U.S. patent application number 12/752365 was filed with the patent office on 2010-10-07 for box opening structure.
Invention is credited to William B. Elliott, Joseph M. Fisher, Timothy J. Green.
Application Number | 20100251674 12/752365 |
Document ID | / |
Family ID | 42825026 |
Filed Date | 2010-10-07 |
United States Patent
Application |
20100251674 |
Kind Code |
A1 |
Fisher; Joseph M. ; et
al. |
October 7, 2010 |
Box Opening Structure
Abstract
A member for opening a rectangular cuboid includes a elongated
body having an insertion section, a delamination and a folding
section sequentially positioned along the longitudinal axis of the
body. The insertion section includes a tapered insertion end
configured for guiding the body into an opening in an end of the
cuboid. The delamination section is configured to laterally
displace first and second flaps of the cuboid relative to each
other away from a first sealed position. The opening section has
oppositely facing sidewalls to deflect the first and second flaps
to a second open position at which the first and second flaps are
opened past first and second sides of the cuboid. A machine having
the opening member and a method of opening a rectangular cuboid are
also included.
Inventors: |
Fisher; Joseph M.; (Depew,
NY) ; Green; Timothy J.; (North Tonawanda, NY)
; Elliott; William B.; (Aiden, NY) |
Correspondence
Address: |
LEYDIG VOIT & MAYER, LTD
TWO PRUDENTIAL PLAZA, SUITE 4900, 180 NORTH STETSON AVENUE
CHICAGO
IL
60601-6731
US
|
Family ID: |
42825026 |
Appl. No.: |
12/752365 |
Filed: |
April 1, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61165667 |
Apr 1, 2009 |
|
|
|
Current U.S.
Class: |
53/492 ;
53/382.1 |
Current CPC
Class: |
B65B 7/20 20130101 |
Class at
Publication: |
53/492 ;
53/382.1 |
International
Class: |
B65B 43/38 20060101
B65B043/38 |
Claims
1. A member for non-destructively opening a rectangular cuboid upon
movement of said cuboid relative to said member along a drive path,
said cuboid having first and second oppositely facing side with
first and second flaps extending from said first and second side
surfaces, respectively, said first and second flaps being folded
into a common plane and secured to each other in a first sealed
position, said member comprising: an elongated body having a
longitudinal axis with an insertion section, a delamination section
and an opening section sequentially positioned along said
longitudinal axis, said body being generally symmetrical about said
longitudinal axis, said insertion section including a tapered
insertion end configured for guiding said body as said body is
inserted into an opening in an end of said cuboid, said
delamination section being configured to laterally displace said
first and second flaps relative to each other away from said first
sealed position, and said opening section having a dimension
transverse to said longitudinal axis to deflect said first and
second flaps to a second opened position at which said first and
second flaps are opened past said first and second sidewalls,
respectively
2. The member of claim 1 wherein said delamination section has a
first sidewall for engaging said first flap of the cuboid and a
second sidewall for engaging said second flap, said first and
second sidewalls defining a generally elongated rectangular
delamination portion with a delamination entrance adjacent said
insertion section and a delamination exit at an opposite end
thereof, and a widthwise distance between said first and second
sidewalls is narrower at said delamination entrance than at said
delamination exit.
3. The member of claim 2 wherein said elongated delamination
section has a generally uniform linear taper therealong.
4. The member of claim 3 wherein said opening section has a first
sidewall for engaging said first flap of the cuboid and a second
sidewall for engaging said second flap, said first and second
sidewalls defining a generally trapezoidal portion with an opening
entrance adjacent said delamination exit of said delamination
section and an opening exit at an opposite end thereof, and a
widthwise distance between said sidewalls is narrower at said
opening entrance than at said opening exit.
5. The member of claim 4 wherein said generally trapezoidal portion
has a generally uniform curvilinear taper therealong.
6. The member of claim 1 wherein said member is generally
planar.
7. The member of claim 1 wherein the elongated body is generally
planar, and the delamination section has side surfaces for engaging
said first and second flaps and that define an elongated, generally
rectangular member with a delamination entrance adjacent said
insertion section and a delamination exit at an opposite end
thereof, a widthwise distance between said side surfaces being
narrower at said delamination entrance than at said delamination
exit with a taper therebetween.
8. The member of claim 7 wherein said generally rectangular member
has a generally uniform taper therealong.
9. The member of claim 7 wherein the opening section has side
surfaces that define a generally trapezoidal member with a
deflection entrance adjacent said delamination exit of said
delamination section and a deflection exit at an opposite end
thereof, a widthwise distance between said side surfaces being
narrower at said deflection entrance than at said deflection exit
with a taper therebetween, and wherein the taper of the width of
said opening section is greater per unit length than the taper of
the width of said delamination section.
10. The member of claim 9 wherein said first and second side
surfaces of said generally rectangular member are linear.
