U.S. patent application number 16/569298 was filed with the patent office on 2020-07-09 for method and apparatus for closing a box.
The applicant listed for this patent is H. J. Paul LANGEN. Invention is credited to H. J. Paul LANGEN.
Application Number | 20200216203 16/569298 |
Document ID | / |
Family ID | 50775335 |
Filed Date | 2020-07-09 |
View All Diagrams
United States Patent
Application |
20200216203 |
Kind Code |
A1 |
LANGEN; H. J. Paul |
July 9, 2020 |
METHOD AND APPARATUS FOR CLOSING A BOX
Abstract
An apparatus for closing a flap on an open end of a box may
include a device having a slot and a mechanism operable to provide
a relative motion between the slot and the flap. The relative
motion may cause the flap to be received into the slot and the flap
to be reoriented to a closed position. A method of closing an open
end of a box being conveyed downstream, with the open end facing
transversely, may include two operations. With a trailing minor
flap on the open end being held in a substantially
upstream-pointing open position, the opposing leading minor flap on
the open end may be closed from a substantially downstream-pointing
open position to a substantially upstream-pointing closed position.
With the leading minor flap being held in the closed position, the
trailing minor flap may be closed from the open position to a
substantially downstream-pointing closed position.
Inventors: |
LANGEN; H. J. Paul;
(Brampton, CA) |
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Applicant: |
Name |
City |
State |
Country |
Type |
LANGEN; H. J. Paul |
Brampton |
|
CA |
|
|
Family ID: |
50775335 |
Appl. No.: |
16/569298 |
Filed: |
September 12, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14646321 |
May 20, 2015 |
10513357 |
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PCT/CA2013/000230 |
Mar 14, 2013 |
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16569298 |
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61729211 |
Nov 21, 2012 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 5/06 20130101; B65B
43/52 20130101; B65B 7/26 20130101; B65B 7/24 20130101; B65B 5/00
20130101 |
International
Class: |
B65B 7/26 20060101
B65B007/26; B65B 43/52 20060101 B65B043/52; B65B 5/06 20060101
B65B005/06; B65B 7/24 20060101 B65B007/24 |
Claims
1. An apparatus for closing a flap on an open end of a box, the
apparatus comprising: (a) a device having a slot; (b) a mechanism
operable to provide a relative motion between the slot and the
flap, the relative motion operable to cause the flap to be received
into the slot to reorient the flap to a closed position.
2. The apparatus of claim 1 wherein said flap is resilient and is
operable to push against an interior surface of said device, and
thereby to assist said flap in being received into said slot.
3. The apparatus of claim 1 wherein during the relative motion
between the slot and the flap of the box, said flap will be
received into said slot and pivot about a first fold line of said
flap to reorient the flap to the closed position.
4. The apparatus of claim 1 wherein the device and the slot are
stationary and the flap moves relative to the device and slot
during said relative motion.
5. The apparatus of claim 1 wherein the device and the slot move
during said relative motion.
6-41. (canceled)
42. A method of closing an open end of a box, said box being
carried downstream by a conveyor with the open end facing
transversely, the method comprising: (a) with a trailing minor flap
on the open end of the box being held in a substantially
upstream-pointing open position, closing the opposing leading minor
flap on the open end of the box from a substantially
downstream-pointing open position to a substantially
upstream-pointing closed position; and (b) with the leading minor
flap being held in the substantially upstream-pointing closed
position, closing the trailing minor flap from the substantially
upstream-pointing open position to a substantially
downstream-pointing closed position.
43. The method of claim 42 wherein the closing of the leading minor
flap is performed during conveyance of the box by the conveyor.
44. The method of claim 42 wherein the closing of the trailing
minor flap is performed with the box being stationary on the
conveyor.
45. The method of claim 42 further comprising inhibiting egress of
any contents of the box by substantially covering the open end of
the box with a rail of the conveyance system during the closing of
the leading minor flap.
46. The method of claim 45 wherein the closing of the leading minor
flap is performed using a slot in the rail.
47. The method of claim 42 further comprising inhibiting egress of
any contents of the box by substantially covering the open end of
the box with a rail of the conveyance system during the closing of
the trailing minor flap.
48. The method of claim 47 wherein the closing of the trailing
minor flap is performed using a slot in the rail.
49. A method of packaging a product in a box, said box having an
open end, said box being carried downstream from a product loading
station to a flap closing station by a conveyor with the open end
facing transversely, the method comprising: (a) at said loading
station loading a product sideways through said open end of said
box; (b) moving said box with said loaded product on said conveyor
downstream to said flap closing station; (c) at said flap closing
stations and with a trailing minor flap on the open end of the box
in a substantially upstream-pointing open position, closing the
opposing leading minor flap on the open end of the box from a
substantially downstream-pointing open position to a substantially
upstream-pointing closed position; and (d) with the leading minor
flap in the substantially upstream-pointing closed position,
closing the trailing minor flap from the substantially
upstream-pointing open position to a substantially
downstream-pointing closed position.
50. The method of claim 49 wherein the closing of the leading minor
flap is performed during conveyance of the box by the conveyor.
51. The method of claim 49 wherein the closing of the trailing
minor flap is performed with the box being stationary on the
conveyor.
52. The method of claim 49 further comprising inhibiting egress of
any contents of the box by substantially covering the open end of
the box with a rail of the conveyance system during the closing of
the leading minor flap.
53. The method of claim 52 wherein the closing of the leading minor
flap is performed using a slot in the rail.
54. The method of claim 49 further comprising inhibiting egress of
any contents of the box by substantially covering the open end of
the box with a rail of the conveyance system during the closing of
the trailing minor flap.
55. The method of claim 54 wherein the closing of the trailing
minor flap is performed using a slot in the rail.
56. The method of claim 49 further comprising inhibiting egress of
the loaded product at the loading station from the box by
substantially covering the open end of the box with a reciprocating
plate that moves between a product loading position wherein product
can be loaded into said box and a product blocking position wherein
said product egress is inhibited.
57-77. (canceled)
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a Continuation of U.S. patent
application Ser. No. 14/646,321 filed on May 20, 2015, which is a
National Phase Entry of International PCT Patent Application Serial
No. PCT/CA2013/000230 filed on Mar. 14, 2013 designating the United
States and which claimed the priority benefit of U.S. Provisional
Patent Application Ser. No. 61/729,211 filed on Nov. 21, 2012. The
entire contents of the aforementioned applications are incorporated
by reference herein.
FIELD OF TECHNOLOGY
[0002] The present invention relates generally to methods and
apparatuses for closing boxes.
BACKGROUND
[0003] Boxes are used to package many different kinds of products
or items. Some in the packaging industry refer to boxes that are
used to package one or more products or items as "cartons." Also in
the industry there are containers/boxes that are known by some as
"cases". Examples of cases include what are known as regular
slotted cases ("RSCs"). In this patent document, including the
claims, the words "box" is used to refer to boxes, cartons, and/or
cases that can be used to package any type of items including
products and/or other cartons. The word "carton" is used
interchangeably with "box" or "case" in this document.
[0004] Cartons come in many different configurations and are made
from a wide variety of materials. Many cartons are foldable and are
formed from a flattened state. A flattened carton is commonly
called a "carton blank." Foldable cartons may be made from an
assortment of foldable materials, including but not limited to
cardboard, chipboard, paperboard, corrugated fibreboard, other
types of corrugated materials, plastic materials, composite
materials, and the like and possibly even combinations thereof.
[0005] In many known systems, carton blanks may be serially
retrieved from a carton magazine in which they are held in a
flattened state, reconfigured from the flattened state into an
erected state, and placed in a slot on a carton conveyor. The
erected carton may then be moved by the carton conveyor to a
loading station where the carton may be filled with one or more
items or products and then sealed. The blanks may be in what is
known as a "knocked-down" state. A "knock down" or "KD" blank may
be have a partially folded configuration and may be partially glued
or otherwise sealed along one side seam, thus being formed in a
generally flattened tubular shape. Erection of KD blanks may
involve pulling apart opposite panels to reconfigure the carton
blank from a flattened tubular configuration to an open tubular
configuration. In the latter configuration, the carton may be
referred to as an erected carton blank or carton, and may be
suitable for delivery to a carton conveyor.
