U.S. patent application number 16/750141 was filed with the patent office on 2020-07-30 for packing case and method of manufacture thereof.
The applicant listed for this patent is Ready Case Ltd.. Invention is credited to James Timothy GATHERCOLE, David Charles KELSO.
Application Number | 20200239177 16/750141 |
Document ID | 20200239177 / US20200239177 |
Family ID | 1000004641221 |
Filed Date | 2020-07-30 |
Patent Application | download [pdf] |
United States Patent
Application |
20200239177 |
Kind Code |
A1 |
GATHERCOLE; James Timothy ;
et al. |
July 30, 2020 |
PACKING CASE AND METHOD OF MANUFACTURE THEREOF
Abstract
A corrugated fibreboard packing case is disclosed, comprising a
plurality of side panels, a base and a lid arranged such that the
packing case defines an enclosed interior volume when the lid is in
a closed configuration; and, first and second adhesive regions
arranged such that when the lid is in the closed configuration, the
first and second adhesive regions overlap, wherein each of the
first and second adhesive regions comprises an adhesive
substantially covered with a release liner, whereby the release
liners may be removed and the adhesives of the first and second
adhesive regions adhered to each other to maintain the lid in the
closed configuration. A blank for a packing case, and a method for
manufacturing a packing case, are also disclosed.
Inventors: |
GATHERCOLE; James Timothy;
(Somerset, GB) ; KELSO; David Charles; (Surrey,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Ready Case Ltd. |
Wiltshire |
|
GB |
|
|
Family ID: |
1000004641221 |
Appl. No.: |
16/750141 |
Filed: |
January 23, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65D 5/3621 20130101;
B65D 2543/00425 20130101; B65D 2301/00 20130101; B65D 5/6611
20130101; B65D 5/0236 20130101; B65D 43/162 20130101; B65D
2543/00537 20130101 |
International
Class: |
B65D 5/02 20060101
B65D005/02; B65D 43/16 20060101 B65D043/16; B65D 5/66 20060101
B65D005/66; B65D 5/36 20060101 B65D005/36 |
Foreign Application Data
Date |
Code |
Application Number |
Jan 24, 2019 |
GB |
1900985.1 |
Claims
1. A corrugated fibreboard packing case comprising: a plurality of
side panels, a base and a lid arranged such that the packing case
defines an enclosed interior volume when the lid is in a closed
configuration; and first and second adhesive regions arranged such
that when the lid is in the closed configuration, the first and
second adhesive regions overlap, wherein each of the first and
second adhesive regions comprises an adhesive substantially covered
with a release liner, whereby the release liners may be removed and
the adhesives of the first and second adhesive regions adhered to
each other to maintain the lid in the closed configuration.
2. The packing case of claim 1, wherein the first adhesive region
is positioned on the lid.
3. The packing case of claim 1, wherein the second adhesive region
is positioned on one of the side panels or the base.
4. The packing case of claim 1, wherein the lid comprises a lid
main section and a lid extension flap integrally connected to the
lid main section along a fold line, and wherein the first adhesive
region is positioned on said extension flap.
5. The packing case of claim 1, wherein one of the side panels
comprises a main section and an extension flap integrally connected
to the main section along a fold line, and wherein the second
adhesive region is positioned on said extension flap.
6. The packing case of claim 2, wherein the lid is integrally
connected to one of the side panels along a lid fold line, and
wherein the packing case further comprises a third adhesive region
positioned inboard of both the first and second adhesive regions
with respect to the lid fold line, said third adhesive region
comprising an adhesive substantially covered with a release
liner.
7. The packing case of claim 6, wherein the third adhesive region
is positioned on the lid.
8. The packing case of claim 6, wherein the third adhesive region
is positioned on one of the side panels or the base.
9. The packing case of claim 2, wherein the lid is integrally
connected to one of the side panels along a lid fold line, and
wherein the lid further comprises an opening section positioned
inboard of the first adhesive region with respect to the lid fold
line, preferably wherein the opening section comprises a removable
section of the lid.
10. The packing case of claim 9, wherein the opening section
extends between opposing edges of the lid.
11. The packing case of claim 1, wherein the packing case comprises
first, second, third and fourth side panels integrally connected
together along fold lines, a base panel connected to a bottom end
of each of the side panels along respective fold lines, the base
panels defining the base of the packing case; and wherein the lid
is integrally connected to a top end of one of the side panels
along a lid fold line.
12. The packing case of claim 1, wherein the packing case is formed
from a blank.
13. The packing case of claim 12, wherein the blank comprises
opposing first and second surfaces, and wherein the first adhesive
region is positioned on the first surface and the second adhesive
region is positioned on the second surface.
14. The packing case of claim 1, wherein the packing case is
collapsible.
15. A blank for a packing case, the blank having opposing first and
second surfaces and comprising; a plurality of side panels, at
least one base panel and a lid integrally connected together along
fold lines such that the blank may be erected to define an enclosed
interior volume of a packing case when the lid is in a closed
configuration, wherein the blank comprises a first adhesive region
on the first surface and a second adhesive region on the second
surface, the first and second adhesive regions being arranged such
that when the packing case is in an erected configuration and the
lid is in the closed configuration, the first and second adhesive
regions overlap; wherein each of the first and second adhesive
regions comprises an adhesive substantially covered with a release
liner, whereby when the blank is erected the release liners may be
removed and the adhesives of the first and second adhesive regions
adhered to each other to maintain the lid in the closed
configuration.
16. The blank of claim 15, wherein the first adhesive region is
positioned on the lid.
17. The blank of claim 15, wherein the blank is formed from
corrugated fibreboard.
18. The packing blank of claim 15, wherein the first and second
adhesive regions are in the form of elongate strips.
19. A method for manufacturing a packing case, the method
comprising: providing a blank comprising a plurality of side
panels, at least one base panel and a lid integrally connected
along fold lines and arranged such that the blank may be erected to
define an enclosed interior volume of a packing case when the lid
is in a closed configuration, wherein the blank comprises opposing
first and second surfaces having respective first and second
regions arranged such that when the packing case is in an erected
configuration, the first and second regions overlap when the lid is
in the closed configuration; folding the blank such that the first
and second regions on the opposing first and second surfaces are
accessible from a common side of the folded blank; applying
adhesive to the first and second regions; and applying a release
liner to each of the first and second regions so as to
substantially cover the adhesive.
