U.S. patent application number 11/728980 was filed with the patent office on 2008-03-20 for apparatus for and method of forming containers and a container blank.
Invention is credited to Alistair Fraser Moore.
Application Number | 20080067225 11/728980 |
Document ID | / |
Family ID | 33397284 |
Filed Date | 2008-03-20 |
United States Patent
Application |
20080067225 |
Kind Code |
A1 |
Moore; Alistair Fraser |
March 20, 2008 |
Apparatus for and method of forming containers and a container
blank
Abstract
A container or container blank (100) comprises a base portion
(2) having a pair of opposed side wall portions (3B,5B) and an
opposed front wall portion (4B) and rear wall portion (6B), each
wall portion (3B,4B,5B,6B) being connected to the base portion (2)
at a fold line (3,4,5,6). Each side wall portion (3B,5B) has inner
and outer sections (3B,7;5B,7) separated by a fold land, the
sections being adapted for folding about the fold land to assume a
position overlying one another, the outer section (7) including
locking means (7A,7B) engagable in the base portion (2) to secure
said overlying position. The front and rear wall portions (4B,6B)
each have a riser section and a lid section (11,10). The base at
least has attached thereto a web of material (12) adapted to retain
an article within a container formed from the blank (100). An
apparatus and method for forming a container blank having a web
attached thereto and an apparatus and method for forming a
container from blank are disclosed with reference to the direction
in which adhesive is applied to secure the material web to the base
and the improved tension characteristics of the web and article
within the container. An apparatus and method for filing, closing
and sealing an open-mouthed container is also disclosed.
Inventors: |
Moore; Alistair Fraser;
(Beccles, GB) |
Correspondence
Address: |
Jovan N. Jovanovic;The Watson Intellectual Property Group, PLC
Suite 200
3133 Highland Drive
Hudsonville
MI
49426
US
|
Family ID: |
33397284 |
Appl. No.: |
11/728980 |
Filed: |
March 27, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
PCT/GB04/04935 |
Nov 22, 2004 |
|
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11728980 |
Mar 27, 2007 |
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Current U.S.
Class: |
229/194 |
Current CPC
Class: |
Y10T 156/12 20150115;
B31B 2105/00 20170801; Y10T 29/52 20150115; B65B 5/028 20130101;
B65B 53/063 20130101; B31B 2120/408 20170801; B31B 50/624 20170801;
Y10T 156/1062 20150115 |
Class at
Publication: |
229/194 |
International
Class: |
B65D 5/50 20060101
B65D005/50 |
Foreign Application Data
Date |
Code |
Application Number |
Sep 27, 2004 |
GB |
0421388.0 |
Claims
1. A container or container blank comprising: a base portion having
a pair of opposed side wall portions and an opposed front wall
portion and rear wall portion, each wall portion being connected to
the base portion at a fold line; each side wall portion having
inner and outer sections, separated by a fold land, the sections
being adapted for folding about the fold land to assume a position
overlying one another, the outer section including locking means
engagable in the base portion to secure said overlying position;
the front and rear wall portions each having a riser section and a
lid section; and at least one portion having attached thereto a web
of material adapted to retain an article within the container or a
container formed from the blank, wherein the material is secured to
at least one portion using adhesive applied in a direction
consistent with the direction in which the web is applied and along
which tension is applied to retain the article within the
container.
2-31. (canceled)
Description
FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus for and method
of forming containers for use in packaging articles, particularly
the packaging of single or multiple flat articles, such as books or
video cassettes and disks such as LP records CDs, CD-ROMs and DVDs.
The invention further relates to a container blank and an apparatus
and method of forming the blank. The invention vet further relates
to a container package (that is, including packaged articles)
constructed using the apparatus, method and/or blank of the
invention. The invention most particularly relates to the method
and apparatus used to form and handle a container blank and to
shape the blank into a package for constraining at least one
article therein for dispatch or storage.
[0002] The invention particularly relates to an apparatus for and
method of modifying container blanks made of card or similar
material, the blanks being modified to include an article retaining
means to secure articles therein and prevent damage-causing
movement within the container formed from the blank. Additionally,
the invention relates to a container forming machine which takes
container blanks having an article retaining means and forms a
packaging containers for articles having a relatively large surface
area as compared to the associated thickness or depth thereof, such
as books, video cassettes and discs of various formats. These
articles need to be held securely container to prevent damage
thereof during transit. A method of forming containers is also
disclosed.
[0003] The methods, apparatus, blanks and final package as
described hereinbelow are described with reference to flat articles
such as those exemplified above, however it should be appreciated
that no such limitation exists.
[0004] It will be appreciated by the skilled addressee that the
invention, although directed towards the packaging of substantially
flat articles, may be applied to any three-dimensional object
locatable within the container and is not limited to similarly
shaped articles such as books and video cassettes.
BACKGROUND TO THE INVENTION
[0005] Increasingly, customers are eschewing the time-consuming
routine of travelling to purchase their shopping and/or business
needs. It is now common for purchases to be made by mail order,
telephone and via the Internet and email. As a consequence, for
goods to be received there is a market increase in the use of
postal and courier services to deliver the purchases.
[0006] The further involvement of postal services and other
delivery systems is different from the traditional mode of shopping
where the customer travels to purchase articles over the counter
and returns using public or their own transport means. In this
scenario, packing or packaging is done at the counter or before the
customer leaves, after which responsibility for damage no longer
resides with the seller. As most postal and courier services either
limit their liability for damage to articles delivered by them or
charge significant premiums for insurance against such damage, it
falls to the retailer, warehouseman or company dispatching the
purchase to ensure there is minimal risk of damage during transit
to the customer. The term "postal" as used herein is intended as a
convenient expression of all local, national and international
dispatch and courier services, including drop-shipping
services.
[0007] With the increased popularity of Internet shopping and the
dispatch of ordered articles via the postal system the requirement
for packaging has increased manyfold. The popularity of such
websites as Amazon.TM. and eBay.TM. have increased the postal
traffic of books, CDs, CDROMs and DVDs amongst others. Due to the
vast turnover of dispatched articles and the inherent risks
associated with the bulk handling of goods, there is a market
requirement for sturdy containers. Additionally, as the volume of
mail order catalogue business increases so to does the volume or
returns. This has a severe consequence on the profitability of the
mail order transaction and, where the returned article is damaged,
the customer must bear responsibility for the damage. This
condition of sale often has repercussions for customer
relationships.
[0008] In other words, a fundamental requirement of any method of
goods transportation is that the goods are not damaged during
transport so that they reach their destinations in a non-damaged
state.
[0009] It has been found in practice, that the packaging of
articles such as books, records, and similar articles having at
least one surface with a relatively large surface area in relation
to depth or thickness of the article has presented, in terms of
packaging, a significant ongoing problem. This problem manifests
itself particularly in situations where the articles are packages
on a production line basis by a packaging method involving the
folding of a card or the like blank into a container for receiving
an article to be packed.
[0010] Containers formed from blanks made of card and cardboard and
other materials suitable for dispatch through the postal services
are well known in the prior art. Generally, the containers are
formed from a relatively simple blank having side walls separated
by fold lines and one or more base and lid portions connected to
one or more of the side walls by corresponding fold lines. To
construct the container an end tab of one side wall is secured to
an edge portion of another side wall and the or each base portion
is folded and secured to form an open-mouthed container. When the
or each article to be dispatched has been placed within the
container, the or each lid portion is folded and secured. The means
of securing the portions to form the container is normally selected
from gluing or stapling.
[0011] There are many examples of the above types of container in
the prior art, including the standard RSC, a modified arrangement
of which is discussed hereinbelow with respect to a detailed
embodiment of the invention.