[0006] In some applications, the carton may have one side closed by
folding and sealing the bottom flaps, and may then be loaded or
filled with one or more items or products from the opposite side
while on the carton conveyor. In this configuration, an open end of
the carton may face generally perpendicularly to a conveyor on
which the carton may be conveyed, and the items or products may be
"side-loaded" substantially horizontally into the carton.
Subsequently, any required additional flap closing (folding) and
sealing such as with glue or tape may be carried out to enclose and
completely close and seal the carton with one or more items or
products contained therein.
[0007] Alternately, for example an erected carton blank can be
reoriented from a side orientation to an upright orientation with
the opening facing upwardly. The erected carton can then be moved
to a loading station or loading system where it can be "top-loaded"
with one or more items, such as products or other carton containing
products. The top opening can then be closed by folding over and
sealing the top flaps. Top loading may be preferred if it is
desired for gravity to help keep loaded items or products in place
just prior to carton sealing. This may come at the expense of
higher complexity. Whereas side-load systems can generally erect,
load and seal cartons on the same carton conveyor, top-load system
often require separate systems for each of these actions.
Typically, a top-load system consists of a carton erector machine
to erect the carton blank, a top-loading machine to load the
erected blank, a carton sealing machine to close the carton after
sealing and a carton conveyor to transport the cartons between
these machines.
SUMMARY
[0008] According to one aspect of the present disclosure there is
provided an apparatus for closing a flap on an open end of a box,
the apparatus comprising: (a) a device having a slot; (b) a
mechanism operable to provide a relative motion between the slot
and the flap, the relative motion operable to cause the flap to be
received into the slot to reorient the flap to a closed
position.
[0009] According to another aspect of the present disclosure there
is provided an apparatus for closing opposing first and second
flaps on an open end of a box, the apparatus comprising: (a) a rail
with a first slot and a second slot defined therein; and (b) a
mechanism operable to provide a first relative motion between the
first slot and the first flap of the box, the first relative motion
operable to cause the first slot to receive and close the first
flap, the mechanism also operable to provide a second relative
motion, opposite to the first relative motion, between the second
slot and the second flap of the box, the second relative motion
operable to cause the second slot to receive and close the second
flap.
[0010] According to another aspect of the present disclosure there
is provided an apparatus for closing a carton, the apparatus
comprising: (a) a carton conveyor for conveying a carton
longitudinally with an open end of the carton facing transversely,
the open end of the conveyed carton having a leading minor flap and
a trailing minor flap; and (b) a minor flap closing device
comprising: (i) a first rail section comprising a first slot for
receiving and closing the leading minor flap of the carton; and
(ii) a second rail section comprising a second slot for receiving
and closing a trailing minor flap of the carton.
[0011] According to another aspect of the present disclosure there
is provided a method of closing an open end of a box, the box being
carried downstream by a conveyor with the open end facing
transversely, the method comprising: (a) with a trailing minor flap
on the open end of the box being held in a substantially
upstream-pointing open position, closing the opposing leading minor
flap on the open end of the box from a substantially
downstream-pointing open position to a substantially
upstream-pointing closed position; and (b) with the leading minor
flap being held in the substantially upstream-pointing closed
position, closing the trailing minor flap from the substantially
upstream-pointing open position to a substantially
downstream-pointing closed position.
[0012] According to another aspect of the present disclosure there
is provided a method of packaging a product in a box, the box
having an open end, the box being carried downstream from a product
loading station to a flap closing station by a conveyor with the
open end facing transversely, the method comprising: (a) at the
loading station loading a product sideways through the open end of
the box; (b) moving the box with the loaded product on the conveyor
downstream to the flap closing station; (c) at the flap closing
stations and with a trailing minor flap on the open end of the box
in a substantially upstream-pointing open position, closing the
opposing leading minor flap on the open end of the box from a
substantially downstream-pointing open position to a substantially
upstream-pointing closed position; and (d) with the leading minor
flap in the substantially upstream-pointing closed position,
closing the trailing minor flap from the substantially
upstream-pointing open position to a substantially
downstream-pointing closed position.
[0013] According to another aspect of the present disclosure there
is provided a system comprising: (a) a loading station for
side-loading one of more products into a plurality of boxes; and
(b) a minor flap closing device comprising: (i) a first rail
section comprising a first slot for receiving and closing a leading
minor flap of each of the plurality of loaded boxes; and (ii) a
second rail section comprising a like plurality of slots, each slot
of the plurality of slots for receiving and closing a trailing
minor flap of a respective one of the plurality of loaded
boxes.
[0014] According to another aspect of the present disclosure there
is provided an apparatus for closing generally opposing first and
second flaps on an open end of a box, the first and second flaps
having distal edges oriented in a generally parallel first
direction, the apparatus comprising: (a) a longitudinally extending
guide rail having a first slot and a second slot defined therein,
the first and second slots being generally oriented in the first
direction; and (b) a mechanism operable to provide a first relative
motion between the first slot and the first flap of the box, the
first relative motion being in a second longitudinal direction that
is generally perpendicular to the first direction, and the first
relative motion operable to cause the first slot to receive and
close the first flap, the mechanism also operable to provide a
second relative motion between the second slot and the second flap
of the box, the second relative motion being in a third
longitudinal direction that is generally perpendicular to the first
direction, and generally parallel but opposite to the second
direction, the second relative motion for causing the second slot
to receive and close the second flap.
[0015] According to another aspect of the present disclosure there
is provided an apparatus for closing opposing first and second
flaps at a first end of a box, and for closing opposing third and
fourth flaps on a second end of the box opposite to the first end,
the apparatus comprising: (a) a first rail having a first slot and
a second slot defined therein; (b) a first closing mechanism
operable to provide a first relative motion between the first slot
and the first flap of the box, the first relative motion for
causing the first slot to receive and close the first flap, the
mechanism also operable to provide a second relative motion,
opposite to the first relative motion, between the second slot and
the second flap of the box, the second relative motion for causing
the second slot to receive and close the second flap; (c) a second
rail disposed on an opposite side of the box to the first rail, the
second rail having a third slot and a fourth slot defined therein;
(d) a second closing mechanism operable to provide a third relative
motion between the third slot and the third flap of the box, the
third relative motion for causing the third slot to receive and
close the third flap, the mechanism also operable to provide a
fourth relative motion, opposite to the first relative motion,
between the fourth slot and the fourth flap of the box, the fourth
relative motion for causing the fourth slot to receive and close
the fourth flap.
[0016] Other aspects and features of the present invention will
become apparent to those of ordinary skill in the art upon review
of the following description of specific embodiments of the
invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] In the figures which illustrate, by way of example only,
embodiments of the present invention:
[0018] FIG. 1 is a schematic diagram of an example box closing
system;
[0019] FIG. 1A is a top plan schematic diagram of the system of
FIG. 1;
[0020] FIGS. 2 to 33 are top right perspective views of an example
box closing apparatus of the system of FIG. 1 in various states of
operation;
[0021] FIGS. 34 to 58 are top left perspective views of the example
box closing apparatus of FIGS. 2 to 33 in various states of
operation;
[0022] FIG. 59 is a top plan view of the example box closing
apparatus of FIGS. 2 to 58;
[0023] FIG. 60 is a top plan view showing a portion of the box
closing apparatus of FIG. 59 in greater detail;
[0024] FIGS. 61 to 69 are perspective views of a box in various
states as it is manipulated by the box closing apparatus of FIGS. 2
to 58;
[0025] FIGS. 70A and 70B illustrate a reciprocating gate portion of
the box closing apparatus of FIGS. 2 to 58 in greater detail;
[0026] FIGS. 71 to 74 are top plan views of the closure of a
leading minor flap of a carton using a portion of the box closing
apparatus of FIG. 60;
[0027] FIGS. 75 to 78 are top plan views of the closure of the
trailing minor flaps of a pair of cartons using a portion of the
box closing apparatus of FIG. 60;
[0028] FIGS. 79 to 95 are top left front perspective views of an
alternative box closing apparatus employing reverse product loading
arms; and
[0029] FIG. 96 is a perspective view of an alternative form of
product loading arm and reverse product loading arm that may be
used in some embodiments.