20. The method of claim 19, wherein the step of folding comprises
connecting at least two panels of the blank together so as to form
a partially assembled packing case that lies substantially flat,
and wherein the first and second regions are accessible from a
common side of the partially assembled packing case.
21. The method of claim 19, wherein the adhesive is applied by
extrusion or spraying.
22. The method of claim 19, wherein the first and second regions
are in the form of elongate strips.
23. The method of claim 19, wherein the method steps are performed
in an in-line process.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to packing cases and
their method of manufacture. In particular, the invention relates
to corrugated fibreboard packing cases which may be sealed shut in
a more reliable manner. The present invention is also related to a
method for manufacturing a packing case.
BACKGROUND TO THE INVENTION
[0002] With the growth of online shopping, there is a large demand
for packaging products that online retailers can ship their goods
in. Goods sold online are generally packed in a packing case at a
retainer's warehouse, with the packing case then shipped to the
customer via courier.
[0003] A conventional means of sealing a packing case is through
the use of a "peel and seal" adhesive strip, typically located on a
lid of the packing case. Such a "peel and seal" strip comprises a
strip of adhesive covered by a release tape. After goods have been
packed into the packing case, an operator removes--or "peels"--the
release tape from the adhesive, with the exposed adhesive used to
adhere the lid to a surface of the case substrate, thus sealing the
case shut for distribution.
[0004] However, there are problems with this approach. Firstly, the
environmental conditions of the warehouse or facility where the
packing takes place are typically not conducive to good sealing of
the cases. Such warehouses or facilities are generally cold, which
increases the viscosity of the adhesive, making it harder for the
adhesive to penetrate the case substrate and form a strong bond.
Secondly, an operator (who is generally working quickly) may not
apply sufficient pressure to the lid when closing the case, such
that the adhesive and the case substrate do not come into intimate
contact.
[0005] Both of these problems can cause the cases to become
partially or completely unsealed before arrival at their final
destination. This is unacceptable, and there is therefore a
requirement to improve the sealing of packaging products.
SUMMARY OF THE INVENTION
[0006] In accordance with a first aspect of the invention there is
provided a corrugated fibreboard packing case comprising: a
plurality of side panels, a base and a lid arranged such that the
packing case defines an enclosed interior volume when the lid is in
a closed configuration; and, first and second adhesive regions
arranged such that when the lid is in the closed configuration, the
first and second adhesive regions overlap, wherein each of the
first and second adhesive regions comprises an adhesive
substantially covered with a release liner, whereby the release
liners may be removed and the adhesives of the first and second
adhesive regions adhered to each other to maintain the lid in the
closed configuration.
[0007] The term "corrugated fibreboard" is generally used to refer
to a material having two or more flat sheets (typically made of
paper) called liners glued to a corrugated inner medium (typically
made of paper) called the fluting such that the fluting is
positioned between the liners. The term "corrugated fibreboard" may
also refer to a material having one liner and one fluting.
Preferably the corrugated fibreboard in the present invention is
single wall fibreboard comprising a fluting positioned
("sandwiched") between two liners. However, double (or more) walled
fibreboard, or single face fibreboard, may also be used.
[0008] By providing first and second adhesive regions that overlap
when the lid is in the closed configuration, the packing case of
the present invention may be sealed in a secure manner by removing
the release liners and adhering the adhesives of the first and
second adhesive regions together to form a bond. The term "sealed"
is used to mean that the packing case is secured shut with the lid
maintained in the closed configuration such that goods are retained
within the packing case, e.g. for transport.
[0009] Thus, the adhesives of the first and second adhesive regions
may be referred to as "sealing adhesives" or "closure
adhesives".
[0010] Typically, the first and second adhesive regions have
substantially the same dimensions and are positioned such that they
fully overlap when the lid is in the closed configuration. However,
the first and second adhesive regions may partially overlap when
the lid is in the closed configuration. The adhesive-adhesive
interface used to seal the packing case in the present invention
forms a secure bond, and does not rely on the adhesive penetrating
the case substrate in order to form the bond. Thus, the present
invention is more robust against the problems of manual operators
packing and sealing cases in (often cold) warehouses that have been
described above in the background to the invention.
[0011] Furthermore, the lid is typically integrally connected to
one of the side panels along a lid fold line and, due to the
properties of the corrugated fibreboard, there is typically a
biasing force to urge the lid towards an open configuration (i.e. a
configuration where the interior of the packing case is
accessible). The bond formed by the adhesives of the first and
second adhesive regions helps to maintain the lid in the closed
configuration against the biasing force.
[0012] The adhesive is preferably a pressure-sensitive adhesive.
The surface of a pressure sensitive adhesive is classed as a very
high viscosity liquid, and it is this feature that provides the
instant bonding characteristic. Typically, pressure sensitive
adhesives comprise a resin or rubber base, tackifiers,
plasticizers, fillers, antioxidants and a carrier if the adhesive
is solvent or waterborne. Preferably, the cohesive strength of the
adhesive is greater than its adhesive strength to prevent the
adhesive separating from the corrugated fibreboard of the packing
case. Preferably, the adhesive of the adhesive regions used in the
present invention is a rubberised hot-melt pressure sensitive
adhesive. An example of such an adhesive is H1625/6 available from
Sealock Ltd., UK.
[0013] Preferably, the adhesives of the first and second adhesive
regions are the same, although in some embodiments they may differ
to provide different adhesion characteristics.
[0014] Each of the first and second adhesive regions comprises an
adhesive substantially covered with a release liner. Thus, each
adhesive region may be said to comprise an adhesive layer and a
release liner layer. The adhesive of each adhesive region is in
contact with the corrugated fibreboard. The release liners (or
release "tapes") cover the adhesive of the respective adhesive
region in order to prevent undesirable adhesion of the first and
second adhesive regions to each other or to other substrates during
storage, and to help prevent degradation of the adhesive during
storage. The release liner typically comprises a heavily calendered
paper base that has been coated with a silicone or fluoropolymer
release (antiadhesive) coating that is in contact with the adhesive
and allows the release liner to be removed when the packing case is
to be sealed.
