This invention relates generally to a manually operated machine for forming a tray from a blank of sheet material, and more specifically to methods and a manually operated machine for forming a tray by wrapping the blank around a mandrel in a field location.
Containers fabricated from paperboard and/or corrugated paperboard material are often used to store and transport goods. These containers can be square, hexagonal, or octagonal, for example. Such containers are usually formed from blanks of sheet material that are folded along a plurality of preformed fold lines to form an erected corrugated container. The panels are rotated to form end walls, side walls, a bottom wall, a top wall, and, in some cases, corner walls of the container. In addition, at least some known containers include reinforced corners or side walls for providing additional strength, including stacking strength.
Moreover, at least some known containers are formed from a blank using a tray-forming machine. At least some such machines wrap the blank about a mandrel, providing strong, uniform containers with tight tolerances and an attendant decrease in wasted blank material. In some cases, however, such as where the containers are intended to be filled at a relatively remote and/or temporary field location, it remains advantageous to transport flat blanks to the field location and form such containers on-site. At least some known tray-forming machines cannot be transported to such field locations and/or cannot be operated at such field locations, due to an absence of available power or transportation infrastructure, for example.
In one aspect, a machine for forming a container from a blank of sheet material is provided. The machine includes a base, a frame coupled for rotation about the base, and a plurality of box-forming stations coupled to the frame. Each box-forming station includes a mandrel coupled to the frame. The mandrel includes a bottom face having two pairs of opposing edges, a pair of opposing side faces, and a pair of opposing end faces. Each side face and end face extends generally from a corresponding edge of the bottom face and is perpendicular to the bottom face. Each box-forming station also includes a first pair of opposing presses each configured to be moved into close proximity to a respective end face of the pair of opposing end faces. Each box-forming station further includes a second pair of opposing presses each configured to be moved into close proximity to a respective side face of said pair of opposing side faces. Each box-forming station additionally includes at least one manually operable mechanism configured to control a position of a first press from among the first pair of opposing presses and the second pair of opposing presses.
In another aspect, a method for forming a container from a blank of sheet material using a machine that includes a mandrel is provided. The blank includes a bottom panel, a first and second side panel each extending from a respective side edge of the bottom panel, a first and second end panel each extending from a respective end edge of the bottom panel, a first and fourth reinforcing panel assembly each extending from a respective side edge of the first end panel, and a second and third reinforcing panel assembly each extending from a respective side edge of the second end panel. The method includes positioning each of a first end wall press, a second end wall press, a first side wall press, and a second side wall press in a receiving position. Each of the first end wall press, the second end wall press, the first side wall press, and the second side wall press are movable between the receiving position and a pressure position. The method also includes aligning the bottom panel with a bottom face of the mandrel. The method further includes moving the first end wall press from the receiving position to the pressure position such that the first end panel is pressed between the first end wall press and a first end face of the mandrel to at least partially form a first end wall of the container. The method additionally includes moving the second end wall press from the receiving position to the pressure position such that the second end panel is pressed between the second end wall press and a second end face of the mandrel to at least partially form a second end wall of the container. The method also includes moving the first side wall press from the receiving position to the pressure position such that the first side panel, at least a portion of the first reinforcing panel assembly, and at least a portion of the second reinforcing panel assembly are pressed between the first side wall press and a first side face of the mandrel to at least partially form a first side wall of the container. The method further includes moving the second side wall press from the receiving position to the pressure position such that the second side panel, at least a portion of the third reinforcing panel assembly, and at least a portion of the fourth reinforcing panel assembly are pressed between the second side wall press and a second side face of the mandrel to at least partially form a second side wall of the container.
In another aspect, a method for forming a plurality of containers from blanks of sheet material by an operator using a machine is provided. The machine includes a plurality of box-forming stations coupled to a frame. The method includes wrapping a first blank about a mandrel of a first box-forming station that is proximate to the operator, and rotating the frame about a base of the machine such that a second box-forming station arrives proximate to the operator. The method also includes wrapping a second blank about a mandrel of the second box-forming station, and rotating the frame about the base of the machine such that the first box-forming station arrives proximate to the operator. The method further includes removing the wrapped first blank from the mandrel of the first box-forming station after an adhesive on the first blank substantially sets to form a first container.
The tray-forming machine and methods for forming corrugated containers described herein overcome the limitations of known tray-forming machines. The machine and methods described herein include a manually operated apparatus configured to wrap a blank of sheet material about a mandrel and secure the wrapped blank while adhesive sets to form the container. The machine and methods described herein also provide for the use of a plurality of box-forming stations by a single operator to facilitate an increased rate of container production. In certain embodiments, the machine and methods described herein advantageously provide for at least one step in a box-forming operation to be controlled by manually operable control mechanisms, without need for electrical power or other infrastructure.
More specifically, first top panel 20 extends from leading edge 16 to fold line 30, first side panel 22 extends from first top panel 20 along fold line 30, bottom panel 24 extends from first side panel 22 along fold line 32, second side panel 26 extends from bottom panel 24 along fold line 34, and second top panel 28 extends from second side panel 26 to trailing edge 18. Fold lines 30, 32, 34 and/or 36, as well as other fold lines and/or hinge lines described herein, may include any suitable line of weakening and/or line of separation known to those skilled in the art and guided by the teachings herein provided.