DETAILED DESCRIPTION
[0030] Referring to FIG. 1, an example box closing system 100 is
schematically represented. The box closing system 100 includes a
carton magazine 102, a carton feeder 104, a box closing apparatus
106 and a controller 108. The example box closing system 100 erects
cartons from knock down (KD) carton blanks (i.e. flattened tubular
carton blanks), loads the erected cartons with a product, closes
(folds) the minor and major flaps of the carton and seals the
carton with the product contained therein.
[0031] The carton magazine 102 holds a stack of carton blanks,
referred to herein individually or collectively as carton blank(s)
110. In the present embodiment, the blanks are KD carton blanks
that may be made from a foldable material such as cardboard,
chipboard, paperboard, corrugated fibreboard, other types of
corrugated materials, plastic materials, composite materials, and
the like and possibly combinations thereof. As a non-limiting
example, the carton material may for example be 1/16 inch
cardboard.
[0032] The carton feeder 104 is a device that serially retrieves
carton blanks 110 from carton magazine 102, reconfigures each
retrieved carton blank 110 from its flattened state into an erected
state, and places the erected carton into a slot 112 on the carton
conveyor 114 of box closing apparatus 106. The carton feeder 104
may for example be a conventional type of rotary carton feeder with
at least one erector head 116, which may comprise a suction cup in
some embodiments. In the illustrated embodiment, the carton feeder
104 operates under the control of controller 108 of FIG. 1
(described below).
[0033] The box closing apparatus 106, which is schematically
represented in FIG. 1, shall be described below in conjunction with
the top right perspective view, top left perspective view, and top
plan view of an example apparatus 106 shown in FIGS. 2, 34 and 59
respectively.
[0034] Referring to FIG. 1, the box closing apparatus 106 includes
a carton conveyor 114 (also referred to as simply a conveyor or as
a conveying system), a product loading station 120, and a minor
flap closing station 130. Other stations and components of the box
closing apparatus 106 are omitted from FIG. 1 for clarity, but will
be described below in conjunction with other figures.
[0035] The carton conveyor 114 used for conveying the cartons 110
may be a conventional carton conveyor that is used to convey
cartons in a packaging system. For example, carton conveyor may
comprise a pair of parallel conveyor chains 134 with upstanding
carton flights 136 attached to the chains (see FIGS. 1 and 2). The
carton flights 136 may be generally secured to and aligned between
the two continuous chains 134 which are supported at each ends by
chain sprockets and between the sprockets by conveyor rails. In the
present embodiment, a set of four flights 136 defines a carton slot
112 for holding a single carton 110 it is conveyed by the conveyor
through the box closing apparatus 106. For example, as shown in
FIG. 2, four labelled flights 136 define a carton slot 112 that is
shown as being empty. The empty slot 112 is shown adjacent to
another carton slot 112 that is occupied, i.e. holds a carton 110.
In the illustrated carton conveyor 114, each carton 110 is placed
into slots 112 with the open carton ends facing in a transverse
direction relative to the longitudinal direction of conveyance D of
the carton conveyor 114 (which transverse direction is sidewards in
the illustrated example). A chain track 135 partially surrounds
each conveyor chain 134 (see FIG. 2).
[0036] Referring again to FIG. 1, the carton conveyor 114 may
further comprise an actuator 132, which may be a servo drive motor
for example, for driving the conveyor, in a direction of conveyance
D, under control of controller 108 (described below). An encoder
associated with the actuator 132 may provide signals indicative of
the position of the conveyor chain and the flights thereon, to
controller 108. In the present embodiment, the conveyor 114 is
driven intermittently, with periodic dwell periods of non-movement
of the conveyor during product loading at product loading station
120 and minor flap closing at minor flap closing station 130, as
will be described. This is not necessarily the case for all
embodiments. In some embodiments, the conveyor may move
continuously. This possibility will be described later. The servo
drive/actuator 132 of the present embodiment may be positioned at
any suitable location on the box closing apparatus 106.
[0037] Referring to FIGS. 1 and 1A, the product loading station 120
is a station at which one of more products 144 are side-loaded into
an open end of the carton 110. Products 144 may be delivered
product loading station by conventional devices such as a product
conveyor sub-system and/or a robotic sub-system. For example a
product conveyor 234 may be provided having a plurality of buckets
secured to conveyor chains and being driven by an actuator 232.
Actuator 232 may be like actuator 132 and may also be controlled by
controller 108. Conveyor 234 may be arranged in generally parallel
orientation compared to conveyor 114 and may be driven in
intermittent movement. The product may be, by way of non-limiting
example, one or more packaged food items, one or more loose items
such rolls of garbage bags, or otherwise. Additionally in some
embodiments, the products 144 may themselves be cartons containing
other items or products and those cartons may be loaded by such a
system into other boxes.
[0038] Also, instead of a product conveyor, a pick and place
robotic system may be employed to deliver products 144 from a
supply of products 144 to a position where the products may be
pushed through guides 148 into the cartons 110. The product loading
station 120 of system 100 is illustrated in more detail in FIGS. 2
and 34.
[0039] Referring to FIGS. 2 and 34, it can be seen that the product
loading station 120 includes a pair of reciprocating arms 140. The
arms reciprocate in a direction that is substantially transverse
(i.e. perpendicular) to the longitudinal conveying direction D of
the carton conveyor 114. The arms 140 are connected by a connecting
member 146 so that the arms reciprocate in unison. The arms 140 and
connecting member may be supported for reciprocating movement by
suitable support frame components. For example, arms 140 may be
received in and supported by support rails (not shown). The arms
140 may be driven in reciprocating movement by any suitable means
such as being interconnected to a double acting pneumatic piston
apparatus with electronic valves controlling the flow of compressed
air to the pneumatic cylinder (all not shown). The electronic
valves may be controlled by controller 108. By having two arms 140
move in unison, two cartons 110 can be side-loaded with product
simultaneously in the illustrated embodiment. Each arm 140 has a
pusher end 142 that may pass through side opening in the buckets of
product conveyor 234 for pushing a respective product 144 into the
carton 110. The pusher ends 142 attached to reciprocating arms may
pass through the bucket of conveyor 234 (not shown) through the
guides 148 and into an open end of a respective carton 110 during
side loading (i.e. during transverse loading). In alternative
embodiments, the number of cartons that are loaded simultaneously
may be greater than two. Alternatively, the cartons may be loaded
one at a time in other embodiments. In some embodiments, the number
of reciprocating arms may match a number of cartons that are being
loaded simultaneously. In other embodiments, alternate sub-systems
for side loading products 144 into the open side of cartons 110 may
be employed, so long as they do not interfere with the flap opening
and closing mechanisms described herein.
[0040] Referring back to the product loading station 120 as
depicted in FIGS. 2 and 34, a pair of channel-shaped product guides
148 aligned with the reciprocating arms 140 guide the product 144
from the buckets (not shown) of the product conveyor 234 into the
open ends of their respective cartons 110 as the product 144 is
pushed by the pusher ends 142 during side-loading. The box closing
apparatus 106 further comprises a reciprocating gate 150, is
adjacent to the conveyor 114, between the product guides 148 and
the conveyor 114. The reciprocating gate 150 may be a plate made
from any suitable material such as steel or aluminium, and may
reciprocate substantially vertically between a closed (raised)
position, as shown in FIGS. 2 and 34 for example, and an open
(lowered) position, as shown in FIG. 14 for example.
[0041] The reciprocating gate 150 is shown in greater detail in
FIGS. 70A and 70B. The views of FIGS. 70A and 70B are side
elevation views from the direction of the reciprocating arms 140,
looking towards the carton conveyor 114.