[0015] The release liner of each adhesive region substantially
completely covers the adhesive of the respective adhesive region.
Preferably, a portion of the release liner of each adhesive region
laterally extends beyond the adhesive so as to allow for ease of
removal.
[0016] Typically, the first and second adhesive regions are in the
form of elongate strips so as to maximise the area over which the
bond may be formed. Consequently, the adhesive of each adhesive
region, and the corresponding release liner, is also in the form of
an elongate strip. However, other geometries of the adhesive
regions are envisaged, such as lines, or square or circular
"patches" for example.
[0017] The first and second adhesive regions are positioned on
respective surfaces of the corrugated fibreboard packing case. The
first and second adhesive regions face each other and overlap when
the lid is in the closed configuration.
[0018] In preferred embodiments, the first adhesive region is
positioned on the lid of the packing case. In such embodiments, the
first adhesive region is located on an inner surface of the lid,
i.e. a surface of the lid that is not exposed to the external
environment when the lid is in the closed configuration.
Preferably, the second adhesive region is positioned on a side
panel or the base of the packing case. The second adhesive region
is located on an outer facing surface of the side panel or base
(i.e. a surface of the side panel or base that is exposed to the
external environment) so as to cooperate with ("face") the inner
surface of the lid on which the first adhesive region is typically
positioned.
[0019] In embodiments, the lid may comprise a lid main section and
a lid extension flap integrally connected to the lid main section
along a fold line, and wherein the first adhesive region is
positioned on said extension flap. When the lid is in the closed
configuration, the extension flap typically overlaps with a side
panel or the base of the packing case.
[0020] In embodiments, one of the side panels may comprise a main
section and an extension flap integrally connected to the main
section along a fold line, and wherein the second adhesive region
is positioned on said extension flap. In such scenarios, the
extension flap is located at an end of the main section opposing
the base of the packing case, and folds inwardly towards the
interior volume of the packing case. The inner surface of the lid
(on which the first adhesive region is typically positioned) then
overlaps with the extension flap such that the first and second
adhesive regions overlap.
[0021] In embodiments, the lid is integrally connected to one of
the side panels along a lid fold line, and wherein the packing case
further comprises a third adhesive region positioned inboard of
both the first and second adhesive regions with respect to the lid
fold line, said third adhesive region comprising an (typically
pressure sensitive) adhesive substantially covered with a release
liner. The lid fold line may be considered as a "hinge" about which
the lid may be moved between its closed configuration and open
configuration. The third adhesive region is positioned inboard of
the first and second regions such that it is closer to the lid fold
line ("hinge") along a path defined by the lid than either the
first or second adhesive regions.
[0022] The third adhesive region preferably has the same
configuration as the first and second adhesive regions described
above (typically the adhesives used in the first, second and third
adhesive regions are the same). In eCommerce applications, once an
end user (typically a customer) has received the goods in the
sealed packing case, he/she may wish to return some goods (for
example if they are the wrong type/size or faulty). It is
convenient, economical and environmentally friendly to return the
goods in the same packing case as they were received in. Thus, once
the sealed packing case (that has been sealed using the first and
second adhesive regions) has been opened by the end user, it can be
re-sealed using the third adhesive region. The user removes the
release liner and adheres the adhesive of the third adhesive region
to a surface of the packing case in order to maintain the lid in
the closed configuration.
[0023] The third adhesive region being inboard of both the first
and second adhesive regions with respect to the lid fold line
advantageously ensures that it is positioned such that the lid may
be returned to and adhered in the closed configuration even if the
region of the lid where the first and second adhesive regions were
initially adhered together is no longer usable (for example
following damage in the opening of the packing case).
[0024] Although the third adhesive region preferably has the same
configuration as the first and second adhesive regions (e.g.
comprises the same adhesive and has the same geometry), it may
differ to the first and second adhesive regions in geometry and/or
the adhesive used.
[0025] The third adhesive region may be positioned on the lid of
the packing case, or on one of the side panels or the base of the
packing case. In embodiments, the packing case may comprise a
fourth adhesive region positioned so as to overlap with the third
adhesive region when the lid is in the closed configuration. Such a
fourth adhesive region comprises an (typically pressure sensitive)
adhesive and release liner as described above.
[0026] In embodiments, the lid may be integrally connected to one
of the side panels along a lid fold line, and wherein the lid
further comprises an opening section positioned inboard of the
first adhesive region with respect to the lid fold line. The term
"inboard" has the same meaning as described above. The opening
section allows for ease of opening of the sealed packing case by
the end user. The opening section is typically a removable section
of the lid. As the opening section is positioned inboard of the
first and second adhesive regions, upon removing the opening
section, the lid may be returned to its open configuration (with
the first and second adhesive regions remaining in the adhered
state).
[0027] The opening section typically comprises a tear tape (e.g.
Rippatape.RTM.) having a tear strength greater than that of the
corrugated fibreboard, and/or a perforated section that may be torn
by the user. The opening section typically extends between opposing
edges of the lid such that on removal of the opening section, the
remaining part of the lid that is still integrally connected to one
of the side panels along the lid fold line is separated from the
part of the lid that has been adhered using the first and second
adhesive regions.
[0028] In scenarios where the packing case comprises both a third
adhesive region and an opening section, the third adhesive region
is positioned inboard of the first and second adhesive regions, and
the opening section, with respect to the lid fold line.
[0029] Typically, the erected packing case has a substantially
rectangular geometry when viewed in plan form. Other geometries of
the erected packing case when viewed in plan form are envisaged
however, for example a square or non-quadrilateral shapes.
