CLIAMS:A method for preparing complex cartons by using machines, said carton being made of paperboard having portions A, B, C, D, E, F, G, H I, J, K; folding lines 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 and gluing positions G1, G2, G3 and G4 and said method comprising the steps of :
(a) pre-breaking a flat carton at folding line 1 to obtain a pre-folding of first flap ;
(b) subjecting the pre-break carton of step (a) to simultaneous aligning and pre-breaking
at folding line 3 to obtain an aligned carton with pre-folding at folding line 3;
(c) folding and pre-breaking the aligned carton of step (b) at folding line 2 and folding line 7 respectively;
(d) Glue application on gluing position G1 on portion G;
(e) pre breaking along folding line 9;
(f) Glue application on gluing positions G2 and G3 on portions E and F respectively;
(g) folding along folding lines 3 and 5 to enable gluing between a part of portion A to G2 and gluing between a part of portion B to G3 to form a swivel tube;
(h) folding along folding line 10 and gluing a part of portion H of folded carton of step (g) at gluing position G1 to obtain a compartment for easy swivel of the tube;
(i) folding along folding line 6;
(j) glue application on gluing position G4;
(k) folding along folding line 8 and pre-breaking glued carton of step (j) at position 9 and gluing a part of portion F at gluing positions G4 to obtain folded carton.

2. The method as claimed in claim 1, wherein the cartons comprise a tube having swivel movement operable with a single push.

3. The method as claimed in claim 1, wherein the cartons are for storing consumer goods.
,TagSPECI:Field of the Invention
The present invention relates to cartons; more specifically to cartons with integrated tube for swivel movement.

Background and the Prior Art
Consumer products are traditionally packed and sold in flip top packs/cartons. In these flip top packs, consumers need to hold the pack in one hand facing the pack front and then flipping the lid backwards to expose and access the products.

Many types of packs and cartons are known in the art specially swivel packs. US8464867 discloses a package for tobacco-related articles comprises an outer shell, a lid, which is adapted to close the top side of the outer shell and can be swiveled about a hinge line, and an inner shell. The inner shell accommodates a plurality of tobacco-related articles and can be shifted in the outer shell from a retracted position to an advanced position, which enables access to the tobacco-related articles. A cutout in the outer shell exposes part of the inner shell and enables transmitting a force onto the inner shell for moving the inner shell. A connector pushes the lid into its opened state when the inner shell is moved into its advanced position and pulls the lid into its closed state when the inner shell is moved into its retracted position.

US 2008/0164162 discloses a cigarette box includes an inner case enclosing a bundle of cigarettes, an outer case enclosing the inner case in a manner allowing the inner case to be moved up and down, and having a hinged lid forming a part of a top wall thereof and a window formed in a side wall to partly expose the inner case, and a link connecting the inner case and the hinged lid. When the inner case is pushed up through the window of the outer case, the link urges the hinged lid upward so that hinged lid is opened. In an open position, the hinged lid provides an access opening projecting from the plane of the top wall of the outer case and facing sideways of the outer case.
The method of preparing cartons which are far complex than any comparable carton available currently is however difficult specifically carton which have integrated tube inside which can swivel and the carton which have multiple folds. Such complex cartons with integrated tube for swivel movement have been claimed in co-pending application no. 958/KOL/2013. In such cartons, the inner tube and outer carton are held by a small 10mm joint which makes it unstable to run on the machine and adds further complexity. There are multiple pre-breakings and folding involved with different positions of gluing which are not feasible on the folder gluer machine and therefore requires a novel, efficient and commercially viable machine manufacturable method.

Objection of the Invention
It is an object of the present invention to overcome the drawbacks of the prior art.
It is another object of the invention to provide a machine manufacturable method for making complex cartons with an integrated tube for swivel movement when pressed to open.

Summary of the Invention
According to one aspect of the present invention there is provided a method for preparing complex cartons by using machines, said carton being made of paperboard having portions A, B, C, D, E, F, G, H I, J, K; folding lines 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 and gluing positions G1, G2, G3 and G4 and said method comprising the steps of :
(a) pre-breaking a flat carton at folding line 1 to obtain a pre-folding of first flap ;
(b) subjecting the pre-break carton of step (a) to simultaneous aligning and pre-breaking
at folding line 3 to obtain an aligned carton with pre-folding at folding line 3;
(c) folding and pre-breaking the aligned carton of step (b) at folding line 2 and folding line 7 respectively;
(d) Glue application on gluing position G1 on portion G;
(e) pre breaking along folding line 9;
(f) Glue application on gluing positions G2 and G3 on portions E and F respectively;
(g) folding along folding lines 3 and 5 to enable gluing between a part of portion A to G2 and gluing between a part of portion B to G3 to form a swivel tube;
(h) folding along folding line 10 and gluing a part of portion H of folded carton of step (g) at gluing position G1 to obtain a compartment for easy swivel of the tube;
(i) folding along folding line 6;
(j) glue application on gluing position G4;
(k) folding along folding line 8 and pre-breaking glued carton of step (j) at position 9 and gluing a part of portion F at gluing positions G4 to obtain folded carton.

