Claims
- 1. A tray forming apparatus for forming a tray from a paperboard blank having a plurality of cuts and fold lines, the blank having a bottom panel, a pair of major side panels connected to the bottom panel along a common fold line, front and rear panels, each connected to the bottom panel along respective common fold lines, a pair of front minor side panels each respectively connected along common fold lines to the front panel, a pair of rear minor side panels each respectively connected to the rear panel, a pair of top major panels each respectively connected to the front and rear panels along a common fold line, a pair of top minor panels connected to each of the top major panels along common fold lines, the tray forming apparatus comprising:
- loading means for conveying a blank along a predetermined path from a stored position to an initial folding position within the apparatus for folding into a partially formed tray;
- first folding means for folding the blank into a partially formed condition by folding the front and rear minor side panels to a position generally perpendicular to their respective front and rear panels, folding the front and rear panels of the blank upwardly from the bottom panel and inwardly to a partially upright position, and folding the major side panels to a partially folded position at an obtuse angle to the bottom panel, the first folding means positioning the bottom panel onto a shuttle surface of the apparatus;
- shuttle means for conveying the partially formed blank downstream from said first folding means along a shuttle surface of the apparatus;
- second folding means positioned downstream from the first folding means, second folding means cooperating with the shuttle means for folding the front and rear panels to a fully folded position placing the minor side panels in contact with the bottom panel, the second folding means comprising top major panel biasing means for biasing each of the top major panels downwardly and inwardly such that the inner surface of each of the top major panels overlies the inner surface of the bottom panel and for generally placing each of the top major panels in contact with an edge of the minor side panels;
- a single pair of spaced-apart adhesive applicators for applying adhesive only to the outer surface of each of the forward minor side panels and the rearward minor side panels during downstream travel thereof as the partially folded blank is guided downstream by the shuttle means and travels between each of said pair of spaced-apart adhesive applicators, the second folding means cooperating with said applicators for holding the minor side panels in their fully folded position; and
- compressing means positioned downstream from the adhesive applicators for compressing the top minor panels and the major side panels against the minor side panels having adhesive thereon so that the inner surfaces of the top minor panels and the major side panels press against the outer surface of the minor side panels of the blank to thereby adhesively secure the blank in an erect tray forming position.
- 2. A tray forming apparatus according to claim 1, wherein said loading means comprises:
- vertical conveying means operable between a first position for receiving the blank from the stored position and a second position for lifting the blank to a vertically displaced position above the stored position; and
- horizontal conveying means operable between the vertically displaced position and the position within said apparatus for folding the blank, said horizontal conveying means operable with said vertical conveying means for sequentially conveying the blank from the stored position to the initial folding position within said apparatus.
- 3. A tray forming apparatus according to claim 2, wherein said vertical and horizontal conveying means comprise vacuum cups for contacting a surface of the blank and attaching to the blank under pressure sufficient for conveying the blank from the stored position to the initial forming position.
- 4. A tray forming apparatus according to claim 1, wherein said first folding means comprises:
- a platen having a length and width dimension proximate the length and width dimension of the bottom panel for fitting within the bottom panel of the blank;
- fold guiding means cooperating with said platen for receiving the blank and inwardly folding the minor side panels, front and rear panels; and
- platen moving means for moving said platen from a first position above the blank, biasing against the blank when in the initial folding position, and moving the blank through said fold guiding means to a position on the shuttle surface wherein the front and rear minor side panels are generally perpendicular to their respective front and rear panels.
- 5. A tray forming apparatus according to claim 4, wherein said fold guiding means comprises:
- minor side panel guide arms positioned for cooperating with said platen in receiving and folding the minor side panels;
- a pair of opposing front and rear panel guide arms positioned for receiving the blank after receipt by said minor side panel guide arms; and
- a pair of opposing major side panel guide arms positioned below said minor side panel guide arms for cooperating with said platen in folding the major side panels to the partially folded position at the obtuse angle to the bottom panel.
- 6. A tray forming apparatus according to claim 5, wherein the obtuse angle is sufficient for cooperating with the adhesive applicators in permitting the application of adhesive only to the outer surface of each minor side panel.
