System and method for automatically closing boxes with cardboard lids

1. A method for automatically closing an open packaging box with a cardboard lid,

said box comprising

a polygonal bottom panel defined by three or more bottom panel edges and

sidewalls joined over respective crease lines to said bottom panel edges, each sidewall forming a substantially right angle with the bottom panel,

said lid comprising

a polygonal top panel defined by three or more top panel edges and corresponding to the bottom panel of the box to be closed and

flaps joined over respective crease lines to said top panel edges and adapted for being folded onto a corresponding one of said sidewalls,

the method comprising:

partially folding each flap along the respective crease line towards a position, in which the flap forms a substantially right angle with said top panel and placing the lid above said box such that the top panel and the bottom panel are substantially aligned and such that each flap overlaps a respective one of the sidewalls,

releasing the lid allowing the lid to be guided by the partially folded flaps into a position on the box, in which the top panel and the bottom panel are aligned, and

further folding each flap onto the respective sidewall fully into said position, in which the flap forms a substantially right angle with the top panel.

2. The method according to claim 1 , wherein, in partially folding said flaps, the flaps are folded to form an angle of 120° to 150° with the top panel.

3. The method according to claim 1 , wherein, in said releasing the lid, the lid is placed 5 to 50 mm, above the box and released to be guided by the partially folded flaps onto the box.

4. The method according to claim 1 , wherein, in said releasing the lid, the lid is released above the box allowing it to fall by gravity onto the box while the partially folded flaps guide the lids onto the box.

5. The method according to claim 1 , wherein elastic suction cups are used to place the lid above the box, which suction cups contract when a vacuum is applied to them for gripping the lid, wherein in said releasing the lid the elastic cups expand and push the lid towards the box.

6. A method for automatically closing an open packaging box with a cardboard lid,

said box comprising

a polygonal bottom panel defined by three or more bottom panel edges and

sidewalls joined over respective crease lines to said bottom panel edges, each sidewall forming a substantially right angle with the bottom panel,

said lid comprising

a polygonal top panel defined by three or more top panel edges corresponding to the bottom panel of the box to be closed and

flaps joined over respective crease lines to said top panel edges and adapted for being folded onto a corresponding one of said sidewalls,

the method comprising:

partially folding each flap along the respective crease line towards a position, in which the flap forms a substantially right angle with said top panel and placing the lid on said box such that the top panel and the bottom panel are substantially aligned and such that each flap overlaps a respective one of the sidewalls,

pushing the top panel slightly into the box to force the sidewalls outward against the flaps and

further folding each flap onto the respective sidewall fully into said position, in which the flap forms a substantially right angle with the top panel.

7. The method of claim 6 , wherein the top panel is simultaneously pushed towards the box in regions around the middle of each top panel edge.

8. The method according to claim 6 , further comprising applying glue to the flaps or the side walls or both prior to folding the flaps onto the side walls.

9. The method according to claim 6 , wherein, in partially folding said flaps, the flaps are folded to form an angle of 120° to 150° with the top panel.

10. The method according to claim 6 , wherein, in said releasing the lid, the lid is released above the box allowing it to fall by gravity onto the box while the partially folded flaps guide the lids onto the box.

11. A system to automatically close an open packaging box with a cardboard lid, said box comprising a polygonal bottom panel defined by three or more bottom panel edges and side walls joint over respective crease lines to said bottom panel edges, each side wall forming a substantially right angle with the bottom panel,

wherein a cardboard blank for said lid comprises a polygonal top panel defined by three or more top panel edges and corresponding to the bottom panel of the box to be closed and flaps joint over respective crease lines to said top panel edges and adapted to be folded onto a corresponding one of said side walls,

the system comprising a lid placement station,

the lid placement station comprising lid holders operable to grip said cardboard blank and lid folders operable to fold each flap partially along the respective crease line towards a position, in which the flap forms a substantially right angle with said top panel,

said lid placement station which:

transports the lid into a position of the lid above said box such that the top panel and the bottom panel are substantially aligned and such that, when folded, each flap overlaps a respective one of the side walls, in which position the lid holders

releases the lid allowing the lid to be guided by the partially folded flaps into a position, in which the top panel edges and the bottom panel are aligned, and

wherein the lid folders then fold each flap onto the respective side wall fully into said position, in which the flap forms a substantially right angle with the top panel.