A container 200 (shown in
In the example embodiment, first side panel 22 and second side panel 26 are substantially congruent and have a rectangular shape. Bottom panel 24 has an octagonal shape. More specifically, first side panel 22 and second side panel 26 have a width W1. Bottom panel 24 has a width W2, which is longer that width W1. Alternatively, width W1 is substantially equal to or longer than width W2. Further, in the example embodiment, side panels 22 and 26 have a first height H1, and bottom panel 24 has a first depth D1 that is larger than first height H1. In an alternative embodiment, height H1 is substantially equal to or larger than depth D1. Alternatively, first side panel 22, second side panel 26, and/or bottom panel 24 have any suitable dimensions that enable blank 10 and/or container 200 to function as described herein.
In the example embodiment, bottom panel 24 may be considered to be substantially rectangular in shape with four cut-off corners or angled edges 40, 42, 44, and 46 formed by cut lines. As such, the cut-off corner edges 40, 42, 44, and 46 of otherwise rectangular bottom panel 24 define an octagonal shape of bottom panel 24. Moreover, each angled corner edge 40, 42, 44, and 46 has a length L1, and angled edges 40 and 44 and angled edges 42 and 46 are substantially parallel. Alternatively, bottom panel 24 has any suitable shape that enables container 200 to function as described herein. For example, bottom panel 24 may be in the shape of a rectangle having corners that are truncated by a segmented edge such that bottom panel 24 has more than eight sides. In another example, bottom panel 24 may be in the shape of a rectangle having corners that are truncated by an arcuate edge such that bottom panel 24 has four substantially straight sides and four arcuate sides. In the exemplary embodiment, each angled edge 40, 42, 44, and 46 includes a crushed area 48 that facilitates forming container 200 from blank 10. More specifically, crushed area 48 enables corner walls 210, 212, 214, and/or 216 (shown in
In the example embodiment, first side panel 22 includes two free side edges 50 and 52, and second side panel 26 includes two free side edges 54 and 56. Side edges 50, 52, 54, and 56 are substantially parallel to each other. Alternatively, side edges 50, 52, 54, and/or 56 are other than substantially parallel. In the example embodiment, each side edge 50, 52, 54, and 56 is connected to a respective angled edge 40, 42, 44, or 46. Each side edge 50, 52, 54, and 56 may be directly connected to a respective angled edge 40, 42, 44, or 46 or, as shown in
First top panel 20 and second top panel 28 are substantially congruent and have a generally trapezoidal shape. More specifically, first top panel 20 includes an angled edge 58 extending from an intersection 60 of fold line 30 and free edge 50 toward an apex 62 and an angled edge 64 extending from an intersection 66 of fold line 30 and free edge 52 toward an apex 68. A free side edge 70 extends from apex 62 to leading edge 16, and a free side edge 72 extends from apex 68 to leading edge 16. Similarly, second top panel 28 includes an angled edge 74 extending from an intersection 76 of fold line 36 and free edge 54 toward an apex 78 and an angled edge 80 extending from an intersection 82 of fold line 36 and free edge 56 toward an apex 84. A free side edge 86 extends from apex 78 to trailing edge 18, and a free side edge 88 extends from apex 84 to trailing edge 18. In addition, first and second top panels 20 and 28 have a depth D2 that is smaller than half of depth D1. In an alternative embodiment, depth D2 is substantially equal to or larger than half of depth D1. It should be understood that first side panel 22, second side panel 26, bottom panel 24, and/or top panels 20 and/or 28 may have any suitable dimensions that enable blank 10 to function as described herein.
In the example embodiment, first top panel 20 includes a first locking slot 100 and a second locking slot 102 defined therethrough. Similarly, second top panel 28 includes locking slots 100 and 102. Each slot 100 and 102 is located, shaped, and sized to receive a stacking tab 204 (shown in
A first end panel 108 extends from bottom panel 24 along a fold line 110 to a free edge 112, and a second end panel 114 extends from bottom panel 24 along a fold line 116 to a free edge 118. Fold line 110 defines a bottom edge of first end panel 108 and an end edge of bottom panel 24, and fold line 116 defines a bottom edge of second end panel 114 and an end edge of bottom panel 24. First and second end panels 108 and 114 each are generally rectangular or square shaped. End panels 108 and 114 each have a depth D3 that is shorter than depth D1 such that end panels 108 and 114 are narrower than bottom panel 24. In the example embodiment, end panels 108 and 114 each have a height H2 that is substantially equal to height H1. Alternatively, height H2 is other than equal to height H1. In the example embodiment, fold line 110 extends between ends of angled corner edges 40 and 42, and fold line 116 extends between ends of angled corner edges 46 and 44.