[0030] Typically, the packing case comprises first, second, third
and fourth side panels integrally connected together along fold
lines, a base panel connected to a bottom end of each of the side
panels along respective fold lines, the base panels defining the
base of the packing case; and wherein, the lid is integrally
connected to a top end of one of the side panels along a lid fold
line. Throughout this specification, the term "fold line" may refer
to a crease line, cut line, slit line, score line or other
manipulation of the corrugated fibreboard that allows the
corrugated fibreboard to fold in a desired manner, as will be
understood by the skilled artisan.
[0031] Preferably, the packing case is formed from a (typically
single) blank. Typically the blank is a die-cut blank, although
alternatively the blank may be cut by a robotic machine or using a
slotting and creasing machine (either a case maker or a printer
slotter). The blank comprises opposing first and second surfaces,
wherein the first adhesive region is positioned on the first
surface and the second adhesive region is positioned on the second
surface. Upon folding the blank during manufacture of the packing
case, the relative orientations of the first and second surfaces
having the first and second adhesive regions positioned thereon is
such that when the lid is in the closed configuration, the first
and second adhesive regions face each other and overlap.
[0032] The packing case is preferably collapsible such that it can
be stored flat. This advantageously vastly reduces the space
required to store the packing cases. The packing cases can then be
erected when required.
[0033] In accordance with a second aspect of the invention there is
provided a blank for a packing case, the blank having opposing
first and second surfaces and comprising; a plurality of side
panels, at least one base panel and a lid integrally connected
together along fold lines such that the blank may be erected to
define an enclosed interior volume of a packing case when the lid
is in a closed configuration, wherein the blank comprises a first
adhesive region on the first surface and a second adhesive region
on the second surface, the first and second adhesive regions being
arranged such that when packing case is in an erected configuration
and the lid is in the closed configuration, the first and second
adhesive regions overlap; wherein, each of the first and second
adhesive regions comprises an adhesive substantially covered with a
release liner, whereby when the blank is erected the release liners
may be removed and the adhesives of the first and second adhesive
regions adhered to each other to maintain the lid in the closed
configuration.
[0034] The adhesive of the first and second adhesive regions is
preferably a rubberised hot-melt pressure sensitive adhesive. An
example of such an adhesive is H1625/6 available from Sealock Ltd.,
UK.
[0035] Preferably, the first adhesive region is positioned on the
lid. The blank may comprise a third adhesive region as described
above with reference to the first aspect. The blank may comprise a
third adhesive region and a fourth adhesive region as described
above with reference to the first aspect. The blank may comprise an
opening section as described above with reference to the first
aspect.
[0036] The blank is typically die-cut, although it is envisaged
that the blank may be cut by robotic machine or by a slotting and
creasing machine (either a case maker or a printer slotter). The
blank is preferably formed from corrugated fibreboard, although
other materials are envisaged such as carton board, pasted solid
board, boxboard, rigid plastic or semi-rigid plastic.
[0037] In accordance with a third aspect of the invention there is
provided a method for manufacturing a (preferably corrugated
fibreboard) packing case, the method comprising: providing a
(preferably die-cut) blank comprising a plurality of side panels,
at least one base panel and a lid integrally connected along fold
lines and arranged such that the blank may be erected to define an
enclosed interior volume of a packing case when the lid is in a
closed configuration, wherein the blank comprises opposing first
and second surfaces having respective first and second regions
arranged such that when the packing case is in an erected
configuration, the first and second regions overlap when the lid is
in the closed configuration; folding the blank such that the first
and second regions on the opposed first and second surfaces are
accessible from a common side of the folded blank; applying
adhesive to the first and second regions; and, applying a release
liner to each of the first and second regions so as to
substantially cover the adhesive.
[0038] The blank is typically formed of corrugated fibreboard,
although other materials are envisaged such as carton board, pasted
solid board, boxboard, rigid plastic or semi-rigid plastic. The
blank may be formed in a separate process (e.g. in a separate
factory) to the method of the third aspect of the invention. In
other embodiments, the method of the third aspect of the invention
may comprise the initial step of forming the blank, preferably by
die-cutting (although other means of forming the blank are
envisaged as discussed above in relation to the second aspect).
[0039] When the packing case is in an erected configuration, the
first and second regions overlap when the lid is in the closed
configuration. The first and second regions also face each other
when the lid is in the closed configuration. This means that the
first and second regions are required to be on opposing surfaces of
the blank. Thus, one way in which the adhesive and release liners
may be applied to the first and second regions is to "flip" the
blank at a stage of the manufacturing process such that the
adhesive and release liners can be applied to the opposing
surfaces. Another way would be to utilise apparatus positioned on
opposing sides of (i.e. "above" and "below") the blank. However,
these methods are inefficient.
[0040] The method of the third aspect of the invention thus
advantageously comprises the step of folding the blank such that
the first and second regions on the opposing first and second
surfaces are accessible from a common side of the folded blank.
This means that there is no requirement to "flip" the blank in
order to apply the adhesive and release liners to the first and
second regions, and the apparatus used for these application steps
may be positioned on the common side (e.g. "above") the folded
blank. This beneficially allows the method to be performed
efficiently (i.e. without having to flip the blank) and with a high
throughput rate. Typically, the method is performed as an in-line
process on a production line comprising a plurality of in-line
units that are configured to perform the steps of the method in a
sequential manner. The ability to manufacture such packing cases
(in particular the folding steps and application of the adhesive
and release liners to the first and second regions) in a single
in-line process is particularly advantageous, as this increases
efficiency and throughput, reduces waste and minimises the
footprint of the apparatus necessary for the manufacture.
[0041] Preferably, the step of folding comprises connecting at
least two (e.g. side and/or base) panels of the blank together so
as to form a partially assembled packing case that lies
substantially flat, and wherein the first and second regions are
accessible from a common side of the partially assembled packing
case. In other words, during this step, the blank is folded and
panels thereof connected together such that on completion of this
stage of the manufacturing process the resulting partially
assembled packing case lies substantially flat. The steps of
applying adhesive to the first and second regions and applying a
release liner to each of the first and second regions are then
carried out on the substantially flat partially formed packing case
in order to form the fully formed (collapsible) packing case.
[0042] The partially assembled packing case lies substantially
flat. In other words it is in a "collapsed" form, typically due to
folding along one of the fold lines.
