U.S. patent application number 12/072990 was filed with the patent office on 2008-07-03 for system and method for assembling a package with a flip-top.
This patent application is currently assigned to Thiele Technologies, Inc.. Invention is credited to Radjoe Bajic, Yugoslav Kokotovic, Peter Tisma, Steven Tisma.
Application Number | 20080155943 12/072990 |
Document ID | / |
Family ID | 34104571 |
Filed Date | 2008-07-03 |
United States Patent
Application |
20080155943 |
Kind Code |
A1 |
Tisma; Peter ; et
al. |
July 3, 2008 |
System and method for assembling a package with a flip-top
Abstract
An automatic packaging machine for forming a latching flip-top
box from a blank. A plurality of mandrels are coupled to a conveyor
system. Each of the mandrels include a mounting block for coupling
the mandrel to the automatic packaging machine, a package-holding
assembly operatively connected to the mounting block and being
rotatable about a first axis from a first position to a second
position, and a flap holder assembly operatively connected to the
mounting block. The flap holder assembly is rotatable about a
second axis substantially perpendicular to the first axis. A
plurality of plows and tucker assemblies sequentially manipulate
portions of the blank in order to form portions of the box.
Inventors: |
Tisma; Peter; (Glenview,
IL) ; Kokotovic; Yugoslav; (Elk Grove Village,
IL) ; Bajic; Radjoe; (Addison, IL) ; Tisma;
Steven; (Schaumburg, IL) |
Correspondence
Address: |
MARK D MILLER;KIMBLE, MACMICHAEL & UPTON
5260 NORTH PALM AVENUE, SUITE 221
FRESNO
CA
93704
US
|
Assignee: |
Thiele Technologies, Inc.
|
Family ID: |
34104571 |
Appl. No.: |
12/072990 |
Filed: |
February 29, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11185250 |
Jul 20, 2005 |
7338423 |
|
|
12072990 |
|
|
|
|
10633337 |
Aug 1, 2003 |
6962556 |
|
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11185250 |
|
|
|
|
Current U.S.
Class: |
53/377.6 ;
53/484 |
Current CPC
Class: |
B65D 5/6623 20130101;
B31B 50/78 20170801; B31B 50/788 20170801; B65B 25/005 20130101;
B65B 43/265 20130101; Y10S 493/911 20130101; B31B 50/54 20170801;
B65B 43/10 20130101; B31B 2120/30 20170801; B31B 2100/00 20170801;
B31B 50/004 20170801; B65D 5/727 20130101 |
Class at
Publication: |
53/377.6 ;
53/484 |
International
Class: |
B65B 51/00 20060101
B65B051/00 |
Claims
1. A mandrel having a mounting block and for use with an automatic
packaging machine and having a mounting block for coupling to the
automatic packaging machine, the mandrel comprising: a
package-holding assembly operatively connected to the mounting
block, the package-holding assembly rotatable about a first axis
from a first position to a second position; and a flap holder
assembly operatively connected to the mounting block, the flap
holder assembly rotatable about a second axis substantially
perpendicular to the first axis.
2. The mandrel of claim l, further comprising a lateral support
member coupled to the mounting block, wherein the package-holding
assembly is rotapanelly connected to the lateral support
member.
3. The mandrel of claim 2, further comprising means for maintaining
the package-holding assembly in the first position relative to the
lateral support member.
4. The mandrel of claim 3, wherein the maintaining means comprises
a latching member coupled to the lateral support member, the
latching member releaseably mating with a bushing on the
package-holding assembly.
5. The mandrel of claim 3, wherein the package-holding assembly
comprises a plurality of gripping arms, the plurality of gripping
arms selectively permitting a package blank to be captured by the
package-holding assembly.
6. The mandrel of claim 5, wherein the package-holding assembly
further comprises a guide mechanism positioned within the plurality
of gripping arms, the guide mechanism holding the package blank
during the assembly thereof.
7. The mandrel of claim 2, wherein the flap holder assembly
includes a plurality of side arms for contacting portions of a
package blank.