11. The member of claim 9 wherein said generally trapezoidal member
has a generally uniform taper therealong.
12. The member of claim 11 wherein said first and second side
surfaces of said trapezoidal member are curvilinear.
13. The member of claim 7 wherein said delamination section
includes a first sidewall for engaging said first flap of the
cuboid and a second sidewall for engaging said second flap and said
deflection section includes a first sidewall for engaging said
first flap of the cuboid and a second sidewall for engaging said
second flap, said first sidewall of said delamination section and
said first sidewall of the opening section forming a continuous
first sidewall to engage said first flap of the cuboid and said
second sidewall of said delamination section and said second
sidewall of the opening section forming a second continuous
sidewall to engage said second flap of the cuboid, and further
including a first tapered surface extending between said continuous
first sidewall and a top surface of said elongated body and a
second tapered surface extending between said continuous second
sidewall and said top surface of said elongated body.
14. The member of claim 7 wherein said elongated body is
symmetrical about a longitudinal axis thereof.
15. A machine for processing a rectangular cuboid, said cuboid
having first and second oppositely facing side surfaces with first
and second flaps extending from said first and second side
surfaces, respectively, said first and second flaps being folded
into a common plane and secured to each other in a first sealed
position, said machine comprising: an opening station having an
elongated body with a longitudinal axis including an insertion
section, a delamination section and an opening section sequentially
positioned along said longitudinal axis, said body being generally
symmetrical about said longitudinal axis, said insertion section
being configured for guiding said body into an opening in an end of
said cuboid, said delamination section being configured to displace
said first and second flaps relative to each other away from said
first sealed position, and said opening section being configured to
deflect said first and second flaps to a second open position at
which said first and second flaps are opened past said first and
second sidewalls, respectively, to provide access to articles
within the cuboid; an indicia applying station for applying indicia
to said articles within said cuboids; and a closing station for
applying adhesive to and returning said first and second flaps to
said first position.
16. The machine of claim 15 wherein said opening station, said
indicia apply station and said closing station are sequentially
positioned along a linear path.
17. The machine of claim 16 further including a transport mechanism
for sequentially moving said cuboids along said linear path.
18. A method of processing a rectangular cuboid, comprising the
steps of: providing a first and second rectangular cuboids, each
said cuboid having first and second oppositely facing side surfaces
generally parallel to a longitudinal axis of said cuboid, first and
second flaps extending from said first and second side surfaces,
respectively, and being folded into a common plane and secured to
each other in a first sealed position to at least partially form a
third surface of said cuboid; providing an opening member along a
drive path for non-destructively separating said first and second
flaps in order to open said cuboid; orienting said first cuboid in
a first orientation with the longitudinal axis thereof being
parallel to said drive path, said first side surface of said first
cuboid being positioned in a first direction relative to said drive
path and said third surface being oriented in a second direction
relative to said drive path; orienting said second cuboid in a
second orientation with the longitudinal axis thereof being
parallel to said drive path, said first side surface of said second
cuboid being positioned in a third direction relative to said drive
path and said third surface being oriented in the second direction
relative to said drive path, said first direction being opposite to
said third direction; moving said first cuboid relative to said
opening member along said drive path whereby said opening member
engages said first and second flaps of said first cuboid to
non-destructively open said first cuboid; and moving said second
cuboid relative to said opening member along said drive path
whereby said opening member engages said first and second flaps of
said second cuboid to non-destructively open said second
cuboid.
19. The method of claim 18 further including the step of applying
indicia to articles within said first and second cuboids after said
moving steps.
20. The method of claim 19 further including the step of applying
adhesive to and closing said first and second flaps of said first
and second cuboids after said applying step.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims the benefit of U.S.
Provisional Patent Application No. 61/165,667, filed Apr. 1, 2009,
which is incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention generally relates to a structure for
opening boxes and, more particularly, to a structure that is
capable of non-destructively opening asymmetrical boxes that are
fed in either of two orientations.
[0003] It is often desirable to automate manufacturing processes
that require significant amounts of labor or are highly repetitive.
However, some processes are more difficult to automate due to the
configuration of the products being processed. In particular,
products that are not uniform or are asymmetrical present unique
problems during the automation process. Further, components that
appear to be symmetrical but in fact are asymmetrical present even
more difficulties.
[0004] One example of a product that appears to be symmetrical but
in fact is asymmetrical is cigarette carton. Each carton typically
has a rectangular or cuboid shape with two long sides connected by
two ends with a top surface integrally formed with and connected to
the two side surfaces. The bottom of the carton is formed by a
first relatively wide flap that extends along the entire length of
one of the sides and with a width equal to that of the top surface
of the carton and a second narrow flap that extends along the
entire length of the other side and which has a width equal to that
of only one third to one half of the width of the carton.