[0012] It will be appreciated that unless the container is designed
to receive the specific article(s) to be dispatched, further
packaging materials will be required to prevent the article(s)
moving about within the container. In the packaging industry
generally there is a move to obviate extraneous packaging materials
and in some countries there are regulations and legislation to
prevent wasteful packaging practices.
[0013] The invention is directed to overcoming some of the
established disadvantages associated with prior art containers,
particularly those realising a container which is adapted for
encapsulating or otherwise securing one or more articles within the
container to prevent damage due to movement within the container
during transit to its destination.
[0014] In an attempt to obviate some of the disadvantages
highlighted above, a solution suggested in the prior art is to
utilise a web of lining material to secure the articles within the
container.
[0015] One established solution is to place the articles for
dispatch in a tray, usually of a cardboard material. The tray and
articles are then wrapped by a web of plastics material which is
subsequently heated to effect a shrink-wrapped package.
Alternatively, the web or film is tensioned around the article(s)
by folding elements of the tray to which the web is attached. This
package is then placed into a pre-formed container which is finally
sealed and marked for dispatch. This arrangement, however, has its
own disadvantages including that, although the articles are bound
together, the tray will often move sufficiently in the container to
dislodge the articles from the tray. Furthermore, this arrangement
does not avoid the use of unnecessary additional packaging
materials and includes an extra stage in the packaging process.
[0016] In another solution proposed by the Applicant in United
Kingdom Patent No. GB 2 343 885 (which is incorporated herein by
reference) there is described a container blank to which a sheet or
web of lining material is secured. This lining material is
shrink-wrappable so that articles may be placed directly into the
container and secured in situ.
[0017] Although providing significant improvements over the prior
art, the container and container blank disclosed in GB 2 343 885 is
not suitable for machine forming into a container. While there is
significant demand for contaminations which are manually formed
(particularly for low volume operation), high volume dispatch
centres or drop-shippers, for example, require fully automated
systems. The advantages of machine forming of a container from a
blank will be apparent to the skilled addressee.
[0018] For cost reasons and to adhere to requirements, in
particular those relating to crush resistance, it is desirable to
make use of the inherent strength provided by the "nape" of
corrugations formed within the cardboard material. It is for this
reason, together with the low failure rate of such material, that
multi-ply, high-grade cardboard materials are considered despite
their relative expense and the accuracy to which the blanks must be
formed. Where inexpensive materials are used, the proportion of
failures and machinery wear increases, consequently machine
downtime and process stoppages deleteriously affect efficiency.
[0019] From reading the prior art, it is known that container
blanks are usually formed using a die-cutting technique which
includes stamping of fold lines. The blanks are then introduced to
a folding station where a container is formed. The open-mouthed
container is then filled and sealed for dispatch. In an alternative
prior art arrangement, the article(s) to be packaged is/are placed
onto a blank and passed to a sealing station where the container is
formed around the article(s) and sealed using hot-melt glue.
[0020] It is an object of the present invention to provide a
packaging system that seeks to alleviate the disadvantages
associated with the prior art and seeks to minimise(s) the risk of
damage to an article during post packaging handling and during
transit.
[0021] Accordingly, it is an object of the invention to provide a
container blank suitable for machine forming and to provide a
container so formed for receiving articles to be secured therein
prior to dispatch.
[0022] It is a further object of the invention to provide an
apparatus for forming container blanks of the invention.
[0023] It is an additional object of the invention to provide an
apparatus for forming and filling containers for dispatch at high
speed and which facilitates the use of standard electronic
interfaces and control instrumentation.
[0024] It is a yet further object of the present invention to
provide a method for the forming and filling of containers in
accordance with the invention.
SUMMARY OF THE INVENTION
[0025] Accordingly, the present invention provides a container
blank comprising: [0026] a base portion having a pair of opposed
side wall portions and an opposed front wall portion and rear wall
portion, each wall portion being connected to the base portion at a
fold line; [0027] each side wall portion having inner and outer
sections, separated by a fold land, the sections being adapted for
folding about the fold land to assume a position overlying one
another, the outer section including locking means engagable in the
base portion to secure said overlying position; [0028] the front
and rear wall portions each having a riser section and a lid
section; and [0029] the base at least having attached thereto a web
of material adapted to retain an article within a container formed
from the blank, wherein the material is secured to the base using
adhesive applied in a direction consistent with the direction in
which the web is applied and along which tension is applied to
retain the article within the container.
[0030] Conveniently, the material adapted to retain an article
within the container formed from the blank is a shrink-wrappable
material.
[0031] Advantageously, the side and end wall portions are so sized
and shaped to be machine foldable.
[0032] Preferably, the container blank is cut from a card material
having a nape oriented to add to the strength of the container
formed.
[0033] The present invention provides a container comprising:
[0034] a base portion having a pair of opposed side wall portions
and an opposed front wall portion and rear wall portion, each wall
portion being connected to the base portion at a fold line; [0035]
each side wall portion having inner and outer sections, separated
by a fold land, the sections being adapted for folding about the
fold land to assume a position overlying one another, the outer
section including locking means engagable in the base portion to
secure said overlying position; [0036] the front and rear wall
portions each having a riser section and a lid section; and [0037]
the base at least having attached thereto a web of material adapted
to retain an article within a container formed from the blank,
wherein the material is secured to the base using adhesive applied
in a direction consistent with the direction in which the web is
applied and along which tension is applied to retain the article
within the container.
[0038] Conveniently, the material adapted to retain an article
within the container formed from the blank is a shrink-wrappable
material.
[0039] Advantageously, the side and end wall portions are so sized
and shaped to be machine foldable.
[0040] Preferably, the container blank is cut from a card material
having a nape oriented to add to the strength of the container
formed.
[0041] The present invention further provides an apparatus for
forming a container blank of the type having an article retaining
means thereon, the apparatus comprising: [0042] means for
dispensing onto a feed conveyor a substantially continuous supply
of container blanks, the blanks being of a desirous pre-formed
profile having a plurality of foldable sections so shaped and sized
as to form a container; [0043] a plurality of nozzles for applying
at least one strip of adhesive to an inner surface of the blank;
[0044] means for dispensing a substantially continuous web of a
shrink-wrappable plastic sheet material and laying a length of said
web onto the adhesive in the inner side of said blank; [0045]
cutting means to slice the web to define the length of web adhered
to the blank; and [0046] conveying means to carry the blank thus
formed to a stacking station or to a storage station.
[0047] Advantageously, the apparatus includes a pressure applying
means for bonding the web material to the inner surface of the
blank.
[0048] Conveniently, the means for dispensing a supply of blanks
comprises a support table having a vacuum operated picker mechanism
which individually selects a blank from the base of a magazine of
blanks and introduces the blank to a glue application station.
[0049] Advantageously, the table includes a blank edge support
means for retaining the blanks within the magazine, the picker
mechanism engaging the base portion of the selected blank and
deflecting it to disengage said edge support means.
[0050] Optionally, the means for dispensing a supply of blanks
comprises a pair of lift tables mounted on a carriage adapted for
lateral movement with respect to the direction of travel of blanks
within the apparatus, the dispensing means including a vacuum
operated picker mechanism which individually selects a blank from
the top of a magazine of blanks and introduces the blank to a glue
application station.
[0051] The present invention yet further provides a method for
forming a container blank of the type having an article retaining
portion thereon, the method comprising: [0052] dispensing onto a
feed conveyor a substantially continuous supply of container
blanks, the blanks being of a desirous pre-formed profile having a
plurality of foldable sections so shaped and sized as to form a
container about an article; [0053] applying at least one strip of
adhesive onto an inner surface of the blank via a plurality of
nozzles; [0054] dispensing a substantially continuous web of a
shrink-wrappable plastic sheet material and laying a length of said
web onto the adhesive in the inner side of said blank; [0055]
cutting the web to define the length of web adhered to the blank;
and [0056] conveying the blank thus formed to a stacking station or
to a storage station.
