUM>" which form the smaller side wall <NUM> of the tray <NUM> is obtained after having inserted the only partially formed tray <NUM> (lacking, in fact, the completion of the smaller side wall <NUM>) inside the "U"-shaped blank <NUM>. Namely, only after having inserted the only partially formed tray <NUM> (lacking, in fact, the completion of the smaller side wall <NUM>) inside the "U"-shaped blank <NUM>, the panel <NUM>" is folded by <NUM>° relative to the panel <NUM>', being, the same, overlapping the panel <NUM>'. At the end of the folding of the panel <NUM>", the appendage <NUM> of the panel <NUM>" is inserted (fixed) into the slot <NUM> obtained through the lower wall <NUM> of the tray <NUM>. In the event that the blank <NUM> does not comprise the appendage <NUM> and the slot <NUM>, then after the blank <NUM> has been removed, glue is applied to the panel <NUM>'.

In other words, the tray <NUM> is inserted inside the "U"-shaped blank <NUM> only partially formed (lacking the completion of the smaller side wall <NUM>) and the folding of the blank <NUM> is completed (by folding the panel <NUM>" by <NUM>° relative to the panel <NUM>') only after having inserted the only partially formed tray <NUM> inside the "U"-shaped blank <NUM>.

According to a different embodiment not illustrated, the tray <NUM> is completely formed (namely, the folding of the blank <NUM> is completed) before inserting the tray <NUM> inside the "U"-shaped blank <NUM> so as not to have to perform further folding operations after tray <NUM> has been inserted into the "U"-shaped blank <NUM>.

According to a preferred embodiment, along the vertical downward path (and before crossing the folding profile <NUM>), the tabs <NUM> are folded (by a suitable folding device <NUM> illustrated schematically in <FIG>) by (almost) <NUM>° relative to to the larger side walls <NUM> and <NUM>, so that by folding the larger side walls <NUM> and <NUM> by <NUM>° relative to the lower wall <NUM>, the tabs <NUM> rest against the panel <NUM>' of the smaller side wall <NUM> (before being enclosed between the two panels <NUM>' and <NUM>" of the smaller side wall <NUM>).

Once in the feeding station S2 the tray <NUM> (formed by folding the blank <NUM>) has been inserted inside the "U"-shaped blank <NUM> and contained in the pocket <NUM>, the pocket <NUM> moves from the feeding station S2 to the feeding station S3, in which the feeding device <NUM> feeds the group of products <NUM>. In the feeding station S3, the group of products <NUM> is inserted into the tray <NUM> which is inside the "U"-shaped blank <NUM> and contained in the pocket <NUM>. Namely, the product <NUM> is inserted into tray <NUM> after having inserted tray <NUM> inside the "U"-shaped blank <NUM> contained in pocket <NUM> and before completing the folding of blank <NUM>.

According to a different embodiment not illustrated, the group of products <NUM> is inserted into the tray <NUM> before inserting the tray <NUM> (at this point already containing the group of products <NUM> and therefore no longer empty) inside the "U"-shaped blank <NUM> contained in the pocket <NUM>.

Once in the feeding station S3 the group of products <NUM> has been inserted into the tray <NUM> that is inside the "U"-shaped blank <NUM> contained in the pocket <NUM>, the pocket <NUM> moves from the feeding station S3 to the folding station S4. In the folding station S4, a folding device <NUM> (illustrated schematically in <FIG>) completes the folding of the blank <NUM> around the tray <NUM> previously inserted into the "U"-shaped blank <NUM> to form the case <NUM> already containing the tray <NUM> (which obviously in turn contains the group of products <NUM>).

As illustrated in <FIG>, in the folding station S4 (to complete the folding of the blank <NUM> around the tray <NUM> previously inserted into the "U"-shaped blank <NUM>), the folding device <NUM> folds the upper wall <NUM> of the case <NUM> over the tray <NUM> and then fold the panel <NUM>' by <NUM>° against the underlying panel <NUM>" and fold the panel <NUM>' by <NUM>° against the underlying panel <NUM>"; the panels <NUM>' and <NUM>' (or the panels <NUM>" and <NUM>") are previously glued to stabilize the shape of the case <NUM> by gluing. Preferably, the folding device <NUM> has fixed folding profiles which fold the upper wall <NUM> of the case <NUM> by exploiting the forward movement of the conveyor <NUM> (preferably at the same time glue is applied to the panel <NUM>" and/or to the panel <NUM>') and has other fixed folding profiles which fold the panels <NUM>' and <NUM>' by exploiting a vertical extraction movement of the pack <NUM> with a sliding opening from the pocket <NUM>. For example, glue can also be applied to the panels <NUM>" and/or <NUM>"; said application can, for example, take place during the vertical extraction movement before the panels <NUM>' and <NUM>' have come into contact with the panels <NUM>" and <NUM>".