[0005] Revenue or tax stamps must be applied to individual packs of
cigarettes and, because the taxes and stamps vary by state, county
and even by city, these stamps are not applied to the packs until
they reach their final destination. However, for ease of handling,
cigarette packs are packaged in the cartons in which they will
ultimately be sold or displayed and then the cartons are packaged
in relatively large boxes that are shipped to the desired location.
Once the boxes of cigarettes reach the destination at which the
revenue stamps will be applied, the boxes are opened and the
cartons removed from the boxes. The cartons are then opened, tax
stamps applied and the cartons re-sealed. As a result, care must be
taken to not tear or damage the cartons when opening them during
the process of applying the revenue stamps so that they may be
re-sealed and subsequently re-shipped.
[0006] During the packaging process at the cigarette factory, after
the cigarette packs are loaded into a carton, a small amount of
adhesive or glue (typically two drops) is applied to the narrow
flap and then the wide flap is rotated or pivoted onto the narrow
flap in order to temporarily seal the carton to facilitate shipping
to the location at which the revenue stamps are applied. The
temporarily sealed cartons are then loaded into boxes for
shipping.
[0007] Once the boxes of cigarettes reach the destination at which
the revenue stamps will be applied, the boxes are opened and the
cartons removed from the boxes. One current automated revenue
stamping machine utilizes an asymmetrical opener or plow which
requires that the cigarette cartons be loaded therein with the
temporarily sealed bottom surface facing upward and with the wide
and narrow flaps that form the bottom surface oriented in a
specific direction (i.e., with the wide flap to the left). Such
asymmetrical opener has a vertical ramp structure over a relatively
short length that deflects the bottom surface upward in order to
disengage the wide flap from the narrow flap and thus open the
upwardly facing bottom surface of each carton. A relatively wide
section then forces the flaps fully open to permit the application
of the revenue stamps.
[0008] Since the cartons are rectangular or cuboid shaped, there
are four possible orientations that will initially appear to be
identical without close inspection. More specifically: 1) top up,
wide flap left; 2) top up, wide flap right; 3) bottom up, wide flap
left; and 4) bottom up, wide flap right. With the current
automation equipment, if the cigarette cartons are not loaded into
the equipment in the one correct orientation, the automation
equipment cannot open the cartons without tearing some portion of
the cartons. Since the cartons are subsequently reused to ship the
cigarette packs to their final destination, damage to the cartons
is undesirable and will result in wasted materials and labor
required to repackage the cigarette packs.
BRIEF SUMMARY OF THE INVENTION
[0009] Accordingly, it is the object to solve the above-described
problems encountered within existing automated cigarette handling
equipment while providing an easy to manufacture, low cost solution
to the problem of properly orienting the cigarette cartons. More
specifically, it would be desirable to provide a structure whereby
the cigarette cartons may be opened in an automated manner
regardless of the orientation of the long and short flaps that form
the surface to be opened. Accordingly, an opening member for
opening a rectangular cuboid such as a cigarette carton upon
relative movement thereof is provided which includes an elongated
body with a longitudinal axis having an insertion section, a
delamination and a folding section sequentially positioned along
the longitudinal axis of the body and with the body being generally
symmetrical about the longitudinal axis. The cuboid has first and
second oppositely facing side surfaces with first and second flaps
extending from the first and second sides, respectively, and with
the first and second flaps folded into a common plane and secured
to each other in a first sealed position. The insertion section
includes a tapered insertion end configured for guiding the body
into an opening in an end of the cuboid. The delamination section
is configured to laterally displace the first and second flaps
relative to each other away from the first sealed position. The
opening section has oppositely facing sidewalls to deflect the
first and second flaps to a second open position at which the first
and second flaps are opened past the first and second sides of the
cuboid to provide access to the interior of the cuboid.
[0010] If desired, the delamination section may have a first
sidewall for engaging the first flap of the cuboid and a second
sidewall for engaging the second flap of the cuboid. The first and
second sidewalls may define a generally elongated rectangular
delamination portion with a delamination entrance adjacent the
insertion section and a delamination exit at an opposite end
thereof. A widthwise distance between the first and second
sidewalls may be narrower at the delamination entrance than at the
delamination exit. The elongated delamination section may have a
generally uniform linear taper therealong. The opening section may
have a first sidewall for engaging the first flap of the cuboid and
a second sidewall for engaging the second flap of the cuboid. The
first and second sidewalls may define a generally trapezoidal
portion with an opening entrance adjacent the delamination exit of
the delamination section and an opening exit at an opposite end
thereof, and a widthwise distance between the sidewalls may be
narrower at the opening entrance than at the opening exit. The
generally trapezoidal portion may have a generally uniform
curvilinear taper therealong. If desired, the opening member may be
generally planar.