Brief Description of Accompanying Figures
Figure 1a illustrates the tool which is used to prepare the open blank which is fed in to the folder and gluer in the present invention.
Figure 1b illustrates the flat cardboard with lines to be folded into the carton of the present invention.
Figure 2 illustrates the formation of tube inside the carton of the present invention.
Figure 3 illustrates the swivel movement of tube inside the carton of the present invention.
Figure 4 illustrates step (a) of pre-breaking a flat carton at folding line 1 to obtain a pre-folding of first flap;
Figure 5 illustrates subjecting step (b) of subjecting the pre-break carton of step (a) to simultaneous aligning and pre-breaking at folding line 3 to obtain an aligned carton with pre-folding at folding line 3;
Figure 6 illustrates step (c) of folding and pre-breaking the aligned carton of step (b) at folding line 2 and folding line 7 respectively to obtain easy fold ability of the tube
Figure 7 illustrates step (e) which is pre breaking along folding line 9 for easy erection of final carton
Figure 8 illustrates step (g) which is folding along folding lines 3 and 5 to enable gluing between a part of portion A to G2 and gluing between a part of portion B to G3 to form a swivel tube;
Figure 9 illustrates step (h) of folding along folding line 10 and gluing a part of portion H of folded carton of step (i) at gluing position G1 to obtain a compartment for easy swivel of the tube;
Figure 10 illustrates step (i) of folding along folding line 6 to bring the tube close to the compartment for easy swivel on the hinge
Figure 11 illustrates output from step (k) which is folding along folding line 8 and pre-breaking glued carton of step (k) at position 9 and gluing a part of portion F at gluing positions G4 to obtain folded carton.
Figure 12a illustrates the blank from which the inner push component is formed.
Figure 12b illustrates the pack formation completed by consecutive 900 inward folding of various panels and tucking in of another panel in available slots.

Detailed description of the Invention
The present invention provides a method comprising a sequence of steps that provide successful production of carton on folder gluer. By following the process steps of the present invention, all the pre-requisite pre-folds in a given length of the machine are covered so that the folding and gluing takes place and the resultant carton is openable with swivel movement without any quality (sticking, aligning and folding) issues inside the carton.

Folding, gluing and affixing at the right places are most essential to the correct formation of a carton. These features become even more critical when the carton to be formed is a complex carton or a super-complex carton. This is essentially because there are an increased number of folds in a complex carton (10 as in the present invention). The present inventors have found that a particular singular sequence of foldings, pre-breaking and gluing leads not just to the desired carton but also a workable carton with desired swivel features and tube which can be made on a machine. The present invention relates to a method for making a carton comprising a tube and one that has a swivel movement operable with a single push.

The present invention provides defective cartons less than 1% which is not feasible by hand pasting method and a significantly higher throughput of cartons in the machine manufacturable method. The cost of manufacturing the carton in this process is significantly lower due to minimal wastage and higher through put. The process according to the present invention cartons enables manufacture at commercial scale at a speed above 5000 cartons/hour.

To perform the present invention an open blank is fed in to the folder and gluer is prepared using the tool shown in figure 1a which is a key step before the process of present invention.

The method according to the present invention can be used for preparing super complex cartons by using machines. In particular it is used for preparing complex cartons by using machines, said carton being made of paperboard having portions A, B, C, D, E, F, G, H I, J, K; folding lines 1, 2, 3, 4, 5, 6, 7, 8, 9, and 10 and gluing positions G1, G2, G3 and G4 and said method comprising the steps of :
(a) pre-breaking a flat carton at folding line 1 to obtain a pre-folding of first flap as illustrated in figure 4;
(b) subjecting the pre-break carton of step (a) to simultaneous aligning and pre-breaking
at folding line 3 to obtain an aligned carton with pre-folding at folding line 3 as illustrated in figure 5;
(c) folding and pre-breaking the aligned carton of step (b) at folding line 2 and folding line 7 respectively as illustrated in figure 6;
(d) Glue application on gluing position G1 on portion G;
(e) pre breaking along folding line 9 as illustrated in figure 7;
(f) Glue application on gluing positions G2 and G3 on portions E and F respectively;
(g) folding along folding lines 3 and 5 to enable gluing between a part of portion A to G2 and gluing between a part of portion B to G3 to form a swivel tube as illustrated in figure 8;
(h) folding along folding line 10 and gluing a part of portion H of folded carton of step (i) at gluing position G1 to obtain a compartment for easy swivel of the tube as illustrated in figure 9;
(i) folding along folding line 6 as illustrated in figure 10;
(j) glue application on gluing position G4;
(k) folding along folding line 8 and pre-breaking glued carton of step (k) at position 9 and gluing a part of portion F at gluing positions G4 to obtain folded carton as illustrated in figure 11.
The folded outer carton as obtained in the present method can be integrated with an inner component. Figure 12a illustrates the inner push component which is needed to be assembled for acting as a push component. The integration of the outer carton and inner push component is part of the co-pending application, namely, application no. 958/KOL/2013. It involves pushing the integrated container for storing the product. After inserting the inner component within the outer carton, a panel of the inner component aligns to the open top of the outer carton and another panel remains accessible from the opening of the outer carton for pushing. The pack formation is completed by consecutive 900 inward folding of other panels and tucking in of another panel in the slot available as illustrated in Figure 12b which is figure 19 of the co-pending application, 958/KOL/2013.