[0042] Referring to FIGS. 70A and 70B, it can be seen that the
example reciprocating gate 150 is generally rectangular, although
it may have other shapes in other embodiments. The reciprocating
gate 150 has two open areas 152A and 152B (referred to generically
or collectively as open area(s) 152). Each open area 152 is
slightly larger than, and similarly shaped as, an open end of a
single carton 110. This is to permit simultaneous end loading of
two cartons 110 when the gate 150 is in the open position.
Generally, the number of open areas 152 may match a number of
cartons 110 that are being simultaneously loaded, which may be only
one or greater than two in alternative embodiments.
[0043] As perhaps best seen in FIGS. 2 and 34 in conjunction with
FIG. 70A, when in the closed (raised) position, a lower portion 154
of the gate 150 forms a rail adjacent to the carton conveyor 114.
After product loading (e.g. as shown in FIG. 70A), the lower
portion 154 of the gate acts as a barrier to prevent product
egress, i.e. to prevent any product 144 that has been loaded into
cartons 110 from falling out of the opens of the cartons as the
loaded cartons 110 are conveyed further downstream. The lower
portion 154 of the gate 150 also acts to keep the minor flaps 111
of the cartons 110 at substantially right angles to the respective
carton side walls to which the minor flaps are connected, both
before and after loading. This is referred to as the fully open (or
simply "open") position of the minor flaps 111. It will be
appreciated that the terms "substantially right angle" and "fully
open" as used herein may include angles slightly larger than 90
degrees (e.g. up to 100 degrees or possibly slightly greater) of a
minor flap in relation to the minor panel to which the flap is
connected. The precise angular measure of a minor flap relative to
its associated minor panel may in part be determined by a proximity
of an adjacent rail, along which the distal tip of the minor flip
is currently riding or sliding along, to the end (i.e. to the
loading end 218 or non-loading end 220) of the carton to which the
minor flap is connected. The more proximate the rail to the end of
the carton, the closer the angle may be to 90 degrees. This angle
may change slightly as the carton is conveyed along the carton
conveyor 114, e.g. as the distal tip of a resilient minor flap
rides or slides along different rails whose transverse offset from
the lateral edge (e.g. loading end) of the carton varies (e.g. like
the different rail portions 172, 174, 176, 178 and 180 of FIG. 60).
The riding or sliding contact is maintained in view of the material
memory of the carton resiliently urging the distal tip of the minor
flap against each one of the different rails. The minor flap
closure technique that is described herein thus does not
necessarily require the angle of the minor flap to be closed
(relative to the minor panel to which the flap is connected) to be
exactly 90 degrees or to be within only several degrees of that
angle. In the "fully open" position, the leading minor flap 226
points substantially downstream. In a closed position, the leading
minor flap 226 points substantially upstream. Conversely, in the
"fully open" position, the trailing minor flap 228 points
substantially upstream. In a closed position, the trailing minor
flap 228 points substantially downstream.
[0044] Referring now to FIG. 14 and FIG. 70B, when the
reciprocating gate 150 in the open (lowered) position, the open
areas 152 in the gate 150 align with the open ends of their
respective cartons 110 to permit the product 144 to be loaded into
the cartons 110. At the same time, the upper portion 156 of the
gate 150 still serves to hold open the minor flaps 111 of the
cartons 110 in their open positions. This prevents the minor flaps
111 from closing during product loading, e.g. due to the memory of
the carton material (i.e. the tendency of the material to return to
its original state, e.g. flat), which could undesirably impede or
obstruct the loading of the product 144 into the cartons.
[0045] Referring to FIGS. 1, 2 and 34, the minor flap closing
station 130 is where the minor flaps 111 of a carton 110, on the
loading end 218 of the carton, are closed. As will be appreciated,
the minor flap closing station 130 is designed to prevent product
egress during closure of the minor flaps. In the illustrated
embodiment, the minor flap closing station 130 is used to close
only the minor flaps on the loading end of the carton. In other
embodiments, it is possible that the minor flaps on both ends (i.e.
on both the loading and non-loading ends) of a carton may be closed
at a minor flap closing station.
[0046] A portion of the minor flap closing station 130 is shown in
greater detail in FIG. 60, which is an enlarged top plan view. It
will be appreciated that the carton conveyor 114 is omitted from
FIG. 60, for the sake of clarity. As illustrated, the minor flap
closing station 130 comprises a minor flap closing device 159
comprising a longitudinal carton guide rail 160, adjacent to the
carton conveyor 114. The rail 160 has a fixed section 162 and a
movable, longitudinally reciprocating section 164. These sections
may be referred to as the fixed rail 162 and reciprocating (or
movable) rail 164, respectively.
[0047] The fixed rail section 162 of the minor flap closing device
159 is defined by two stationary rail portions 172 and 174 that are
attached to bars 173 and 175 respectively. Bars 172 and 174 may be
suitably attached to part of a support frame (not shown). The rail
portions 172 and 174 define a slot 166 therebetween, i.e. within
the fixed rail 162. This slot, which may be referred to as the
leading minor flap closing slot 166, is used to catch and fold the
leading minor flap on the loading end 218 of a carton 110 (e.g.
leading minor flap 226 in FIG. 61 or 70A, for example, as described
below) as the carton is conveyed past the slot. The rail portions
172 and 174 are separated by a width W1, which is the width of slot
166 as measured longitudinally. The downstream rail portion 174
(being so identified based on the direction D of conveyance) is
offset inwardly, i.e. towards the conveyor 114, by an offset A1,
relative to rail portion 172. That is, the downstream side of the
slot 166 is inwardly offset relative to the upstream side of the
slot. Put another way, the slot 166 is partially upstream-facing.
As will be appreciated, this may facilitate receiving or "catching"
of a leading minor flap within the slot as a carton 110 is conveyed
by conveyor 114 past the slot 166. In some embodiments, the offset
A1 may be omitted (i.e. may equal zero). This may be done, e.g., if
the desired "catching" effect can be achieved without the offset
(possibly due to the memory of the leading, downstream-pointing
minor flap 111, which may tend to point the flap transversely from
the conveyor 114). The width W1 and/or offset A1 of the slot 166
may be adjustable in some embodiments.
[0048] In some embodiments, the rail portions 172 and 174 may each
be formed as longitudinally extending plates and be made from a
thin material, such as 1/16 inch or ten gauge sheet metal for
example. The reason is that a slight offset between the rails 172
and 174 in that case may be sufficient for the planar rail portions
172 and 174 to be fully non-coplanar with respect to each other.
Such an arrangement may tend to limit a risk of a
downstream-pointing leading minor flap 226 that is being conveyed
downstream, impacting an upstream edge of the rail portion 174 as
it is thrust through the slot 166. Depending upon such factors as
carton material resiliency, conveyor speed, and slot width, it may
not be required for the rail portions 172 and 174 to be fully
non-coplanar in every embodiment.
[0049] Referring to FIG. 60, the reciprocating rail 164 section of
the minor flap closing device 159 has a pair of slots 168 and 170
defined therewithin, which may be referred to as trailing minor
flap closing slots 168 and 170. The distance between the slots 168
and 170 is substantially equal to a pitch P of the conveyor 114
(i.e. the distance between corresponding points on adjacent
cartons). These slots are used to substantially simultaneously fold
the trailing minor flaps (e.g. trailing minor flap 228 in FIG. 61
or FIG. 70A, for example, as described below) of a pair of cartons
110 that are temporarily stationary (i.e. in a dwell period) on the
carton conveyor 114, adjacent to the reciprocating rail. The slots
168 and 170 operate in essentially the opposite way as the leading
minor flap closing slot 166 in the sense that, rather than the
cartons 110 being conveyed past the fixed slot 166 to cause the
leading minor flap to close, the slots 168 and 170 are conveyed, by
way of downstream movement of the reciprocating rail 164 in which
the slots are defined, past respective trailing minor flaps of two
adjacent cartons 110, to cause those trailing minor flaps to
close.