[0011] An alternate opening structure may be provided for opening
the rectangular cuboid upon relative movement of the cuboid in an
insertion direction. The opening structure includes a generally
planar, elongated member with an insertion section having an
insertion end dimensioned for guiding the member into an opening in
the cuboid as the cuboid is moved relative to the opening
structure. A delamination section is provided with side surfaces
for engaging the first and second flaps and defines an elongated,
generally rectangular member with a delamination entrance adjacent
the insertion section and a delamination exit at an opposite end
thereof, a widthwise distance between the side surfaces may be
narrower at the delamination entrance than at the delamination exit
with a taper therebetween. A deflection section is provided with
side surfaces that define a generally trapezoidal member with a
deflection entrance adjacent the delamination exit of the
delamination section and a deflection exit at an opposite end
thereof. A widthwise distance between the side surfaces may be
narrower at the deflection entrance than at the deflection exit
with a taper therebetween wherein the taper of the width of the
deflection section is greater per unit length than the taper of the
width of the delamination section.
[0012] If desired, the generally rectangular member may have a
generally uniform taper therealong. The first and second side
surfaces of the generally rectangular member may be linear. If
desired, the trapezoidal member may have a generally uniform taper
therealong. The first and second side surfaces of the trapezoidal
member may be curvilinear.
[0013] If desired, the delamination section may include a first
sidewall for engaging the first flap of the cuboid and a second
sidewall for engaging the second flap of the cuboid and the
deflection section may include a first sidewall for engaging the
first flap of the cuboid and a second sidewall for engaging the
second flap. The first sidewall of the delamination section and the
first sidewall of the deflection section may form a continuous
first sidewall to engage the first flap of the cuboid and the
second sidewall of the delamination section and the second sidewall
of the deflection section may form a second continuous sidewall to
engage the second flap of the cuboid. A first tapered surface may
extend between the continuous first sidewall and a top surface of
the elongated member and a second tapered surface may extend
between the continuous second sidewall and the top surface of the
elongated member. A third tapered surface may extend between the
continuous first sidewall and a bottom surface of the elongated
member and a fourth tapered surface may extend between the
continuous second sidewall and the bottom surface of the elongated
member. If desired, first and second sidewalls may have a thickness
less than half of the thickness of the delamination section. If
desired, the elongated member may be symmetrical about a
longitudinal axis thereof.
[0014] A further opening structure may be provided for opening the
rectangular cuboid upon movement of the cuboid relative to the
opening structure in an insertion direction. The structure may
include a generally planar elongated member having an insertion
section, a detachment section and an opening section in sequence
along the insertion direction. The insertion section may include a
tapered insertion end dimensioned for guiding the member into an
opening between at least one of the first and second flaps and an
end surface of the cuboid as the cuboid is moved relative to the
opening structure. The detachment section may have first and second
sidewalls that define an elongated, generally rectangular member
with a detachment entrance adjacent the insertion section and a
detachment exit at an opposite end thereof. A widthwise distance
between the sidewalls may be narrower at the detachment entrance
than at the detachment exit with a generally uniform taper
therebetween. The detachment section may further include a first
tapered surface extending between the first sidewall and a top
surface of the detachment section and a second tapered surface
extending between the second sidewall and the top surface of the
detachment section. The first sidewall and the first tapered
surface may engage the first flap and the second sidewall and the
second tapered surface may engage the second flap to displace the
first and second flaps from the first closed position. The opening
section may have first and second sidewalls that define a generally
trapezoidal member with an opening entrance adjacent the detachment
exit of the detachment section and an opening exit at an opposite
end thereof. A widthwise distance between the sidewalls may be
narrower at the opening entrance than at the opening exit.
[0015] If desired, a first tapered surface may extend between the
first sidewall of the detachment section and a top surface of the
detachment section and a second tapered surface may extend between
the second sidewall of the detachment section and the top surface
of the detachment section. The first sidewall of the detachment
section and the first sidewall of the opening section may form a
continuous first side surface and the second sidewall of the
detachment section and the second sidewall of the opening section
may form a second continuous side surface. The first tapered
surface of the detachment section and the first tapered surface of
the opening section may form a continuous first tapered surface and
the second tapered surface of the detachment section and the second
tapered surface of the opening section may form a second continuous
tapered surface.
[0016] If desired, the first and second sidewalls of the
rectangular member may be generally linear. If desired, the
generally trapezoidal member may have a generally uniform taper
therealong and the taper of the width of the opening section may be
greater per unit length than the taper of the width of the opening
section. If desired, the elongated member may be symmetrical about
a longitudinal axis thereof.
[0017] A machine for processing the rectangular cuboid may also be
provided. The machine includes an opening station for opening the
cuboids, an indicia applying station for applying indicia to the
articles within the cuboids and a closing station for applying
adhesive to and returning the first and second flaps of the cuboid
to their closed position. The opening station has an elongated body
member with a longitudinal axis. The body member is generally
symmetrical about the longitudinal axis and includes an insertion
section, a delamination section and an opening section sequentially
positioned along the longitudinal axis. The insertion section is
configured for guiding the body member into an opening in an end of
the cuboid. The delamination section is configured to displace the
first and second flaps relative to each other away from their
closed position. The opening section is configured to deflect the
first and second flaps to a second open position at which the first
and second flaps are opened past the first and second sidewalls,
respectively, to provide access to articles within the cuboid.