[0043] The step of folding comprises connecting at least two panels
of the blank together. The panels are preferably connected by
gluing (using a "joining adhesive" such as PVA glue and/or a hot
melt adhesive that is typically different to the adhesive applied
to the first and second regions to form the adhesive regions),
although other connecting means such as stapling or stitching may
be used. The joining adhesive is typically different to the
("sealing") adhesive applied to the first and second regions to
form the first and second adhesive regions. The glued and folded
partially assembled packing cases may then be compressed in order
to form a good bond in the glued regions and maintain the partially
assembled packing cases in their substantially flat form.
[0044] Typically, the at least two panels that are connected
together comprise two side panels that are connected together.
Furthermore, the blank may comprise two or more base panels (in
preferred embodiments the blank comprises a base panel connected to
a bottom end of each of the side panels along respective fold
lines) and the at least two panels that are connected together
comprise two base panels that are connected together. Typically,
the step of folding comprises connecting (e.g. gluing) two side
panels together and connecting (e.g. gluing) at least two base
panels together to form the partially assembled packing case.
[0045] Subsequent to the folding step, the adhesive used for
sealing the packing case is applied to the first and second
regions, typically by extrusion (using one or more applicator
extruders), or by spraying (using one or more spray nozzles (e.g.
slot nozzles)). It is also envisaged that applicator wheels may be
used to apply the adhesive. The release liner is typically applied
from a spool of release liner material and cut to the requisite
size. The release liner is typically applied immediately after the
application of the adhesive.
[0046] The adhesive that is applied to the first and second regions
is preferably a rubberised hot-melt pressure sensitive adhesive. An
example of such an adhesive is H1625/6 available from Sealock Ltd.,
UK
[0047] The method may further comprise the step of applying
adhesive to a third region (typically the same adhesive as applied
to the first and second regions), and applying a release liner to
the adhesive of the third region in order to form a third adhesive
region with the benefits discussed above. In such embodiments, the
first, second and third regions are accessible from a common side
of the partially assembled packing case. The method may further
comprise applying adhesive and a release liner to a fourth region
to form a fourth adhesive region.
[0048] In some embodiments, the method of the third aspect of the
invention may comprise applying a tear tape to the partially
assembled packing case to facilitate ease of opening of the sealed
packing case. In such embodiments, the lid is integrally connected
to one of the side panels along a lid fold line, and the tear tape
is applied to an opening section positioned inboard of the first
region with respect to the lid fold line, preferably where the
opening section comprises a removable section of the lid. Such an
opening section typically extends between opposing edges of the
lid.
BRIEF DESCRIPTION OF THE DRAWINGS
[0049] The invention will now be described with reference to the
figures, in which:
[0050] FIG. 1 is a perspective view of a corrugated fibreboard
packing case according to a first embodiment of the invention;
[0051] FIG. 2 is a perspective view of the corrugated fireboard
packing case according to the first embodiment, with the lid shown
in the closed configuration;
[0052] FIG. 3 is a flow diagram outlining the main steps of a
method for manufacturing a packing case according to the
invention;
[0053] FIG. 4 is a diagram illustrating a blank used to manufacture
the packing case of the first embodiment of the invention;
[0054] FIG. 5 is a diagram showing the packing case of the first
embodiment of the invention during manufacture;
[0055] FIG. 6 is a perspective view of a corrugated fibreboard
packing case according to a second embodiment of the invention,
and;
[0056] FIG. 7 is a diagram illustrating a blank used to manufacture
the packing case of the second embodiment.
DETAILED DESCRIPTION
[0057] FIG. 1 is a perspective view of an erected corrugated
fibreboard packing case according to a first embodiment of the
invention. The packing case has four side panels 101a, 101b, 101c
and 101a (only side panels 101a and 101b are visible in the view of
FIG. 1) that define a rectangular geometry when the case is viewed
in plan form. However, in other embodiments, the side panels may
have substantially the same dimensions such that the case is
substantially square when viewed in plan form. Other,
non-quadrilateral, geometries defined by the side panels are also
envisaged.
[0058] The case further comprises a base (not visible in the view
of FIG. 1) and a lid 130 integrally connected to side panel 101c
(see FIG. 4) along fold line 120. In this embodiment, the lid 130
comprises a lid main panel 130a and a lid extension flap 130b
integrally connected along fold line 131. FIG. 1 illustrates the
case 100 with the lid 130 in an open configuration (i.e. the case
is not sealed and the interior of the case is accessible). With the
lid 130 in the open configuration, the desired goods can be
packaged into the case--typically by an operator in a warehouse or
packing facility--before closing the lid such the lid is in a
closed configuration where the interior of the case is not
accessible (illustrated in FIG. 2). With the lid in the closed
configuration, the side panels, base and lid define an enclosed
interior volume.
[0059] As shown in FIG. 1, side panel 101a comprises a (second)
adhesive region 142 on its outer facing surface (i.e. the surface
exposed to the external environment when the lid is in the open
configuration). The adhesive region 142 is in the form of an
elongate strip. The lid 130 comprises a corresponding (first)
adhesive region 140 on the inner surface of the lid extension flap
130b. It is to be noted that as the first adhesive region 140 is on
the inner surface of the lid extension flap, it is not visible in
the views of FIGS. 1 and 2. However, the first adhesive region 140
is still highlighted in dashed lines for clarity of
understanding.
[0060] The adhesive regions 140 and 142 are positioned such that
when the lid is in the closed configuration, they substantially
overlap and face each other, as shown in FIG. 2. Each adhesive
region therefore has substantially the same geometry. In this
embodiment, each adhesive region is in the form of an elongate
strip. The direction of elongation is along the principal axis
(i.e. axis of longest dimension) of the side panel 101a and lid
extension flap 130b, thereby advantageously maximising the area
over which adhesion takes place. However, in other embodiments,
alternative geometries for the adhesive regions are envisaged, such
as lines or square or circular geometry.