- 7. A tray forming apparatus according to claim 4, further comprising a frame having a rear portion, a front portion, and a side loading portion, said shuttle surface carried within said frame guide rails extending along said shuttle surface from the rear portion to the front portion of said frame, and wherein said shuttle means comprises a shuttle guide arm operable between the rear portion and the front portion of the frame for moving the partially formed blank downstream guided by said guide rails, and shuttle arm drive means carried by the frame and operable with the shuttle guide arm for moving the blank downstream.
- 8. A tray forming apparatus according to claim 7, wherein said second folding means comprises a pair of top panel guide arms positioned above said shuttle surface, wherein the partially formed blank is received therebetween and for cooperating with said shuttle guide arm for folding the major panels and the top major panels into their respective fully folded positions.
- 9. A tray forming apparatus according to claim 1, wherein said single pair of spaced-apart adhesive applicators comprises a glue gun positioned for depositing hot glue onto the minor side panels.
- 10. A tray forming apparatus according to claim 1, wherein said compressing means comprises:
- a compression arm for each of the front and rear minor side panels, said compression arm movable from a stored position above the partially formed blank to a compression position wherein an end portion of said compression arm is biased against the bottom panel;
- a first clamp carried by each compression arm, said first clamp positioned for biasing its respective minor side panel against the bottom panel when the compression arm is in the compression position with its arm bottom portion biased against the bottom panel;
- a second clamp carried by each compression arm, said second clamp having an angle bend for folding the top minor panel over and at an acute angle to the minor side panel; and
- a pair of opposing compression plates positioned for receiving the blank and its partially folded major side panels therebetween, said pair of opposing compression plates movable for receiving and biasing the major side panels and top minor panels against their respective minor side panels having adhesive thereon for fully folding the blank into the tray.
- 11. A tray forming apparatus for forming a tray from a paperboard blank having a plurality of cuts and fold lines, the blank having a bottom panel, a pair of major side panels connected to the bottom panel along a common fold line, front and rear panels, each connected to the bottom panel along respective common fold lines, a pair of front minor side panels each respectively connected along common fold lines to the front panel, a pair of rear minor side panels each respectively connected to the rear panel, a pair of top major panels each respectively connected to the front and rear panels along a common fold line, a pair of top minor panels connected to each of the top major panels along common fold lines, the apparatus comprising:
- loading means for loading one of a plurality of blanks to be transported along a predetermined path of travel from a stored position to an initial folding position for folding into a partially formed tray;
- folding means for folding the blank into a partially formed condition wherein front and rear panels are in a folded position generally perpendicular to the bottom panel thus placing the minor side panels in contact with the bottom panel, said folding means biasing each of the top major panels downwardly and inwardly such that the inner surface of each of the top major panels overlies the inner surface of the bottom panel and placing each of the top major panels in contact with an edge of the minor side panels, said folding means further folding the pair of major side panels at an obtuse angle to the bottom panel;
- a pair of spaced-apart adhesive applicators adjacent and along a downstream path of travel from said folding means, said pair of applicators operable for applying adhesive only to the outer surface of each of the forward minor side panels and the rearward minor side panels during downstream travel thereof, said folding means cooperating with said applicators for holding the minor side panels in their fully folded position; and
- compressing means positioned adjacent and downstream from the adhesive applicators for compressing the partially formed blank having adhesive thereon and forming the blank into a tray.
- 12. A tray forming apparatus according to claim 11, wherein the path of travel for the blank being handled by said loading means comprises a vertical path from the stored position to a horizontal path to the initial folding position, said vertical and horizontal paths within an imaginary plane perpendicular to the downstream path of travel.
- 13. A tray forming apparatus according to claim 11, wherein said loading means comprises:
- vertical conveying means operable between a first position for receiving the blank from the stored position and a second position for lifting the blank to a vertically displaced position above the stored position; and
- horizontal conveying means operable between the vertically displaced position and the initial folding position for folding the blank, said horizontal conveying means operable with said vertical conveying means for sequentially conveying the blank from the stored position to the initial folding position within said apparatus.
- 14. A tray forming apparatus according to claim 13, wherein said vertical and horizontal conveying means comprise vacuum cups for contacting a surface of the blank and attaching to the blank under pressure sufficient for conveying the blank from the stored position to the initial forming position.