In the embodiment illustrated in <FIG>, the tray <NUM> is internally "bare" (empty) as it is devoid of supports for the products <NUM>; according to a different embodiment illustrated in <FIG>, the tray <NUM> is a supporting structure <NUM> for the products <NUM> which is preferably connected to at least one larger side wall <NUM> or <NUM> of the tray <NUM>.

According to a preferred embodiment, the support structure <NUM> is formed by folding and gluing the blank <NUM> before inserting the at least partially formed tray <NUM> inside the "U"-shaped blank <NUM> and the support structure <NUM> is flattened before inserting the at least partially formed tray <NUM> into the "U"-shaped blank <NUM> so as to give the blank <NUM> a flat shape (as illustrated in <FIG>).

<FIG> show a possible embodiment of the support structure <NUM>, whereas <FIG> and <FIG> show a different embodiment of the support structure <NUM>.

The support structure <NUM> illustrated in <FIG> comprises three housings <NUM>, each configured to house a single product <NUM> and is obtained through an upper wall <NUM> (parallel to the lower wall <NUM> of the tray <NUM>) divided into two distinct and side by side halves. Each half of the upper wall <NUM> of the support structure <NUM> is connected along a pre-weakened longitudinal folding line to a corresponding larger side wall <NUM> or <NUM> of the tray <NUM> by means of a connecting strip <NUM> which is folded by <NUM>° relative to the middle of the upper wall <NUM> and rests against (and is preferably glued to) the corresponding larger side wall <NUM> or <NUM> of the tray <NUM>. A connecting strip <NUM> is connected to the larger side wall <NUM> of the tray <NUM> along a pre-weakened longitudinal folding line. Furthermore, the support structure <NUM> comprises a lower wall <NUM> which rests against (and is preferably glued to) the lower wall <NUM> of the tray <NUM> and is connected to the two halves of the upper wall <NUM> by means of two connecting strips <NUM> folded at <NUM>° both relative to lower wall <NUM>, and relative to the upper wall <NUM>.

The support structure <NUM> illustrated in <FIG> and <FIG> is different from the support structure <NUM> illustrated in <FIG>, since in the support structure <NUM> illustrated in <FIG> and <FIG> the upper wall <NUM> is formed by a single undivided piece (instead of two side by side halves) and the lower wall <NUM> of the tray <NUM> is connected to the upper wall <NUM> by means of a corresponding connecting strip <NUM> resting against (and preferably glued to) the larger side wall <NUM> of the tray <NUM>.

According to a particular embodiment not illustrated, the pack <NUM> can comprise one (or more) sealing labels which fix the tray <NUM> to the case <NUM> before the first opening. In particular, said sealing label can be fixed (glued in a removable manner, for example with re-stick glue) to the smaller side wall <NUM> of the tray <NUM> and to the upper <NUM> or lower <NUM> wall of the case <NUM>. In said case, upon first opening the user will have to remove the label in order to then be able to slide the tray <NUM> out of the case <NUM>.

According to a further alternative embodiment not illustrated, the smaller side wall <NUM> of the tray <NUM> could be made in a similar way to the smaller side wall <NUM> of the tray. In said case, the wall <NUM> would also be a fixed and non-elastically deformable wall. In said case, the sliding of the tray <NUM> relative to the case would be facilitated exclusively by the recess provided on the upper wall <NUM> of the case <NUM>.

The embodiments described herein can be combined with one another without departing from the scope of the present invention.

The wrapping method described above has numerous advantages.

In the first place, the wrapping method described above allows to reduce fixed costs (namely, equipment costs), since to manufacture the pack <NUM> with a sliding opening a single packer machine <NUM> is sufficient, which allows, in a small space, to fold together both a blank <NUM> to form a case <NUM>, and a blank <NUM> to form a tray <NUM>.

Furthermore, the wrapping method described above allows to operate at a relatively high operating speed (measured as number of packs <NUM> with a sliding opening per unit of time) while guaranteeing at the same time a high quality (precision) in folding the blanks <NUM> and <NUM>.

Claim 1:
A wrapping method to manufacture a pack (<NUM>) with a sliding opening comprising a tray (<NUM>), which contains at least one product (<NUM>), and a case (<NUM>), which houses, on the inside, the tray (<NUM>) in a sliding manner; the wrapping method comprises the steps of:
folding a first blank (<NUM>) designed to manufacture the case (<NUM>) so as to give the first blank (<NUM>) a "U"-shaped conformation having an open upper end;
folding a second blank (<NUM>) designed to manufacture the tray (<NUM>) so as to manufacture the tray (<NUM>);
inserting the at least partially formed tray (<NUM>) into the first "U"-shaped blank (<NUM>); and
completing the folding of the first blank (<NUM>) around the tray (<NUM>) previously inserted into the first "U"-shaped blank (<NUM>) so as to manufacture the case (<NUM>) already containing the tray (<NUM>);
the wrapping method is characterized in that it comprises the further step of inserting the product (<NUM>) into the tray (<NUM>) after having inserted the tray (<NUM>) into the first "U"-shaped blank (<NUM>) and before completing the folding of the first blank (<NUM>).