[0057] Advantageously, the method includes applying pressure to the
inner surface of the blank to bond the web material.
[0058] The present invention further provides an apparatus for
forming a container from a container blank of the type having an
article retaining portion thereon, the apparatus comprising: [0059]
feeding station for dispensing onto a feed conveyor a substantially
continuous supply of container blanks, each blank having a length
of shrink-wrappable material adhered thereto and having a plurality
of foldable sections so shaped and sized as to form a container
about an article; [0060] container forming station having an
actuator member that abuts the inner surface of the base of the
container blank and forces the blank into a container-forming die,
the die being so formed and shaped as to cause sections of the
blank to fold about pre-formed score lines; [0061] at least one
packing station where one or more articles are placed into the open
mouth of the formed container; [0062] article retaining station
where manipulator means bring one end of the shrink-wrappable
material into position to overlie the other end and adhere the
overlying sections together;
[0063] shrink-wrapping station where heat is applied to the
overlying ends of the material so that the or each article placed
in the container at the packing station is secured therein;
[0064] lid closing station where the lid portions are brought
together in overlying relationship so that pre-applied
pressure-sensitive adhesive thereon seals the lid closed; and
[0065] a dispatch conveyor which carries the container through
final stages or to storage.
[0066] Conveniently, the feeding station comprises a pivotable
destacking arm adapted to individually select a blank from magazine
of vertically stacked blanks.
[0067] Optionally, the feeding station comprises a pair of lift
tables mounted on a carriage adapted for lateral movement with
respect to the direction of travel of blanks within the apparatus,
the dispensing means including a vacuum operated picker mechanism
which individually selects a blank from the top of a magazine of
blanks and introduces the blank to a glue application station.
[0068] The present invention further provides a method for forming
a container from a container blank of the type having an article
retaining portion thereon, the method comprising: [0069] dispensing
onto a feed conveyor a substantially continuous supply of container
blanks, each blank having a length of shrink-wrappable material
adhered thereto and having a plurality of foldable sections so
shaped and sized as to form a container about an article;
[0070] abutting the inner surface of the base of the container
blank with an actuator member and forcing the blank into a
container-forming die, the die being so formed and shaped as to
cause sections of the blank to fold about pre-formed score lines;
[0071] placing one or more articles into the open mouth of the
formed container; [0072] bringing one end of the shrink-wrappable
material into position to overlie the other end and adhering the
overlying sections together; [0073] applying heat to the overlying
ends of the material so as to secure the or each article placed in
the container; [0074] closing the lid portions in overlying
relationship so that pre-applied pressure-sensitive adhesive
thereon seals the lid closed; and [0075] conveying the container
through final stages or to storage.
[0076] The invention yet further provides an apparatus for feeding
open-mouthed containers via a packing station to a sealing and
closing station in preparation for dispatch or storage of the
packaged articles, the apparatus comprising: [0077] feeding means
for conveying open-mouthed containers onto a buffer conveyor;
[0078] a stacking conveyor comprising at least one intake conveyor
fed by the buffer conveyor; [0079] a discharge conveyor for
transporting filled containers from a packing station; [0080] a
heating zone for applying heat to a shrink-wrap retaining means
within the containers to secure the contents therein; and [0081] a
lid closing means.
[0082] The invention yet further provides a method of for feeding
open-mouthed containers via a packing station to a sealing and
closing station in preparation for dispatch or storage of the
packaged articles, the method comprising: [0083] feeding
open-mouthed containers onto a buffer conveyor; [0084] feeding
containers from said buffer conveyor to a stacking conveyor; [0085]
filling the containers at a packing station and placing the filled
containers on a discharge conveyor; [0086] applying heat to a
shrink-wrap retaining means within the containers to secure the
contents therein; and [0087] closing and sealing the or each lid
portion of the container.
[0088] Additional features of the invention and its advantages,
together with further objectives of the invention will be apparent
from the detailed description of the preferred embodiments below,
when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0089] The invention will now be described more particularly with
reference to the accompanying drawings which show, by way of
example only, a construction of container blank, an apparatus for
forming a container blank, a method of constructing a container
blank, an apparatus for forming a container from a blank and a
method of forming a container suitable for dispatch, in accordance
with the invention. In the drawings:
[0090] FIG. 1a is a plan view of a prior art container blank
suitable for packaging articles by manually folding sections of the
blank about an article to form a container therefore;
[0091] FIGS. 1b and 1c are top plan views of a container formed
from the prior art blank of FIG. 1 illustrating the fixing of a
plastics material sheet thereto and the resultant distribution of
the holding forces applied to the article constrained within the
container;
[0092] FIG. 2a is a plan view of a container blank in accordance
with the invention, the container being both manually and machine
foldable;
[0093] FIGS. 2b and 2c are top plan views of a container formed
from the blank of FIG. 2a illustrating the fixing of a plastics
material sheet thereto and the resultant distribution of the
holding forces applied to the article constrained within the
container;
[0094] FIG. 3a is a plan view of an apparatus for applying the
plastics material sheet to the pre-formed blank of FIG. 2a;
[0095] FIG. 3 b is a side elevation of the apparatus of FIG. 3a
having a first arrangement of blank feeding mechanism for metering
one blank at a time into the apparatus;
[0096] FIG. 3c is a side elevation of the apparatus of FIG. 3a
having a second arrangement of blank feeding mechanism;
[0097] FIG. 3d is a first arrangement of blank feeding mechanism
comprising a support table for metering blanks to the lining
apparatus;
[0098] FIGS. 3e(i) to 3e(v) are end elevations on Arrow x of FIG.
3c, showing the second arrangement of blank feeding mechanism;
[0099] FIG. 4 is a schematic side elevation of a container forming
apparatus;
[0100] FIG. 5 is a series of twelve views or vignettes illustrating
the initial introduction of the sequential steps of forming a
container, including the introduction of subsequent blanks;
[0101] FIGS. 6a and 6b are side elevations of the process steps of
forming a container from a blank using an alternative arrangement
of container forming apparatus;
[0102] FIGS. 6c(i) to 6c(v) are end elevations on Arrow X of FIG.
6a, showing an arrangement of blank feeding mechanism, similar to
that shown in FIGS. 3e(i) to 3e(v);
[0103] FIG. 7 is a schematic plan view of a filling and packing
apparatus;
[0104] FIGS. 8a to 8c are a plan view, a side elevation and an end
elevation of a heat chamber for shrink wrapping the articles within
the containers; and
[0105] FIG. 9 is a plan view of a RSC container blank modified to
include an article retaining means.
DETAILED DESCRIPTION OF THE DRAWINGS
[0106] In the description that follows, the terms "left", "right",
"upstream" and "downstream" should be regarded with respect to the
drawings only and relate to the processing and conveyance of a
blank and container formed from the blank as it moves through the
apparatus. In this arrangement, "upstream" represents the source of
raw material or a yet-to-be-processed container blank and
"downstream" towards the accumulation point for storage or
dispatch.
[0107] The terms "side walls" and "end walls" are used conveniently
to describe pairs of opposed walls and should not be considered as
limiting. Certain portions or tabs are also described in a similar
fashion, again only to assist the reader.
[0108] Referring now to the drawings, and initially to FIG. 1a, a
prior art arrangement of container blank 1, as disclosed in United
Kingdom Patent No. 2 343 885, is shown. The blank 1 is cut from
craft card and includes a central land that forms the base 2 of a
container formed from the blank. The central land or base 2 is
defined by base fold lines 3,4,5,6. Riser fold lines 3A,4A,5A,6A
are formed in the blank to run parallel to but spaced from the fold
lines 3,4,5,6, respectively, to define end and side walls
3B,5B;4B,6B which in turn define the depth of the container to be
formed by the blank.