- 15. A tray forming apparatus according to claim 11, wherein said folding means comprises:
- a platen having a length and width dimension proximate the length and width dimension of the bottom panel for fitting within the bottom panel of the blank;
- fold guiding means cooperating with said platen for receiving the blank and inwardly folding the minor side panels, front and rear panels; and
- platen moving means for moving said platen from a first position above the blank, biasing against the blank when in the initial folding position, and moving the blank through said fold guiding means to a position on the shuttle surface wherein the front and rear minor side panels are generally perpendicular to their respective front and rear panels.
- 16. A tray forming apparatus according to claim 15, wherein said fold guiding means comprises:
- minor side panel guide arms positioned for cooperating with said platen in receiving and folding the minor side panels;
- a pair of opposing front and rear panel guide arms positioned for receiving the blank after receipt by said minor side panel guide arms; and
- a pair of opposing major side panel guide arms positioned below said minor side panel guide arms for cooperating with said platen in folding the major side panels to the partially folded position at the obtuse angle to the bottom panel.
- 17. A tray forming apparatus according to claim 16, wherein the obtuse angle is sufficient for cooperating with the adhesive applicators in permitting the application of adhesive only to the outer surface of each minor side panel.
- 18. A tray forming apparatus according to claim 11, further comprising a frame having a rear portion, a front portion, and a side loading portion, a shuttle surface carried within frame guide rails extending along said shuttle surface from the rear portion to the front portion of said frame, and shuttle guide means operable between the rear portion and the front portion of the frame for moving the partially formed tray along the downstream path of travel guided by said guide rails for moving the blank downstream.
- 19. A tray forming apparatus according to claim 18, wherein said folding means comprises a pair of top panel guide arms positioned above said shuttle surface, wherein the partially formed blank is received therebetween for cooperating with said shuttle guide means for folding the major panels and the top major panels into their respective fully folded positions.
- 20. A tray forming apparatus according to claim 11, wherein said pair of spaced-apart adhesive applicators comprises a single glue gun positioned on each side of the partially formed tray for depositing hot glue onto the minor side panels.
- 21. A tray forming apparatus according to claim 11, wherein said compressing means comprises:
- a compression arm for each of the front and rear minor side panels, said compression arm movable from a stored position above the partially formed tray to a compression position wherein an end portion of said compression arm is biased against the bottom panel;
- a first clamp carried by each compression arm, said first clamp positioned for biasing its respective minor side panel against the bottom panel when the compression arm is in the compression position with its arm bottom portion biased against the bottom panel;
- a second clamp carried by each compression arm, said second clamp having an angle bend for folding the top minor panel over and at an acute angle to the minor side panel; and
- a pair of opposing compression plates positioned for receiving the partially formed tray and its partially folded major side panels therebetween, said pair of opposing compression plates movable for receiving and biasing the major side panels and top minor panels against their respective minor side panels having adhesive thereon for fully folding the blank into the tray.
- 22. A tray forming apparatus for forming a tray from a paperboard blank having a plurality of cuts and fold lines, the blank having a bottom panel, a pair of major side panels connected to the bottom panel along a common fold line, front and rear panels, each connected to the bottom panel along respective common fold lines, a pair of front minor side panels each respectively connected along common fold lines to the front panel, a pair of rear minor side panels each respectively connected to the rear panel, a pair of top major panels each respectively connected to the front and rear panels along a common fold line, a pair of top minor panels connected to each of the top major panels along common fold lines, the tray forming apparatus comprising:
- first folding means for folding the blank into a partially formed condition by folding the front and rear minor side panels to a position generally perpendicular to their respective front and rear panels, folding the front and rear panels of the blank upwardly from the bottom panel and inwardly to a partially upright position, and folding the major side panels to a partially folded position at an obtuse angle to the bottom panel, said first folding means positioning the bottom panel onto a shuttle surface of said apparatus;
- shuttle means for conveying the partially formed blank downstream from said first folding means along a shuttle surface of said apparatus;
- second folding means positioned downstream from said first folding means, second folding means cooperating with said shuttle means for folding the front and rear panels to a fully folded position placing the minor side panels in contact with the bottom panel, said second folding means comprising top major panel biasing means for biasing each of the top major panels downwardly and inwardly such that the inner surface of each of the top major panels overlies the inner surface of the bottom panel and for generally placing each of the top major panels in contact with an edge of the minor side panels;
- adhesive applicator means for applying adhesive only to the outer surface of each of the forward minor side panels and the rearward minor side panels during downstream travel thereof as the partially folded blank is guided downstream by said shuttle means and travels between each of said pair of spaced-apart adhesive applicators, said second folding means cooperating with said applicators for holding the minor side panels in their fully folded position; and
- compressing means positioned downstream from the adhesive applicator means for compressing the partially folded blank to thereby adhesively secure the blank into an erected tray.
