Method and apparatus for setting up a carton

Information

  • Patent Grant
  • 6726613
  • Patent Number
    6,726,613
  • Date Filed
    Tuesday, November 12, 2002
    22 years ago
  • Date Issued
    Tuesday, April 27, 2004
    21 years ago
Abstract
A method and apparatus for squaring knocked down slotted boxes employs an L-shaped support and forming platform onto which a partially opened box is applied so that the junction of the two legs of the L-shape is received within the box and a leading flap (and its fold line connection to the box) and a trailing flap (and its fold line connection to the box) each contact one of the legs to fold these flaps outward and tend to square the box. The trailing flap is moved from one leg onto the other which normally will be substantially flat and horizontal so that the leading and trailing flaps are folded perpendicular to the axis of the sleeve portion of the box while the side flaps positioned between the leading and trailing flaps remain in the plane of their respective box wall as the carton is moved into an operating station.
Description




FIELD OF INVENTION




The present invention relates to simplified a manual method and a facilitating apparatus for erecting and squaring a knocked down cartons




BACKGROUND OF THE INVENTION




One of the principal packaging cartons used in commerce is formed a slotted knocked down box blank, which normally consist of a sleeve with closure flaps in the form of bottom forming flaps foldably connected to one end of the sleeve and top closure flaps foldably connected to the other end of the sleeve. Such sleeves are usually 4 sided i.e. having 4 walls connected together at the intersection of a pair of adjacent walls by a manufacturer's joint, These knocked down box blanks are shipped flat (knocked down i.e. with opposite walls in face to face relationship) and are then erected, squared and formed into a box in the packager's plant by closing the flaps at one end of the sleeve (usually the bottom flaps) form.




Many different systems have been devised for mechanically opening squaring and forming these blanks into cartons with one end closed and the opposite end open to permit goods to be packed therein. These systems are generally either automatic i.e. done by machinery or manual. The so formed open ended cartons are then the filled with product (again either automatically by equipment or manually, the carton closed by closing systems that mechanically or manually fold the closure flaps (top flaps) into closed position substantially perpendicular to the axis of the sleeve to provide a filled and closed carton ready for shipping.




Mechanical devices include devices that move the blank through a series of stations that perform the desired operations in sequence along the way. In many of these systems some form of stop against which the blank is force is used to open and square the sleeve and plows are used to fold the closure flaps into closed position. The goods to be packaged may as above indicated be manually packed or automatically packed into the carton. In manual systems the sleeve supported on a table or the like on the ends of its closure flaps at one of the sleeve (flaps parallel to their respective side walls of the sleeve) is forces against a stop and squared and the uppermost set of flaps are folded to closed position and fixed in this closed position by taping, stapling gluing etc. in a closing station. The open-ended cartons so formed are then ready for filling and closing. This filling and closing in a manual system may be done in the same or a different closing station. Obviously the axial length of the carton supported on the ends of flaps at one end of the sleeve and with the other end closed is shorter than the axial length of the carton with both ends closed, thus the relative spacing between the support table and the closing equipment (taping, stapling gluing etc. equipment) must be change for closing the packed box necessitating an adjustable table height in a single station packing system so that the height may be change when sealing tone end of the empty sleeve and sealing the filled and closed box.




BRIEF DESCRIPTION OF THE PRESENT INVENTION




It is the object of the present invention to provide a simple method and apparatus to facilitate the setting up or squaring of a knocked down sleeve type folding (slotted) box and forming it into a box.




It is also an object of the present invention to provide a method and apparatus wherein the height of the supporting table or the like need not be changed when closing the sleeve to form the open ended box or when closing the filled box.




Broadly the present invention relates to a method of squaring a knocked down folding box formed by a sleeve with a first set of closure flaps connected by a first set of fold lines to one end of said sleeve and a second set of closure flaps connected by a second set of fold lines to a second end of said sleeve remote from said one end of said sleeve, said method comprising partially opening said box and moving said box toward an L-shaped support and forming platform formed by a pair of legs interconnected by a filleted corner so that said filleted corner is received within said sleeve and a leading flap of said first set flaps is moved against a first substantially horizontal leg of said pair of legs to fold said leading flap on its fold line of said first set of fold lines connecting it to a leading wall of said sleeve outward relative to said sleeve and a trailing flap of said first set of flaps is moved against a second of said pair of legs to fold said trailing flap on its fold line of said first set of fold lines connecting it to a trailing wall of said sleeve outward relative to said sleeve and moving said box along said legs to bring said trailing flap onto said first leg and position said leading and trailing flaps substantially perpendicular to a longitudinal axis of said sleeve to provide said box in a substantially squared condition.