Each end panel 108 and 114 includes a pair of mirror image stacking extensions 120 and 122. More specifically, each stacking extension 120 and 122 forms a portion of stacking tab 204 (shown in
In the example embodiment, a reinforcing panel assembly 138 extends from each side edge of each end panel 108 and 114. Each side edge is defined by a respective one of fold lines 140, 142, 144, and 146. Fold lines 140, 142, 144, and 146 are substantially parallel to each other. Alternatively, fold lines 140, 142, 144, and/or 146 are other than substantially parallel. In the example embodiment, each reinforcing panel assembly 138 includes a free bottom edge 90. Angled edge 58, free edge 50, angled edge 40, at least a portion of free edge 70, and a first respective bottom edge 90 define a cutout 92; angled edge 64, free edge 52, angled edge 46, at least a portion of free edge 72, and a second respective bottom edge 90 define a cutout 94; angled edge 74, free edge 54, angled edge 42, at least a portion of free edge 86, and a third respective bottom edge 90 define a cutout 96; and angled edge 80, free edge 56, angled edge 44, at least a portion of free edge 88, and a fourth respective bottom edge 90 define a cutout 98. In addition, first top panel 20 is separated from adjacent reinforcing panel assemblies 138 by side edges 70 and 72, and second top panel 28 is separated from adjacent reinforcing panel assemblies 138 by side edges 86 and 88.
Each reinforcing panel assembly 138 is substantially similar and includes an outer reinforcing panel assembly 148 and an inner reinforcing panel assembly 150 connected to each other along a fold line 152. Fold line 152 defines a side edge of outer reinforcing panel assembly 148 and a side edge of inner reinforcing panel assembly 150. Moreover, outer reinforcing panel assembly 148 includes a corner panel 154 and a first reinforcing side panel 156, and inner reinforcing panel assembly 150 includes an inner reinforcing corner panel 158, a second reinforcing side panel 160, and an inner end panel 162. Each reinforcing panel assembly 138 is configured to form a reinforcing corner assembly 202 (shown in
A respective outer reinforcing panel assembly 148 extends from each of end panels 108 and 114 along each of fold lines 140, 142, 144, and 146. Further, a respective inner reinforcing panel assembly 150 extends from each outer reinforcing panel assembly 148 along each fold line 152. In the example embodiment, a notch 164 is formed along each fold line 152 between inner reinforcing panel assembly 150 and outer reinforcing panel assembly 148. In alternative embodiments, any or all notches 164 are not present. In the example embodiment, inner reinforcing corner panel 158 and second reinforcing side panel 160 have a combined width W3, and outer reinforcing panel assembly 148 has a width W4 which is substantially equal to width W3. Further, in the example embodiment, inner and outer reinforcing panel assemblies 150 and 148 have a height H3 that is substantially equal to height H1 of first side panel 22 and second side panel 26. In an alternative embodiment, height H3 is other than equal to height H1. In the example embodiment, each outer reinforcing panel assembly 148 includes a fold line 166 that divides each outer reinforcing panel assembly 148 into corner panel 154 and first reinforcing side panel 156. Fold line 166 defines a side edge of corner panel 154 and a side edge of first reinforcing side panel 156, and fold line 152 defines another side edge of first reinforcing side panel 156. In the example embodiment, corner panel 154 and first reinforcing side panel 156 are substantially rectangular.
Further, each inner reinforcing panel assembly 150 includes fold lines 168 and 170 that divide each inner reinforcing panel assembly 150 into second reinforcing side panel 160, inner reinforcing corner panel 158, and inner end panel 162. More specifically, second reinforcing side panel 160 extends from first reinforcing side panel 156 along fold line 152, inner reinforcing corner panel 158 extends from second reinforcing side panel 160 along fold line 168, and inner end panel 162 extends from inner reinforcing corner panel 158 along fold line 170 to a free edge 172. Fold line 168 defines a side edge of inner reinforcing corner panel 158 and a side edge of second reinforcing side panel 160, fold line 170 defines a side edge of inner reinforcing corner panel 158 and a side edge of inner end panel 162, and fold line 152 defines another side edge of second reinforcing side panel 160. In the example embodiment, corner panel 154 and inner reinforcing corner panel 158 are substantially congruent, and first and second reinforcing side panels 156 and 160 are substantially congruent. Further, each free edge 172 is generally co-linear with one of leading edge 16 and trailing edge 18; however, free edge 172 can have any suitable position with respect to leading edge 16 and/or trailing edge 18 that enables blank 10 and/or container 200 to function as described herein.
Each corner panel 154 and each inner reinforcing corner panel 158 have a width W5 that is substantially equal to length L1. In addition, each first reinforcing side panel 156 and second reinforcing side panel 160 have a width W6 that is larger than width W5. In alternative embodiments, width W6 is smaller than or approximately equal to width W5. Further, in the example embodiment, each inner end panel 162 has a depth D4 that is equal to approximately half of depth D3 of each of first and second end panels 108 and 114. In embodiments in which end panels 108 and/or 114 include vent holes 174, inner end panels 162 include corresponding vent holes 174 that are configured to align with vent holes 174 defined through end panels 108 and/or 114 when container 200 is formed from blank 10. In an alternative embodiment, depth D4 is other than equal to approximately half of width D3.