[0018] If desired, the opening station, the indicia apply station
and the closing station may be sequentially positioned along a
linear path. The machine may include a transport mechanism for
sequentially moving the cuboids along the linear path.
[0019] A method of processing a rectangular cuboid includes
providing first and second rectangular cuboids. Each cuboid has
first and second oppositely facing side surfaces generally parallel
to a longitudinal axis of the cuboid. First and second flaps extend
from the first and second sides, respectively, and are folded into
a common plane and secured to each other in a first sealed position
to at least partially form a first surface of the cuboid. An
opening member is provided along a drive path for non-destructively
separating the first and second flaps in order to open the cuboid.
The first cuboid is oriented with the longitudinal axis thereof
being parallel to the drive path and the first side of the first
cuboid is positioned in a first direction relative to the drive
path and the first surface is oriented in a second direction
relative to the drive path. The second cuboid is oriented with the
longitudinal axis thereof being parallel to the drive path and the
first side of the second cuboid is positioned in a third direction
relative to the drive path and the first surface is oriented in the
second direction relative to the drive path. The first direction is
opposite to the third direction. The first cuboid is moved relative
to the opening member along the drive path whereby the opening
member engages the first and second flaps of the first cuboid to
non-destructively open the cuboid. The second cuboid is moved
relative to the opening member along the drive path whereby the
opening member engages the first and second flaps of the second
cuboid to non-destructively open the cuboid.
[0020] If desired, indicia may be applied to articles within the
first and second cuboids after the cuboids are opened. In addition,
adhesive may be applied to the first and second flaps and the flaps
closed after the indicia is applied to the articles within the
cuboids.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] Various other objects, features and advantages of the
present invention will become more fully appreciated and better
understood when considered in conjunction with the accompanying
drawings wherein like-referenced characters designate the same or
similar parts throughout the several views in which:
[0022] FIG. 1 is a front view of a revenue stamp applying machine
including the box opening member of the present invention;
[0023] FIG. 2 is a top plan view of the revenue stamp applying
machine of FIG. 1;
[0024] FIG. 3 is a perspective view in somewhat schematic form of
the carton opening member of the present invention with various
cartons depicted;
[0025] FIG. 3a is an end view of one of the cartons immediately
prior to engagement of the carton by the carton opening member;
[0026] FIG. 4 is a perspective view of the carton opening member of
the present invention in an orientation similar to that of FIG.
3;
[0027] FIG. 5 is a perspective view of the carton opening member of
FIG. 4 but with carton opening member rotated 180 degrees;
[0028] FIG. 6 is another perspective view of the carton opening
member of FIG. 4 taken generally from the front depicting the path
of a carton to be opened;
[0029] FIG. 7 is a side view of the carton opening member of FIG.
4;
[0030] FIG. 8 is a top plan view of the carton opening member of
FIG. 4; and
[0031] FIG. 9 is a bottom view of the carton opening member of FIG.
4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0032] The following description is intended to convey the
operation of exemplary embodiments of the invention to those
skilled in the art. It will be appreciated that this description is
intended to aid the reader, not limit the invention. As such,
references to a feature or aspect of the invention are intended to
describe the feature or aspect of the embodiment of the invention,
not to imply that every embodiment of the invention must have the
described characteristic.
[0033] Referring to FIGS. 1 and 2, revenue stamp applying machine
10 includes a feed conveyor 12 onto which cigarette cartons 20
(FIG. 3) are loaded and then moved laterally or perpendicular (in
the direction of arrow "A") relative to the longitudinal axes of
the cigarette cartons. Drive conveyor 13 is provided to move
cartons 20 sequentially along a linear path "B" from the feed
conveyor 12 towards printer head 14 at which revenue stamps are
applied. Prior to reaching printer head 14, the carton 20 is opened
by carton opening member or plow 30 which contacts the flaps 27, 28
that form the top wall of carton 20 in order to de-laminate the
bottom surface of the carton formed by the two flaps. As the
cigarette carton moves past opening member 30 (from left to right
as viewed in FIGS. 1 and 2), the flaps are opened sufficiently wide
in order to permit the revenue stamps to be applied to the bottom
of each pack of cigarettes (not shown). After opening carton 20 and
applying revenue stamps to the cigarette packs, drive conveyor 13
moves each carton along linear path "B" to glue tower 15 which is
located downstream from printer head 14 to apply glue to the narrow
flap 28 of the top wall 24 of carton 20. Drive conveyor 13 then
moves each carton 20 past a flap closing structure 17 for closing
or deflecting flaps 27, 28 back to a closed position in order to
re-seal the top of each carton 20. The re-sealed cartons 20 are
then removed from machine 10 and may be returned to the boxes in
which they were originally shipped or some other box or container
as desired.