[0050] It will be observed that, in the present embodiment, there
is only one slot 166 for closing leading minor flaps but two slots
168 and 170 for closing the trailing minor flaps of two respective
cartons. The single slot 166 is sufficient for the closing leading
minor flaps of all cartons 110 that are conveyed past it, because
mere conveyance (i.e. indexing) of a carton past the slot 166
causes the leading minor flap to close (as will be described below
in greater detail). In contrast, the design choice for having two
slots 168 and 170 for closing trailing minor flaps was made in part
due to the fact that the upstream product loading station 120 is
designed to simultaneously load two cartons 110, and due to the
fact that the product loading is performed with the cartons being
stationary (i.e. with the carton conveyor 114 in a dwell period).
In particular, in order to receive and close a trailing minor flap
of a carton 110 using a slot in an adjacent rail, it is desired to
cause the slot to move in a downstream direction relative to the
carton, past the flap. While it would also be possible to move the
carton upstream relative to the slot, such upstream movement may be
considered detrimental to throughput. The use of a pair of slots
168 and 170, separated by a distance substantially equal to the
pitch P, allows the reciprocating rail 164 to substantially
simultaneously close the trailing minor flaps 228 of each of a pair
of stationary loaded cartons 110 during the dwell period. If only a
single slot were used to close the trailing minor flaps 228 of two
cartons during the dwell period, it may be necessary to move the
reciprocating rail 164 longitudinally over a distance that is
greater than the pitch P between cartons. Moreover, if such a slot
were required to move downstream past the leading minor flap 226 of
carton 110B to reach the trailing minor flap 228 of carton 110A,
the slot might catch and undesirably re-open the leading minor flap
226 of carton 110B. Thus, it may be desirable, although not
necessarily required, for the number of slots in the reciprocating
rail of the minor flap closing station 130 to match the number of
cartons being simultaneously loaded at the upstream product loading
station 120.
[0051] Referring to FIG. 60, the slots 168 and 170 in the
reciprocating rail 164 are defined by three rail portions 176, 178
and 180 mounted on respective arms 182, 184 and 186. The arms 182,
184, 186 are in turn mounted to respective plates 192, 194 and 196,
and the plates are mounted to a longitudinal member 188. The
lateral position of arms 182, 184 and 186 is individually
adjustable, and the longitudinal position of plates 192, 194 and
196 is individually adjustable.
[0052] The first two rail portions 176 and 178 are separated by a
width W2, and the second two rail portions 178 and 180 are
separated by a width W3. The upstream rail portion 176 is offset
inwardly, i.e. towards the conveyor 114, by an offset A2 relative
to middle rail portion 178. Similarly, the middle rail portion 178
is offset inwardly by an offset A3 relative to the downstream rail
portion 180. That is, the upstream side of each of slots 168 and
170 is inwardly offset relative to the downstream side of the slot.
Put another way, each of the slots 168 and 170 is partially
downstream facing. As will be appreciated, this may facilitate
receiving or "catching" of respective trailing minor flaps within
the slots the slots move downstream past respective cartons 110. It
will be appreciated that the offsets A2 and A3 may be omitted (i.e.
may equal zero) in some embodiments, for similar reasons that the
offset A1 may be omitted in some embodiments. The widths W2 or W3
and offsets A2 and A3 are adjustable by way of adjustment of the
arms 182, 184, 186 and plates 192, 194, 196. However, it is
possible that the width or offset (if any) of either one or both of
the slots 168, 170 may be fixed in some embodiments.
[0053] In some embodiments, the rail portions 176, 178 and 180 may
each be formed as longitudinally extending plates and may be made
from a thin material, such as 1/16 inch or ten gauge sheet metal
for example. The reason is that a slight offset between the rail
portions in that case may be sufficient for the planar rail
portions 176, 178 and 180 to be fully non-coplanar with respect to
one another. Such an arrangement may tend to limit a risk of a
upstream-pointing trailing minor flap 228, impacting an upstream
edge of the rail portion 176 or 178 as the flap 228 is thrust
through the slot 168 or 170 respectively. Depending upon such
factors as carton material resiliency, speed of the reciprocating
rail 164, and width of slots 168 and 170, it may not be required
for rail portions 176 and 178, or rail portions 178 and 180, to be
fully non-coplanar in every embodiment.
[0054] The longitudinal member 188 is fixedly mounted to a carriage
198. Carriage 198 may in turn be configured for sliding
longitudinal movement along a supporting rail member 206 (FIG. 60).
Rail member 206 may be supported on part of a support frame (not
shown).
[0055] Carriage 198 may be operable to reciprocate longitudinally
by the action of reciprocating piston arm 200 relative to the fixed
cylinder 202 mounted to fixed mounting bar 204. Mounting bar 204
may also be attached to the support frame (not shown). The piston
arm 200 and cylinder 202 may for example comprise a double-acting
pneumatic actuator, such as the model DFM-25-80-P-A-KF Part #170927
made by Festo. The pneumatic actuator may be supplied with
pressurized air communicated through electronic solenoid valves for
causing the piston arm to retract and extend. The solenoid valves
may for example be a model CPE14-M1Bh-5J-1/8 made by Festo and may
be controlled by controller 108. Alternatively, a linear servo
drive system may be provided for this actuator. Such a servo drive
system could be controlled by controller 108. The minor flap
closing device 159 is considered to include, among other
components, the piston arm 200, cylinder 202, carriage 198,
longitudinal member and arms 182, 184, 186.
[0056] Referring again to FIG. 1, the box closing system 100 also
comprises a controller 108. The controller 108 generally controls
the operation of the box closing system 100, including subsystems
such as the carton feeder 104 and various box closing apparatus
subsystems including the carton conveyor 114, the product loading
station 120, and the minor flap closing device 159 at the minor
flap closing station 130. The control of these subsystems is
illustrated schematically by dashed lines in FIG. 1. The controller
108 may also receive input from various sensors, such as optical
sensors or encoders for example, which are not expressly
illustrated. These sensors may provide feedback regarding the
presence of cartons at certain positions within the system 100 or
of the position of various moving parts within the system 100 for
example. To controller 108 may also control other actuators in box
closing apparatus 106, such as servo motors or DC motors, drives,
vacuums, vacuum generators and vacuum cups for example. Controller
108 may be any suitable controller, such as a programmable logic
controller ("PLC"). For example, controller 108 may be or may
include a unit chosen from the Logix 5000 series devices made by
Allen-Bradley/Rockwell Automation, such as the ControlLogix 5561
device.
[0057] Electrical power can be supplied to the controller 108, and
to all the various actuators, motors and sensors that are described
herein. Compressed air can also be supplied to vacuum generators
and pneumatic actuators that may be used to drive certain
components, such as the reciprocating gate 150 or the reciprocating
rail 164, through valve devices such as solenoid valves that are
controlled by controller 108. Servo motors may be connected to and
in communication with servo drives that are in communication with
and controlled by controller 108.
[0058] In some embodiments, a human operator may input commands
and/or view status of the box closing system 100 through a Human
Machine Interface (HMI) module, in electronic communication with
controller 108, that may be physically attached to box closing
system 100 for example.
[0059] Various other components of the box closing apparatus 106
will be described during the description of operation of the system
100.
[0060] Operation of the box closing system 100 is described below
with reference to the top right perspective views of FIGS. 2 to 33,
the top left perspective views of FIGS. 34 to 58, and the top plan
views of FIGS. 59 and 60. FIGS. 2 to 33 show the progression of a
single example pair of cartons through the box closing apparatus
106 from a top right perspective, and FIGS. 34 to 58 show the
progression of that same example pair of cartons through the box
closing apparatus 106 from a top left perspective. Reference will
also be made to FIGS. 61-68, which show perspective views of a
carton 110 in various states or configurations as it is manipulated
by the box closing system 100.
[0061] In each of FIGS. 2 to 58, a parenthesized measurement (e.g.
0'', 2.5'', etc.) appears below the figure label. This measurement
represents a current distance, in inches, of a leading edge of a
leading carton 110A from a baseline starting position S (see FIG.