In the example embodiment, inner end panel 162 includes a minor stacking extension 176 extending from a top edge 178 thereof. Minor stacking extension 176 has a shape that at least partially corresponds to the shape of stacking extension 120 or 122 such that minor stacking extension 176 aligns with a respective stacking extension 120 or 122 to form a stacking tab 204. In the example embodiment, minor stacking extension 176 is substantially similarly shaped to a respective stacking extension 120 or 122, except minor stacking extension 176 includes a straight side edge 180 rather than a shape corresponding to notch 124. In alternative embodiments, minor stacking extension 176 has any suitable shape and position that enables blank 10 and/or container 200 to function as described herein. Further, in the example embodiment, inner end panel 162 includes a notch 182 defined in bottom edge 90. Notch 182 is shaped to correspond to at least a portion of stacking slot 130 defined in end panel 108 and/or 114. As such, when container 200 is formed from blank 10, inner end panel 162 does not obstruct stacking slot 130, such that when containers 200 are stacked, a lower stacking tab 204 (shown in
To construct container 200 from blank 10, in the example embodiment, each inner reinforcing panel assembly 150 is folded about fold line 152 such that inner reinforcing panel assembly 150 and outer reinforcing panel assembly 148 are in an at least partially overlying relationship, and such that inner end panel 162 is in an at least partially overlying relationship with at least a portion of a respective first or second end panel 108 or 114. More specifically, blank 10 is folded along fold line 152 such that corner panel 154 and inner reinforcing corner panel 158 are substantially aligned in an at least partially overlying relationship, first and second reinforcing side panels 156 and 160 are substantially aligned in an at least partially overlying relationship, and inner end panel 162 and at least a portion of first or second end panel 108 or 114 are substantially aligned in an at least partially overlying relationship. In the example embodiment, inner end panel 162, a respective end panel 108 or 114, reinforcing side panels 156 and 160, and/or corner panels 154 and 158 are secured in the above-described relationships. For example, inner end panel 162 may be adhered to a respective end panel 108 or 114, reinforcing side panels 156 and 160 may be adhered together, and/or corner panels 154 and 158 may be adhered together.
Outer and inner reinforcing panel assemblies 148 and 150 are rotated about fold lines 140, 142, 144, and 146 and fold lines 170. Further, reinforcing side panels 156 and 160 are rotated about fold lines 166 and 168 toward corner panels 154 and 158 before or after outer and inner reinforcing panel assemblies 148 and 150 are rotated about fold lines 140, 142, 144, and 146 and fold lines 170. In the example embodiment, outer and inner reinforcing panel assemblies 148 and 150 and reinforcing side panels 156 and 160 are rotated such that reinforcing side panels 156 and 160 are substantially perpendicular to end panels 108 and 114. First and second end panels 108 and 114 are then rotated about fold lines 110 and 116, respectively, toward interior surface 12. A reinforcing corner assembly 202 is formed by corner panels 154 and 158, reinforcing side panels 156 and 160, and inner end panel 162. When reinforcing corner assemblies 202 are formed, each minor stacking extension 176 aligns with a respective stacking extension 120 or 122 to form a stacking tab 204. First end panel 108 with a pair of inner end panels 162 forms a first end wall 206, and second end panel 114 with a pair of inner end panels 162 forms a second end wall 208. Each end wall 206 and 208 includes a pair of stacking tabs 204 extending from an upper edge thereof. Further, each pair of corner panels 154 and 158 forms a respective corner wall 210, 212, 214, or 216.
First side panel 22 is rotated about fold line 32 toward interior surface 12, and second side panel 26 is rotated about fold line 34 toward interior surface 12. More specifically, first side panel 22 and second side panel 26 are rotated to be substantially perpendicular to bottom panel 24. Interior surface 12 of first side panel 22 is secured to exterior surface 14 of two adjacent first reinforcing side panels 156, and interior surface 12 of second side panel 26 is secured to exterior surface 14 of two adjacent first reinforcing side panels 156. In the example embodiment, first side panel 22 and second side panel 26 are adhered to respective first reinforcing side panels 156. Alternatively, first side panel 22 and/or second side panel 26 are otherwise attached to respective first reinforcing side panels 156 using, for example, fasteners, a bonding material, such as glue or an adhesive, and/or any suitable method for attached the panels. In the example embodiment, first side panel 22 and two pairs of reinforcing side panels 156 and 160 form a first side wall 218, and second side panel 26 and two pairs of reinforcing side panels 156 and 160 form a second side wall 220.
When container 200 is formed, interior surface 12 of side walls 218 and 220 is adjacent the product. Further, height H1 of side walls 218 and 220 is sized to correspond to a height of the products within container 200 such that height H1 is substantially equal to or greater than the height of the products. Bottom panel 24 forms a bottom wall 222 of container 200, and bottom wall 222, side walls 218 and 220, end walls 206 and 208, and corner walls 210, 212, 214, and 216 define cavity 224 of container 200. In the exemplary embodiment, bottom edges 90 of reinforcing corner assemblies 138 are substantially aligned with fold lines 32, 34, 110, and 116 and angled edges 40, 42, 44, and 46. In
Referring to
As shown in
Machine 1000 also includes a frame 1020 coupled for rotation about base 1002. More specifically, in the example embodiment, frame 1020 is configured to be rotatable with respect to base 1002 about axis 1008. For example, frame 1020 includes a turntable 1022 coupled to support structure 1016 of base 1002. In alternative embodiments, frame 1020 is configured to rotate about an axis (not shown) other than axis 1008, which may be oriented other than substantially vertically. In an embodiment, machine 1000 includes a limited number of structural components, each of which are configured for ease of coupling to other components, to facilitate transporting machine 1000 to a field location in a disassembled condition and assembling machine 1000 at the field location.
