METHOD AND FACILITY FOR ENVELOPING AN ITEM TO BE PACKAGED

Abstract

A method for enveloping an item to be packaged includes supplying the item to a wrapping unit using a first feed unit, cutting a packaging blank having two side flaps, a base flap, and a closing flap to size, supplying the packaging blank to the wrapping unit using a second feed unit, combining the item and the packaging blank in the wrapping unit, and wrapping the item with the packaging blank, wherein the item and the packaging blank are supplied to the wrapping unit in a line and in opposite directions, at least in one section. This method further includes wrapping the item by folding the side flaps, and by folding the base flap, in any order, gluing the side flaps and the base flap together, and wrapping the item by folding the closing flap.

Description

The invention relates to a process for enveloping of the item to be packaged with the method steps of (a) supplying the item to be packaged to a wrapping unit by way of a first feed unit, (b) cutting a packaging blank to size from a provided material, (c) supplying the packaging blank to the wrapping unit by way of a second feed unit, (d) combining the item to be packaged and the packaging blank in the wrapping unit, and (e) wrapping the item to be packaged with the packaging blank by way of the wrapping unit, wherein the item to be packaged and the packaging blank are supplied to the wrapping unit in at least one section in a line and in mutually opposite directions. Furthermore, the invention relates to a facility for enveloping an item to be packaged, with a receiving unit and a cutting unit for producing packaging blanks from a provided material, a wrapping unit, a first feed unit for supplying the item to be packaged to the wrapping unit and a second feed unit for supplying the packaging blanks to the wrapping unit, wherein the first and the second feed unit are arranged such that supplying the item and the packaging blanks occurs in at least one section in a line and in mutually opposite directions.

Both the item to be packaged and the packaging pass through many different stations from the production of the item, in particular magazines, (advertising) brochures or letters and packages to the finished, packaged item. The production of the item and the production of the package are spatially separated from each other and combined manually or automatically by an enveloping facility only during the enveloping process. However, such decentralized production of the individual packaging components leads to additional production costs, among other things, due to transport and storage costs, and longer production times, among other things, due to the transport routes, or loss of production when the item or the packaging material is not in stock and must be ordered externally.

Newer enveloping facilities therefore attempt to take over individual production steps in the production of the item or the packaging and thus to reduce the production time and production costs. The production of the item, in particular printing, cutting and sorting of the blanks is typically handled by an internal production unit and the item is passed directly to the enveloping facility. This item is then automatically placed by the enveloping facility in the provided packaging. This type of enveloping facility has the disadvantage that the packaging must be produced externally, resulting in additional transportation and storage costs.

In other enveloping facilities both the production of the item as well as the production of the package is assumed by the enveloping facility. In this case, a web of material is printed by an external printing unit such that initially the entire item is printed on the web of material, for example, individual sheets of a letter, before a packaging blank, for example an envelope with an address field, is printed onto the web of material. This completed web with multiple alternating items and packaging blanks is then added to the enveloping facility, which cuts the web of material in accordance with the items and the packaging blanks and then combines both of them. However, this method has the disadvantage that due to the common web of material the items and packaging blanks are always made of the same material. Such a limitation of the materials is in many cases undesirable.

It is therefore the object of the invention to provide a method for enveloping an item to be packaged and a corresponding facility, which allow a particularly flexible, easy and quick packaging of the item while keeping the production costs and production times low.

Regarding the method, this object is attained with the invention in that the packaging blank includes two side flaps, a bottom flap and a closure flap, and in that the wrapping of the item to be packaged includes the additional method steps: wrapping the item to be packaged by folding the side flaps, and wrapping the item to be packaged by folding the bottom flap, in any order, adhesively joining the side flaps and the bottom flap, wrapping the item to be packaged by folding the closure flap. With respect to facility, this object is attained in that the packaging blank includes two side flaps, a bottom flap and a closure flap and the wrapping unit includes means for folding the side flaps and the bottom flap, means for adhesively joining the side flap and the bottom flap, and means for wrapping the item to be packaged by folding the closure flap.