8. A mandrel for use with an automatic packaging machine in forming
a package with a flip-top, comprising: a mounting block for
coupling the mandrel to the automatic packaging machine, a
package-holding assembly operatively connected to the mounting
block, the package-holding assembly having a free end and a fixed
end, the free end having a secured position and an unsecured
position and being rotatable about a first axis between the secured
position and the unsecured position; a lateral support member
coupled to the mounting block, wherein the package-holding assembly
is rotapanelly connected to the lateral support member; a latch
coupled to the lateral support member for releasably connecting the
free end of the package-holding assembly; and a flap holder
assembly operatively connected to the mounting block, the flap
holder assembly rotatable about a second axis substantially
perpendicular to the first axis.
9. The mandrel of claim 8, wherein the package-holding assembly
includes a plurality of gripping arms for selectively permitting a
package blank to be captured by the package-holding assembly.
10. The mandrel of claim 9, wherein the package-holding assembly
further comprises a guide mechanism positioned within the plurality
of gripping arms, the guide mechanism holding the package blank
during the assembly thereof.
11. The mandrel of claim 8, wherein the flap holder assembly
includes a plurality of side arms for contacting portions of a
package blank.
12. A method of forming a latching flip-top box having a flip-top
portion hingedly connected to the box along a minor axis of the
box, comprising the steps of: providing a box blank; placing the
unitary box blank in a mandrel, the mandrel, coupled to a conveyor
system and comprising: a package-holding assembly rotatable about a
first axis from a first position to a second position; and a flap
holder assembly operatively connected to the package-holding
assembly, the flap holder assembly rotatable from a retracted
position to an extended position about a second axis substantially
perpendicular to the first axis, folding a first lower flap of the
box blank with a first plow; folding a second lower flap of the box
blank onto the first lower flap with a second plow; folding a third
lower flap of the box blank onto the second lower flap with a third
plow; applying an adhesive to the third lower flap; folding a
fourth lower flap of the box blank onto the third lower flap with a
fourth plow; rotating the package-holding assembly about the first
axis from the first position to the second position; folding a
first front upper panel of the box blank with a first tucker
assembly; folding a latching panel of the box blank using the first
tucker assembly; folding a second front upper panel of the box
blank using a fifth plow; rotating the flap holder assembly from
the retracted position to the extended position, the flap holder
assembly folding a flip top panel and first and second flip-top
wing panels of the box blank; folding a first wing panel of the box
blank using a second tucker assembly; folding a second wing panel
of the box blank using the second tucker assembly; applying
adhesive to either exposed surfaces on the first and second wing
panels or an underside of a front flip-top panel; folding the front
flip-top panel onto the exposed surfaces of the first and second
wing panels using a sixth plow; rotating the flap holder assembly
from the extended position to the retracted position; rotating the
package-holding assembly about the first axis from the second
position to the first position; folding a first rear upper panel of
the box blank using a seventh plow; applying adhesive to either an
exposed surface on the first rear upper panel or an underside of a
second rear upper panel; folding the second rear upper panel onto
the exposed surface of the first rear upper panel using an eighth
plow.
13. The method of claim 12, further comprising the step of using a
ninth plow to eject the latching flip-top box from the mandrel.
14. The method of claim 12, wherein the mandrel includes a latching
mechanism for releasably securing the package-holding assembly in
the first position.
15. The method of claim 12, wherein the package-holding assembly
includes a plurality of gripping arms, the plurality of gripping
arms opening to allow a box blank to enter the package-holding
assembly.
Description
CROSS-REFERENCE TO RELATED PATENT APPLICATIONS
[0001] This is a divisional of U.S. patent application Ser. No.
11/185,250 filed on Jul. 20, 2005, which is a divisional of U.S.
Utility patent application Ser. No. 10/633,337 filed on Aug. 1,
2003, now U.S. Pat. No. 6,962,556, both of which are incorporated
herein by this reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates generally to automatic
packaging machines. More particularly, the present invention
relates systems and method for assembling self-latching boxes
and/or packages with a flip top.
BACKGROUND OF THE INVENTION
[0003] Various types of automatic packaging machines are known and
used for assembling paperboard and/or cardboard packages from
precut box blanks. These packages can be used to hold a wide
variety of items, ranging from chewing gum to candy to office
supplies: U.S. Pat. Nos. 4,578,929; 4,548,593; 4,716,714;
4,829,751; 4,856,566; 4,982,556; 5,010,929; 5,072,573; 5,144,790;
and 6,195,959 are examples of packaging machines which may be used
to load small items into different types of packages.
