Patent Application
20090149306
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1. Field of the Invention
This invention concerns a method and a machine for adjusting the height of cardboard boxes(or crates), corrugated fiberboard or similar sheet material, with a square or rectangular cross section, for example, for shipping various goods and merchandise.
The technical domain of the invention is that of machines for processing, cutting, manufacturing or sealing of packaging materials or that of the manufacture or application of adjusting materials for such packing.
This invention is more particularly related to the height adjustment of boxes or crates used for preparing orders of a single item or multiple items, and more generally of boxes or crates in which the contents have variable volumes from one box to another. Boxes of this type are known to be made by machines using sheet blanks featuring different flaps that are glued together or held together by an adhesive bond.
2. Description of Related Art Including Information Disclosed Under 37 CFR 1.97 and 37 CFR 1.98.
Boxes are known that, after they are formed, consist of five sides, with a square or rectangular bottom and a girdling composed of four side walls. The well-known boxes of this type are called “American half-boxes”, “boats” or “bell boxes”. These boxes are, after they are filled, closed by a lid. One is familiar with lids that have four flaps that are turned down and glued together on the sides of the crate. Lids are also known in which the various flaps have previously been formed by proper fitting or gluing. These covers are inserted on the top of the case and united with the case by gluing, stitching or by a metal or plastic strap.
Boxes or crates are known that, after forming, consist of five walls, like the boxes previously described, and four top flaps. Each of these flaps is connected to one of the side walls of the case by a scored line. The known boxes of this type are called “American boxes”.
Once filled, these boxes are closed by folding over the four top flaps that are secured in position by glue, stitches or by a metal or plastic strap. The described boxes have the characteristic of providing a constant volume after manufacture and closure.
Several methods are applied by users or are integrated into the case-forming or case-sealing machines, for immobilizing the various objects, the unit volume of which will vary from one case to another.
Thermo-shrinkable plastic layers are known in which one or several sheets are sealed to the bottom or the side walls of the case while it is being formed. After the case is filled, these layers are folded over on the stack of objects, then shrunk by passing them through a heating tunnel. One is also familiar with polystyrene particles that are spread inside the case after it is filled to take up any unused space.
Also known are the inflatable plastic pockets that are arranged inside the boxes to fill up this unused space.
One is also familiar with the shredded cardboard or paper sheets of various shapes, placed inside the boxes to fill up any unused space.
Fastening sheets provided with flaps are also known, and these sheets are introduced in the case to contact the stack of objects. Then, the flaps are attached to the internal faces of the side walls of the case to ensure that objects are held secure.
These manufacturing methods have numerous drawbacks.
The securing methods are often burdensome.
The fastening devices, except when they are made from the same material as the packing itself, must be necessarily separated from the cardboard packing prior to any waste collection and potential recycling. On the other hand, the materials used are more often than not difficult to recycle. Such waste collection and recycling involve complex and very burdensome operations. Performing these operations is difficult and requires complex automated machines or a large number of man-hours. The cost of these operations is therefore high.
The shipped volume, which is the same as the volume of the manufactured case, is quite often much greater than the usable volume, which corresponds to the volume of the objects placed inside the case. The result is an increase in transportation costs of the boxes.
A method is also known to involve removal of the top section of the boxes, located above the stack of objects so as to reduce the height of the box to the usable height and to secure the objects by placing the top cover as close as possible to the top of the stack of objects.
This method also has some drawbacks.
Breaking down the box is a delicate task that entails the use of dangerous cutting tools.
The automatic removal of the top cut portion of the box is a difficult task that also generates a significant volume of waste that must be collected and disposed of.
Automating this process requires the making of complex machinery. The challenge therefore consists of providing a means to secure the objects inside the boxes used for packing and shipping packages with variable usable volume, and reducing the volume of these boxes as much as possible to this usable volume, without resorting to any fastening material and without removing a portion of material of this box, and without making any cuts to this box at all.
The solution to this problem consists of providing a method for adjusting the height of a box made of a pliable material, consisting of a base and at least four side walls, by folding the high portions of said side walls of said box on top of the stack of objects placed in said box.
The method used for adjusting the height of said boxes is noteworthy.
After having placed the bottom of the box in an essentially horizontal position, on each of said side walls, a horizontal score (scoring) is made at a height essentially the same as that of the top of said stack of objects.
On each of the angles of the box, an oblique score (scoring) is made where one end is located at the intersection between both said horizontal scores. The other end is at the upper ridge of one of the side walls, so that said oblique score will form an angle of about 45° (degrees) with the horizontal plane at the bottom of said box.