2) along the carton conveyor 114. The larger the distance, the
further the carton has been conveyed downstream along the conveyor
114. The indicated distance may facilitate correlation of carton
position between right and left hand perspective views (e.g. in
both of FIGS. 3 and 5, the distance is 2.5''; thus the figures are
correlated in terms of lead carton position). A caveat is that,
during dwell periods (e.g. as shown in FIGS. 12 to 17 and 44 to
49), the current distance may remain the same (e.g. 36''), despite
the fact that other actions may be occurring (e.g. product loading
or minor flap closing). Thus, when two figures indicate the same
parenthesized current distance, they do not necessarily represent
the same moment in time.
[0062] Referring to FIG. 1, the erector head 106 of carton feeder
104 picks up a KD carton blank 110 from carton magazine 102,
reconfigures the blank from a flattened state into an erected
state, and placed the erected carton 110 in a slot 112 on a carton
conveyor 114 with open ends facing sidewards, as shown in FIGS. 2
and 34. In FIGS. 2-58, this carton is referred to as carton 110A to
distinguish it from another carton 110B that will be shown in FIGS.
6-33 and 38-58. The initial configuration of the erected carton 110
is as shown in FIG. 61. In FIG. 61, the carton is referred to
generically as carton 110 (rather than specifically as carton 110A
or 110B).
[0063] Referring to FIG. 61, a top right perspective view of an
example of one kind of carton 110 that can be processed by box
closing system 100 is shown. Other types of carton blanks, tubular
carton blanks, and tubular carton blanks of different sizes can be
processed by alternative embodiments.
[0064] The example carton 110 has an upper major panel 210 and an
opposed lower major panel 212. These panels are integrally
interconnected to a leading minor panel 214 and an opposed trailing
minor panel 216, with the terms "leading" and "trailing" being with
respect to a direction of conveyance D by carton conveyor 114. The
shape of the erect carton 110 is generally cuboid. The major and
minor panels 210, 212, 214 and 216 may alternatively be referred to
as walls of the carton 110.
[0065] The erected carton 110 has a loading end 218 and a
non-loading end 220. The distinction between these is that, during
product loading at the product loading station 120, the product 144
is loaded through the loading end 218 but not through the
non-loading end.
[0066] On the loading end 218, an upper major flap 222 and a lower
major flap 224 are connected along fold lines to respective walls
of the box, namely to upper major panel 210 and lower major panel
212 respectively. Similarly, a leading minor flap 226 and a
trailing minor flap 228 are connected along fold lines to leading
minor panel 214 and trailing minor panel 216, respectively. Minor
flaps accordingly oppose one another at the loading end 218 of the
carton 110. It is understood that the fold lines need not be
expressly formed and may not be visible in some embodiments. The
leading and/or trailing minor flaps 226 and 228 may be referred to
generically or collectively as minor flaps 211.
[0067] On the non-loading end 220, an upper major flap 232 and a
lower major flap 234 are connected along fold lines to upper major
panel 210 and lower major panel 212 respectively. Similarly, a
leading minor flap 236 and a trailing minor flap 238 are connected
along fold lines to leading minor panel 214 and trailing minor
panel 216, respectively.
[0068] In some embodiments, the fold lines may be formed by a
weakened area of material or with a crease forming apparatus. The
effect of the fold lines is that a flap can be opened or closed,
i.e. swung about an edge of an adjacent panel or wall to which the
flap is connected, along the fold line.
[0069] Referring to FIGS. 3 and 35, the carton conveyor 114 conveys
the carton 110A downstream until the leading minor panel 214 is
adjacent to kicker 240. The kicker 240, driven by an actuator 242
such as a servo motor or other suitable actuator, rotates
clockwise, striking an interior side of the leading minor flap 226
with its leading flat edge as the carton 110A continues to be
conveyed in downstream direction D. This causes the leading minor
flap 226 to swing open in the conveyance direction D, and results
in the minor flap 226 pointing outwardly from the carton 110A at
substantially a right angle to the adjacent leading minor panel
214, i.e. downstream in the open position, as shown in FIG. 62. The
kicker may be any kind of suitable kicker (rotary, disk, or
otherwise).
[0070] Moreover, due to the continued downstream conveyance of the
carton 110A, before the leading minor flap 226 has an opportunity
to return to its original position as shown in FIG. 61 (due to
material memory for example), the leading minor flap 226 is caught
by the leading, ski-shaped end of stationary guide rail 248 (FIG.
4), which keeps the leading minor flap 226 pointing downstream in
the open position as the carton 110A is conveyed downstream, with
the flap 226 sliding along the rail 248. It will be appreciated
that the timing of the kicker strike upon the flap 226 relative to
the conveyor speed and the degree of resiliency of the carton
material may necessitate precise control of these elements to
avoid, e.g., a premature "snap-back" of the minor flap to a
transverse orientation and a resultant inadvertent closure of the
leading minor flap 226.
[0071] At the same time, the upper and lower major flaps 222 and
224 are spread apart, i.e. folded upwardly and downwardly
respectively, to the substantially open positions that are shown in
FIG. 5, through contact with the upper major flap lifter rod 246
and the lower major flap lifter rod 250, respectively, as the
carton 110A is conveyed in the downstream direction D. The upper
major flap 222 is held in this position by the upper major flap
lifter rod 246 throughout product loading and at least part of the
minor flap closing that occurs subsequently, since the length of
rod 246 extends through the product loading station 120 and into
the minor flap closing station 130. The lower major flap lifter rod
250 keeps the lower major flap 224 open until the carton reaches
the product loading station 120, at which point the gate 150 will
hold the lower major flap 224 open. After the product loading
station 120, it may not necessarily be required to keep the flap
224 open.
[0072] Meanwhile, on the non-loading side of the carton 110A, an
opposing guide rail 249 (shown, e.g., in FIGS. 2, 3 and 34) comes
into contact with the leading minor flap 236 as the carton 110A is
conveyed downstream. This causes the leading minor flap 236 to be
folded (see FIG. 36) to a closed position in which the flap 236 is
pointing upstream at substantially a right angle to the adjacent
leading minor panel 214 (see FIG. 62). Subsequently, the upper and
lower major flaps 232 and 234 on the non-loading side are spread
apart upwardly and downwardly, respectively, to the substantially
open positions that are shown in FIGS. 5 and 37, through contact
with the stationary upper major flap lifter rod 252 and the
stationary lower major flap lifter rod 254, respectively (see FIG.
37). For clarity, the upper major flap 232 is shown edge-on in the
perspective view of FIG. 37 and thus appears as a line in that
drawing. The state of the carton 110A at this stage is as shown in
FIG. 63.
[0073] Referring to FIGS. 6 and 38, further downstream conveyance
of the carton 110A causes an interior surface of the trailing minor
flap 228 on the loading end of carton 110A to contact the end of
stationary guide rail 248. As the carton 110A is conveyed further,
this contact causes the trailing minor flap 228 to fold open in the
upstream direction (see FIG. 7) until it reaches the fully open
position shown in FIGS. 8 and 64. The rail 248 keeps the flap 228
open as the flap 228 slides along the rail 248. On the non-loading
end 220 of the carton 110A, kicker 244, driven by an actuator 245
such as a servo motor or other suitable actuator, rotates
counter-clockwise, with its leading flat edge rotating towards the
exterior side of the trailing minor flap 238 of the carton 110A
(see FIGS. 5 and 37). When the kicker 244 strikes the exterior side
of trailing minor flap 238 (see FIGS. 6 and 38), the flap 238
swings towards the downstream direction to a closed position, in
which the flap 238 points towards the (already closed) opposing
leading minor flap 236, and in which the flap 238 is at
substantially a right angle to the adjacent trailing minor panel
216, as shown in FIG. 64. The kicker may be any kind of kicker
(rotary, disk, or otherwise). It will be appreciated that the
timing of the kicker strike upon the flap 228 relative to the
conveyor speed and the degree of resiliency of the carton material
may necessitate precise control of these elements to avoid, e.g., a
premature "snap-back" of the minor flap 228 to a transverse
orientation and a resultant inadvertent opening of the trailing
minor flap 228.