Advantageous embodiments of the invention are subject of the dependent claims.

The invention proceeds from the consideration that the production costs and production times are significantly influenced by the use of external production facilities and resulting delivery times and required storage space. A reduction of these costs and production times can therefore be achieved when both the item to be packaged and the packaging can be manufactured on site. A further reduction is possible, when also the storage of the items or packages produced on site can be avoided and the production and enveloping can take place within a single facility. For a most flexible and customizable enveloping, the packages are not produced before being combined with the item to be packaged, but rather only packaging blanks are provided. To avoid further process steps and supply of the packaging blanks over several feed conveyors, packaging blanks are made in one piece and already complete. This means that they already include the side flaps, the bottom flap and the cover flap, and the packaging blank need not be made or completed only in a further step, before or after the material is supplied, for example in the form of a wrapper. These packaging blanks are combined with the item and the item is only thereafter wrapped by folding the packaging blank. Changes in the feed direction should therefore always be avoided to facilitate easy combination and accurate positioning of the item and the packaging blanks. For this reason, the item and the packaging blanks are supplied from a bird's-eye-view in a line and in mutually opposite directions. This opposing arrangement makes the two feed units and the upstream units that supply and/or produce the packaging blank and the item particularly easily accessible.

For providing a most stable and secure package, the side edges are folded first, then the bottom cover, and only thereafter the closure flap. Such a sequential order of folding and gluing enables the production of standard (letter) envelopes that meet the particularly stringent requirements for stability of the packaging. With this folding sequence, the maximum space for the item to be packaged can be provided for predetermined package sizes, for example by guidelines from the letter or parcel delivery service. In an alternative embodiment, the bottom flap may be folded first, followed by folding the side edges and the closure flap. In this type of folding, the side edges and the bottom flap are adhesively joined outside. A possible contact between the adhesive material and the material can thus be prevented.

In a particularly advantageous embodiment, the item to be packaged and the packaging blanks are combined in line and in the same direction for fast and secure enveloping of the item. This allows the item to be readily and accurately positioned on the packaging blanks and combined, without relative movement of the item and the packaging blank. This also enables a continuous operation of the facility with a constant supply of packaging blanks without necessitating short downtimes or a stop-and-go approach.

For a particularly precise folding of the packaging blank, folding in the direction of movement of the packaging blank is consistently avoided. The side edges are folded parallel to the direction of movement and the packaging blank is positioned underneath the item so that the bottom flap can be folded against the direction of movement. In a particularly preferred embodiment, to prevent the closure flap from folding in the direction of movement of the packaging blank, the direction of movement of the already partially wrapped item is rotated by about 90°, without rotating the packaging blank. Folding of the closure flap parallel to the direction of movement is made possible only by this rotation. This particular guiding of the packaging blank during folding enables the production of packages and, in particular envelopes, wherein the folded edge of the closure flap and the folded edge of the bottom flap are arranged substantially parallel to one another. Size requirements, for example stipulated by a letter or parcel delivery entity, can then be readily satisfied. However, other forms of packaging may also be prepared depending on customer specifications by suitably selecting the change in angle of the direction of movement.

In a preferred embodiment for applications having substantial variety, in particular for the production of packages and envelopes with window elements, a window element is cut into the packaging blank while or after the packaging blank is cut to size. This window element is then covered by a window foil. The window foil is glued to the inside of the packaging blank and completely covers the window element.

In the present facility, the packaging blanks are cut directly from a web of material. This means that any addresses, advertising fields or company logos can already be printed on the packages on the web of material. However, this has the disadvantage that some changes or errors can result in the replacement of the entire web of material. In an advantageous embodiment, to provide printed envelopes particularly flexibly and cost-effectively, the cut-to size packaging blanks are printed rather than the web of material. A single, non-printed web of material can then be used for producing the packaging. With this approach, storage of printed webs of materials or waste of whole webs of material due to misprints or order changes can thus be avoided. In an alternative or additional advantageous embodiment, printing of the packaging after the item is wrapped is also contemplated.