A plurality of box-forming stations 1030 is coupled to frame 1020. In the example embodiment, each box-forming station 1030 includes at least one support member 1032 extending outwardly from frame 1020. Additionally, each box-forming station 1030 includes a mandrel 1040 coupled to the at least one support member 1032. Alternatively, each mandrel 1040 is coupled to frame 1020 in another suitable fashion. Each mandrel 1040 includes a plurality of faces, including a bottom face 1058 that faces generally outwardly from axis 1008. Bottom face 1058 has a shape that substantially corresponds to a shape of bottom panel 24 (shown in
In the example embodiment, corner faces 1042, 1046, 1050, and 1054 each have a shape substantially corresponding to a shape of corner panel 154 and inner reinforcing corner panel 158. First end face 1044 and second end face 1052 each have a shape substantially corresponding to a shape of first end panel 108 and second end panel 114, respectively. First side face 1048 and second side face 1056 each have a shape substantially corresponding to a shape of first side panel 22 and second side panel 26, respectively. Thus, an external shape of mandrel 1040 is complementary to an internal shape of at least a portion of container 200.
Returning to
First end wall press 1100 is configured such that its face 1112 is positioned in close proximity to first end face 1044 when first end wall press 1100 is in pressure position 1110, and second end wall press 1102 is configured such that its face 1114 is positioned in close proximity to second end face 1052 when second end wall press 1102 is in pressure position 1110. In this context, “close proximity” is defined as proximity within a distance that is less than or equal to a maximum desired wall thickness of container 200. Conversely, first end wall press 1100 is configured such that its face 1112 is positioned away from first end face 1044 when first end wall press 1100 is in receiving position 1108, and second end wall press 1102 is configured such that its face 1114 is positioned away from second end face 1052 when second end wall press 1102 is in receiving position 1108.
Each box-forming station 1030 further includes a first manually operable mechanism 1103 configured to control a position of a first press of first pair of opposing presses 1100, 1102. In the example embodiment, first manually operable mechanism 1103 is operably coupled to first end wall press 1100 and configured to mechanically control the position of first end wall press 1100. More specifically, first end wall press 1100, frame 1020, and first manually operable mechanism 1103 are coupled together such that first end wall press 1100 is disposed in receiving position 1108 when first manually operable mechanism 1103 is set to a catch position 1121, and first end wall press 1100 is disposed in pressure position 1110 when first manually operable mechanism 1103 is set to a release position 1123. First manually operable mechanism 1103 provides for at least one step in the box-forming operation to be mechanically controlled by an operator using a manually operated control mechanism, as will be described herein. Alternatively or additionally, first manually operable mechanism 1103 may be configured to control one of a second pair of opposing presses, as will be described herein.
First cross bar 1133 is coupled to first end wall press 1100. Catch slot 1129 has a relatively short length, such that when first cross bar 1133 is positioned in catch slot 1129, catch slot 1129 permits only limited rotation of first end wall press 1100 toward mandrel 1040 before first cross bar 1133 is mechanically stopped by an end of catch slot 1129. Thus, interface plate 1125 is operable to suspend first end wall press 1100 in receiving position 1108 when first cross bar 1133 is positioned in catch slot 1129. In contrast, release slot 1127 is elongated relative to catch slot 1129, such that release slot 1127 permits rotation of first end wall press 1100 towards mandrel 1040 into pressure position 1110 when first cross bar 1133 is positioned in release slot 1127.
A handle 1105 extends from first end wall press 1100 proximate to first cross bar 1133. To operate first manually operable mechanism 1103 to place first end wall press 1100 in receiving position 1108, an operator grasps handle 1105 and raises first end wall press 1100 until cross bar 1133 traverses transition slot 1131 into catch slot 1129. The operator may then release handle 1105, and first end wall press 1100 rotates slightly downward under its own weight until cross bar 1133 is mechanically stopped in catch slot 1129, suspending first end wall press 1100 in receiving position 1108.
A holding member 1109 is coupled to interface plate 1125 proximate to transition slot 1131. When first end wall press 1100 is in receiving position 1108, holding member 1109 also is proximate to handle 1105. To operate first manually operable mechanism 1103 to place first end wall press 1100 in pressure position 1110, the operator grasps handle 1105, lifts handle 1105 slightly to move cross bar 1133 along catch slot 1129 toward transition slot 1131, and presses holding member 1109. For example, holding member 1109 is configured to enable the operator to press holding member 1109 using the thumb of the hand that is grasping handle 1105. Holding member 1109 moves interface plate 1125 relative to cross bar 1133 such that cross bar 1133 moves through transition slot 1131 into release slot 1127. The operator may then use handle 1105 to guide first end wall press 1100 as it rotates downward under its own weight into pressure position 1110, where, in the example embodiment, cross bar 1133 is mechanically stopped in release slot 1127. Additionally or alternatively, first end wall press 1100 may rotate downward until first end wall press face 1112 is mechanically stopped by mandrel 1040.