The present inventors have found that if the above mentioned process is not followed or one of the steps is skipped the following concerns arise:
a. Collapsed tube – If step (a) is not done. Step (a) is also not interchangeable to a later position as it is not possible to pre-break after forming the tube
b. Collapsed tube – Step (b) cannot be replaced or skipped as it will result in buckled carton if pre-breaking and aligning is not done
c. Buckled carton – If step (b) is not done
d. Improper / Skewed tube – Step (e) and Step (g) is not interchangeable and Step (e) and step (g) will result in improper skewed carton if not done in above stated method
e. Poor swivel movement of tube – Step (h) if not done in above stated method can lead to poor formation of compartment for easy swivel
f. Poor click sound and swivel movement of tube while open and closure of the tube through a push component – If any of the steps are not done in accordance to the method of the present invention.

The present inventors have found that the known cartons attract dust, finger prints and seepage and patches of glue in unwanted areas when done in manual process and such events can be avoided by using the process of the present invention.

The cartons made in accordance with the present invention can be used for storing consumer goods such as premium pens, pencils, electronic cigarette, memory stick, chocolates, chewing gums.

The present invention is hereinafter illustrated by way of non-limiting examples.

Example 1
It was observed that if the process of the present invention is altered as follows then the desired carton is not obtained:
Cartons were prepared using the following processes
Process A
(b) Simultaneous aligning and pre-breaking at folding line 3 to obtain an aligned carton with pre-folding at folding line 3;
(c) folding and pre-breaking the aligned carton of step (b) at folding line 2 and folding line 7 respectively;
(d) Glue application on gluing position G1 on portion G;
(e) pre breaking along folding line 9;
(f) Glue application on gluing positions G2 and G3 on portions E and F respectively;
(g) folding along folding lines 3 and 5 to enable gluing between a part of portion A to G2 and gluing between a part of portion B to G3 to form a swivel tube;
(h) folding along folding line 10 and gluing a part of portion H of folded carton of step (i) at gluing position G1 to obtain a compartment for easy swivel of the tube;
(i) folding along folding line 6;
(j) glue application on gluing position G4;
(k) folding along folding line 8 and pre-breaking glued carton of step (k) at position 9 and gluing a part of portion F at gluing positions G4 to obtain folded carton.
Observation:
It was observed that even though the carton was formed, the inner tube collapsed because it fails to break open at position 1. Hence step (a) is extremely important for the carton to be formed

Process B
(a) pre-breaking a flat carton at folding line 1 to obtain a pre-folding of first flap ;
(b) subjecting the pre-break carton of step (a) to simultaneous aligning and pre-breaking
at folding line 3 to obtain an aligned carton with pre-folding at folding line 3;
(c) folding and pre-breaking the aligned carton of step (b) at folding line 2
(d) Glue application on gluing position G1 on portion G;
(e) pre breaking along folding line 9;
(f) Glue application on gluing positions G2 and G3 on portions E and F respectively;
(g) folding along folding lines 3 and 5 to enable gluing between a part of portion A to G2 and gluing between a part of portion B to G3 to form a swivel tube;
(h) folding along folding line 10 and gluing a part of portion H of folded carton of step (i) at gluing position G1 to obtain a compartment for easy swivel of the tube;
(i) folding along folding line 6;
(j) glue application on gluing position G4;
(k) folding along folding line 8 and pre-breaking glued carton of step (k) at position 9 and gluing a part of portion F at gluing positions G4 to obtain folded carton.

Observation:
It was observed that the final carton will buckle during formation as the position 7 is not pre-broken.

Process C
(a) pre-breaking a flat carton at folding line 1 to obtain a pre-folding of first flap ;
(b) subjecting the pre-break carton of step (a) to simultaneous aligning and pre-breaking
at folding line 3 to obtain an aligned carton with pre-folding at folding line 3;
(c) folding and pre-breaking the aligned carton of step (b) at folding line 2 and folding line 7 respectively;
(d) Glue application on gluing position G1 on portion G;
(e) pre breaking along folding line 9;
(f) Glue application on gluing positions G2 and G3 on portions E and F respectively;
(g) Gluing between a part of portion A to G2 and gluing between a part of portion B to G3 to form a swivel tube;
(h) folding along folding line 10 and gluing a part of portion H of folded carton of step (i) at gluing position G1 to obtain a compartment for easy swivel of the tube;
(i) folding along folding line 6;
(j) glue application on gluing position G4;
(k) folding along folding line 8 and pre-breaking glued carton of step (k) at position 9 and gluing a part of portion F at gluing positions G4 to obtain folded carton.
Observation:
It was observed that improper / skewed tube was formed. Since the folding along folding lines 3 and 5 and is not done