[0109] Referring specifically to each end wall 3B,5B, an over-tab
fold line 3D,5D is formed in the blank running parallel to the
riser fold line 3A,5A. The distance between the riser fold lines
and over-tab fold lines fold lines 3D,5D is effectively twice the
thickness of that of the card material from which the blank is
formed, for reasons to be mentioned hereinafter. The dimensions of
the blank are such that the portion thereof extending outwardly of
the over-tab fold lines 3D,5D define tuck-in flaps 7, each having
short rectangular extensions 7A,7B that are formed to engage
corresponding receiving slots 8A,8B disposed in the base 2
immediately adjacent the end wall base fold lines 3,5.
[0110] A removable push-out portion 9 is disposed centrally along
the outer edge of each end wall 3B,5B such that the push-out
portion 9 includes a substantially rectangular part 9A that bridges
the space between the riser fold line 3A,5A and the over-tab fold
lines 3D,5D and a semicircular part 9B opening into the end wall
itself 3B,5B. End corner regions 7C of the tuck-in flaps 7 are
angled to facilitate folding of the blank during the container
forming process.
[0111] Referring now to the side walls 4B,6B, each end thereof is
provided with a tuck-in flap 4C,6C having the same height dimension
as the side walls 4B,6B which define the depth of the container to
be formed from the blank. The tuck-in flaps 4C,6C are foldable over
the end-flap fold lines 4D,6D to be positioned adjacent the inner
face of the end walls 3B,5B. Consequently, the tuck-in flaps must
be, in its longest dimension, slightly less than half of the width
(long dimension) of the end walls 3B,5B but sufficiently long to
provide structural support for the container thus formed without
encroaching on the area adjacent to the push-out portion 9. The
tuck-in flap 4C,6C are parallel components that enhance the overall
strength of the finished container. At least one of the free
corners of the tuck-in flaps 4C,6C is tapered to facilitate easier
folding.
[0112] A first lid forming portion 10 extends from one side wall 6B
and is connected thereto via the side wall riser fold line 6A. Each
end of the first lid portion 10 includes a fold-in flap 10B
foldable around a lid-flap fold line 10C. As will be noted from
FIG. 1a, a corner of the fold-in flap 10B is shaped to facilitate
the manual folding or "tucking-in" of the lid end flap 10B.
[0113] The depth of the first lid portion 10, that is from the
riser fold line 6A to a free edge 10G of the lid portion 10, the
edge 10 G essentially comprising the leading edge of the blank 100.
It will be noted from FIG. 1a that the width of the first lid
portion, that is, the distance between the fold-in flap lines 10C,
is less than the distance between the adjacent side wall end-flap
fold lines 6D. This is to allow the lid flaps 10B to fold inside
the end wall tuck-in flaps 7 when an open-mouthed container is
formed.
[0114] A second lid portion 11 extends from the other side wall 4B
by way of the corresponding riser fold line 4A. This lid forming
portion 11 is deeper than the first lid forming portion 10 so that
the second lid portion 11 partially overlies the first lid portion
10 when folded over the open-mouthed container when formed.
[0115] Similarly to the first lid portion 10, each end of the
second lid portion 11 includes a pair of tuck-in flaps 11B that are
foldable about lid-flap fold lines 11C that align with the inner
long edge of the rectangular slot 8A in the base 2. Each end of the
second lid part 11 also includes a second tuck-in flap 11D which
folds about a fold line 11E. These second flap fold lines 11E fold
outside the lid flap fold lines 11C and are in line with the base
fold lines 3,5 of the respective end walls 3B,5B. When folded into
position, the second tuck-in flaps 11D engage the aperture defined
by the rectangular part 9A of the removable push-out portions 9.
The two flaps 11B and 11D are shaped to facilitate the actual
tucking-in process.
[0116] To form a container from the prior art blank of FIG. 1a, the
side walls 4B,6B are folded through 90.degree. at the base fold
lines 4,6 into an upright position relative to the base 2. The side
wall tuck-in flaps 4C,6C are folded in at a right angle relative to
the associated side wall 4B,6B and to align with the other base
fold lines 3,5. The end walls 3B,5B are folded to the vertical
position relative to the base 2 and the associated outer flap parts
7 are folded inwards firstly over the corresponding riser fold
lines 3A,5A and subsequently over the over-tab fold lines 3D,5D to
form a sandwich of the side wall tuck-in flaps 4C,6C between the
inner surfaces of the end walls 3B,5B and their corresponding
tuck-in flaps 7. It will be noted that the semicircular part 9B of
the aperture formed by the removal of the push-out portion 9 lies
externally of the thus formed end wall. The tuck-in flap extensions
7A,7B are then pushed into engagement with the corresponding
receiver slots 8A,8B. This thus defines the form of the
open-mouthed container.
[0117] The lid tuck-in flaps 10B,11B are folded to a position
perpendicular to their respective lid portions 10,11. The shorter
tuck-in flaps 11D of the second lid portion 11 are turned to the
positions in which they are able to engage the rectangular part 9A
of the removable push-out portion 9. The lid portion 10 is then
folded along the side wall riser fold line 6A to overlie the base
part 2 and the tuck-in flaps 10B of the lid 10 are positioned to
lie against the now inwardly facing surface of the end wall tuck-in
flaps 7. The second lid portion 11 is subsequently folded along its
riser fold line 4A to overlie the open-mouthed container and a
proportion of the first lid portion 10. The tuck-in flaps 111B of
the second lid portion 11 are also positioned adjacent the exposed
surface of the end wall tuck-in flaps 7 and the shorter tuck-in
flaps 11D of the lid 11 are engaged in the rectangular aperture
9A.
[0118] It will be found that thus folded blank provides a stiff
rectangular box like container.
[0119] In practice, in accordance with the requirements of
packaging method involved the article to be packed (not shown) is
required to be placed at a required location within the thus formed
container, the location usually being symmetrically positioned
within the dimensions of the base. After such a placement, the
blank is folded in the manner discussed around the previously
positioned article.
[0120] This means that if the size of the article is such that it
effectively fills the container the article when in the container
is not likely to move about within the container during prior
transit. If, however, the article is smaller than the interior of
the containers it follows that the article would be at least
relatively free to displace within the container and thus be prone
to possible damage during transit.
[0121] It will be appreciated that when, for example, a large
number of similar articles are to be packed such as compact discs,
books, and other flat articles are involved it does not follow that
always only single articles are involved. Clearly, in the case of
books their thickness can vary within wide limits.
[0122] Also, it is clearly not commercially possible to provide for
every differently sized article a precisely dimensioned container
tailored for each such article so that the article is an exact fit
in the container. In view of this it is conventional practice to
provide a range of differently sized containers, with each
container of the range being intended to accommodate a range of
possible sizes of articles. This practice has the result that if an
article is an exact fit in the container relative displacement is
not likely to occur. Whereas if the article is dimensionally
smaller than the maximum size accommodatable by a container any
such articles would be effectively free to move about within the
container in a manner set by the nature of any post packaging
handling.
[0123] In order to deal with this problem it is proposed accordance
with an aspect of the invention to provide the container forming
blank 1 with an auxiliary/inner packaging for the article that is
adapted to restrain the article against movement after it is placed
at the requires location upon the container base. With this
arrangement when the blank is folded into container form, the
auxiliary packaging is effectively automatically brought into its
displacement restraining condition.