[0061] Each adhesive region 140, 142 comprises a pressure-sensitive
adhesive that is applied onto the surface of the corrugated
fibreboard. The adhesive is a pressure-sensitive hot-melt adhesive
based on a rubber/resin blend (such as H1625/6 available from
Sealock Ltd., UK), and the same adhesive is used for each of the
first and second adhesive regions 140, 142 that are used to seal
the packing case. Each adhesive region comprises a respective
release liner substantially completely covering the adhesive.
Release liner 152 of second adhesive region 142 is visible in the
view of FIG. 1. Each release liner is thus preferably in the form
of an elongate strip, and preferably extends laterally beyond the
adhesive of its respective adhesive region such that a portion
(152a) of the release liner is not adhered to the adhesive so as to
allow for ease of removal of the release liner. The release liner
comprises a paper substrate having a silicone or fluropolymer
release (antiadhesive) coating that has a much lower adhesion
strength to the adhesive than the corrugated fibreboard so as to
enable ease of removal of the release liner from the adhesive.
[0062] When the case 100 is to be sealed (i.e. after being packed),
an operator removes the release liner from each of the adhesive
regions 140, 142 such that the adhesive is exposed in each adhesive
region 140, 142. The operator then mates the exposed adhesive of
the two adhesive regions 140, 142 by applying pressure to the lid
extension flap 130b, thereby adhering the lid extension flap 130b
to the outer facing surface of side panel 101a. This maintains the
lid 130 in the closed configuration with a secure bond formed
between the adhesives of the adhesive regions 140, 142.
[0063] Optionally, the lid extension flap 130b further comprises
tabs 128a, 128b that oppose each other on opposing outer edges of
the lid extension flap 130b. The tabs 128a, 128b are defined by
perforations 127 extending inwards from the outer edges of the lid
extension flap. An opening strip (illustrated at 129) extends
between the tabs 128a, 128b. The tabs and opening strip are
positioned inboard of the adhesive region 140 with respect to the
fold line 120 where the lid is integrally connected to side panel
101c. Therefore, an end user, on receipt of the packing case, may
easily open the packing case by pulling one or both of the tabs
128a, 128b so as to tear the corrugated fibreboard along the
opening strip 129, separating the part of the lid having adhesive
region 140 (which will still be adhered to adhesive region 142)
from the remainder of the lid 130, thereby allowing the lid to be
opened. This advantageously allows the lid to be easily opened by
the end user without having to break the bond between adhesive
regions 140 and 142. This also allows for any tampering of the case
to be easily detected. In alternative embodiments, the packing case
may comprise one tab 128 that may be used to open the lid along
opening strip.
[0064] In this embodiment, the opening strip 129 comprises a tear
tape on the inner surface of the lid extension flap 130b, with the
tear tape having a greater tear strength than the corrugated
fibreboard (the region of the tear tape 129 is highlighted for ease
of understanding). In alternative embodiments the opening strip 129
may be defined by perforations extending between perforations 127
of the tabs 128a, 128b.
[0065] The lid extension flap 130b optionally further comprises a
third adhesive region 144 positioned inboard of the first adhesive
region 140 with respect to lid fold line 120, and on an inner
surface of the lid extension flap 130b. (It is to be noted that as
the third adhesive region 140 is on the inner surface of the lid
extension flap, it is not visible in the views of FIGS. 1 and 2.
However, the third adhesive region 144 is still highlighted for
clarity of understanding.) In other words, when an end user opens
the case by using opening strip 129, the remaining part of the lid
extension flap 130b that is still integrally connected to lid main
panel 130 comprises the third adhesive region.
[0066] In a similar manner to the first and second adhesive regions
140, 142, the third adhesive region 144 comprises a rubberised
hot-melt pressure sensitive adhesive covered by a release liner.
The adhesive and release liner of the third adhesive region are
typically the same as those used for the first and second adhesive
regions. The third adhesive region 144 advantageously allows the
end user to re-seal the packing case 100 should they wish to (for
example for returning items to the distributor) by removing the
release liner and adhering the remaining section of the lid
extension flap 130b to the surface of the side panel 101a using
third adhesive region.
[0067] In this embodiment, the third adhesive region 144 is on the
inner surface of lid extension flap 130b. However, in other
embodiments (not shown), the third adhesive region may be
positioned on the outer surface of side panel 101a. In such a
scenario, the third adhesive region 144 is positioned inboard of
the second adhesive region 142 with respect to the fold line 120
such that it cooperates with (i.e. overlaps with and faces) the
remaining part of the lid extension flap 130b that is still
integrally connected to lid main panel 130 after opening strip 129
has been used to open the case.
[0068] Unlike in the warehouse or facility in which the original
packing and sealing of the cases takes place, the end user
typically has ample time to ensure that a secure bond is formed
when re-sealing the case using the third adhesive region. However,
embodiments in which the side panel 101a comprises a fourth
adhesive region (not shown) positioned so as to cooperate with
(i.e. overlaps and faces) the third adhesive region (in the same
manner as the first and second adhesive regions described above)
are also envisaged for further security when re-sealing the packing
case. The adhesive and release liner of such a fourth adhesive
region are typically the same as those used for the first, second
and third adhesive regions.
[0069] FIG. 3 is a flow diagram outlining the steps of a preferred
method for manufacturing the packing case 100 described above with
reference to FIGS. 1 and 2. The steps of the method will now be
described with reference to FIGS. 4 and 5. The manufacture of the
packing case 100 typically takes place on an in-line production
line comprising a plurality of in-line units that are configured to
(typically sequentially) perform the steps of the method. It will
be understood that at least some of the method steps in FIG. 3 may
be performed in an alternative order; for example steps S400 and
S500 may be performed in the reverse order, or may be performed
substantially simultaneously.
[0070] At step S100, a die-cut corrugated fibreboard blank 100a is
provided. The blank may have been produced separately from the
production line, or may be cut at a cutting unit on the same
production line where the remainder of the method steps are
performed. The blank 100a is illustrated in FIG. 4. All lengths in
FIG. 4 are defined in the y-direction, and all widths are defined
in the x-direction. The blank 100a is formed from a single piece of
corrugated fibreboard, and has first and second opposing surfaces.