Each box-forming station 1030 further includes a second manually operable mechanism 1122 configured to control a position of a second press of first pair of opposing presses 1100, 1102. In the example embodiment, second manually operable mechanism 1122 is operably coupled to second end wall press 1102 and configured to mechanically control the position of second end wall press 1102. More specifically, second end wall press 1102, frame 1020, and second manually operable mechanism 1122 are coupled together such that second end wall press 1102 is disposed in receiving position 1108 when second manually operable mechanism 1122 is set to a first position 1120, and second end wall press 1102 is disposed in pressure position 1110 when second manually operable mechanism 1122 is set to a second position 1124. Second manually operable mechanism 1104 provides for at least one step in the box-forming operation to be mechanically controlled by an operator using a manually operated control mechanism, as will be described herein. Alternatively or additionally, second manually operable mechanism 1122 may be configured to control one of a second pair of opposing presses, as will be described herein.
In the example embodiment, lever 1104 is rotatably coupled to first end wall press 1100 via a second cross bar 1119. More specifically, lever 1104 is rotatable in the plane of illustration in
Similarly, to operate second manually operable mechanism 1122 to place second end wall press 1102 into receiving position 1108, the operator grasps lever 1104 and rotates it from second position 1124 to first position 1120. Linkage plate 1126 rotates with lever 1104, rotating pinned joint 1128 from relatively higher elevation 1141 to relatively lower elevation 1139. This change in position of pinned joint 1128 lowers rod 1118 downwards, and rod 1118 causes second end wall press 1102 to rotate away from mandrel 1040 into receiving position 1108. In alternative embodiments, any suitable linkage may be used to operably couple second end wall press 1102 to lever 1104.
With reference to
First side wall press 1130 is configured such that, when first side wall press 1130 is in pressure position 1140, side face 1134 is positioned in close proximity to first side face 1048, mitered face 1142 is positioned in close proximity to second corner face 1046, and mitered face 1144 is positioned in close proximity to third corner face 1050. Similarly, second side wall press 1132 is configured such that, when second side wall press 1132 is in pressure position 1140, side face 1136 is positioned in close proximity to second side face 1056, mitered face 1146 is positioned in close proximity to first corner face 1042, and mitered face 1148 is positioned in close proximity to fourth corner face 1054. Conversely, first side wall press 1130 is configured such that side face 1134, mitered face 1142, and mitered face 1144 are positioned away from mandrel 1040 when first side wall press 1130 is in receiving position 1138, and second side wall press 1132 is configured such that side face 1136, mitered face 1146, and mitered face 1148 are positioned away from mandrel 1040 when second side wall press 1132 is in receiving position 1138.
In the example embodiment, first side wall press 1130 is coupled to frame 1020 via a hinge 1150, and second side wall press 1132 is coupled to frame 1020 via a hinge 1152. Hinge 1150 and hinge 1152 are configured such that first side wall press 1130 and second side wall press 1132 are movable by hand between receiving position 1138 and pressure position 1140 by a typical human operator. In alternative embodiments, any suitable mechanical structure may be used to movably couple first side wall press 1130 and second side wall press 1132 to frame 1020.
Additionally, each box-forming station includes a locking mechanism 1160 configured to releasably maintain first side wall press 1130 and second side wall press 1132 in pressure position 1140. In the example embodiment, locking mechanism 1160 includes a first locking member 1162 coupled to first side wall press 1130, a second locking member 1164 coupled to second side wall press 1132, and a clasp 1166 operable to releasably couple first locking member 1162 and second locking member 1164 when first side wall press 1130 and second side wall press 1132 are in pressure position 1140. Clasp 1166 is configured to apply tension to first locking member 1162 and second locking member 1164 in the coupled position, thereby maintaining first side wall press 1130 and second side wall press 1132 in close proximity to mandrel 1040. In alternative embodiments, any suitable mechanical structure may be used to releasably maintain first side wall press 1130 and second side wall press 1132 in pressure position 1140. For example, in an embodiment, locking mechanism 1160 includes respective springs coupled to hinge 1150 and hinge 1152 that each are configured to selectively bias first side wall press 1130 and second side wall press 1132, respectively, into pressure position 1140 when first side wall press 1130 and second side wall press 1132 are moved to within a predefined distance of pressure position 1140.
In another alternative embodiment, at least one manually operable mechanism (not shown) similar to first manually operable mechanism 1103 or second manually operable mechanism 1122, described above, is configured to control the second pair of opposing presses 1130, 1132. The manual control mechanism may be a lever, a hand-crank, or any other suitable structure that allows the manually operable mechanism to control the second pair of presses 1130, 1132 in a manner similar to that described for the control of either of the first pair of presses 1100, 1102.