In a preferred embodiment, to reduce the storage costs and the required storage volume, the item, which is usually a letter, a flyer or a brochure, may also be cut from a web of material, with the cut-to size pieces supplied directly to the wrapping unit. As with envelopes, it is here also conceivable to cut the item from a non-printed web of material and to only print individually with a printing unit after cutting. In a particularly preferred embodiment, for combining the item to be packaged and the packaging blank with particular positional accuracy, the items to be packaged together are collected, after being cut to size, by a collecting unit and supplied together to the wrapping unit. It is conceivable that the collecting unit also performs a desired folding, gluing or other types of joining of the collected item.

The advantages attained with the invention are, in particular, that as a result of a special supply of the item and the already completed packaging blank, both can be particularly easily combined in the wrapping unit. Consequently, external production facilities can be consistently eliminated both in the production of the item and in the production of the packaging, so that the item can be packaged at low cost and with short downtimes. In addition, the materials used for the items and the packaging can determined freely and independent from each other and the dimensions of the cut pieces can be individually adjusted.

An exemplary embodiment of the invention will now be described in more detail with reference to a drawing, which shows in:

FIG. 1 a schematic diagram of the method for enveloping an item to be packaged,

FIG. 2 a schematic diagram of an enveloping facility.

Identical parts have in all figures identical reference symbols.

The schematic diagram of the method of FIG. 1 includes a first web of material 1 for the packaging blanks. The material of the web 1 can be chosen arbitrarily and according to the customer specifications; usually paper is used in different strengths, as well as a packaging foil. In a first process step 2, the web of material 1 is cut by way of a cutting unit 4 to produce packaging blanks 6. The cuts can be made to size for creating a special individual design, which can also be changed from one packaging blank 6 to another packaging blank 6 by a corresponding control of the cutting unit. This enables a direct and optimum adaptation to the item 8 to be packaged. When the web of material 1 and hence also the packaging blanks 6 are already be completely printed, the packaging blank 6 is supplied in the next process step 10 to the wrapping unit 12. Otherwise, the packaging blank 6 can be printed individually and separately in an unillustrated process step by a printing unit 14 before being supplied to the wrapping unit 12. In addition or alternatively, the web of material 1 may have already been printed by another printing unit 62. This has the advantage that printing can occur over the entire subsequent cut-to-size piece, thus eliminating system-induced non-printed edges. The package can be printed on both sides, i.e. outside and inside, by using two sequentially arranged printing units.

Furthermore, in another process step prior to feeding to the wrapping unit or in conjunction with cutting the packaging blank 6, a window element 68 is cut into the packaging blank 6 and later closed with a window foil. In this way, packages with a window, in particular envelopes, can be produced.

The schematic diagram of the method of FIG. 1 furthermore includes a second web of material 16 for the manufacture of the item 8 to be packaged This second web of material 16 is cut 22 with a second cutting unit 18 into individual parts of the item 20. When the second web of material 16 is not yet printed, the individual parts of the item 20 can in a further process step be printed individually in an (unillustrated) additional printing unit. The parts of the item 20 are then supplied 26 to a collection unit 24. This collection unit 24 is able to sort the parts of the item 20 and merge them into a single item 8. In addition, by using the collection unit 24, the item 8 can be folded, glued, embossed, connected with a staple or paperclip, or otherwise processed according to customer specifications. Furthermore, external enclosures 64, such as, credit cards, CDs or promotional items, can be manually or automatically added 66 to the item 8 by using the collection unit 24. The finished item 8 is thereafter fed 28 to the wrapping unit 12.

For particularly reliable and precise positioning of the item 8 on the associated packaging blank 6 and an error-free further processing by the wrapping unit 12, the supply paths 10, 28 are arranged in a line, but in opposite directions. This makes rotating the item 8 in the plane of movement or the packaging blank during conveyance unnecessary, as well as an undesirable displacement of the packaging blank 6 through changes in the feed direction. However, the material 8 and the packaging blank 6 are joined in a line and in the same direction. This avoids relative movements between the two and the item 8 can be placed with excellent positional accuracy in a particularly simple manner, for example by setting the item down on the packaging blank 6. With this particular type of feeding, the item 8 to be packaged in the wrapping unit 12 is located on the inside of the packaging blank 6.