The top portion of each of said side walls is folded toward the center of the box, around said horizontal score, with an angle of about 90°, and simultaneously the various flaps are folded over one another, separated by said oblique scores, which make up the high portions of these side walls, around said oblique scores with an angle of about 180°, so as to place said high portions of said side walls on a substantially horizontal plane.
In an advantageous application of the process of the invention, each of said horizontal scores is obtained by placing a mandrel inside of said box, with said mandrel having a horizontal sharp-edged ridge positioned against the internal face of the side wall at the score line to be made. The action of a roller (traveling wheel), which is applied and pressed against the external face of this side wall and moved along this ridge, flattens said side wall against said ridge.
Advantageously, each of said creases or scoring marks is obtained by placing a mandrel inside said box. The mandrel has an anvil, which is positioned against the internal face of the side wall at the score line to be made. By the action of a tool that has a steel ridge, which is applied and pressed against the external face of said side wall, the tool makes said oblique score, crushing said side wall against said anvil.
In an advantageous application, said chuck is stationary and the height of said rollers and said tools is fixed. The vertical positioning of said box is in relation to said mandrel, rollers and tools, so that said horizontal creases or horizontal scorings, made at a height essentially the same as that of the top of said stack of objects, are achieved by the placement of said box around said mandrel, generated by the upward vertical movement of an elevator supporting said box.
Advantageously, after making said horizontal scores and said oblique scores, a horizontal stress is exerted initially on the high portions of said side walls that have oblique scores, in order to ensure their partial folding toward the center of the box. The folding brings about, simultaneously, the partial folding of the high portions of side walls not provided with oblique scores, which are adjacent. Then, a vertical stress directed toward the bottom on the high portions of said side walls is exerted, until their complete folding so as to place them horizontally, at about the top of the stack of objects.
The result of these operations, is that on the one hand, the height of the box has been reduced to the usable height corresponding to the height of the stack of objects previously placed inside the box. Also, the volume of the crate has been reduced to a space close to the usable volume corresponding to the volume of the objects previously placed inside said box.
On the other hand, a secure fitting of the objects placed in the box can be easily achieved by placing a cover as close as possible to the top of the stack of objects and by the presence of the different flaps between the objects and the cover, folded over from the high portions of the side walls of said box.
Thus, by the process of the invention, the objects placed inside the box are perfectly secured inside and the volume of the box is reduced, which lowers the shipping costs of said box, without using any fastening material other than the box itself, and without removing any portion of the material of this box, or performing any cutting operations on the box. The implementation of the process of the invention does not generate any fiberboard trim, so that no waste retrieval, storage and disposal operations are necessary during the process of filling, height adjusting and sealing of the box. Additionally, this invention concerns a machine for adjusting the height of the box consisting of a base and at least four side walls, folding the high portions of said side walls of the box on top of the stack of objects previously placed in said box.
The machine is noteworthy in that it comprises:
In an advantageous way of carrying out the invention, said machine consists of a fixed mandrel and an elevator located below said mandrel and designed to place said box around the latter.
Advantageously, for each of said horizontal creases to be made, the machine contains a horizontal sharp-edged ridge set on the lower portion of said mandrel, and a roller that moves along said ridge crushing said side wall against said ridge.
Advantageously, said machine also comprises, for each of said oblique creases to be made, a fixed anvil on the side of said mandrel and a tool that has a sharp-edged ridge that can move toward said anvil as it crushes said side wall against said anvil.
According to an advantageous way of carrying out the invention, said elevator consists of a base plate or lower plate and a second plate or upper plate on which the crate rests. The upper plate is mobile in relation to said lower plate, so that, as the elevator moves upward vertically, the box and the upper plate come to a stop when the top of said stack of objects lodged in the box comes into contact with the lower face of said mandrel. The movement of the lower plate can proceed with a predetermined amplitude (independently from the box filling level) because of the relative movement of said upper plate in relation to said lower plate.
Advantageously, said machine also comprises a die and a second elevator located below said die and designed to position, by an upward vertical movement, said box in said die, in order to fold the high portions of the side walls of the box, so as to place them on the horizontal plane, located substantially at the top of the stack of objects.
Advantageously, said die consists of at least one deflector, which exerts, at the beginning of the movement of positioning said box in said die, a stress with a horizontal component on the high portions of the side walls that have oblique creases, ensuring their partial fold toward the center of the box. The die also consists of at least one pressure plate, which exerts, at the end of the movement that inserts said box in said die, a vertical stress on the high portions of the side walls that do not have an oblique crease, ensuring the complete folding of the high portions of all side walls in order to bring them in a horizontal plane located at about the top of the stack of objects.