12. The system according to claim 11 , wherein said lid holders of the lid placement station comprise elastic suction cups for gripping the lids.

13. A system to automatically close an open packaging box with a cardboard lid, said box comprising a polygonal bottom panel defined by three or more bottom panel edges and side walls joint over respective crease lines to said bottom panel edges, each side wall forming a substantially right angle with the bottom panel

wherein gripping a cardboard blank for said lid comprises a polygonal top panel defined by three or more top panel edges and corresponding to the bottom panel of the box to be closed and flaps joint over respective crease lines to said top panel edges and adapted for being folded onto a corresponding one of said side walls,

the system comprising a lid placement station,

the lid placement station comprising lid holder operable to hold said cardboard blank and lid folders operable to fold each flap partially along the respective crease line towards a position, in which the flap forms a substantially right angle with said top panel,

said lid placement station which:

transports the lid into a position of the lid above said box such that the top panel and the bottom panel are substantially aligned and such that, when folded, each flap overlaps a respective one of the side walls, and

places the lid on the box such that the top panel and the bottom panel are aligned and such that, seen onto each side wall, when folded each flap overlaps a respective one of the side walls

the lid placement station further comprising pushers operable to push the top panel, when the lid is in said position, slightly into the box to force the side walls outward against the flaps and

wherein the lid folders then fold each flap onto the respective side wall fully into said position, in which the flap forms a substantially right angle with the top panel.

14. A method for automatically packaging varying shipment sets in custom-sized cardboard boxes, comprising:

obtaining the overall length, width and height dimensions of a shipment set consisting of one or more item(s) to be packaged,

calculating, based on said information, the layout of a cardboard box blank for a box comprising a polygonal bottom panel defined by three or more bottom edges and side walls joined over respective crease lines to said bottom panel edges, each side wall forming in the folded state a substantially right angle with the bottom panel, and calculating based on said information the layout of a cardboard lid layout for a lid comprising a polygonal top panel, the polygonal top panel defined by three or more top panel edges and corresponding to the bottom panel of the box to be closed and flaps joint over respective crease lines to said top panel edges and adapted for being folded onto a corresponding one of said side walls,

cutting and creasing cardboard to form a cardboard box blank and a cardboard lid blank having the calculated layouts,

conveying the shipment set onto the bottom panel prior or after folding a box out of said cardboard box blank,

partially folding each flap along the respective crease line towards a position, in which the flap forms a substantially right angle with said top panel and placing the lid above said box such that the top panel and the bottom panel are substantially aligned and such that each flap overlaps one of the sidewalls,

releasing the lid allowing it to be guided by the partially folded flaps into a position on the box, in which the top panel and the bottom panel are aligned, and

folding each flap onto the respective sidewall fully into said position, in which the flap forms a substantially right angle with the top panel.

15. A method for automatically packaging varying shipment sets in custom-sized cardboard boxes, comprising:

obtaining the overall length, width and height dimensions of a shipment set consisting of one or more item(s) to be packaged,

calculating, based on said information, the layout of a cardboard box blank for a box comprising a polygonal bottom panel defined by three or more bottom edges and side walls joined over respective crease lines to said bottom panel edges, each side wall forming in the folded state a substantially right angle with the bottom panel, and calculating based on said information the layout of a cardboard lid layout for a lid comprising a polygonal top panel, the polygonal top panel defined by three or more top panel edges and corresponding to the bottom panel of the box to be closed and flaps joint over respective crease lines to said top panel edges and adapted for being folded onto a corresponding one of said side walls,

cutting and creasing cardboard to form a cardboard box blank and a cardboard lid blank having the calculated layouts,

conveying the shipment set onto the bottom panel prior or after folding a box out of said cardboard box blank,

partially folding each flap along the respective crease line towards a position, in which the flap forms a substantially right angle with said top panel and placing the lid above said box such that the top panel and the bottom panel are substantially aligned and such that each flap overlaps one of the sidewalls,

pushing the top panel slightly into the box to force the sidewalls outward against the flaps, and

folding each flap onto the respective sidewall fully into said position, in which the flap forms a substantially right angle with the top panel.