With reference to
Additionally, the operator at least partially rotates first end panel 108, along with each aligned inner end panel 162, about fold line 110 towards mandrel first end face 1044, such that exterior surface 14 of first end panel 108 is in position to be contacted by face 1112 when first end wall press 1100 is moved from receiving position 1108 to pressure position 1110. While first end panel 108 is so positioned, the operator moves first manually operable mechanism 1103 into release position 1123, such that first end wall press 1100 moves into pressure position 1110, as described above. First end panel 108, along with each aligned inner end panel 162, is pressed between first end wall press face 1112 and mandrel first end face 1044. Thus, the pressure exerted by first end wall press 1100 facilitates adhering first end panel 108 to each aligned inner end panel 162 to form first end wall 206 of container 200.
Additionally, the operator at least partially rotates second end panel 114, along with each aligned inner end panel 162, about fold line 116 towards mandrel second end face 1052, such that exterior surface 14 of second end panel 114 is in position to be contacted by face 1114 when second end wall press 1102 is moved from receiving position 1108 to pressure position 1110. While second end panel 114 is so positioned, the operator operates second manually operable mechanism 1122 into second position 1124, such that second end wall press 1102 moves into pressure position 1110, as described above. Second end panel 114, along with each aligned inner end panel 162, is pressed between second end wall press face 1114 and mandrel second end face 1052. Thus, the pressure exerted by second end wall press 1102 facilitates adhering second end panel 114 to each aligned inner end panel 162 to form second end wall 208 of container 200.
In addition, the operator may apply a suitable adhesive to at least one of exterior surface 14 of each reinforcing panel assembly 138 and interior surface 12 of a corresponding portion of the adjacent side panel 22. For example, the operator applies a suitable adhesive to at least one of exterior surface 14 of first reinforcing side panel 156 and interior surface 12 of an adjacent portion of side panel 22. Alternatively, a suitable adhesive may have been pre-applied to the described areas of blank 10. The operator also at least partially rotates first side panel 22 about fold line 32 towards mandrel first side face 1048, such that exterior surface 14 of first side panel 22 is in position to be contacted by side face 1134 when first side wall press 1130 is moved from receiving position 1138 to pressure position 1140. While first side panel 22 is so positioned, the operator moves first side wall press 1130 into pressure position 1140, as described above. First side panel 22, along with the first and second overlying sets of first reinforcing side panel 156 and second reinforcing side panel 160, is pressed between side face 1134 of first side wall press 1130 and mandrel first side face 1048; the first overlying set of corner panel 154 and inner reinforcing corner panel 158 is pressed between mitered face 1142 and mandrel second corner face 1046; and the second overlying set of corner panel 154 and inner reinforcing corner panel 158 is pressed between mitered face 1144 and mandrel third corner face 1050.
Thus, for each of the first and second overlying sets of first reinforcing side panel 156 and second reinforcing side panel 160, the pressure exerted by first side wall press 1130 facilitates adhering first reinforcing side panel 156, second reinforcing side panel 160, and first side panel 22 together to form first side wall 218 of container 200. Moreover, for the first overlying set of corner panel 154 and inner reinforcing corner panel 158, the pressure exerted by first side wall press 1130 facilitates adhering corner panel 154 and inner reinforcing corner panel 158 to each other to form first corner wall 210, and for the second overlying set of corner panel 154 and inner reinforcing corner panel 158, the pressure exerted by first side wall press 1130 facilitates adhering corner panel 154 and inner reinforcing corner panel 158 to each other to form second corner wall 212 of container 200.
Similarly, the operator ensures that, for a third reinforcing panel assembly 138 coupled to second end panel 114, a corresponding third overlying set of corner panel 154 and inner reinforcing corner panel 158 is positioned generally adjacent to mandrel fourth corner face 1054, and a corresponding third overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 is positioned generally adjacent to mandrel second side face 1056. The operator further ensures that, for a fourth reinforcing panel assembly 138 coupled to first end panel 108, a corresponding fourth overlying set of corner panel 154 and inner reinforcing corner panel 158 is positioned generally adjacent to mandrel first corner face 1042, and a corresponding fourth overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 is positioned generally adjacent to mandrel second side face 1056. For example, if the third and fourth reinforcing panel assemblies 138 are not in the described position after respective end panels 108 and 114 are pressed by respective end wall presses 1100 and 1102, the operator may manually rotate the respective overlying set of corner panel 154 and inner reinforcing corner panel 158 toward respective mandrel corner face 1054 and 1042 about respective fold line 170 and fold line 146 or 142. Additionally or alternatively, the operator may manually rotate the respective overlying set of first reinforcing side panel 156 and second reinforcing side panel 160 toward mandrel second side face 1056 about respective fold lines 166 and 168.