Advantageously, this second elevator also features a base plate or lower plate and a secondary plate or upper plate on which the box rests, before folding its top parts. This upper plate is mobile in relation to said lower plate, so that, when the elevator moves upward vertically, the box and the upper plate stop when the fold-back of all side walls is completely achieved. The movement of the lower plate can proceed with a predetermined amplitude (independent of the box filling level), because of the relative movement of said upper plate in relation to said lower plate.
In an advantageous way of carrying out the invention, said machine also comprises means for depositing, on the external face of certain flaps that make up the high portions of the side walls that have oblique creases, glue points or beads which allow for bonding said flaps to one another after folding of said flaps, one on top of another. The high portions of all the box side walls are held in a substantially horizontal plane after they are completely folded back, in spite of the elasticity of the pliable material used to make the box.
The advantages obtained by the invention will be better understood through the following description that relates to the attached drawings, which illustrate, without any limiting characteristic, a particular way of carrying out the process and building a machine according to the invention.
In the presentation below, words, such as “horizontal” “vertical”, “upper”, “lower”, are used considering the position and optimal movements of boxes during different phases of the process for adjusting the height of these boxes. Nevertheless, it is stressed that these words are not of a limiting nature, since these movements may be made in directions close to horizontal or vertical or both.
As indicated, this box 1 can be made of corrugated fiberboard, solid fiberboard or any other equivalent material made of pliable sheets.
The crease of each side wall is made by crushing the fiberboard between a roller and a ridge as the roller moves. This crushing is itself achieved by adjusting the roller-to-ridge distance at a smaller dimension than the nominal thickness of the fiberboard sheet used to make said box or by activating devices designed to press the roller flat against the ridge, for example, by using springs.
It should be noted that said devices represent one of the advantageous ways of building the machine. Other ways of execution could be used for which the movements of the rollers would be independent from one another or associated in a different way. It would also be possible to build a machine for which the horizontal creases would be made with the help of anvils and tools with sharp-edged ridges, such as provided for making oblique scores in the way of execution that was retained.
This
The creases are made by crushing the fiberboard between the ridges of the tools and the anvils and can be adjusted by regulating the pressing force of these tools against the anvils. It should be noted that said arrangements represent one of the advantageous ways of building the machine. Other ways of execution could be used for which the oblique creases would be made on other fiberboard walls or by differently associating the tools and their movements. It would also be possible to build a machine for which the oblique creases would be made with the help of sharp-edged ridges mounted on the mandrel and moving rollers, as provided for making horizontal creases in the way of carrying out the invention that has been retained.
This figure also shows base plate or lower plate 15 mounted on the moving part of elevator 14 and secondary plate or upper plate 16 moving in relation to said base plate.
This figure also shows guide columns 28a, 28b and 28c, which guide the vertical movements of said plate 16 in relation to said plate 15 following an axis of linear movement.
Thus, in the upward vertical movement of said elevator 14, while the top of the stack of objects placed in box 1 comes into contact with the lower face of said mandrel 9, said box 1 and said upper plate 16 stop, and said lower plate 15 continues its movement produced by linear actuator 30. This construction arrangement allows for simple steering of said driver 30 with always the same upper limit stop position, regardless of the level to which said box 1 may be filled.
Finally, return springs 29a, 29b and 29c are placed between plates 15 and 16, which return said upper plate 16 to a reference position in relation to said lower plate 15 when there is a loss of contact between the top of the stack of objects and the lower face of said mandrel 9 during a return descent of said elevator 14.
On this figure, a deflector device 18 operates, in an initial phase, upon the upward movement of said elevator 20, on the upper ridges of side walls 1a and 1c of box 1, exerting on them a horizontal force that tends to fold the high portions of said side walls toward the center of said crease 1.
It is understood that the folding of the high portions of side walls 1a and 1c, in this first phase, simultaneously brings about a folding toward the center of said box 1 of the high portions of adjacent side walls 1b and 1d and with which they are linked at the angles of said box 1.
This figure also shows two press box devices 19a and 19b.
It is clear that the folding of the upper portions of side walls 1b and 1d, in this second phase, simultaneously results in a folding, toward the center of said box 1, the upper portions of adjacent side walls 1a and 1c. They are linked at the angles of said box 1, so that these are also brought in the horizontal plane located substantially at the top of the stack of objects.