Preferably said second set of flaps are folded on their respective fold lines of said second set of fold lines to close one end of said sleeve and said box is moved on said first leg into a closing station wherein said second set of flaps are secured in closed position substantially perpendicular to said longitudinal axis and closing said sleeve to form an open box.




Preferably said method further comprises inverting said open box and placing same on said one leg, folding said first set of flaps into a closed position and moving said box with said first set of flaps folded to closed position on said first leg into said closing station wherein said first set of flaps are secured in closed position substantially perpendicular to said longitudinal axis and closing said sleeve to form a closed box.




Preferably side flaps of said first set of flaps each is connected to its adjacent side wall of said sleeve interconnecting said leading and trailing walls of said sleeve by its side fold line of said first set of fold lines and said side flaps remain substantially parallel with said longitudinal axis when said box is squared and moved along said first leg into said closing station.




Preferably said leading wall is forced against a stop in said closing station to define the position of said leading wall in said closing station and to aid in ensuring said box is in said squared condition.




Broadly the present invention also relates to an apparatus for squaring a knocked down folding box comprises an L-shaped support and forming platform, said L-shaped support and forming platform being formed by a first substantially horizontal leg and a second leg extending downward from one end of said first leg, said legs being interconnected at their adjacent ends by a filleted corner, means for adjusting the width of said L-shaped support and forming platform to accommodate different sizes of said folding boxes, box operating station having means for operating on said box positioned spaced above said first leg and means for adjusting the spacing of said operating means relative to said first leg to accommodate different lengths of said boxes.




Preferably said box operating means comprises a box closure means and said operating station has a stop against which said box is moved to ensure said box is square in said closure station.




Preferably said operating station further includes ejector means for ejecting a closed box from said operating station after said box has been closed. Preferably said stop is part of said ejector means.











BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)




Further features, objects and advantages will be evident from the following detailed description of the preferred embodiments of the present invention taken in conjunction with the accompanying drawings in which;





FIG. 1

is an isometric view of a typical slotted carton formed from a knocked down blank.





FIG. 2

is a schematic isometric illustration of a device constructed in accordance with the principles of the present invention for erecting (squaring and closing one end of cartons such as the one illustrated in FIG.


1


.





FIGS. 3A

to


3


F schematic illustration of the sequence of steps that are preferably used in practicing the present invention.





FIGS. 4

,


5


and


6


schematically show in greater detail than in

FIG. 3

the main steps in the sequence of forming of a box with one end closed and of the equipment employed.











DETAILED DESCRIPTION OF THE INVENTION




The method (sequence of steps) and the essential elements of the apparatus for carrying out the present invention are illustrated in FIG.


1


.




As shown in

FIGS. 1 and 4

and the right hand image of

FIG. 3A

a box or carton


10


in the form of a slotted knocked down box


10


having a first set of closure flaps


12


(only 2 of 4 shown in

FIG. 1

) connected to the walls of the sleeve portion


14


of the box or box blank


10


by a first set of fold lines


16


The first set of flaps


12


includes a leading flap


18


(see

FIGS. 3

,


4


, and


5


) (leading in the direction of movement of the carton when closing the flaps


12


) and a trailing flap


20


(see

FIGS. 1

,


3


,


4


,


5


and


6


) (trailing in the direction of movement of the carton when closing the flaps


12


) each connected to its adjacent wall of the sleeve


14


by one of the first set of fold lines


16


namely fold lines


22


and


24


respectively (see

FIGS. 1

,


3


,


4




5


and


6


). A second set of closure flaps


28


is connected to the opposite end of the sleeve


14


to the flaps


12


by a second set of fold lines


30


. The flaps


12


and set of fold lines


16


are essentially the same as the flaps


28


and fold lines


30


and function in essentially the same manner to close the opposite ends of the sleeve


14


as will be described below. The flaps


12


may form the bottom of the filled carton and the flaps


28


the top or vice versa.




