Patent Application
20080271416
Corrugated packaging is well-known to transport a variety of goods, such as produce and dry bulk goods. Typical corrugated boxes are manufactured from a flat of corrugated fiberboard that is subsequently creased or scored to provide controlled bending of the corrugated board. Often, slots are cut to provide flaps on the box. Such boards are known in the art as box blanks.
Large numbers of box blanks may be rapidly assembled to form a box using a tray former. Thereafter, the resulting box, after being filled with product, is sealed by a well-known case sealing apparatus. Such case sealing apparatuses are efficient and effective at applying adhesives to flaps for further assembly and typically include a sealer applicator to apply the adhesive. In the past, the sealer applicator applied beads of adhesive to only a specific area of the flap, regardless of the size of the flap. As an example, existing boxes usually include flaps or end panels that range between five inches to 12 inches deep. Currently available sealer applicators apply adhesive beads to only the lower three-four inches of the flaps.
Because currently available applicators apply adhesive to only the lower three or four inches of the end panel, box manufacturers are required to increase the paper grade of the corrugated box blank to maintain the strength of the enclosure formed by the end panels. This adds to the expense of the box.
Thus, there exists a need for a sealer applicator that readily accepts boxes of varying sizes to apply a sealing material to a box blank for assembly.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
A sealer applicator for a fiberboard container assembler is provided. The sealer applicator includes a housing defining a first guide surface and a plurality of applicator assemblies disposed within the housing. The sealer applicator also includes at least one trigger in communication with the plurality of applicator assemblies, the at least one trigger adapted to reciprocate the plurality of applicator assemblies between an “ON” state, wherein each of the applicator assemblies apply a closure material to a container, and an “OFF” state when the least one trigger is actuated.
The foregoing aspects and many of the attendant advantages of this invention will become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:
A sealer applicator 20 constructed in accordance with one embodiment of the present disclosure may be best understood by referring to
The sealer applicator 20 includes a housing 30 suitably manufactured from a high strength material, such as stainless steel. The housing 30 includes a plurality of guide surfaces 32-36. The guide surfaces 32-36 are configured to lift either the major flap 26 or minor flap 28 away from the box 24 and maintain it in a substantially horizontal position to permit application of a closure material to the box 24, as described in greater detail below.
A leading edge 38-42 of each guide surface 32-36 is tapered to accommodate boxes having bent or folded flaps 26 or 28. In the event that either flap 26 or 28 is bent during the assembly process, the optional tapered leading edge 38-42 provides a transition for the flap as it enters one of the guide surfaces 32-36. This helps minimize the risk of a bent flap ensnaring an otherwise blunt end of the guide surface.
The seal applicator 20 also includes a plurality of applicator assemblies disposed within the housing 30. Although the plurality of applicator assemblies are illustrated and described as being disposed within the housing 30, the scope of the disclosure is not intended to be so limited. As a non-limiting example, the plurality of applicator assemblies may be remotely located from the housing, such as on an adjacent structure. Therefore, such embodiments are within the scope of the present disclosure.
In the illustrated embodiment, the sealer applicator 20 includes a total of five applicator assemblies 50-58 disposed within the housing 30. The placement and number of the applicator assemblies 50-58 within the housing 30 is not intended to be limiting and, therefore, may change to accommodate a large number of spray patterns. The non-limiting illustrated embodiment includes a first set of three applicator assemblies 50-54 grouped together, and two separate applicator assemblies 56 and 58 disposed above the first set of applicator assemblies 50-54.
A wide variety or types of applicator assemblies are within the scope of the present disclosure. One such applicator assembly is a well-known hot melt glue module adapted to apply a well-known closure material, such as adhesive. Other types of closure materials, such as tape, staples, and straps, are within the scope of the present disclosure.
The sealer applicator 20 also includes at least one trigger 60 in communication with the plurality of applicator assemblies in a manner well-known in the art. Although the illustrated embodiment includes a total of three triggers 60, it should be apparent that the disclosure is not intended to be so limited. As a non-limiting example, a single trigger 60 may be in communication with all of the applicator assemblies, while other embodiments contemplated by the present inventors also include having a single trigger for each applicator assembly 50-58. Thus, such embodiments are also within the scope of the present disclosure.
Still referring to
One type of trigger 60 includes a photoelectric glassfiber sensor, such as Model BT24S manufactured and sold by Banner Engineering Corp., and a programmable photoeye, such as Model Q45BB6F manufactured and by Banner Engineering Corp. The photoelectric sensor is in communication with the photoeye, such that when a box 24 is detected by the photoelectric sensor, it sends a signal to the photoeye. Upon receipt of the signal, the photoeye starts a timing cycle. The timing cycle initiates a delay phase from zero and starts counting upon receipt of the signal. The delay phase is a function of the travel speed of the box 24 on the conveyor 22 to allow the conveyor 22 to properly position the box 24 adjacent the applicator assemblies 50-58.
At the expiration of the delay phase, the photoeye begins an application phase. During the application phase, at least one of the applicator assemblies 50-58 is actuated into the ON state to apply a bead of closure material to the box 24. This phase is adjustable and is programmable to apply the closure material to the box 24 as a function of the length of the box 24. At expiration of the application phase, the applicator assembly is returned to its OFF state and the photoeye is reset to begin a new cycle upon receipt of a new signal from the sensor.
Although the trigger 60 is described as including a time delay, it should be apparent that the appended claims are not intended to be so limited. As a non-limiting example, the trigger 60 may be a momentary switch. With such a trigger 60, when the presence of a box 24 is detected, the trigger 60 actuates the applicator assembly 50 into the ON state, wherein a bead of closure material is applied to one of the flaps 26 or 28 of the box 24. As soon as the trigger 60 fails to sense the presence of the box 24, the applicator assembly is returned to its normal OFF condition or state. Further, other types of triggers 60, such as mechanically actuated switches, are also within the scope of the present disclosure.
Additional operational aspects of the sealer applicator 20 may be best understood by referring to
Referring to
As seen best by referring to
Applying a closure material across a greater surface area of a box provides a greater bonding area between flaps of a box. This results in greater box strength in the bonding area which, in turn, allows a box manufacturer to use a lower grade paper and, therefore, lower the cost of such a box. Thus, the sealer applicator of the present disclosure provides an improvement over applicators currently available in the market.
While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.