[0004] Conventional automatic packing machines include a conveyor,
usually an endless link chain conveyor, which travels through or
past a number of work stations extending between a magazine
containing package blanks and a product discharge end. Usually, the
package blanks are a stack of die cut paperboard or cardboard
blanks which are picked up one-at-a-time by vacuum cups and then
put into package-forming mandrels carried by the conveyor. Panels
and flaps on the bottom of the blank are folded by a series of
plows and sealed in order to close the package. A pre-determined
amount of product is then placed in the package. Next, panels and
flaps forming a top of the package are folded and sealed. Then the
package is discharged onto any suitable conveyor, into a shipping
carton, or to another device for receiving the completed product
containing packaging.
[0005] Conventionally, a plow is a strip of metal, or the like,
extending along a length of the conveyor and in a location where
the panels and flaps are to be folded. First, panels and flaps
forming the bottom of the package encounter the plows and then are
folded as the conveyor carries the package past the plow. Then, a
pre-determined amount of product is placed in the package. Next,
panels and flaps forming a top of the package are folded and sealed
in a similar manner. Depending upon product packaging needs, the
package may or may not be wrapped in a transparent film which is
sealed. Finally, the package is discharged onto any suitable
conveyor, into a shipping box or another suitable device for
receiving the product containing package.
[0006] Often, the product presents special considerations which
require the packaging machine to perform unique functions as the
package is formed and filled. These functions may be performed by
special parts which are attached to or positioned near the
conveyor. Many examples of such special parts are shown and
described in the above-cited patents.
[0007] One type of conventional package which is often used for
candy and mints is commonly referred to as a "flip-top" box or
package. Such a package is made from a single, unitary, die cut
blank of thin cardboard stock. A flip-top package has a bottom
section which is in the form of a rectangular parallelepiped. The
top of the package is in the form of a hood connected to the bottom
along a crease line which acts as a hinge. The hood moves away from
or over the top of the package in order to open or close it. It is
necessary for the packaging machine to first form the blank into
the package, then count a specific number of small items, such as
candy coated chewing gum, next deposit them in the package, and
finally close and seal the package. One such "flip-top" package is
shown in prior art FIG. 1.
[0008] Prior art FIG. 2 shows one type of example automatic
packaging machine for assembling the type of "flip-top" package of
FIG. 1. This machine is described in detail in U.S. Pat. No.
6,195,959 and is incorporated herein by reference. This system uses
a two-part mandrel which is joined by a single hinge. One of the
two hinged parts includes a roller thereon for following a cam
track having a quarter turn spiral therein. As the roller follows
the spiral causing one hinged part to move through a quarter turn,
the flip-top is folded over and formed.
[0009] In the conventional "flip-top" package shown in FIG. 1, the
hinge of the flip-top joins the flip-top to the entire width of the
(longer) major plane of the package. As a result, when the flip-top
is opened, the entire top area of the package is exposed. Recently,
however, a new type of "flip-top" package has been developed. This
new package is shown at 98 in FIG. 3. The package 98, like the
conventional package of FIG. 1, includes a flip-top 101 hingedly
connected to an upper portion 103 of the package. Unlike the
conventional package, however, the flip-top's hinge 105 runs along
the (shorter) minor plane of the package, substantially
perpendicular to the hinge line of the conventional "flip top"
package. Furthermore, the hinge 105 runs across the middle of the
package top, unlike the conventional package. As a result, the new
package 98 has a hole 108 within a side panel 106 of the package 98
instead of having the top entirely open when the flip-top 101 is
"flipped open."
[0010] This new type of "partial flip-top" package requires several
more distinct flaps than the previous packages, which adds a
significant amount of complexity to any machine for assembling and
filling the packages. In particular, problems arise because the
mandrels used in the conventional assembly devices are not properly
aligned to fold down the top panels of the package blank to form
the flip-top of the package. Several additional steps are therefore
required to complete the assembly process. This results in
increased complexity and assembly time, diminishing the assembly
machine's efficiency.