A device


100


for erecting and closing the cartons or boxes


10


is form by an L shaped support and forming platform


40


formed by a pair of legs


42


and


44


interconnected at their adjacent ends by a curved section that forms a fillet connection


46


. The first leg


42


of the pair of legs preferably is substantially horizontal and the second leg


44


of the pair of legs extends downward there from so that the included angle θ there between is preferably less than 90° i.e. in the order of about 65 to about 80°. This selection of the preferred size of the included angle θ is based on the functioning of the device to open and square the carton, and it's preferred size is selected so that the free end


48


of the downwardly extending second leg


44


has lees tendency to interfere with the operator's legs.




The filleted connection


46


has a radius r to permit the trailing end of the blank


10


as it is being erected to move smoothly from the downwardly extending leg


44


over the curved section


46


and onto the leg


42


. It has been found that this radius r for efficient operation should be at least about 2 inches (5 centimeters).




In the illustrated arrangement the legs


42


and


44


are each formed by a pair of parallel members; leg


42


by members


42


A and


42


B and leg


44


; by members


44


A and


44


B interconnected by their respective curved sections


46


A and


46


B.




In some cases it may be desirable to make the system adjustable for different sized boxes for use in plants where different sized boxes are to be processed on the same machine. To accommodate this the spacing between the members


42


A,


44


A and


46


A and their respective opposed or cooperating members


42


B,


44


B and


46


B may be made adjustable. For example a suitable adjustment mechanism which in the illustrated arrangement comprises a screw type adjuster


50


expands or reduces the spacing between the members


42


A,


44


A and


46


A and their respective opposed or cooperating members


42


B,


44


B and


46


B may be provided to adjust the width of the support


40


(i.e. legs


42


and


44


) as illustrated by the arrow


52


(see

FIG. 2

) to accommodate different sized boxes


10


.




Positioned adjacent to the end of the leg


42


remote from leg


44


is an operating station


110


that may incorporate any suitable operating mechanism such as a labeler or closing mechanism or the like. In the illustrated arrangement a flap sealer


60


which may take the form of a stapler, taper or gluer or any other suitable flap-sealing device has been shown. If multiple size boxes are to be processed the size of the operating station


110


e.g. the flap sealer


60


may have to be change either by physically changing the sealer or by adjusting the effective size of the sealer depending on the type of sealer being used and the height of this device


60


relative to the leg


42


may have to be adjusted as indicated by the arrow


62


to accommodate sleeves


14


of different axial lengths.




The station


110


preferably will also include a squaring ejector


70


which in the illustrated arrangement is formed by a bar


72


supported by arms


74


and biased to ejecting position (as indicated in dash lines in

FIG. 2

) by a biasing means such as pneumatic means


76


but other means may be used. The bar


72


is oriented to be parallel to the surface of the leg


42


and perpendicular to the intended direction of movement of the carton


10


into the station


110


and is spaced above the table or leg


42


by a distance such that the leading flap


18


as will be described below may pass under it and the bar contact directly the leading wall of the carton or box


10


and aid in squaring the box


10


.




The stroke of the bar


72


is set so that when in fully retracted position it insures that the carton


10


being operated upon in the operating station


110


e.g. the sealer


60


are relatively position as desired with the leading wall of the sleeve


14


pressed against the bar


72


. As will be described below, when the operation in the operating station


110


is completed the carton


10


is released and the sealer


60


retracted if required and the bar


72


is moved to eject the carton from the sealing or closing station


110


by the biasing means


76


.




In the illustrated system conventional plowing guides not shown may be provided to contact sidewalls of the sleeve


14


and aid in squaring the box


10


.




It will be apparent that for more versatile machines the position of the bar


72


for positioning different sized boxes


10


will be made adjustable.




As shown in

FIG. 3A

the partially opened box blank


10


is manually (or mechanically) moved down as indicated by the arrow


200


to a position wherein the curved portion


46


connecting the legs


42


and


44


is received within the sleeve portion


14


of the box


10


. In this position the leading flap


18


and its connecting fold line, lead fold line


22


, are moved against the support surface of the leg


42


to fold the flap


18


outward relative to the sleeve


14


and similarly the tailing flap


20


and its connecting fold line, trailing fold line


24


, are moved against the surface of the leg


44


to fold the flap


20


outward relative to the sleeve


14


as shown in the FIG.