In addition, the operator may apply a suitable adhesive to at least one of exterior surface 14 of each reinforcing panel assembly 138 and interior surface 12 of a corresponding portion of the adjacent side panel 26. For example, the operator applies a suitable adhesive to at least one of exterior surface 14 of first reinforcing side panel 156 and interior surface 12 of an adjacent portion of side panel 26. Alternatively, a suitable adhesive may have been pre-applied to the described areas of blank 10. The operator also at least partially rotates second side panel 26 about fold line 34 towards mandrel second side face 1056, such that exterior surface 14 of second side panel 26 is in position to be contacted by side face 1136 when second side wall press 1132 is moved from receiving position 1138 to pressure position 1140. While second side panel 26 is so positioned, the operator moves second side wall press 1132 into pressure position 1140, as described above. Second side panel 26, along with the third and fourth overlying sets of first reinforcing side panel 156 and second reinforcing side panel 160, is pressed between side face 1136 of second side wall press 1132 and mandrel second side face 1056; the third overlying set of corner panel 154 and inner reinforcing corner panel 158 is pressed between mitered face 1148 and mandrel fourth corner face 1054; and the fourth overlying set of corner panel 154 and inner reinforcing corner panel 158 is pressed between mitered face 1146 and mandrel first corner face 1042.
Thus, for each of the third and fourth overlying sets of first reinforcing side panel 156 and second reinforcing side panel 160, the pressure exerted by second side wall press 1132 facilitates adhering first reinforcing side panel 156, second reinforcing side panel 160, and second side panel 26 together to form second side wall 220 of container 200. Moreover, for the third overlying set of corner panel 154 and inner reinforcing corner panel 158, the pressure exerted by second side wall press 1132 facilitates adhering corner panel 154 and inner reinforcing corner panel 158 to each other to form third corner wall 214, and for the fourth overlying set of corner panel 154 and inner reinforcing corner panel 158, the pressure exerted by second side wall press 1132 facilitates adhering corner panel 154 and inner reinforcing corner panel 158 to each other to form fourth corner wall 216 of container 200.
In the example embodiment, after first side wall press 1130 and second side wall press 1132 are each positioned in pressure position 1140, the operator releasably couples first locking member 1162 and second locking member 1164 together using clasp 1166, as described above. In alternative embodiments, any other suitable structure is provided to maintain first side wall press 1130 and second side wall press 1132 in pressure position 1140, as described above.
With reference to
Moreover, the operator may rotate frame 1020 a fourth time to bring the first box-forming station 1030 proximate to the operator again. In the example embodiment, the adhesive applied to first blank 10 prior to or during the wrapping process is substantially set when the operator rotates frame 1020 to reach first box-forming station 1030 again. For example, the time required to wrap the second, third, and fourth blanks 10 at respective second, third, and fourth box-forming stations 1030, and/or the pressure applied to the walls of container 200 by the first pair of presses 1100, 1102 and second pair of presses 1130, 1132 of the first box-forming station, facilitates setting of the adhesive on first blank 10. Thus, the operator may uncouple locking mechanism 1160, move the second pair of presses 1130, 1132 to receiving position 1138, move second manually operable mechanism 1122 to first position 1120 to return second end wall press 1102 to receiving position 1108, move first manually operable mechanism 1103 to catch position 1121 to return first end wall press 1100 to receiving position 1108, and remove a first container 200 (formed from first blank 10) from mandrel 1040 of the first box-forming station 1030. The first container 200 will be in the configuration shown in
While machine 1000 includes four box-forming stations 1030 in the example embodiment, it should be understood that any number of box-forming stations 1030 may be included on machine 1000 without departing from the scope of the current disclosure. Moreover, although machine 1000 may be advantageously operated by a single operator, it is also contemplated that multiple operators may use machine 1000 simultaneously. For example, in an embodiment, two operators are positioned respectively on opposite sides of machine 1000, such that a first operator may work at the first box-forming station while a second operator works at the third box-forming station. The use of two operators may be advantageous in embodiments where a time required to wrap a complex blank about a mandrel is such that the adhesive on a previously wrapped blank substantially sets after one additional blank is wrapped.
The example embodiments described herein provide a manually operated machine and methods for forming a tray from a blank of sheet material by wrapping the blank around a mandrel. As compared to typical hand-forming of containers from blanks, the example embodiments advantageously provide an increased precision in the folding and positioning of panels of the blank through the use of the mandrel. As a result, the blanks used may be manufactured to tighter tolerances, thereby facilitating a decreased waste of sheet material. Additionally, as compared to typical hand-forming of containers from blanks, the example embodiments advantageously facilitate a faster process in which a single operator may form containers at a plurality of box-forming stations, without a need for the operator to physically relocate himself or herself from one station to the next and/or carry blanks from one station to the next. Moreover, the example embodiments do not require electrical power, a flat floor, or other infrastructure support, and thus facilitate providing the above-described advantages in a field location that may be remote from such infrastructure.
Example embodiments of methods and a machine for forming a container from a blank are described above in detail. The methods and machine are not limited to the specific embodiments described herein, but rather, components of systems and/or steps of the methods may be utilized independently and separately from other components and/or steps described herein. For example, the machine may also be used in combination with other blanks and containers, and is not limited to practice with only the blank and container described herein.
Although specific features of various embodiments of the invention may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the invention, any feature of a drawing may be referenced and/or claimed in combination with any feature of any other drawing.
This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.