SUMMARY
[0011] It is therefore one object of the invention to provide an
improved system and method for assembling a "flip top" package.
[0012] It is another object of the invention to provide a system
and method for assembling a "flip-top" package where the flip-top
of the package is hingedly connected to the top of the package
along a hinge line running through the middle of the package
top.
[0013] It is another object of the invention to provide a system
and method for assembling a "flip-top" package that includes a
minimal amount of manual labor.
[0014] It is still another object of the invention to provide a
system and method for assembling a "flip-top" package that can be
assembled in a minimal amount of time.
[0015] In accordance with the invention and the above examples of
objects, a system and method is provided for assembling a "partial
flip-top" box or package in a highly efficient manner. In a
preferred embodiment, a plurality of mandrels are coupled to an
"endless link" chain conveyor. Each mandrel includes a mounting
bracket for coupling the mandrel to a rail. The bracket is
operatively connected to a package-holding subassembly. The
package-holding assembly includes a gripping mechanism for holding
the package blank during assembly. The package-holding assembly is
rotatable about a first axis relative to the rest of the mandrel. A
flap holder subassembly is also operatively connected to the
bracket. The flap holder assembly is rotatable about a second axis
substantially perpendicular to the first axis. The rotation of the
package-holding assembly permits the package blank to be moved into
various orientations such that the blank can be quickly and
efficiently assembled into a "partial flip-top" package. In one
preferred embodiment of the invention, the system and method
results in up to 400 partial flip-top packages being assembled per
minute.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a partial perspective view of a prior art latching
flip-top package;
[0017] FIG. 2 is a perspective view of a prior art automatic
packaging machine for assembling the flip-top package of FIG.
1;
[0018] FIG. 3 is a perspective view of a latching "partial"
flip-top package in the closed position;
[0019] FIG. 4 is a perspective view of the package of FIG. 3 in the
open position;
[0020] FIG. 5 is a plan view of a fully unassembled package blank
for the package of FIG. 3 (viewing the outside surface of the
blank);
[0021] FIG. 6 is a perspective view of a mandrel used to form and
close the flip-top package of FIG. 3, with the mandrel including a
package-holding assembly in a fully retracted position;
[0022] FIG. 7 is a side view of the mandrel of FIG. 6;
[0023] FIG. 8 is a perspective view of the mandrel of FIG. 6 with
the package-holding assembly in a partially rotated position;
[0024] FIG. 9 is a perspective view of the mandrel of FIG. 6 with
the package-holding assembly in a fully rotated position;
[0025] FIG. 10 is a side view of the mandrel of FIG. 9;
[0026] FIG. 11 is a perspective view of the mandrel of FIG. 6 with
the package-holding assembly in a fully rotated position and a flap
holder assembly in a fully rotated position;
[0027] FIG. 12 is a perspective view of a partially assembled
partial flip-top package;
[0028] FIG. 13 is a perspective view of a partially assembled
partial flip-top package in its state as the package-holding
assembly is being rotated;
[0029] FIG. 14 is a perspective view of a first tucker assembly for
folding two of the panels of the partial flip-top package of FIG.
3;
[0030] FIG. 15 is a perspective view of a second tucker assembly
for folding two of the panels of the partial flip-top package of
FIG. 3;
[0031] FIG. 16 is a representation of one plow folding the top
flip-top panel;
[0032] FIG. 17 is a representation of another plow folding the
first rear upper panel; and
[0033] FIG. 18 is a flow chart representing the package assembly
process according to one embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0034] FIGS. 3 and 4 show a paperboard package 98 including a
"partial" latching flip-top package flip-top 101 which is folded,
formed, filled, and sealed by an automatic package machine
according to one form of the invention. The package 98, has the
flip-top 101 hingedly connected to an upper portion 103 of the
package 98. The hinge 105 between the flip-top 101 and the upper
portion 103 runs along the (shorter) minor plane of the package,
substantially perpendicular to where the hinge line would be on a
conventional "flip top" package. The hinge 105 runs across the
middle of the upper portion 103. The package 98 includes a hole 108
within a minor side panel 106 of the package 98 instead of having
the top entirely open when the flip-top 101 is "flipped open." In
this new package, the hole 108 is exposed when the flip-top 101 is
flipped open, as shown in FIG. 4, and the hole 108 is unexposed
when the flip-top 101 is closed.