3


A.




It is preferred but not necessary that the leading and trail flaps


18


and


20


be major (longer than the minor flaps as measured parallel to their fold line connection to the sleeve


14


) flaps of the box


10


as illustrated so that the side flaps


32


are formed by minor flaps (shorter than the major flaps as measured parallel to their fold line connection to the sleeve


14


) only one shown (see FIGS.


1


and


3


). Obviously in a square cross section box


10


all flaps have essentially the same length.




The opened and reasonably squared carton


10


is moved as indicated by the arrow


210


(see

FIG. 3B

) with the flaps


18


and


20


and their respective fold lines


22


and


24


held in contact with the surfaces of the legs


42


and


44


(

FIG. 3A

) so that the trailing fold line


24


and flap


20


are moved into position on the supporting surface of the leg


42


and the flaps


18


and


20


extend substantially perpendicular to the tubular axis


400


(see FIGS.


1


and

FIG. 3B

) of the sleeve


14


and parallel to the surface of leg


42


. If an ejector


70


is provided the leading wall


14


L (see

FIGS. 3A and 3B

and

FIG. 4

) into contact with the bar


72


which finalizes the squaring of the box


10


(see

FIGS. 4 and 5

and FIG.


3


B). In this position the other flaps


28


(which will normally form the bottom of the packed box


10


) are folded into closed position in the illustrated arrangement manually (see FIG.


5


).




The box


10


with the flaps


28


at the end not in contact with the leg


42


folded into closed position is moved manually into the operating station


110


forcing the bar


72


rearward against the biasing means


70


and when properly positioned in this station


110


the sealer


60


or the like is activated in this case to secure the flaps


28


in closed position. In the illustrated arrangement an adhesive type tape


80


is applied to tape the flaps


28


in closed position and then the sealer


60


retracts and the carton


10


with one end closed is ejected from the station


110


by movement of the bar


72


to its normal or rest position as shown in Stages


1


and


2


see that arrow


220


(FIG.


3


C and FIG.


6


).




Next the carton


10


is inverted to position the closed end (flaps


28


) on the leg


42


and either the leading or trailing wall of the sleeve in the preceding operations leading (in the illustration the trailing flap


20


has become the leading flap in FIG.


3


D and preferably in contact with the bar


72


and the carton


10


may be packed with goods as indicated by the arrows


230


(see FIG.


3


D).




After the carton


10


has been filled the set of flaps


12


(flaps


18


,


20




32


etc.) are folded on their respective fold line of the set of fold lines


16


to close the open end of the box


10


(in the same manner as the flaps


28


were folded to closed position (see

FIG. 5

) and the box moved as shown in

FIG. 3E

which is essentially the same as

FIG. 3C

described above into the operating station


110


and the sealer


60


or the like activated to perform its function e.g. to secure the flaps


12


in closed position (as illustrated), in the illustrated arrangement by applying a second tape


82


similar to the tape


80


described above to provide a filled and closed carton ready for shipment.




As indicated in

FIG. 3F

generally a plurality of such filed and closed cartons or boxes


10


are stacked on a suitable pallet


90


or the like to form a pallet load and such loads are then shipped as required.




Having described the invention, modifications will be evident to those skilled in the art without departing from the scope of the invention as defined in the appended claims.