The first ("top") surface is visible in FIG. 4, and the second
("bottom") surface opposes the first surface and is consequently
not visible in FIG. 4.
[0071] The blank 100a comprises first 101a, second 101b, third 101c
and fourth 101d side panels, integrally connected together along
respective parallel fold lines 103a-c extending along the lengths
of the side panels. Each side panel has substantially the same
length. When erected the first 101a and third 101c side panels
oppose each other, and second 101b and fourth 101d side panels
oppose each other so as to define the side panels of the erected
packing case 100. The folds 101a-c are defined such that the top
surfaces of side panels 101a-d are on the interior of the erected
packing case.
[0072] In the present embodiment, side panels 101a and 101c have a
width which is greater than the width of side panels 101b and 101d
such that when erected, the packing case 100 is substantially
rectangular when viewed in plan form. However, in other
embodiments, the side panels may each have the same width such that
the packing case is substantially square when viewed in plan form.
In further embodiments, non-quadrilateral geometries defined by the
side panels are also envisaged.
[0073] The blank 100 comprises base panels 104a and 104b of a first
type integrally connected to side panels 101a and 101c along
respective fold lines 105a, 105b, and base panels 106a and 106b of
a second type integrally connected to side panels 101b and 101d
along respective fold lines 107a and 107b. The length of each of
the base panels is substantially the same. Together, the base
panels define the base of the erected packing case. Base panels
104a, 104b comprise lobed sections 109a and 109b integrally
connected along respective fold lines 110a and 110b. When the
packing case is fully erected, the lobed sections 109a, 109b
deflect around each other by bending at the respective fold lines
110a and 110b. When the packing case is fully erected, the lobed
sections 109a, 109b lie substantially flat on the base of the
packing case and interlock with each other to prevent the base of
the packing case from opening. The case can be collapsed by
deflecting the lobed sections such that they no longer
interlock.
[0074] The blank 100a comprises lid a 130 that is integrally
connected to side panel 101c along fold line 120. As has been
described above in relation to FIGS. 1 and 2, the lid comprises lid
main panel 130a and lid extension flap 130b integrally connected to
the lid main panel along fold line 131. As can be seen in FIG. 4,
the lid extension flap 130b comprises first region 140' and third
region 144'. These regions do not comprise adhesive at this stage
of the process, and define the regions to which adhesive and
release liner will be applied in order to form the first 140 and
third 144 adhesive regions of the packing case. The first 140' and
third 144' regions are on the top surface of the blank 100.
[0075] The lid extension flap 130b further comprises tabs 128a and
128b defined by perforations 127 as have been previously described.
Opening strip region 129' (which does not yet comprise a tear tape)
is also shown, with region 129' being located on the top surface of
the blank 100a.
[0076] Side panel 101a comprises second region 142' to which
adhesive and a release liner will be applied in order to form
second adhesive region 142. The second region 142' is on the bottom
surface of the blank 100a (and as such is illustrated in dashed
lines). In other words, the second region 142' is on the opposing
surface of the blank to the first region 140' and the third region
144'.
[0077] Side panel 101a comprises main section 101a' and first
extension flap 114 connected thereto along fold line 115. The side
panel 101a also comprises a second extension flap 116 integrally
connected to the main section 101a' along fold line 117.
[0078] The blank 100a further comprises top inner panels 121a and
121b integrally connected to side panels 101b and 101d along
respective fold lines 122a and 122b. Top inner panels 121a, 121b
are also integrally connected to lid 130 along respective fold
lines 123a, 123b. Top inner panels 121a, 121b further comprise
respective fold lines 124a, 124b. When the lid 130 of the erected
packing case is folded over, top inner panels 121a, 121b fold
inward along fold lines 124a, 124b (i.e. into the enclosed volume
of the packing case) such that they ensure good closure between the
side panels 101b, 101d and the lid 130.
[0079] At step S200, the packing case is partially assembled from
the blank. During this step, the gluing and folding processes
necessary to provide the final packing case are carried out at
respective gluing and folding unit(s) on the production line.
However, neither the adhesives of the adhesive regions 140, 142,
144, nor the tear tape, are applied during this step.
[0080] In this embodiment, during step S200, glue is applied to the
top surface of the region of side panel 101d that overlaps with
extension flap 114 when the packing case is assembled, and to the
top surfaces of glue regions 129a and 129b on base panels 104a,
104b at a gluing unit. The glue (or "joining adhesive") is
typically PVA glue applied by spraying from nozzles. Alternatively,
or in addition, a hot-melt adhesive (different to the adhesive used
for adhesive regions 140, 142, 144) may be used, which is typically
extruded.
[0081] The blank is then conveyed to folding unit which carries out
the suitable folding operations such that the extension flap 114 is
glued to the top surface of side panel 101d (i.e. the surface
exposed to the internal environment when the packing case is
erected). Gluing extension flap 114 to side panel 101d connects the
outermost side panels (i.e. panels 101a, 101d), thereby connecting
the side panels of the packing case.
[0082] The folding unit also performs the necessary folding
operations such that the topsides of the glue regions 129a and 129b
are glued to the undersides of base panels 106a, 106b.
[0083] It will be appreciated that the exact sequence of gluing and
folding processes when partially assembling the packing case in
step S200 may vary. For example, some folding steps may occur
before application of the glue. It is to be noted that the gluing
processes in partially assembling the packing case in step S200 are
separate to the application of the adhesives that form the adhesive
regions used to seal the packing case (described below).
[0084] These gluing and folding steps form a partially assembled
packing case 100b, and are performed such that the partially
assembled packing case has substantially flat form, as shown in
FIG. 5. Here, the partially assembled packing case is provided in
flat form by folding along fold lines 103b and 103c for example.
The substantially flat partially assembled packing case then
preferably enters a compression unit where it is held flat while
the glue applied by the gluing unit sets and forms a bond. This may
typically take between 1 and 10 minutes (e.g. for PVA glue)
depending on temperature, relative humidity etc. If a hot melt
adhesive is used in the gluing and folding process a significant
bond is formed almost instantly (on the order of seconds).