[0035] FIG. 5 shows a paperboard package blank 99 that is
ultimately assembled into the package 98 shown in FIGS. 3-4. The
package blank 99 includes a first major side 100, a second major
side 102, a first minor side 104 and a second minor side 106. The
second minor side 106 includes a hole 108 prepunched therein. When
the package 98 is fully assembled and filled, the packaged product
is ejected through the hole 108. An inner panel 110 is attached to
the edge of the second minor side 106 opposite the second major
side 102. According to one particular preferred embodiment, the
inner panel 110 is pre-secured to the inside of the first major
side 100 before the blank 99 enters the package machine. Preferably
glue or some other type of adhesive or adhesion method is used to
secure the inner panel 106 to the first major side 100.
[0036] The bottom of the package is formed by the combination of a
first minor lower flap 112, a second minor lower flap 114, a first
major lower flap 116 and a second major lower flap 118. As is
discussed herein, in the most preferred embodiment these flaps are
sequentially folded during the assembly process such that the
second major lower flap is the outermost flap when the package 98
is completed, serving as the "bottom" of the package.
[0037] A latching panel 122 is coupled to the top of the second
minor side 106. The latching panel 122 is folded downward during
the assembly process. When the package 98 is fully assembled, the
latching panel 122 will come into contact with the underside of the
flip-top 101, providing a certain degree of resistance and helping
to keep the flip-top 101 in the closed position relative to the
rest of the package 98. The flexibility of the latching panel 122
enables it to be released from the flip-top 101 when the flip-top
101 is manually opened to the position shown in FIG. 4. Yet, the
resilience of the latching panel 122 is such that the flip-top 101
is again captured when closed.
[0038] A first front upper panel 124 is coupled to the first major
side 100, and a second front upper panel 120 is coupled to second
major side 102. Similarly, a first rear upper panel 134 is coupled
to the first major side 100; and a second rear upper panel 136 is
coupled to the second major side 102. As will be discussed herein,
the first and second front upper panels 124 and 120 eventually
cooperate to the top portion of the package 98 between the flip-top
101 and the rest of the package 98, the first and second rear upper
panels 134 and 136 eventually cooperating to form the top of the
package 98 behind the flip-top 101.
[0039] The flip-top 101 of the package 98 is formed by the folding
of several sequential panels as is discussed herein. A rear
flip-top panel 126a is coupled to the first minor side 104 on one
edge and an intermediate flip-top panel 127 on an opposite edge. A
front flip-top panel 132 is coupled to the intermediate flip-top
panel 127 on an edge of the intermediate flip-top panel 127
opposite the rear flip-top panel 126a. First and second flip-top
wing panels 126b and 126c, respectively, are also coupled to the
intermediate flip-top panel 127 on opposite sides thereof. The
first flip-top wing panel 126b has a first wing panel 128 coupled
to one edge thereof. Similarly, the second flip-top wing panel 126c
has a second wing panel 130 coupled to one edge thereof.
[0040] The back of the top portion of the package 98 is formed by
the subsequent folding of a first rear upper panel 134 and a second
rear upper panel 136. The first rear upper panel 134 is connected
to the first major side 100, and the second rear upper panel 136 is
coupled to the second major side 102.
[0041] The present invention provides an automatic packaging
machine which forms, fills and closes the package shown and
described in FIGS. 3-5 and FIGS. 12-13, by use of a mandrel 200
shown in FIGS. 6-11.
[0042] The automatic packaging machine comprises a plurality of the
mandrels 200 coupled to a conveyor system. An example of a
conventional conveyor system is shown in prior art FIG. 2. As shown
in FIGS. 6-11, each of the mandrels 200 comprises a mounting block
202 that couples the mandrel 200 to a suitable conveyor, an example
of which is shown in prior art FIG. 2, so that the mandrel 200 is
carried by and moves with the conveyor. In one embodiment of the
invention, the conveyor comprises a link chain. The mounting block
202 is operatively connected to a package-holding assembly 204. The
package-holding assembly 204 includes a movable gripper 206
surrounding a guide mechanism 208 for holding a package blank 99
during assembly. The gripper 206 includes a first gripper half 210
and a second gripper half 212, each of which is capable of moving
away from each other in order to allow a package blank 99 to be
placed within the guide mechanism 208. After the blank is placed
within the guide mechanism 208 first gripper half 210 and the
second gripper half 212 move towards each other. It is also
possible that the first gripper half 210 can be formed from two
pieces, as can the second gripper half 212 and the guide mechanism
208.