Claims
  • 1. A method of squaring a knocked down folding box formed by a sleeve with a first set of closure flaps connected by a first set of fold lines to one end of said sleeve and a second set of closure flaps connected by a second set of fold lines to a second end of said sleeve remote from said one end of said sleeve, said method comprising partially opening said box and moving said box toward an L-shaped support and forming platform formed by a pair of legs interconnected by a filleted corner so that said filleted corner is received within said sleeve and a leading flap of said first set of flaps is moved against a first substantially horizontal leg of said pair of legs to fold said leading flap on its fold line of said first set of fold lines connecting it to a leading wall of said sleeve outward relative to said sleeve and a tailing flap of said first set of flaps is moved against a second leg of said pair of legs to fold said trailing flap on its fold line of said first set of fold lines connecting it to a trailing wall of said sleeve outward relative to said sleeve and moving said box along said legs to bring said trailing flap onto said first leg and position said leading and trailing flaps substantially perpendicular to a longitudinal axis of said sleeve to provide said box in a substantially squared condition.
  • 2. A method as defined in claim 1 wherein said second set of flaps are then folded on their respective fold lines of said second set of fold lines to close one end of said sleeve and said box is moved on said first leg into a closing station wherein said second set of flaps are secured in closed position substantially perpendicular to said longitudinal axis and closing said sleeve to form an open box.
  • 3. A method as defined in claim 2 further comprising inverting said open box and placing same on said first leg, folding said first set of flaps into closed position and moving said box with said first set of flaps folded to closed position on said first leg into said closing station without adjusting the relative positions of said closure station and said first leg and securing said first set of flaps in closed position substantially perpendicular to said longitudinal axis and closing said sleeve to form a closed box.
  • 4. A method as defined in claim 3 wherein side flaps of said first set of flaps each connected with its adjacent side wall of said sleeve interconnecting said leading and trailing walls of said sleeve by its side fold line of said first set of fold lines and said side flaps remain substantially parallel with said longitudinal axis when said box is squared and moved along said first leg into said closing station.
  • 5. A method as defined in claim 4 wherein said leading wall is forced against a stop in said closing station to define the position of said leading wall in said closing station and to aid in ensuring said box is in said squared condition.
  • 6. A method as defined in claim 3 wherein said leading wall is forced against a stop in said closing station to define the position of said leading wall in said closing station and to aid in ensuring said box is in said squared condition.
  • 7. A method as defined in claim 2 wherein side flaps of said first set of flaps each connected with its adjacent side wall of said sleeve interconnecting said leading and trailing walls of said sleeve by its side fold line of said first set of fold lines and said side flaps remain substantially parallel with said longitudinal axis when said box is squared and moved along said first leg into said closing station.
  • 8. A method as defined in claim 5 wherein said leading wall is forced against a stop in said closing station to define the position of said leading wall in said closing station and to aid in ensuring said box is in said squared condition.
  • 9. A method as defined in claim 2 wherein said leading wall is forced against a stop in said closing station to define the position of said leading wall in said closing station and to aid in ensuring said box is in said squared condition.
  • 10. A method as defined in claim 1 wherein side flaps of said first set of flaps each connected to its adjacent side wall of said sleeve interconnecting said leading and trailing walls of said sleeve by its side fold line of said first set of fold lines and said side flaps remain substantially parallel with said longitudinal axis when said box is squared and moved along said first leg into said closing station.
  • 11. A method as defined in claim 1 wherein said leading wall is forced against a stop in said closing station to define the position of said leading wall in said closing station and to aid in ensuring said box is in said squared condition.
  • 12. An apparatus for squaring a knocked down folding box comprises a L-shaped support and forming platform, said L-shaped support and forming platform being formed by a pair of L-shaped supports, each said L-shaped support being formed by a first substantially horizontal leg and a second leg extending downward from one end of said first leg, said legs being interconnected at their adjacent ends by a filleted corner, means for adjusting the width of said L-shaped support and forming platform to accommodate different sizes of said folding boxes, box operating station having means for operating on said box positioned spaced above said first leg and means for adjusting the spacing of said operating means relative to said first leg to accommodate different lengths of said boxes.
  • 13. An apparatus as defined in claim 12 wherein said box operating means comprises a box closure means and said operating station has a stop against which said box is moved to ensure said box is square in said box closure means.
  • 14. An apparatus as defined in claim 13 wherein said operating station further includes ejector means for ejecting a box from said operating station.
  • 15. An apparatus as defined in claim 14 wherein said stop is part of said ejector means.
  • 16. An apparatus as defined in claim 12 wherein said operating station further includes ejector means for ejecting a box from said operating station.
US Referenced Citations (6)
Number Name Date Kind
3477349 Berney Nov 1969 A
3605377 Sabel Sep 1971 A
4170929 McDowell Oct 1979 A
4213285 Mancini Jul 1980 A
4578054 Herrin Mar 1986 A
5180355 Inoue Jan 1993 A