[0124] In the above description of the prior art blank no
consideration has been given to the article retaining means which
comprises a flexible lining material secured to the base 2 of the
blank 1. As schematically shown in FIG. 1b, a sheet or film 12 of
lining material is attached to the base 2 by two lines of adhesive
13 applied as continuous lines adjacent the side wall base fold
lines 4,6. It will be appreciated by the skilled addressee that the
adhesive may be applied as broken lines or over an extended area of
the base 2 depending on the attachment strength required. The
lining material sheet 12 is large enough to overlie the lid forming
portions 10,11 as indicated by the film flaps 14,15 of FIG. 1b.
[0125] When packaging an article 16 it is placed on the lining
material 12 and the two flaps 14,15 are folded over the article 16.
Depending on the nature of the article being packed, the overlying
edge regions of the lining material flaps 14,15 are stuck together
to hold the article firmly in place. This can be done either prior
to the container being formed from the blank or after.
[0126] FIG. 1c schematically illustrates a container of the
invention in an open-mouthed configuration in which one or more
articles have been constrained using the lining material 12. The
lining material covers the base 2 of the container with enough
length to overlap each end thereof so as to allow the free ends of
the film to be stuck together. Tension lines 17 indicate the
restraining mechanism of the film 12. If thought convenient, lines
of adhesive are provided around the four sides of the base 2 to
hold the lining 12.
[0127] A machine-foldable blank 100 of the present invention will
now be described with reference to FIGS. 2a to 2c. For the sake of
convenience and consistency of description like portions of the
machine foldable blank 100 will be described with numerals common
to those used with respect to the prior art blank 1. In common with
the prior art blank 1, as described with reference to FIGS. 1a to
1c, the blank 100 is cut from craft card and includes a central
land that forms the base 2 of the container formed from the blank
100. The base 2 is defined by fold lines 3,4,5,6 and riser fold
lines 3A,4A,5A,6A are formed in the blank 100 to run parallel to
but spaced from the base fold lines 3,4,5,6, respectively, to
define end and side walls 3B,5B;4B,6B which in turn define the
depth of the container to be formed by the blank 100.
[0128] Referring specifically to each end wall 3B,5B, an over-tab
fold line 3D,5D is formed in the blank running parallel to the
riser fold line 3A,5A, the distance between the riser fold lines
3A,5A and the over-tab fold lines 3D,5D being effectively twice the
thickness of the card material from which the blank 100 is cut, for
the same reasons as described with respect to the prior art blank
1.
[0129] The end walls 3B,5B of the blank 100 include tuck-in flaps 7
extending outwardly of the over-tab fold lines 3D,5D. The tuck-in
flaps 7 each have short profiled extensions 7A,7B which are formed
to engage corresponding receiver slots 8A,8B disposed in the base 2
immediately adjacent the end wall base fold lines 3,5.
[0130] It will be noted that the length of the over tab fold lines
3D,5D are marginally shorter than the adjacent riser fold lines
3A,5A so that a bevelled edge is formed to facilitate smooth and
rapid machine folding. Similarly, the extensions 7A,7B are profiled
to facilitate smooth and rapid machine registration of the tabs
7A,7B into their corresponding receivers 8A,8B. The modified
profiles obviate the requirement to profile the distal corners of
the tuck-in flaps 7. The square corners of the flaps 7 provide
additional rigidity and strength to the container thus formed and
facilitate machine forming. More particularly, it should be noted
that the end wall riser fold lines 3A,5A are formed using deeper
and/or larger perforations than those of the corresponding over-tab
fold lines 3D,5D to ensure that the riser fold lines 3A,5A fold
before the over-tab fold lines 3D,5D. This is important not only to
facilitate the correct formation of the container but also to
correctly position the extension tabs 7A,7B for engagement into the
corresponding receivers 8A,8B. Ideally, the perforations forming
the over-tab fold lines 3D,5D extend 50% of the corresponding
number, length or depth (as appropriate) of the perforations
forming the end wall riser fold lines 3A,5A.
[0131] In comparing the final folding stages of the container
formed from the blank 100 of the present invention and that of the
exemplifying prior art, as shown in FIG. 1a, it will be noted that
the shorter tuck-in flaps 11D of the second lid portion 11 have
been removed to allow for machine closing of the lid and that the
push-out portion 9 is no longer required. As a consequence of
obviating the push-out portion 9, the land formed between the end
wall riser fold lines 3A,5A and the over-tab fold lines 3D,5D is
continuous along the end wall, thereby strengthening the end wall
portions of the container.
[0132] Although the above modifications and many of those described
hereinbelow are visually insignificant, it has been found that such
changes aid folding and forming to a disproportionate degree and,
more importantly, facilitate machine folding. Additionally, certain
features of the prior art blank 1, particularly those to aid manual
handling (such as the removable push-out portions 9 and the flaps
11D inserted therein), are now obviated.
[0133] Referring now to each side wall 4B,6B each end thereof is
provided with a tuck-in flap 4C,6C having substantially the same
height dimension as the side walls 4B,6B which defines the depth of
the container to be formed by the blank 100. The tuck-in flaps
4C,6C are foldable over end flap fold lines 4D,6D to be positioned
adjacent the inner face of the end walls 3B,5B. Consequently, the
tuck-in flaps 4C,6C must be, in their longest dimension, slightly
less than half of the width (long dimension) of the end walls 3B,5B
and provide significant structural integrity for the end walls. At
least one of the free corners of the tuck-in flaps 4C,6C is rounded
to facilitate machine folding.
[0134] As before, a first lid forming portion 10 extends from one
side wall 6B and is connected thereto via the corresponding riser
fold lines 6A. Each end of the first lid forming portion 10
includes a fold-in flap 10B foldable around a lid flap fold line
10C. As will be noted from FIG. 2a, the fold-in lid flaps 10B are
profiled so that machine folding is facilitated. A first leading
side edge 10E of each lid flap 10B is bevelled to provide a
straight edge which presents a parallel even edge to the formed end
walls 3B,7;5B,7 as the first lid portion 10 is folded towards the
now open-mouthed container. A trailing edge 10 F of each, lid flap
10B has a rounded profile corresponding to the arc transcribed by
the lid portion 10 as it is closed over said open-mouthed
container.
[0135] The depth of the first lid portion 10 is from the riser fold
line 6A to a free edge 10G of the lid portion 10, the edge 10G
essentially comprising the leading edge of the blank 100. As such
there is a registration shape 12 cut into the free edge 10G for
positioning the blank within a forming machine. A corresponding
registration shape 12 may be formed on a trailing edge 11E of a
second lid portion 11. The registration shape assists with the
automatic handling of blanks and allows leading edge or trailing
edge sensor registration.
[0136] The second lid portion 11 extends from the opposite side
wall 4B to that of the first lid portion 10, by way of a
corresponding riser fold line 4A. This lid portion 11 is wider,
from the riser fold line to the trailing edge 11G, than the first
lid portion 10 so the second lid portion 11 partially overlies the
first lid portion 10 when folded onto the open-mouthed
container.
[0137] Similarly to the first lid portion 10, the second lid
portion 11 includes a pair of tuck-in flaps 11B that are foldable
about lid flap fold lines 11C. The leading edge 11E of each lid
flap 11B is bevelled and rounded to assure smooth machine folding.
Adjacent the trailing edge 11G of the lid 11, bevelled end portions
11F are formed to ensure that the glued-down trailing edge 11G does
not present any corners or portions which could be snagged or
pulled when the container is closed.