This figure also shows the base plate or lower plate 21 mounted on the moving part of elevator 20 and the secondary plate or upper plate 22 moving in relation to said lower plate. This
Thus, in the upward vertical movement of said elevator 20, when said deflector 18 and said pressure devices 19a and 19b have completely folded the upper portions of the box side walls, said box 1 and said upper plate 22 stop and said lower plate 21 continue movement produced by linear actuator 35. This construction arrangement allows a simple steering of said actuator 35 with always the same upper limit stop position, regardless of the level to which said box 1 is filled.
Finally, return springs 34a, 34b and 34c are placed between plates 21 and 22, which bring said upper plate 22 to a reference position in relation to said lower plate 21 when there is a loss of contact between the folded walls of said box 1 and the lower portion of said die 17 during the return descent movement of said elevator 20.
It is obvious that, during the upward movement of said elevator 20, said horizontal creases 7a and 7c came into contact with deflector 18. The deflector 18 was then pulled upward by said box 1 to the end of the upward movement of said elevator 20. Guide columns 31a and 31b of said deflector 18 are in relation to said pressure devices 19a and 19b, and spring 32a was compressed by the relative movement of said deflector 18 in relation to said pressure devices 19a and 19b.
Upon completion of this upward movement, the upper ridge of wall 1b came into contact with the lower face of said pressure device 19b, and the upper ridge of wall 1d came into contact with the lower face of said pressure device 19a.
This movement resulted in completely folding down the upper portions of said walls 1b and 1d, until they meet in a horizontal plane, contacting the lower face of said pressure devices 19a and 19b. Folding of the upper portions of said walls 1b and 1d also resulted in the upper portions of said walls 1a and 1c to be folded toward the center of said box 1, until they also meet in a substantially horizontal plane, under the upper portions of said walls 1b and 1d.
As the upper portions of said walls 1b and 1d came together in a horizontal plane, coming into contact with the lower faces of said pressure devices 19a and 19b, the vertical movement, of said box 1 and of the second plate or upper plate 22 which carries it, was stopped as the main plate or lower plate 21 proceeded with its upward movement. Guide columns 33a, 33b and 33c of said plate 22 are in relation to said plate 21, and springs 34a, 34b and 34c were compressed by the relative movement of said plates 21 and 22.
This figure shows that the upper portions of said side walls 1a, 1b, 1c and 1d of said box 1 were brought substantially into a horizontal plane.
Oblique creases 8aa and 8ab are made on wall 1a, and oblique creases 8ca and 8cb are made on wall 1c.
Said creases 7a, 8aa and 8ab have created three flaps 1aa, 1ab and 1ac on the upper portion of said wall 1a, and said creases 7c, 8ca and 8cb have also created three flaps 1ca, 1cb and 1cc on the upper portion of said wall 1c. The upper portion of wall 1c is thus comprised of one trapezoidal center flap 1ac and two triangular flaps 1aa and 1ab that are connected to the center flap by folding lines, respectively 8aa and 8ab, while the high portion of wall 1c consists of one trapezoidal center flap 1cc and two triangular flaps 1ca and 1cb that are connected to the center flap by folding lines, respectively 8ca and 8cb.
In this figure, the different flaps separated by said oblique creases are also simultaneously folded over one another by pivoting around said oblique creases. Said flap 1aa is folded on said flap 1ac by pivoting around said crease 8aa, said flap 1ab is folded on said flap 1ac by pivoting around said crease 8ab, said flap 1ca is folded over said flap 1cc by pivoting around said crease 8ca, and said flap 1cb is folded over said flap 1cc by pivoting around said crease 8cb. Upon completion of the movement, the pivoting angle of said flaps between them will be about 180° as said flaps will have been brought into a substantially horizontal plane.
Glue points 37aa, 37ab, . . . , situated on the surface of at least one of the flaps 1aa, 1ab, intended to come into contact with the surface of another flap 1ac, 1cc, . . . , are applied before the folding of the upper portion of walls 1a, 1b, 1c, 1d of the box, thus ensuring that said upper portion is kept folded back in horizontal position
In order not to extend and complicate unnecessarily the description and the drawings, programmable automation devices, motorization and transmission devices that ensure the operation of the different work stations of the machine are now described. These controllers, motorization and transmission devices are not within the scope of the invention, and they are well known to the experts in the field.
| Number | Date | Country | Kind |
|---|---|---|---|
| 0412375 | Nov 2004 | FR | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/FR2005/002864 | 11/18/2005 | WO | 00 | 7/5/2007 |