[0034] In this description, representations of direction such as
up, down, left, right, front, rear and the like used for explaining
the structure and movement of each part of the disclosed
embodiments are not absolute, but relative. These representations
are appropriate when each part of the disclosed embodiment is in
the position shown in the Figures. If the position of the disclosed
embodiment changes, these representations are to be changed
according to the change in the position of the disclosed
embodiment.
[0035] Referring to FIGS. 3 and 3a, carton 20 is a rectangular
cuboid with a pair of elongated oppositely facing sidewalls 21, 22
that are interconnected by a bottom wall or surface 23, an
oppositely facing top wall or surface 24 and a pair of oppositely
facing end walls or surfaces 25 and 26. Bottom wall 23 is
integrally connected and extends from sidewalls 21 and 22. End
walls 25 and 26 as well as top wall 24 are formed by folding over
flaps that extend from each sidewall 21, 22 and gluing them or
otherwise adhering them together. More specifically, top wall 24 is
formed by a combination of wide flap 27 that extends from sidewall
22 and narrow flap 28 that extends from sidewall 21. Accordingly,
opening flaps 27, 28 provides access to the interior of carton 20.
Flaps 27, 28 are depicted in an open position in phantom in FIG. 3
to show their relative size difference.
[0036] During the manufacturing process, after the cigarette packs
(not shown) are loaded into the cartons, the narrow flap 28 is
folded down so as to be perpendicular to sidewall 21. An adhesive
or glue is applied to narrow flap 28 and then wide flap 27 is
folded down so as to be perpendicular to sidewall 22 and engage the
adhesive on narrow flap 28 to create the laminated structure (FIG.
3a) that forms top wall 24. Two circular drops of adhesive are
typically applied to narrow flap 28 in order to temporarily secure
wide flap 27 and narrow flap 28 together during the initial
transportation of the packs of cigarettes prior to the application
of the revenue stamps to the bottom of the cigarette packs. End
walls 25 and 26 are similarly formed with wide and narrow flaps
although only the wide flaps can be seen as the visible portion of
end walls 25 and 26. In addition, since end walls 25, 26 are not
intended to be temporarily secured, the wide and narrow flaps that
form end walls 25 and 26 are secured using a standard elongated
length of adhesive or glue rather then a small amount as is used
with wide flap 27 and narrow flap 28. It should be noted that
cartons 20, as depicted in FIGS. 3 and 3a, are actually upside down
with the actual top surface of carton 20 being bottom wall 23 and
the bottom surface of carton 20 being top wall 24. Carton 20 is
inverted during the process of applying the revenue stamps as such
stamps are adhered to the bottom of each pack of cigarettes.
[0037] Referring to FIG. 3, the carton opening member 30 is
depicted in a somewhat schematic manner showing the relationship
between carton opening member 30 and a first carton 20 aligned with
the longitudinal axis "L" of opening member 30 immediately prior to
the carton 20 being moved towards opening member 30. Additional
cartons 20', 20'', 20''' are laterally aligned as they would be at
feed conveyor 12. However, cartons 20, 20'' have the wide flap on
the left while cartons 20', 20''' have the wide flaps on the right.
It should be noted that, for clarity, flaps 27, 28 are depicted as
being somewhat open, so that the orientation of the wide flap 27
and narrow flap 28 may be seen. Carton opening member 30 is secured
in place by a frame 31 of revenue stamp applying machine 10 through
the use of bolts 32, spacers 33 and other components as is known in
the industry in order to secure carton opening member 30 in the
desired position.
[0038] As carton 20 is fed towards carton opening member 30,
sidewalls 21, 22 are engaged by pinch wheels 16 (FIGS. 1 and 2) in
order to squeeze sidewalls 21, 22 adjacent to top wall 24. This
causes top wall 24 (including both wide flap 27 and narrow flap 28)
to bow or pucker upward and create opening 29 (FIG. 3a) between end
wall 26 and top wall 24.
[0039] Referring to FIGS. 4-9, carton member opening 30 is a
generally flat, elongated structure that is symmetrical about
longitudinal axis "L." Opening member 30 maybe generally divided
into three sections--a tapered insertion section 40, a generally
rectangular delamination or detachment section 50 and a generally
trapezoidal shaped opening or unfolding section 60. It should be
noted that because the transition between each of these sections is
smooth and opening member 30 is designed to open cartons of
different sizes, it is difficult to identify the exact location
where one section ends and another section begins.