[0138] The blank 100 further includes a heat shrinkable lining
material 12 which is attached to the base 2, at least. FIGS. 2b and
2c illustrate the layout and use of the lining material or film 12
in conjunction with a machine foldable blank 100. A length of
lining material 12, comprising a web or film of heat-shrinkable
plastics material, is laid onto the open blank and secured thereto
by lines of adhesive 13 disposed on the base 2 of the blank 100,
the lines being parallel to the direction of travel of the blank
through a liner apparatus for producing blanks having retaining
means in accordance with the invention, as described in detail
hereinbelow. The lines of adhesive extend from the side wall base
fold lines 4,6 towards the central longitudinal axis of the base 2
of the blank 100. The number and position of the adhesive lines 13
is selected according to the use to which the container is to be
put.
[0139] It will be appreciated by the skilled reader that by
applying the glue lines parallel to the direction of travel of a
blank through the apparatus applying the liner, the glue may be
applied continuously and at high speed. The momentum of the blank
as it is processed need not be interrupted. Additionally, by
applying the glue in this orientation, the shrink wrapping of
articles within the container is enhanced as the film/lines can
pull together between the glue lines to give a better grip on the
articles contained.
[0140] In the illustrated embodiment, four lines of adhesive are
used to fix the central portion of the film to the blank 100. Two
flaps 14,15 of the material or film 12 are adapted to be folded
over the contents of the container, however, during assembly of the
blank and transport thereof, the flaps 14,15 are retained in
position by one or more "glue spots". 13a applied to the underside
of the lid portions 10,11. Advantageously, the blank can be machine
folded to form an open-mouthed container without risk of the film
being dislodged or trapped by folding portions during the container
forming process or during automated or manually filling the
container. Additionally, by using simple glue spots to retain the
flaps 14,15 to the lid portions, the flaps can easily be torn away
from the lid portions 10,11 when required to cover or overlie the
contents of the container. FIG. 2c shows particularly the
advantages of using a plurality of glue lines 13 to retain articles
16 within the container formed by the blank 100. The flaps 14,15
are pulled away from the glue spots 13a on the lid portions 10,11
and laid one end over the other. Heat is applied, usually via a hot
air stream or within a heat chamber, and the heat-shrinkable
material film 12 draws in around the or each article 16. A
plurality of tension lines are formed between the article(s) and
the adhesive lines 13 to retain the article(s) in place.
[0141] As discussed hereinabove, the orientation of the blank and
the direction of travel of a blank through a machine is described
with respect to the leading and trailing edges 10G, 11G of the
blank 100 and the terms "upstream" and "downstream" are defined
with respect to the source of materials and the conveying
destination, respectively. The fact that materials may be sourced
from different physical direction is irrelevant to the above
definition.
[0142] With reference now to FIGS. 3a and 3b, a first arrangement
of apparatus 20 for forming blanks of the type having an article
retaining means 12 thereon is shown. Simply put, a stack of cut
blanks 100 as described hereinabove are passed through the
apparatus 20 which applies a sheet of lining material 12 thereto to
form the lined blank of the invention. The blank liner apparatus is
controlled via a central microprocessor-based controller unit (not
shown).
[0143] In the illustrated embodiment, the liner apparatus 20
comprises a first arrangement of blank feeding mechanism 22
comprising a magazine adapted to receive plain blanks cut to the
required specification. The mechanism, as is described in more
detail hereinbelow, is provided at the upstream end of the liner
apparatus 20 and includes a vacuum circuit 24 and optionally a
mechanical pusher 25 to introduce blanks individually to a glue
application station 26. Gripper or nip rollers 28 are used to guide
the blank between top and bottom feed belts 29 which carry the
blank past glue applicator guns 30 at which time hot melt glue is
selectively applied to the blanks. The hot melt glue is applied by
four glue guns 30 fed via heated hoses 31 from a hot melt glue
storage tank 32 under microprocessor control. The hot melt adhesive
is applied to the blank by a reciprocating compressed air position
pump to generate pressure and solenoid operated applicator guns 30
to open the pressure circuit to atmosphere, thereby accurately
firing the adhesive onto the board at points controlled by the
central control unit in accordance with the requirements determined
by the shape and design of the blank 100. The blank is then fed to
the liner application station 35 where shrink-wrap material 36 is
applied to the blank. The material is fed to the application
station 35 from a film drive system 37.
[0144] The shrink-wrap material 36 is provided as a film web from a
reel 38 mounted for rotation on a gravity axis 39 positioned
towards the downstream end of the apparatus. As a first reel 38 of
the material is depleted, the gravity axis 39 moves to activate a
splicing mechanism of the type well appreciated in the art. An
accumulator comprising a dancing arm roller 40 ensures that film is
provided to the apparatus during splicing so that an uninterrupted
supply is achieved. The film web is fed via a series of support
rollers 42 through a non-return gripper 43 to a pressure roller
arrangement 45 which adheres the film 36 to the blank 100 and
applies pressure to spread the glue between the blank and the liner
12 of film material 36. A film web cutter 46 has a transverse
cutter which operates "on the fly" and cuts using a cold blade
protected within a slotted anvil.
[0145] In an alternative arrangement (not shown), the web material
is applied to the blank in two separate sections, whereby at least
a central region of the base remains uncovered by the material. In
such an arrangement, the operation of the cutter defines the length
and position of the web applied to the blank. If required, the base
has no web material applied thereto and lengths of web material are
adhered only to the end walls.
[0146] A transfer conveyor 47 moves the blank with liner 12 towards
a pair of speeder pinch belts 49 which accelerate the blank and
liner onto a collating table 50. When the table 50 is full, a
discharge transfer mechanism 51 moves the accumulated stack of
blanks to an ejector table 52, which comprises a conveyor 53
disposed at 90.degree. to the direction of travel of the blanks
through the apparatus 20.
[0147] FIG. 3c illustrates a second arrangement of apparatus for
forming blanks which features an alternative arrangement of blank
feeding mechanism 70 but in all other respects is identical to the
apparatus of FIGS. 3a and 3b.
[0148] FIG. 3d is a perspective elevation of the first arrangement
of blank feeding mechanism 60 provided at the upstream end of the
lining apparatus 20. The mechanism comprises a support table 61
having a pair of adjustable side plates 62, each having an inwardly
facing blank edge engagement portion 63. An end plate 65 is
provided to square the stack of blanks into a magazine feed. On the
underside of the table 61 an upwardly facing vacuum operated
suction cup 66 is provided on a pair of rails 67 along which the
cup is free to move. To feed a single blank into the blank lining
apparatus 20, the suction cup 66 is brought upwardly into contact
with a blank 100 from the base of the stack. The vacuum is switched
ON and the cup 66 engages the blank. The cup is then moved
downwardly, deflecting the centre of the blank so that the edges
thereof are pulled from the blank edge engagement portions of the
side plates 62. The individual blank is then presented to the
lining apparatus 20 by the movement of the cup 66 along the rails
67. Gripper rollers 28 of the lining apparatus 20 then take the
blank as the vacuum to the cup 66 is released. The suction cup
assembly then moves back along the rails 67 to its central
position, ready to select the next blank.
[0149] Referring now to FIGS. 3e(i) to 3e(v), the second
arrangement of blank feeding mechanism 70 comprises a pair of lift
tables A,B positioned side by side on a wheeled shuttle carrier 72.
From start-up, a first lift table A is loaded with a stack of
blanks 100 in a first side position. The shuttle carrier 72 is then
moved so that the centre of the first table A aligns with a vacuum
picker mechanism 75. Individual blanks are fed into the machine
using the picker mechanism 75 which comprises a vacuum pump 76 and
a picker arm 75 having an array of suction cups 77 thereon. The
vacuum is presented at the suction cups 77 via a series of flexible
hoses 78 and associated couplings with valves controlled by a
sub-controller unit in communication with the central
microprocessor controller.
[0150] In common with the first arrangement of picker mechanism of
FIG. 3d, the vacuum pump 76 is run continuously and the vacuum at
the suction cups 77 is switched ON and OFF according to the
required action and/or the position of the picker arm with respect
to the machine.