- 23. A tray forming apparatus according to claim 22, further comprising loading means for conveying a blank along a predetermined path from a stored position to an initial folding position within said apparatus for folding into a partially formed tray.
- 24. A tray forming apparatus according to claim 23, wherein said loading means comprises:
- vertical conveying means operable between a first position for receiving the blank from the stored position and a second position for lifting the blank to a vertically displaced position above the stored position; and
- horizontal conveying means operable between the vertically displaced position and the position within said apparatus for folding the blank, said horizontal conveying means operable with said vertical conveying means for sequentially conveying the blank from the stored position to the initial folding position within said apparatus.
- 25. A tray forming apparatus according to claim 24, wherein said vertical and horizontal conveying means comprise vacuum cups for contacting a surface of the blank and attaching to the blank under pressure sufficient for conveying the blank from the stored position to the initial forming position.
- 26. A tray forming apparatus according to claim 22, wherein said first folding means comprises:
- a platen;
- fold guiding means cooperating with said platen for receiving the blank and inwardly folding the minor side panels, front and rear panels; and
- platen moving means for moving said platen from a first position above the blank, biasing against the blank when in the initial folding position, and moving the blank through said fold guiding means to a position on the shuttle surface wherein the front and rear minor side panels are generally perpendicular to their respective front and rear panels.
- 27. A tray forming apparatus according to claim 26, wherein said fold guiding means comprises:
- minor side panel guide arms positioned for cooperating with said platen in receiving and folding the minor side panels;
- a pair of opposing front and rear panel guide arms positioned for receiving the blank after receipt by said minor side panel guide arms; and
- a pair of opposing major side panel guide arms positioned below said minor side panel guide arms for cooperating with said platen in folding the major side panels to the partially folded position at the obtuse angle to the bottom panel.
- 28. A tray forming apparatus according to claim 27, wherein the obtuse angle is sufficient for cooperating with the adhesive applicators in permitting the application of adhesive only to the outer surface of each minor side panel.
- 29. A tray forming apparatus according to claim 22, wherein said second folding means comprises a pair of top panel guide arms positioned above said shuttle surface, wherein the partially formed blank is received therebetween and for cooperating with said shuttle guide arm for folding the major panels and the top major panels into their respective fully folded positions.
- 30. A tray forming apparatus according to claim 22, wherein said compressing means comprises:
- a compression arm for each of the front and rear minor side panels, said compression arm movable from a stored position above the partially formed blank to a compression position wherein an end portion of said compression arm is biased against the bottom panel;
- a first clamp carried by each compression arm, said first clamp positioned for biasing its respective minor side panel against the bottom panel when the compression arm is in the compression position with its arm bottom portion biased against the bottom panel;
- a second clamp carried by each compression arm, said second clamp having an angle bend for folding the top minor panel over and at an acute angle to the minor side panel; and
- a pair of opposing compression plates positioned for receiving the blank and its partially folded major side panels therebetween, said pair of opposing compression plates movable for receiving and biasing the major side panels and top minor panels against their respective minor side panels having adhesive thereon for fully folding the blank into the tray.