[0043] Each mandrel 200 includes a support member 214 connected to
a side of the mounting block 202. The package-holding assembly 204
is rotatably connected to the support member 214 at a first axis
216. A latching member 218 is attached to the support member 214 at
an end substantially opposite the first axis 216. The latching
member 218 is capable of capturing and fixing the position of a
bushing 220 on the package-holding assembly 204. When the latching
member 218 releases the bushing 220, the package-holding assembly
204 is capable of rotating about the first axis 216, which is
substantially vertical according to one preferred embodiment of the
invention.
[0044] Each of the mandrels 200 also includes a flap holder
assembly 222 operatively connected to the support member 214. The
flap holder assembly 222 is rotatable about a second axis 224 which
is substantially perpendicular to the first axis 216. The flap
holder assembly 222 is used primarily to push down the rear
flip-top portion 126a and also push down the connected portions
that comprise the flip-top 101 towards the rest of the package
98.
[0045] According to a preferred embodiment shown in FIGS. 14-15, a
first tucker assembly 400 and a second tucker assembly 420 are used
to make additional folds in the package 98. Both the first tucker
assembly 400 and the second tucker assembly 420 are attached to the
package machine and strategically located to come into contact with
multiple panels.
[0046] The first tucker assembly 400 comprises a first tucker 402
with multiple flanges 408. The first tucker 402 is coupled to a
rotatable shaft 404 which is operatively connected to a transverse
member 406, with the transverse member 406 ultimately connected to
the rest of the machine of the present invention. The second tucker
assembly 420 comprises a second tucker 422 including a pair of
slots 424 and is operatively connected to the rest of the package
machine in a manner substantially identical to that of the first
tucker 402.
[0047] The first tucker 402 is positioned such that the leading
edges of two of its flanges 408 sequentially come into contact with
the second front upper panel 120 and the latching panel 122,
pushing both panels downward and into the appropriate positions.
Similarly, the pair of slots 424 on the second tucker 422
sequentially "catch" the first wing panel 128 and the second wing
panel 130, folding them inward to their new positions.
[0048] The assembly of the package 98 in a most preferred
embodiment is generally as follows and as represented in FIG. 18.
As discussed above, glue or some other type of conventional
adhesion method is used to secure the inner panel 106 to the first
major side 100 before the package blank 99 is placed into the
machine. The package blank 99 is moved into the machine by use of a
plurality of suction devices (not shown) that "grab" the package
blank 99 and transport it to a mandrel 200. Before receiving the
package blank 99, the first gripper half 210 and the second gripper
half 212 open, shown at 500, to allow the package blank 99 to enter
the guide mechanism 208, shown at 502. After the package blank 99
has been inserted into guide mechanism 208, the first gripper half
210 and the second gripper half 212 close, shown at 504.
[0049] After the package blank 99 is placed within the guide
mechanism 208, the mandrel 200 moves along a conveyor. At step 506,
the first minor lower flap 112 comes into contact with a first plow
(not shown), folding the first minor lower flap 112 inward. The
second minor lower flap 114 is then folded inward by a second plow
(not shown), shown at step 508. The first major lower flap 116 then
comes into contact with a third plow (not shown), folding the first
major lower flap 116 inward at 510. A glue or some other type of
adhesive is then applied to the exposed side of the first major
lower flap 116, shown at step 512. Immediately thereafter, a fourth
plow (not shown) folds the second major lower flap 118 onto the
first major lower flap 116, shown at 514.
[0050] At this stage, the bottom of the package 98 is completely
assembled. At step 516, a cam on the machine acts against the
mandrel 200, causing the latching member 218 to disengage from the
bushing 220 and causing the package-holding assembly 204 to rotate
approximately ninety degrees about the first axis 216 from the
position shown in FIGS. 6-7 to the position shown in FIGS.