[0151] When the blanks 100 are in position in the stack or
magazine, the picker arm 75 moves to engage the upper surface of
the top blank in the stack. When the arm engages the stack the
vacuum is switched to the suction cups which grip the blank. A
pressure differential switch in the vacuum circuit will register
whether the cups have obtained an adequate grip to lift the board
from the stack. The picker arm 75 is then moved back to a central
position with the blank and subsequently is extended to carry the
blank in a downstream direction, placing the leading edge 10G of
the blank 100 between a pair of rotating nip rollers 28 which carry
the blank into the lining apparatus 20.
[0152] At the instant the nip rollers 28 grip the blank and
commence feeding it into the lining apparatus, a valve switches to
remove the vacuum pressure from the suction cups 77 thereby
releasing the board. The picker arm 75 then returns towards the
central position until the trailing edge 11G of the blank passes a
sensor which via the controller signals the picker arm 75 to engage
another blank from the stack. The next blank is fed to the nip
rollers 28 as before with a relatively small gap (say 50 mm)
between the trailing edge 11G of one blank and the leading edge 10G
of the subsequent blank.
[0153] As the stack is depleted, the first lift table A elevates to
supply a continuous feed of blanks to the picker arm. As the table
reaches its upper lift limit with a predetermined number of boards
(say 30) left in the stack, a support mechanism comprising edge
support plates 79 moves under the remaining blanks and the first
lift table A is withdrawn. At this time, a second lift table B has
been fully loaded with blanks and is ready to replace the position
occupied by the first table A.
[0154] Provided confirmation is received that the second table B is
loaded, the shuttle carrier 72 is signalled to move the second
table B towards the central position to align with the picker
mechanism 75 as the first table A is lowered and is made ready to
receive a subsequent load of blanks. During this procedure, the
picker arm 75 continues to table blanks from the support mechanism
plates 79. When the stack on the second table B is aligned with the
picker mechanism 75, the blanks remaining on the support plates are
dropped onto the top of the stack as the support plates are
withdrawn. This stack is then raised by the lift table B so that
the uppermost blank is in the appropriate position to be engaged by
the picker arm. The support plates 79 again engage the underside
edges of the last blank remaining in the stack when the level
reaches a preset amount. This means the machine can be run
continuously without stoppage to maximise productivity rates.
[0155] FIG. 4 is an overview of a container forming apparatus 120
in which a magazine of lined container blanks 100 are stacked
vertically on a conveyor 122. A destacking arm 123, mounted for
rotation about a pivot 124, includes suction cups 125 for selecting
individual blanks from the front of the magazine to present said
blanks to container forming tools 127,128 movable along a carriage
arm 130. The container forming apparatus 120 includes a vacuum
circuit, elements of which will be described in more detail
hereinafter, which is powered via a continuously operated pump and
switched to and from air cylinders and suction cups via valves
operated under microprocessor control.
[0156] The container forming apparatus 120 further includes a
static folding die 135 having peripheral edge portions 136 adapted
to deflect elements of a container blank sequentially to facilitate
the formation of a container in conjunction with the forming tools
127,128. The folding die 135 includes suction cups 138 to engage
the base 2 of a container being formed so that the container is not
inadvertently withdrawn from the die 135 with the primary forming
tool 127 when it is retracted. Air cylinders 139 are positioned on
opposite sides of the folding die to urge elements of the container
blank to urge elements of the container blanks inwardly so that
they may be engaged during the downward stroke of one of the
forming tools 127,128. The carriage arm 130 provides a rail along
which the primary and secondary forming tools 127,129 move. Wheeled
coupling arrangements 140 are attached to a tool carrying support
member 142 to which the forming tools 127,128 are secured a fixed
distance apart. The tools are fixed to the support member 142 by
telescopic cylinders 145 which are pneumatically operated in this
embodiment. The primary forming tool 127 includes blank engaging
suction cups 147 attached to the vacuum circuit via the support
member 142 which also conveys pneumatic power to the telescopic
cylinders 145 and to air cylinder 148 provided within the secondary
forming tool 128. Adjacent the folding die 135, and spaced
therefrom a distance equal to the distance separating the primary
and secondary forming tools, 127,128, there is provided a discharge
conveyor 150 for transporting open-mouthed containers to a filling
station or to storage.
[0157] Each step of the container forming process, as illustrated
in the twelve vignettes or frames making up FIG. 5, will now be
described. The destacking arm 123 includes a series of suction cups
125 which attach to the front (unlined) surface of the leading one
of a magazine loaded with lined container blanks 100. The front
surface of the blank once folded becomes the outer surface of the
container thus formed. The magazine has a predetermined capacity
but operationally is replenished to provide a continuous supply of
vertically stacked blanks to the destacking arm 123.
[0158] The sequence is shown at the start of a production run with
no containers in the process of being formed. In Frame 1, a first
blank is selected by the destacking arm 123 when the arm moves from
a horizontal rest position about its pivot 124 to the front surface
of the leading board in the magazine. A vacuum is switched to the
suction cups 125 which engage the blank and separate it from the
magazine stack. The blank is carried with the arm as it pivots
towards its horizontal rest position. In Frame 2, the primary and
secondary forming tools 127,128 move together on the support member
142 as it is driven along the carriage arm 130 and the primary
forming tool 127 is lowered to abut the now horizontal blank, as
supported by the destacking arm. The suction cups 147 on the base
of the primary forming tool 127 engage the inner lined side of the
blank at the base 2 and the vacuum is switched OFF at the
destacking arm suction cups 125 and ON at the tool suction cups
147. As illustrated by Frame 4, the blank is then lifted by the
primary forming tool suction cups 147 and the support member 142
moves the primary forming tool 127 towards a precise position over
the container folding die 135. At the same time, the destacking arm
123 rotates about the pivot 124 from its horizontal rest position
towards the new leading (second) blank in the magazine. As the
blank is engaged by the suction cups 125 of the destacking arm, as
illustrated in Frame 5, the primary forming tool 127 lowers the
first blank towards the folding die 135 and "stuffs" the blank into
the die.
[0159] As the blank is "stuffed" into the die, the following
folding actions occur: [0160] the side wall tuck-in flaps 4C,6C are
deflected to a substantially vertical position; [0161] the longer
side wall base fold lines 4,6 are deflected substantially
vertically, which has the effect of moving the tuck-in flaps 4C,6C
into position adjacent the shorter end wall base fold lines 3,5;
and [0162] the end wall base fold lines 3,5 are deflected, hereby
forming an open-mouthed cuboid shape.
[0163] In Frame 6, the cuboid shape is retained in the folding die
135 by the suction cups 138 disposed in the bottom of the die and
the primary forming tool 127 is then withdrawn from the cuboid as
the vacuum to the forming tool suction cups 147 is removed. As the
tool is withdrawn, the subsequent blank is taken from the magazine
by the destacking arm 123, as described above.
[0164] When the new blank is in a horizontal position, as shown in
Frame 7, the support member 142 is moved along the carriage arm 130
so that the primary forming tool 127 is disposed over the region of
the blank due to form the base 2 of the next container and the
secondary forming tool 128 is disposed over the folding die 135
containing the open-mouthed cuboid shape of the preceding blank. At
this stage, the folding die air cylinders 139 (one pair on each
side) push pistons to fold the tuck-in flap positions of each end
wall 3B,5B over the lighter riser fold lines 3A,5A (thereby
ensuring that the fold occurs at the riser fold lines 3A,5A in
advance of any folding along the over-tab fold lines 3D,5D). The
pistons retain the flap portions 7 in a substantially horizontal
position. It should be noted that the pistons are disposed towards
the edges of the flap portions 7 so as not to impede the secondary
forming tool 128 when it descends into the folding die.