[0074] Moreover, due to the continued downstream conveyance of the
carton 110A, before the trailing minor flap 238 has an opportunity
to return to its original position as shown in FIG. 63 (again, due
to material memory for example), the trailing minor flap 238 is
caught and held closed, by the same stationary guide rail 249 (FIG.
4) that closed the leading minor flap 236, as the carton 110A
continues to be conveyed downstream (see FIG. 39).
[0075] The resulting configuration of the carton 110A at this stage
is as shown in FIG. 64. This is referred to as the "loading
configuration" of the carton.
[0076] Referring to FIG. 40, as the carton 110A is conveyed further
downstream, the non-loading end 220 of the carton 110A reaches, and
is conveyed alongside, a back-up rail 260. The back-up rail 260
holds the leading and trailing minor flaps 236 and 238, on the
non-loading end 220 of the carton 110A, in their closed positions,
through sliding abutment of the flaps 236 and 238 against the rail
260, as the carton 110A is conveyed towards the product loading
station 120 (see FIGS. 39-44). The back-up rail 260 also provides a
backing to prevent inadvertent product egress out of the
non-loading end 220 of the carton 110A during product loading at
the product loading station 120.
[0077] Referring again to FIGS. 39-44 as well as to FIGS. 7-12, the
loading end 218 of the carton 110B reaches and is conveyed
alongside the inwardly-facing side of the reciprocating gate 150,
which is in the raised position. Specifically, the carton 110B is
conveyed alongside the lower portion 154 of the reciprocating gate
150 (see FIG. 70A). The reciprocating gate 150 holds the leading
and trailing minor flaps 226 and 228 on the loading end 218 of the
carton 110A in their open positions as the carton 110A is conveyed
into the product loading station 120. This is perhaps best seen in
FIGS. 39-44.
[0078] When the carton 110A has been conveyed into the product
loading station 120 to the position shown in FIG. 44, the carton
conveyor 114 suspends its downstream movement, i.e. downstream
conveyance pauses. This pause may be referred to as a dwell period
or a stationary index. In the present embodiment, the dwell period
permits the product 144 to be loaded into the cartons 110 using
reciprocating arms 140 that are not configured for synchronized
indexing alongside to-be-loaded cartons on conveyor 114 (i.e. the
dwell period facilitates loading using arms 140 whose position on
the longitudinal axis of the conveyor 114 is stationary). It will
be appreciated that alternative embodiments may permit indexed
product loading, i.e. loading while cartons are being conveyed.
Such systems may not require a dwell period but may involve
additional equipment for achieving synchronized motion between the
product loading equipment and the carton conveyor.
[0079] Referring back to FIGS. 3-14 and 38-44, it can be seen that
a second carton 110B is placed on the carton conveyor 114, in the
adjacent slot 112 immediately upstream of the slot 112 in which the
first carton 110A was placed. Carton 110B is indexed just behind
carton 110A on the conveyor 114, and is manipulated in the same
fashion as carton 110A, described above. In the result, the carton
110B achieves the same loading configuration as carton 110A (see
FIG. 64). Thus, at the commencement of the dwell period, two
cartons 110A and 110B are situated in the product loading station
120, with an open loading end 218 of each carton 110A and 110B
being vertically aligned with a respective open area 152A and 152B
in the gate 150 (see FIGS. 12 and 44).
[0080] At this stage, the reciprocating gate 150 is lowered (see
FIGS. 13 and 45). In particular, the lower portion 154 of the gate
150 is retracted below a level of the carton conveyor 114, with the
upper portion 156 of the gate 150 being correspondingly lowered
until the open areas 152A and 152B in the gate 150 align with the
open loading ends 218 of the respective cartons 110A and 110B (e.g.
in the position shown in FIG. 70B). In this position, the upper
portion 156 of the gate 150 continues to hold open the minor flaps
111 of the cartons 110 in their open positions, but the open
loading ends 218 of the cartons are exposed for product loading by
virtue of alignment with open areas 152A and 152B.
[0081] The mechanism for moving the reciprocating gate 150 may for
example be a pneumatic actuator supplied with pressurized air
communicated through electronic solenoid valves for causing a
piston arm, to which the reciprocating gate 150 may be attached, to
retract and extend. The pneumatic actuator may be supported on part
of the support frame.
[0082] Product loading is illustrated in FIGS. 14-17 and 45-49.
With both cartons 110A and 110B being stationary (i.e. with the
conveyor 114 in a dwell period) and in their loading configurations
(as in FIG. 64), the reciprocating arms 140 begin to move
horizontally towards the carton conveyor 114 substantially
transversely to the longitudinal axis of carton conveyor 114. The
pusher ends 142 push product 144 along product guides and into the
open ends 218 of the cartons 110A and 110B, until the product 144
is fully contained within the cartons 110A and 110B (see FIGS. 14,
15 46 and 47). Thereafter, the reciprocating arms 140 are retracted
so that the pusher ends 142 are clear of the reciprocating gate 150
(FIGS. 16 and 48). Then the reciprocating gate 150 is raised back
to the closed position (FIGS. 17 and 49). The dwell period thus
concludes.
[0083] Referring to FIGS. 18 and 50, the carton conveyor 114
resumes downstream indexing (movement) of both cartons 110A and
110B. As the cartons exit the product loading station 120 and enter
the minor flap closing station 130, product egress is prevented by
the lower portion 154 of the reciprocating gate 150, which acts as
a barrier or rail along which the open loading ends 218 of the
cartons 110 are conveyed with their minor flaps still in the open
position. At this time, reciprocating arms 140 are more fully
retracted, out from within the product guides 148, to make room for
subsequent reloading of the product guides 148 with additional
product 144 for the next cycle.
[0084] Closure of the leading minor flap 226 of the first carton
110A by the minor flap closing device 159 in the upstream-most
portion of the minor flap closing station 130 is illustrated in
FIGS. 18-20, with additional reference to FIG. 60. It will be
appreciated that, in FIG. 18-20, the reciprocating rail 164 is
positioned at or near a limit of its upstream extent of travel,
i.e. not with piston arm 200 extended in the downstream direction
as shown in FIG. 60, but rather with piston arm 200 largely or
completely retracted within cylinder 202.
[0085] Referring to FIG. 18, as the leading carton 110A approaches
the leading minor flap closing slot 166, a distal tip of the
downstream-pointing leading minor flap 226 of carton 110A, which is
sliding along an interior surface of rail portion 172 in the open
position, is thrust through slot 166. Put another way, the distal
tip of the leading minor flap 226 is received or "caught" by the
slot 166 and protrudes partially through the slot 166. This is
illustrated in top plan view in FIG. 71 (it is noted that FIG. 71
is not necessarily to scale, nor are FIGS. 72-78, described below,
necessarily to scale). As earlier noted, the ability of slot 166 to
catch the leading minor flap 226 in this way may be facilitated, at
least in part, by the fact that the slot 166 is slightly
upstream-facing in the present embodiment (i.e. there is an offset
A1 between rail portions 172 and 174, as shown in FIG. 60). This
offset is not necessarily present in all embodiments. Additionally
the natural resiliency (memory) of the material may also cause the
minor flap 226 to be pushed into and through slots 166. It should
be noted that in some embodiments an external force may be applied
to the interior surface of the minor flap 226 when it is proximate
slot 166. This could be done for example by directing a flow of gas
(eg. air) from a nozzle against the surface of the minor flap, to
push the minor flaps 228 against the rail sections 178 and 180
respectively. A flow of pressurized air emitted from the nozzle may
be controlled by suitable valves that are in communication with
controller 108.
[0086] Referring to FIG. 19, as the carton 110A is conveyed further
downstream, contact between the downstream edge of the slot 166
(i.e. the upstream end of rail portion 174) and the exterior
surface of the leading minor flap 226 causes the flap 226 to be
swung (i.e. to pivot or be folded about its fold line with the
leading minor panel 214), from its former open position, to an
orientation in which it protrudes transversely from the carton
conveyor 114 through slot 166. This is illustrated in top plan view
in FIG. 72. Further downstream indexing of the carton 110A causes
the leading minor flap 226 to point partially upstream, as shown in
FIG. 73.