[0040] Insertion section 40 includes a semi-circular tip 41 with
tapered lead-in or edge 41' dimensioned to be narrower than the
width of opening 29 in carton 20 that is created when carton 20 is
squeezed by the pinch wheels 16. Sidewalls 42, 43 of insertion
section 40 are tapered slightly in a generally linear manner so
that insertion section 40 is narrower towards tip 41 and wider
towards delamination section 50. Although sidewalls 42, 43 are
generally vertical, a tapered, sloped or curved section 42', 43'
extends from each sidewall 42, 43, respectively, to upper surface
44 of insertion section 40. As best seen in FIG. 7, opening member
30 is somewhat planar with a flat lower surface 35 and an upper
surface 34 that includes a tapered lead-in 41' followed by sloped
upper surface 44 of insertion section 40 which is thinner towards
tip 41 and increases in thickness closer to delamination section
50.
[0041] Delamination or disengagement section 50 is an elongated,
generally rectangular planar shaped portion with a slight lateral
taper (as best seen in FIG. 8) that functions to disengage wide
flap 27 from narrow flap 28 during the opening process by either
shearing the adhesive used to temporarily hold wide flap 27 and
narrow flap 28 together or by disengaging or shearing the glue from
one of the wide flap 27 or narrow flap 28 of sidewalls 21, 22
during the delamination process. Delamination section 50 includes
vertical sidewalls 52, 53 that extend from sidewalls 42, 43,
respectively, of insertion section 40. The width of delamination
section 50 increases gradually along the length thereof in a
generally linear manner from the beginning or entrance adjacent
insertion section 40 to opening section 60. Enlarged sloped or
tapered edges 52', 53' extend from the respective sidewalls 52, 53
to upper surface 54 of opening section 50. It should be noted that
opening member 30 is configured to open cartons of different widths
(i.e., the distance from one sidewall 21 to the other sidewall 22)
which may vary from 1.5 inches to 2.5 inches. As a result, when
used with a wide carton, the portion of tapered surfaces 52', 53'
towards tip 41 of insertion section 40 may not engage carton 20 and
thus could conceivably be considered part of insertion section 40
rather than delamination section 50. It can be seen that the
leading portions of tapered sections 52', 53' are generally narrow
towards tip 41 and become wider towards the center of delamination
section 50 along the length of longitudinal axis "L."
[0042] Opening or unfolding section 60 has a generally trapezoidal
shape as defined by sidewalls 62, 63 as best seen in FIG. 8. More
accurately, inasmuch as sidewalls 62, 63 diverge outwardly in a
somewhat curved manner, the shape of unfolding section 60 may be
more appropriately characterized as a pair of diverging curved
lines such as a portion of a hyperbola. Sidewalls 62, 63 extend
from sidewalls 52, 53 of delamination section 50. The rate at which
the taper of opening section 60 increases is greater per unit
length than the rate at which the taper of delamination section 50
increases. Unfolding section 60 includes tapered sections 62', 63'
that extend from vertical sidewalls 62, 63 to upper surface 64 of
unfolding section 60 and extend from tapered sections 52', 53' of
delamination section 50. In addition, unfolding section 60 has a
pair of countersunk bores 65 aligned transverse to longitudinal
axis "L" and three bores 66 positioned along longitudinal axis "L"
in order to more accurately mount and position opening member 30
relative to the path of travel of carton 20.
[0043] Sidewalls 42, 43 of insertion section 40, sidewalls 52, 53
of delamination section 50 and sidewalls 62, 63 of unfolding
section 60 are all interconnected and form a pair of continuous
smooth sidewalls and tapered section 52', 53' of delamination
section 50 and tapered sections 62' and 63' of unfolding section 60
are interconnected and form a pair continuous, smooth surfaces that
combine with the continuous, smooth sidewalls to engage carton 20
and, more particularly, wide flap 27 and narrow flap 28. As seen
best in FIG. 6, a vertical cross-section through delamination
section 50 would show that upper surface 54 coupled with tapered
surfaces 52', 53' and sidewalls 52, 53 create a shape designed to
closely match opening 29 in carton 20 that is created when pinch
wheels 16 squeeze the sidewalls 21, 22 of carton 20.
[0044] As best seen in FIG. 9, lower surface 35 of opening member
30 includes tapered lower surfaces 32, 33 adjacent thereto. Tapered
lower surface 32 extends from lower surface 35 to the continuous
sidewall formed by sidewall 42 of insertion section 40, sidewall 52
of delamination section 50 and sidewall 62 of unfolding section 60.
Similarly, tapered lower surface 33 extends from lower surface 35
of member 30 to the continuous sidewall formed by sidewall 43 of
insertion section 40, sidewall 53 of delamination section 50 and
sidewall 63 of unfolding section 60. Tapered lower sections 32 and
33 are provided in order to reduce the likelihood of tearing of
carton 20 as opening member 30 engages carton 20 during
processing.
[0045] As depicted, opening member 30 is a one-piece structure
approximately twelve to thirteen inches long that is symmetrical
about its longitudinal axis "L" and is formed of aluminum with a
hardened or anodized outer surface. In the alternative, it may be
formed from other suitable materials such as ferrous and
non-ferrous metals, ceramics, plastic and the like that have
sufficient strength, wear and manufacturability
characteristics.