In a first wrapping operation 30, the side flaps 32 of the packaging blank 6 are folded parallel to the direction of movement of the packaging blank 6 and wrapped around the item 8. Simultaneously or in a subsequent process step, the outside of the side flaps is coated with an adhesive film. In a second wrapping operation 34, the bottom flap 36 is then folded against the direction of movement of the packaging blank 6, wrapped around the item 8 and glued to the side flaps 32.

To prevent a fold in the direction of movement, the direction of movement of the packaging blank 6 and the item 8 inside is rotated by approximately 90°, however, without changing the orientation of the packaging blank 8. With this change of the direction of movement relative to the orientation of the packaging blank 8, the closure flap 40 can be folded 38 parallel to the new direction of movement of the packaging blank 8. With this type of rotation of the direction of movement, the folding edges of the closure flap 40 and of the bottom flap 36 are arranged approximately parallel to each other, so that particularly symmetric packages can be produced. During this folding 38, the package is closed and the item 8 completely packaged. Depending on the further processing of the packaged item 42, the closure flap 40 can be glued directly to the end of the bottom flap 36 during folding. To this end, in another earlier process step or in a process step performed during folding, an adhesive film can be applied directly in the end region of the bottom flap 36 and/or on the inside of the closure flap 40.

An exemplary embodiment of the enveloping facility 43 is schematically shown in FIG. 2. The enveloping facility 43 includes a packaging unit 44 for producing and supplying the packaging blanks 6 to a wrapping unit 12 and an item unit 46 for manufacturing, sorting, collecting and feeding the item 8 also to this wrapping unit 12.

The packaging unit 44 includes—in the order of process steps—a receiving unit 48 for the packaging material, such as a web or reel of material 1, a cutting unit 4 which cuts this packaging material into packaging blanks 6, a first and a second printing unit 14, 62 which prints the packaging blanks 6 as needed, and a feed unit 50 for supplying the packaging blanks 6 to the wrapping unit 12. In addition, the packaging unit may include a unit for cutting and applying window elements 68 to the packaging blank.

The item unit 46 also includes a separate receiving unit 52 for a web or reel of material 16. Parts of the item 20 are cut from the web of material 16 in a downstream, second cutting unit 18. These parts can optionally be individually printed by another unillustrated printing unit. A collection unit 24 is arranged downstream of the cutting unit 18, where the parts of the item 20 can be collected, sorted and further processed. Additional enclosures or other parts of the item 8 to be packaged can be supplied externally either manually or automatically. The collected item 8 to be packaged is transferred to the wrapping unit 12 via a dedicated feed unit 54.

The enclosure unit 12 is configured to safely and permanently enclose the item 8 to be packaged with the supplied packaging blank 6 in multiple folding and gluing steps. For the simplest and most accurate folding of the closure flap, the wrapping unit 12 is L-shaped, wherein the side flap and the bottom flaps are folded in a first partial area 56 and the closure flap is folded in a second partial area 58, whereby the first partial area 56 is rotated by about 90°. The wrapping unit according to the exemplary embodiment of FIG. 2 moreover includes a dedicated printing unit 60, where the finished end product 42 can be printed again or for the first time, as needed.

The feed units 50, 54 of the packaging blank 6 and of the item 8 are arranged such that they are supplied—in a bird's eye view—in a line and in opposite directions. The packaging blank 6 is hereby brought into proximity of the wrapping unit 12 at a lower level, i.e. below the wrapping unit 12, whereas the item 8 is supplied to the wrapping unit at a higher level above. When the packaging blank 6 is fed to the wrapping unit 12, the packaging blank 6 is moved along a segment of an arc or of a circle. This corresponds to a roller-type rotation of the packaging blank 6 which, however, need not be realized with a roller element, but can also be accomplished with a suitable arrangement of conveyor belts or similar transport elements. With this type of rotation of the packaging blank 6, its orientation relative to the direction of movement does not change, thus preventing a shift during the movement and hence a later inaccurate positioning.