- 31. A method for forming a tray from a flat paperboard blank having a plurality of cuts and fold lines, the blank having a bottom panel, a pair of major side panels connected to the bottom panel along a common fold line, front and rear panels, each connected to the bottom panel along respective common fold lines, a pair of front minor side panels each respectively connected along common fold lines to the front panel, a pair of rear minor side panels each respectively connected to the rear panel, a pair of top major panels each respectively connected to the front and rear panels along a common fold line, a pair of top minor panels connected to each of the top major panels along common fold lines, the tray forming method comprising the steps of:
- loading a blank by conveying it along a predetermined path from a stored position to an initial folding position for folding into a partially formed tray;
- initially folding the blank into a partially formed condition comprising the steps of:
- folding the front and rear minor side panels to a position generally perpendicular to their respective front and rear panels;
- folding the front and rear panels of the blank upwardly from the bottom panel and inwardly to a partially upright position; and
- folding the major side panels to a partially folded position at an obtuse angle to the bottom panel, said initially folding step positioning the bottom panel onto a shuttle surface of the apparatus;
- conveying the partially formed blank downstream along a shuttle surface;
- folding the front and rear panels to a fully folded position for placing the minor side panels in contact with the bottom panel, the front and rear panel folding step comprising the step of biasing each of the top major panels downwardly and inwardly such that the inner surface of each of the top major panels overlies the inner surface of the bottom panel and for generally placing each of the top major panels in contact with an edge of the minor side panels;
- applying adhesive from a single pair of spaced-apart applicators only to the outer surface of each of the forward minor side panels and the rearward minor side panels during downstream travel thereof as the partially folded blank is guided downstream and travels between each of said pair of spaced-apart adhesive applicators; and
- compressing the top minor panels and the major side panels against the minor side panels having adhesive thereon so that the inner surfaces of the top minor panels and the major side panels press against the outer surface of the minor side panels of the blank, thereby adhesively securing the blank in an erect tray forming position.
- 32. A tray forming method according to claim 31, wherein the loading step comprises the steps of:
- lifting the blank from a stored position to a vertically displaced position above the stored position; and
- conveying the blank horizontally from the displaced position to the initial folding position.
- 33. A tray forming method according to claim 32, wherein the loading steps comprise the steps of contacting a surface of the blank with vacuum cups and attaching the cups to the blank under pressure sufficient for the lifting and conveying steps.
- 34. A tray forming method according to claim 31, wherein the step of initially folding the blank comprises the steps of:
- biasing a platen against the bottom panel of the blank; and
- inwardly folding the minor side panels, front and rear panels by moving the blank through folding guides to a position on a shuttle surface wherein the front and rear minor side panels are generally perpendicular to their respective front and rear panels.
- 35. A tray forming method according to claim 34, wherein the folding guides comprise:
- minor side panel guide arms positioned for cooperating with the platen in receiving and folding the minor side panels;
- a pair of opposing front and rear panel guide arms positioned for receiving the blank after receipt by said minor side panel guide arms; and
- a pair of opposing major side panel guide arms positioned below said minor side panel guide arms for cooperating with said platen in folding the major side panels to the partially folded position at the obtuse angle to the bottom panel.
- 36. A tray forming method according to claim 35, wherein the obtuse angle is sufficient for cooperating with the adhesive applicators in permitting the application of adhesive only to the outer surface of each minor side panel.
- 37. A tray forming method according to claim 34, further comprising the step of:
- biasing a shuttle guide against the partially formed tray for conveying the partially formed tray downstream along guide rails extending along a shuttle surface; and
- moving the partially formed blank downstream guided by the guide rails.
- 38. A tray forming method according to claim 37, wherein the front and rear panel folding step comprises the steps of:
- receiving the partially formed tray between top panel guide arms positioned above the shuttle surface for cooperating with the shuttle guide arm for folding the major panels and the top major panels into their respective fully folded positions therebetween and for cooperating with said shuttle guide arm; and
- folding the major panels and the top major panels into their respective fully folded positions.
- 39. A tray forming method according to claim 31, wherein the adhesive applying step comprises the step of providing a single pair of spaced-apart adhesive applicators positioned for depositing hot glue onto the minor side panels.
- 40. A tray forming method according to claim 31, wherein the compressing step comprises the steps of:
- moving a compression arm from a stored position above a travel path for the partially formed tray to a position for biasing the arm against the bottom panel;
- biasing the compression arm against the bottom panel proximate each of the front and rear minor side panels;
- clamping each minor side panel against the bottom panel;
- folding the top minor panel over and at an acute angle to the minor side panel; and
- moving a pair of opposing compression plates toward the partially folded tray; and
- biasing the major side panels and top minor panels against their respective minor side panels having adhesive thereon for fully folding the blank into the tray.