[0165] Frame 8 shows the primary forming tool engaging the
subsequent blank as supported by the destacking arm, as the
secondary forming tool is forced into the folding die. In this
sequence, the secondary forming tool 128 folds the tuck-in flap
portions 7 into the open-mouthed cuboid shape of the container and
the air cylinders 148 within the secondary forming tool 128 include
pistons which force the tuck-in flap positions 7 against the side
wall tuck-in flaps 4C,6C. This pushes the short rectangular
extensions 7A,7B of each flap portion 7 into the corresponding
receiver slots 8A,8B disposed in the base 2 immediately adjacent
the end wall base fold lines 3,5.
[0166] The pistons of the air cylinders 148 within the secondary
forming tool 128 include spikes at their free ends so that by
engaging the material of the newly formed open-mouthed container,
the container is withdrawn from the folding die when the secondary
forming tool 128 is retracted therefrom, as illustrated in Frame 9.
This action occurs concurrently with the lifting of the subsequent
blank from the destacking arm 123 by the primary forming tool
127.
[0167] In Frame 10 the destacking arm 123 again rotates towards the
leading blank in the magazine as the forming tool support member
142 moves the primary forming tool with the subsequent blank and
the secondary forming tool with the open-mouthed container over the
folding die 135 and the discharge conveyor 150, respectively. This
step is essentially the fully-loaded view of the apparatus as shown
earlier (in Frame 4).
[0168] Again, as the destacking aim 123 engages the leading blank
in the magazine, the primary forming tool "stuffs" a blank into the
folding die 135, commencing the folding step as before, and, as
shown in Frame 11, the secondary forming tool 127 places the
open-mouthed container onto the discharge conveyor 150. The pistons
of the air cylinders 148 within the secondary forming tool 128 are
withdrawn so that the spikes at the ends thereof disengage the
material of the container. As the stuffing and folding of the
subsequent container takes place, a new blank is grabbed by the
suction cups 125 of the destacking arm 123. When the destacking arm
carries the new blank towards the horizontal rest position, as
shown in Frame 12, the primary and secondary tools are withdrawn
from their respective partially formed and fully formed
open-mouthed containers.
[0169] The containers thus formed are conveyed by the discharge
conveyor 150 either to storage or, more conveniently, to a filling
and sealing machine. The lid portions 10,11 remain standing
substantially vertically throughout the forming process after the
blank has been "stuffed" into the folding die. The tuck-in flaps
10B,11B protrude sidewardly from the first and second lid portions
10,11 as the container is discharged from the apparatus.
[0170] Referring now to FIGS. 6a and 6b, an alternative arrangement
of container forming apparatus 160 is shown. As in FIG. 4, the
forming apparatus 160 includes a static folding die 135 and primary
and secondary forming tools 127,128 for engagement therewith. The
forming tools are spaced apart on a support member 142 moveable
along a carriage arm 130 and moveable vertically by means of
telescopic cylinders 145, as before. In this arrangement, the
magazine for feeding lined blanks 100 to the forming apparatus
comprises a stack of blanks mounted on support tables A,B, similar
to the arrangement described in detail in FIGS. 3e(i) to 3e(v). As
the operation and loading of the tables is so similar to that
previously described, no further detail appears necessary here. As
shown in FIGS. 4 and 5, the sequential steps to forming a container
are unchanged with the omission of the destacking arm thereof.
[0171] FIG. 7 illustrates a filling and closing station 170 for
containers of the type disclosed herein. In the illustrated
embodiment, tow container forming apparatus 120 are the first
forming a smaller size container relative to the larger container
formed by the second apparatus. The open-mouthed containers are fed
from their respective discharge conveyors 150 to a buffer conveyor
172 which in turn places containers in a two level accumulator 175
adjacent a plurality of packing tables 178. The containers are
manually removed from the accumulator 175 and packed with the
contents and the flaps 14,15 of the liner material 12 are torn from
the glue spots 13a attaching them to the lid portions 10,11 to be
laid over one another over the contents 16 of the container. A
label indicating the destination of the contents is then adhered to
a side wall or a lid portion of the container and the filled
container is placed onto a discharge conveyor disposed beneath the
accumulator 175. The discharge conveyor includes a zoned region 180
terminated with a drop gate 181. Containers are metered through the
gage 181 to a transfer zone 182 from which they are fed through a
"shrink tunnel" 184 comprising a heating chamber as detailed
hereinbelow with reference to FIGS. 8a to 8c. Heat applied to the
exposed liner material 12 overlying the contents 16 of the
container causes the material 12 to shrink around the contents 16
creating the tension lines 17 in the material as referred to in
FIG. 2c. The contents are now restrained within the container which
is passed through a visual inspection station 186 for lid closure,
sealing and dispatch.
[0172] Ideally, lid closure and sealing is automated using well
established techniques. Referring now to FIGS. 8a to 8c, a heat
chamber 187 of the "shrink tunnel" 184 is shown. As discussed
above, the zoned region 180 of the discharge conveyor includes a
drop gate 181 which is moved by a lid opener mechanism. A container
passed through the gate 181 is fed onto a further conveyor 190 by a
pusher mechanism 191 to effect a 90.degree. transfer onto said
conveyor 190 which transports the open-mouthed container and
contents through the heat chamber 187. A fan 193 blows heated air
directly down into the container and expelled air is recirculated
back towards the fan 193 for reheating. The heat chamber 187 runs
at approximately 175 C with low dwell time to ensure no damage to
the contents for dispatch.
[0173] It will be appreciated by the skilled addressee that machine
forming of the blank facilitates fast and efficient forming of the
open-mouthed containers for subsequent reception of materials. It
will be further appreciated that by adapting the magazine, the
folding tools and the folding die, other blanks which have been
modified for machine folding may also be considered. For example
and with reference to FIG. 9, a substantially standard blank of the
well-known RSC case may be modified to include a shrink-wrappable
liner film thereon. The RSC case blank 200 has four side walls
201,202,203,204 and a securing flap 205, which is normally folded
around fold line 205a from the final side wall 204 inside the first
side wall 201 and glued or stapled thereto. Base portions
211,212,213,214 are attached to their respective side walls via
fold lines 201A,202A,203A,204A and lid or top portions
221,222,223,224 are attached to their respective side walls via
further fold lines 201B,202B,203B,204B. The RSC case blank 200
includes a web of film 230 which extends at least over the side
walls 201,202,203,204, over at least a portion of the base portions
211,212,213,214 and over substantially all of the lid portions
221,222,223,224. The web of film 230 is adhered to the base
portions by glue lines 232 positioned so as to ensure mechanical
entrapment of the web 230 when the base portions 211,212,213,214 of
the RSC case are folded. Glue spots 233 are provided to adhere the
web 230 to the top or lid portions to prevent the web falling into
the container during formation and during conveying or loading.
Additionally, the glue spots 233 prevent the web 30 from becoming
entangled in the container forming apparatus. Before the container
is closed, the web is mechanically separated from the lid positions
to overlie the contents of the case. Heat is then applied directly
or indirectly to the web to shrink-wrap the contents in place to
attenuate potentially damaging movement of the contents during
freight or further conveying, for example.
[0174] It will be appreciated by the skilled addressee that the
shrink-wrappable web material web may be substitute by different
materials which can be bonded to secure the contents of the
container therein. Materials having selectively applied adhesives
or materials having characteristics which enable the free ends
thereof to adhere to one another with sufficient strength to
achieve the desired results (including in a manner akin to
so-called "cling-films") may also be used.
[0175] It will of course be understood that the invention is not
limited to the specific details described herein, which are given
by way of example only, and that various modifications and
alterations are possible within the scope of the appended
claims.
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