[0046] In operation, a series of cartons 20 are removed from a box
and placed on feed conveyor 12 of revenue stamp applying machine 10
with top wall 24 facing upward. The left or right orientation of
wide flap 27 and narrow flap 28 does not matter as long as top wall
24 faces upward and the longitudinal axis of carton 20 extends in a
direction parallel to longitudinal axis "L" of opening member 30.
The individual cartons are fed by the feed conveyor 12 from the
loading station to the drive conveyor 13 at which point the
longitudinal axis of each carton 20 is aligned with longitudinal
axis "L" of opening member 30.
[0047] Drive conveyor 13 moves carton 20 towards opening member 30
and pinch wheels 16 squeeze sides 21, 22 of carton 20 so that top
wall 24 of carton 20 bows upward to create opening 29 (FIG. 3a)
defined by the flat upper surface or top edge 26' of end wall 26
and the bowed or curved top wall 24. As carton 20 moves towards
opening member 30, the leading edge 41 of member 30 enters opening
29 between top wall 24 and end wall 26. As insertion section 40
enters opening 29, insertion section 40 will engage carton 20 with
sidewalls 42, 43 and top wall 44 of insertion section 40 engaging
wide flap 27 and narrow flap 28 of carton 20 and lower surface 35
of guide member 30 sliding along the top edge 26' of end wall 26.
The sidewalls 42, 43 of insertion section 40 transition into the
sidewalls 52, 53 of delamination section 50 so that the expanding
profile of delamination section 50 will engage wide flap 27 and
narrow flap 28 immediately adjacent of sidewalls 21, 22 of carton
20. In addition, tapered sections 52', 53' together with upper
surface 54 of delamination section 50 engage the arcuate shaped
laminated top surface formed by wide flap 27 and narrow flap 28
which are glued together. As the cross section of delamination
section 50 gradually becomes larger, the engagement of delamination
section 50 with wide flap 27 and narrow flap 28 will shear the
adhesive or shear the bond between the adhesive and the flaps 27,
28 in order to separate or disengage the flaps from each other. By
matching the profile of delamination section 50 with that of
opening 29 between top wall 24 and the top surface 26' of sidewall
26, force concentrations are reduced on flaps 27, 28 and thus the
likelihood of tearing either flap or any portion of carton 20 is
reduced.
[0048] The location at which flaps 27, 28 will become disengaged
will vary based upon the dimensions of carton 20 being opened. In
general, the cartons range in length from approximately 9.75 to
11.5 inches, in the width from approximately 1.5 to 2.5 inches, and
in height from approximately 2.75 to 5 inches. Opening member 30 as
depicted is designed to open a wide range of carton sizes.
Delamination section 50 tapers gradually and in a generally linear
manner so that the expansion of the cross section or profile of
delamination section 50 occurs relatively slowly in order to reduce
the likelihood of tearing of carton 20. In the embodiment shown,
opening member 30 is typically inserted approximately five inches
into carton 20 prior to the initial disengagement or delamination
of upper flap 27 from lower flap 28 but may range from two to eight
inches depending upon numerous factors including the dimensions of
the carton, the location of the adhesive between wide flap 27 and
narrow flap 28, as well as the type of adhesive and paper used.
[0049] As the carton is pushed past delamination section 50 and
wide flap 27 and narrow flap 28 move away from each other, flaps
27, 28 engage unfolding section 60 whereat sidewalls 62, 63 cause
flaps 27, 28 to deflect or unfold from the position at which they
were somewhat overlapping and adjacent to each other and move to a
deflected or unfolded position in which the plane of each flap 27,
28 extends outward past the plane of its respective sidewall 22,
21. This will provide substantial access to the packs of cigarettes
surface in order to permit the application of the revenue stamps.
It should be noted that the taper of sidewalls 62, 63 of unfolding
section 60 increases substantially faster per unit length than the
taper of sidewalls 52, 53 of delamination section 50 so that the
flaps 27, 28 are rapidly deflected or moved to the open position
once they have become disengaged or delaminated by delamination
section 50.
[0050] Preferred embodiments of this invention are described
herein, including the best mode known to the inventors for carrying
out the invention. Variations of those preferred embodiments may
become apparent to those of ordinary skill in the art upon reading
the foregoing description. The inventors expect skilled artisans to
employ such variations as appropriate, and the inventors intend for
the invention to be practiced otherwise than as specifically
described herein. Accordingly, this invention includes all
modifications and equivalents of the subject matter recited in the
claims appended hereto as permitted by applicable law. Moreover,
any combination of the above-described elements in all possible
variations thereof is encompassed by the invention unless otherwise
indicated herein or otherwise clearly contradicted by context.
* * * * *