With such conveyance of the item 8 and of the packaging blank 6, the item can be accurately positioned on the packaging blank 6. Only then can the item 8 be completely wrapped. Prefabricated and externally produced packages can thus be dispensed with.

LIST OF REFERENCE SYMBOLS

• 1 first web of material
• 2 process step: cutting the first web of material
• 4 cutting unit
• 6 packaging blank
• 8 good, item
• 10 process step: feeding to the wrapping unit
• 12 wrapping unit
• 14 printing unit
• 16 second web of material
• 18 cutting unit
• 20 parts of the item
• 22 process step: cutting the second web of material
• 24 collection unit
• 26 process step: feeding to the collecting unit
• 28 process step: feeding to wrapping unit
• 30 process step: folding the side flaps
• 32 side flaps
• 34 process step: folding the bottom flap
• 36 bottom flap
• 38 process step: folding the closure flap
• 40 closure flap
• 42 final item
• 43 enveloping facility
• 44 packaging unit
• 46 item unit
• 48 receiving unit of the packaging unit
• 50 feed unit of the packaging unit
• 52 receiving unit of the item unit
• 54 feed unit of the item unit
• 56 partial area of the wrapping unit
• 58 partial area of the wrapping unit
• 60 printing unit
• 62 printing unit
• 64 external supplements
• 66 process step: feeding of the external supplements
• 68 window element

Claims

1-12. (canceled)

13. A method of enveloping an item to be packaged, comprising: supplying the item to be packaged to a wrapping unit by way of a first feed unit,cutting a packaging blank made of a provided material to size, said packaging blank having two side flaps, a bottom flap and a closure flap,supplying the packaging blank to the wrapping unit by way of a second feed unit in at least one section in a line, and in mutually opposite directions,combining the item to be packaged and the packaging blank in the wrapping unit,wrapping the item to be packaged with the packaging blank by way of the wrapping unit, wherein wrapping the item to be packaged further comprises:wrapping the item to be packaged by folding of the side flaps and by folding of the bottom flap, in any order,adhesively joining the side flaps and the bottom flap, andwrapping the item to be packaged by folding of the closure flap.

14. The method of claim 13, wherein the item to be packaged and the packaging blank are combined in the wrapping unit in a line and in mutually opposite directions.

15. The method of claim 13, further comprising rotating a direction of movement of the item, when the closure flap is folded and adhesively joined, by substantially 90° in relation to a direction of movement of the item, when the side flaps and the bottom flap are folded and adhesively joined.

16. The method of claim 13, wherein cutting the packaging blank to size further comprises: cutting a window element in the packaging blank, andcovering the window element with a window foil.

17. The method of claim 13, further comprising printing the packaging blank before supplying the packaging blank to the wrapping unit.

18. The method of claim 13, further comprising printing the packaging blank after wrapping the item in the wrapping unit.

19. The method of claim 13, wherein the item to be packaged supplied to the wrapping unit is cut from a second web of material.

20. The method of claim 19, further comprising collecting a plurality of packaging blanks from the second web of material for the item to be packaged before supplying the item to the wrapping unit.

21. A facility for enveloping an item to be packaged, comprising: a receiving unit and a cutting unit for producing from a provided material packaging blanks comprising two side flaps, a bottom flap and a closure flap,a wrapping unit comprising means for folding the side flaps and the bottom flap, means for adhesively joining the side flaps and the bottom flap, and means for wrapping the item to be packaged by folding of the closure flap,a first feed unit for supplying the item to be packaged to the wrapping unit, anda second feed unit for supplying the packaging blanks to the wrapping unit,wherein the first and second feed unit are arranged so as to supply the item to be packaged and the packaging blanks in at least one section in a line and in opposite directions.

22. The facility of claim 21, further comprising at least one printing unit.

23. The facility of claim 21, further comprising a second web of material and a second cutting unit for producing the item to be packaged.

24. The facility of claim 23, further comprising a collection unit.