9-10.
[0051] Once the package-holding assembly 204 has been rotated
ninety degrees, the mandrel 200 reaches the first tucker assembly
400. At step 518, one of the flanges 408 of the first tucker 402
comes into contact and folds down the second front upper panel 120.
This is followed at step 520 by another of the flanges 408 of the
first tucker 402 coming into contact with the latching panel 122,
folding it downward and outward from the center of the package 98.
This moves the latching panel 122 into a loosely folded position
where it is later caught by the panels on the flip-top 101, thereby
creating a latching condition. Glue or another type of adhesive is
then placed on the exposed surface of the second front upper panel
120, shown at 522. This is followed at step 524 by a fifth plow
(not shown) coming into contact with and folding down the first
front upper panel 124 onto the exposed surface of the second front
upper panel 120.
[0052] At step 526, the flap holder assembly 222 is rotated
approximately ninety degrees about the second axis 224. This action
causes the front flip-top panel 132 to fold downward towards the
rest of the package 98. Simultaneously, first and second side
members 230 and 232 on the flap holder assembly 222 come into
contact with the first and second flip-top wing panels 126b and
126c, respectively, causing them to fold inward (if necessary, a
small spacer 233 can be used to achieve a precise alignment and
positioning of the first and/or second flip-top wing panels 126b
and 126c).
[0053] The mandrel 200 then reaches the second tucker assembly 420.
The slots 424 on the second tucker 422 then sequentially grab and
fold the first wing panel 128 and the second wing panel 130 inward,
shown at steps 528 and 530. At step 532, glue or another type of
adhesive is then applied to the exposed surfaces of the first and
second wing panels 128 and 130. It is also possible to locate the
glue or another type of adhesive on the underside of the front
flip-top panel 132. A sixth plow 300 is then used at step 534 to
fold the front flip-top panel 132 downward and secure it to the
exposed sides of the first and second wing panels 128 and 130. This
effectively forms the lid 101 of the package 98.
[0054] At step 535, the package-holding assembly 204 is rotated
back about the first axis 216 from the second position to the first
position. The next step of the process, represented at 536,
involves the package-holding assembly 204 rotating back to its
original position. This can be accomplished by the use of a cam or
other conventional system known to those skilled in the art. At
step 538, a seventh plow 302 contacts and folds downward a first
rear upper panel 134. At step 540, glue or another type of adhesive
is applied to the exposed side of the first rear upper panel 134.
This is followed at step 542 by an eighth plow (not shown)
contacting and folding downward the second rear upper panel 136
onto the exposed surface of the first rear upper panel 134. At step
544, the completed package 98 is discharged from the mandrel 200,
where any suitable means is, provided to carry the box 98 away for
disposition.
[0055] As discussed above, a series of plows are provided for
making a series of strategic folds in the package 98. FIGS. 16 and
17 illustrate how two exemplary plows operate to fold individual
panels. In FIG. 17, the sixth plow 300 is used to fold the front
flip-top panel 132. In FIG. 16, the seventh plow 302 is used to
fold down the first rear upper panel 134. A series of other plows
(not shown) are used through the assembly process to make other
folds in a manner that is known to those skilled in the art.
According to a preferred embodiment of the invention, all of the
plows remain stationary during the assembly process, while each
individual mandrel 200 moves the packages 98 into contact with the
plows.
[0056] At one stage during the package assembly process, the
product to be packaged is deposited into the partially-completed
package 98. In one preferred embodiment of the invention, this
occurs between steps 514 and 516, when the bottom of the package 98
has been completely assembled; but the top of the package 98
remains open. However, it is possible that the filling of the
package could occur at some other time. The filling process is
performed automatically by methods known by those skilled in the
art.
[0057] Using the preferred system described herein, up to about 400
packages can be assembled per minute, while maintaining a fully
automated system.
[0058] It should be understood that the above description of the
invention and the specific examples and embodiments, while
indicating the preferred embodiments of the present invention, are
given by demonstration and not limitation. For example, it is
possible to use different types of tuckers and plows in various
orders to complete the assembly of the package 98. Many changes and
modifications within the scope of the present invention may
therefore be made without departing from the spirit of the
invention, and the invention includes all such inventions and
modifications.
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