- 41. A method for forming a tray comprising the steps of:
- initially folding a flat paperboard blank into a partially formed condition comprising the steps of:
- folding front and rear minor side panels of the blank to a position generally perpendicular to each of their respective front and rear panels;
- folding front and rear panels of the blank upwardly from the bottom panel and inwardly to a partially upright position; and
- folding major side panels to a partially folded position at an obtuse angle to the bottom panel, said initially folding step positioning the bottom panel onto a shuttle surface of the apparatus;
- conveying the partially folded blank downstream along a shuttle surface;
- folding the front and rear panels to a fully folded position for placing the minor side panels in contact with the bottom panel;
- applying adhesive only to the outer surface of each of the forward minor side panels and the rearward minor side panels; and
- compressing the top minor panels and the major side panels against the minor side panels having adhesive thereon so that the inner surfaces of the top minor panels and the major side panels press against the outer surface of the minor side panels of the blank, thereby adhesively securing the blank in an erect tray forming position.
- 42. A tray forming method according to claim 41, further comprising the step of loading a flat paperboard blank for the initially folding step by conveying it along a predetermined path from a stored position to an initial folding position for folding into a partially formed tray.
- 43. A tray forming method according to claim 42, wherein the loading step comprises the steps of:
- lifting the blank from a stored position to a vertically displaced position above the stored position; and
- conveying the blank horizontally from the displaced position to the initial folding position.
- 44. A tray forming method according to claim 43, wherein the lifting and conveying steps comprise the steps of contacting a surface of the blank with vacuum cups and attaching the cups to the blank under pressure sufficient for the lifting and conveying steps.
- 45. A tray forming method according to claim 41, wherein the front and rear panel folding step comprises the step of biasing each of the top major panels downwardly and inwardly such that the inner surface of each of the top major panels overlies the inner surface of the bottom panel and for generally placing each of the top major panels in contact with an edge of the minor side panels.
- 46. A tray forming method according to claim 41, wherein the adhesive applying step comprises the step of applying hot glue from a single pair of spaced-apart applicators.
- 47. A tray forming method according to claim 41, wherein the step of initially folding the blank comprises the steps of:
- biasing a platen against the bottom panel of the blank; and
- inwardly folding the minor side panels, front and rear panels by moving the blank through folding guides to a position on a shuttle surface wherein the front and rear minor side panels are generally perpendicular to their respective front and rear panels.
- 48. A tray forming method according to claim 46, wherein the folding guides comprise:
- minor side panel guide arms positioned for cooperating with the platen in receiving and folding the minor side panels;
- a pair of opposing front and rear panel guide arms positioned for receiving the blank after receipt by said minor side panel guide arms; and
- a pair of opposing major side panel guide arms positioned below said minor side panel guide arms for cooperating with said platen in folding the major side panels to the partially folded position at the obtuse angle to the bottom panel.
- 49. A tray forming method according to claim 41, further comprising the steps of:
- biasing a shuttle guide against the partially formed tray for conveying the partially formed tray downstream along guide rails extending along a shuttle surface; and
- moving the partially formed blank downstream guided by the guide rails.
- 50. A tray forming method according to claim 41, wherein the front and rear panel folding step comprises the steps of:
- receiving the partially formed tray between top panel guide arms positioned above the shuttle surface for cooperating with the shuttle guide arm for folding the major panels and the top major panels into their respective fully folded positions therebetween and for cooperating with said shuttle guide arm; and
- folding the major panels and the top major panels into their respective fully folded positions.
- 51. A tray forming apparatus according to claim 41, wherein the compressing step comprises the steps of:
- moving a compression arm from a stored position above a travel path for the partially formed tray to a position for biasing the arm against the bottom panel;
- biasing the compression arm against the bottom panel proximate each of the front and rear minor side panels;
- clamping each minor side panel against the bottom panel;
- folding the top minor panel over and at an acute angle to the minor side panel; and
- moving a pair of opposing compression plates toward the partially folded tray; and
- biasing the major side panels and top minor panels against their respective minor side panels having adhesive thereon for fully folding the blank into the tray.
CROSS REFERENCE TO RELATED APPLICATION
This application is a continuation-in-part of application Ser. No. 758,095 filed Nov. 29, 1996 for Tray Forming Apparatus And Method Of Forming Same, issuing as U.S. Pat. No. 5,782,732.
US Referenced Citations (26)
Foreign Referenced Citations (2)
Number |
Date |
Country |
4102166A1 |
Jul 1992 |
DEX |
2 037 697 |
Jul 1980 |
GBX |
Continuation in Parts (1)
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Number |
Date |
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Parent |
758095 |
Nov 1996 |
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