[0085] As will be appreciated, in this flat form, the top surface
of the lid 130 (i.e. the inner surface of the lid 130 when the case
is erected) and the bottom surface of the side panel 101a (i.e. the
outer facing surface of the side panel 101a when the case is
erected) are accessible from the same side of the partially
assembled packing case 100b. This advantageously means that the
first 140', second 142' and third 144' regions are accessible from
the same side of the partially assembled packing case 100b (in
other words they are on the same side of the partially assembled
packing case). This is in contrast to the blank 100a, where the
first 140', second 142' and third 144' regions were not accessible
from the same side of the blank.
[0086] At step S300, a rubberised hot-melt pressure sensitive
adhesive is applied to the first 140', second 142' and third 144'
regions at an adhesive application unit. The application of the
adhesive is performed by applicator extruders or spray nozzles, and
the adhesive application unit typically comprises separate
applicator heads configured to apply adhesive to each region.
(Alternatively, there may be a plurality of adhesive application
units.) The adhesive is typically applied so as to substantially
completely cover the respective region to which it is applied.
[0087] At optional step S400, a tear tape is applied to opening
strip region 129' at a tear tape application unit.
[0088] At step S500, a release liner is applied to the adhesive in
each of the first, second and third regions at respective release
liner application units (or a single unit with multiple
applicators). The release liner is typically applied from a spool
on the release liner application unit, and cut to the appropriate
size. Typically, the release liner is applied and cut such that a
portion of the release liner laterally extends from the applied
adhesive so as to "overhang" the adhesive. The overhanging part of
the release liner allows for ease of peeling from the adhesive when
the packing case is desired to be sealed.
[0089] In embodiments where a tear tape is applied, this may be
performed substantially simultaneously with the application of the
release liners in step S500, and may be applied by the same
application unit(s).
[0090] The application of the adhesive and release liner to first
140', second 142' and third 144' regions, optionally together with
a tear tape to opening strip region 129' forms the fully assembled
(collapsed) packing case which may be erected as required.
[0091] Advantageously, as each of the regions 140', 142' and 144'
(and 129') is accessible from a common (i.e. same) side of the
(flat) partially assembled packing case, the adhesive application
unit(s), release liner application unit(s) and tear tape
application unit may be positioned on a common side of (e.g.
"above") the production line, without the blank or the partially
assembled packing case required to be turned over in order to apply
the adhesives, release liners and tear tape. This beneficially
increases the efficiency of the manufacturing process and reduces
footprint of the production line. In particular, the steps of
partially assembling the packing case (S200), and applying the
adhesive, tear tape (where applied) and release liners (i.e. steps
S300, S400 and S500) in a single in-line process is a particular
advantage in the present invention.
[0092] FIG. 6 illustrates a corrugated fibreboard packing case 200
according to an alternative embodiment of the invention (with the
lid 230 in an open configuration), and FIG. 7 illustrates a blank
200a that may be used to form the packing case 200 using the method
of FIG. 3. Like reference numerals have been used to illustrate
similar parts to those discussed above in the first embodiment.
[0093] In this embodiment, the lid 230 does not comprise a lid
extension flap as in the first embodiment, and the length of the
lid (defined along the y-axis in FIG. 7) is substantially equal to
the width of side panel 210b (defined along the x-axis in FIG.
7).
[0094] As can be seen in FIG. 6, first adhesive region 240 is in
the form of an elongate strip on the inner surface of the lid 230.
The first adhesive region comprises an adhesive and a release liner
250 in the same manner as described in the first embodiment. In
this embodiment, the second adhesive region 242 is positioned on
extension flap 216 that is an integral part of side panel 201a. In
other words, and as also shown in FIG. 7, side panel 201a comprises
main section 210a' and extension flap 216 integrally connected
thereto along fold line 217. The second adhesive region 242 is in
the form of an elongate strip having substantially the same
dimensions as the first adhesive region, and comprises an adhesive
and release liner 252 in the same manner as described in the first
embodiment. As with the first embodiment, the adhesives of the
first and second adhesive regions of packing case 200 are the same
(a rubberised hot-melt pressure sensitive adhesive such as H1625/6
from Sealock Ltd., UK).
[0095] As with the first embodiment, the first and second adhesive
regions are such that when the lid is in the closed configuration
(with the extension flap 216 folded inwards), the first and second
adhesive regions overlap and face each other. Thus, when the
packing case 200 of the second embodiment has been packed with the
desired goods, the operator may remove the release liners 250, 252
from both the first and second adhesive regions and adhere the
adhesives of the adhesive regions together in order to seal the
packing case.
[0096] The lid 230 (optionally) further comprises tabs 228a and
228b having an opening strip 129 extending there between. The tabs
228a, 228b and opening strip 129 are located inboard of the first
adhesive region 240 with respect to the fold line 220 integrally
connecting side panel 201c and lid 230. The tabs and opening strip
are illustrated in FIG. 7 but have been omitted from FIG. 6 for
clarity purposes.
[0097] The packing case 200 of the second embodiment may be
manufactured in the same way as described above in relation to the
first embodiment, with an appropriate corrugated fibreboard blank
200a illustrated in FIG. 7. First region 240' and second region
242' corresponding to the first and second adhesive regions 240,
242 are located on opposing surfaces of the blank. However, on
partially assembling the packing case (step S200), the first 240'
and second 242' regions are transposed onto a common side of the
flat partially assembled packing case, allowing for ease of
application of the adhesive and release liners in the same manner
as described above.
[0098] It will be noted that the base panels 204a, 206a, 204b and
206b of the second embodiment differ from the first embodiment.
However, together they form the base of the erected packing case
200, as will be appreciated by the skilled artisan. In this
embodiment, base panel 204b comprises protrusion 205a which
cooperates with slot 205b at the bottom of side panel 201a when the
packing case is erected so lock the protrusion 205a in place and
provide rigidity to the base.
[0099] The packing cases of both the first and second embodiments
have been described as having an opening strip to allow for easy
opening of the sealed packing case. It will be appreciated that
this feature is optional, and in some embodiments the packing case
does not comprise such an opening strip, with the end user required
to open the case by other means, for example by cutting.
* * * * *