[0087] Turning to FIG. 20, upon still further downstream indexing
of the carton 110A, the upstream limit of rail portion 174 closes
the leading minor flap 226 more fully, i.e. folds the flap 226 to
its closed position, as illustrated in FIG. 65. By virtue of the
continued conveyor movement, the carton 110A essentially pulls the
leading minor flap 226 downstream by its fold-line proximal edge,
withdrawing it from slot 166 with the flap 226 now pointing in the
upstream direction and being in the closed position, as shown in
FIG. 74. At this stage, the rail portion 174 holds the flap 226
closed (as in FIG. 21), with the exterior surface of flap 226
sliding along interior surface of the rail portion 174.
[0088] It will be appreciated that, when the trailing minor flap
228 is conveyed past slot 166, the slot 166 does not close the flap
228 as it did flap 226. The reason is that the trailing minor flap
228 points upstream rather than downstream as it is conveyed past
slot 166. As a result, the distal tip of the trailing minor flap
228 will effectively be dragged across the slot 166 rather than
being thrust through it.
[0089] It will also be appreciated that, throughout the
above-described closure of the leading minor flap 226, the rail
portions 172 and/or 174 substantially abut, cover or block the open
loading end 218 of the carton 110A, as the flap 226 is conveyed
past the slot 166 (albeit there may be a small transverse gap
between the open end 218 of the carton 110A and the interior side
of the rail portion 172, so that the conveyor does not cause the
portion of the leading minor panel 214 of carton 110A immediately
adjacent to the fold line with the leading minor flap 226 to strike
the upstream edge of the rail portion 174). This abutment, coverage
or blocking may advantageously inhibit or preclude egress of
product or other carton contents during closure of the leading
minor flap 226. This advantage is not necessarily present in
conventional minor flap closure techniques. For example, in systems
where a leading minor flap is closed by a guide rail or other fixed
structure in the manner shown for leading minor flap 236 in FIG. 36
for example, the arc through which the minor flap is to swing about
its fold line during closure is typically intentionally kept open,
precisely so that closure of the minor flap is unimpeded. To the
extent that any product contained in a carton whose leading minor
flap is being so closed is jostled (e.g. due to normal conveyor
movement), the jostled product may undesirably fall out of the
carton through the intentionally open area. The presently described
approach may be less prone to such difficulties. Moreover, use of
the slot 166 may be less complex and less expensive than other
approaches used in the industry to address the "product egress
during minor flap closure" problem, such as the use of top-loading
systems wherein gravity tends to keep top-loaded product inside a
carton prior to carton closure.
[0090] Referring again to FIG. 50, as the leading carton 110A is
being conveyed downstream, the lower major flap 234 on the
non-loading end 220 starts to ride up the stationary lower major
flap plough 262. Upon further downstream conveying of the carton
110A, the contact with the plough 262 causes the lower major flap
234 to close (see FIG. 51), resulting in the carton configuration
shown in FIG. 66. The lower major flap 234 of the second carton
110B is closed in the same way (see FIG. 52). The lower major flaps
234 of both cartons 110A and 110B are thereafter held closed, when
in the minor flap closing station 130, by the stationary lower
major flap retainer rail 264 (see FIG. 52).
[0091] In FIGS. 22-24 and FIG. 51, the leading minor flap 226 of
the second carton 110B is closed in the same way that the leading
minor flap 226 of the first carton 110A was closed (see FIGS.
18-20, described above).
[0092] Referring to FIG. 25, downstream conveying of the cartons
110A and 110B continues, until the trailing minor flaps 228 of each
of the cartons 110A and 110B just pass slots 168 and 170 of the
reciprocating rail 164. At that point, the carton conveyor 114
again suspends its downstream movement, i.e. reaches another dwell
period. This is shown in FIGS. 26 and 52.
[0093] It will be appreciated that, in the present embodiment, the
commencement of the dwell period during which the trailing minor
flaps 228 of cartons 110A and 110B are closed matches the
commencement of the dwell period during which an upstream pair of
cartons 110 are loaded with product 144. This design leverages the
dwell period for use not only for product loading, but also for
loading-side trailing minor flap closure. That is, because the
reciprocating rail 164 is designed to pass the cartons 110A and
110B in the downstream direction in order to close the trailing
minor flap 228 in any event, the box closing apparatus 106 has been
designed to do this when the (now-loaded) cartons are in a dwell
period. Although reciprocating rail 164 could feasibly be designed
to close trailing minor flaps 228 of moving cartons with the carton
conveyor 114 in motion, in that case the reciprocating rail 164
would need to move in the downstream direction at a speed that is
faster than the speed of carton conveyor 114, and possibly to have
a longer extent of travel than in the present embodiment, to be
able to overtake the moving cartons 110A and 110B.
[0094] Closure of the trailing minor flaps 228 of the cartons 110A
and 110B by the reciprocating rail 164 portion of the minor flap
closing device 159 is shown in FIGS. 26-29 and FIGS. 75-78.
[0095] Referring to FIG. 26, with the cartons 110A and 110B
stationary on the conveyor 114, the reciprocating rail 164
commences longitudinal downstream movement alongside carton
conveyor 114. This is caused by the commencement of extension of
piston arm 200 from cylinder 202 (see FIG. 60). As the slots 168
and 170 in the reciprocating rail 164 pass the upstream-pointing
trailing minor flaps 228 of cartons 110B and 110A respectively, the
distal tips of the trailing minor flaps 228 are thrust through the
respective slots 168 and 170. Put another way, the distal tips of
the trailing minor flaps 228 of cartons 110B and 110A are received
or "caught" by the slots 168 and 170 respectively and protrude
partially therethrough. This is illustrated in top plan view in
FIG. 75. As earlier noted, the ability of slots 168 and 170 to
catch the trailing minor flaps 228 in this way may be facilitated,
at least in part, by the fact that the slots 168 and 170 are
slightly downstream-facing in the present embodiment (i.e. there is
an offset A2 between rail portions 176 and 178 and an offset A3
between rail portions 178 and 180, as shown in FIG. 60). These
offsets may be diminished or possibly absent in some embodiments.
Additionally the natural resiliency (memory) of the material may
also cause the minor flap 228 to be pushed into and through slots
168 and 170. It should be noted that in some embodiments an
external force may be applied to the interior surface of the minor
flaps 228 when they are proximate slots 168 and 170. This could be
done for example by directing a flow of gas (eg. air) from a nozzle
against the surface of the minor flap, to push the minor flaps 228
against the rail sections 178 and 180 respectively. A flow of
pressurized air emitted from the nozzle may be controlled by
suitable valves that are in communication with controller 108.
[0096] Referring to FIG. 27, as the reciprocating rail 164 moves
further downstream, contact between the upstream edges of the slots
168 and 170 (i.e. the downstream limits of rail portions 176 and
178 respectively) and the exterior surfaces of the trailing minor
flaps 228 of cartons 110B and 110A respectively causes the flaps
228 to be swung (i.e. to pivot or be folded about their fold lines
with their trailing minor panels 216), from their former open
position, to an orientation in which they protrudes transversely
from the carton conveyor 114 through slots 168 and 170. This is
illustrated in the top plan view of FIG. 76. Further downstream
movement of reciprocating rail 164 causes the trailing minor flaps
228 to point partially downstream, as shown in the top plan view of
FIG. 77.
[0097] Turning to FIG. 28, upon further downstream longitudinal
movement of the reciprocating rail 164, the downstream ends of rail
portion 176 and 178 close the trailing minor flaps 228 of cartons
110B and 110A more fully, i.e. fold the trailing minor flap 228 to
their closed positions, as illustrated in FIGS. 29 and 67 for
example. At this stage, the reciprocating rail 164 ceases its
longitudinal movement, with interior surfaces of the rail portions
176 and 178 holding closed the flaps 228 of cartons 110B and 110A,
respectively, e.g. as shown in the top plan view of FIG. 78. The
downstream limit of movement of the reciprocating rail 164 is such
that the slots 168 and 170 do not reach the leading minor flaps 226
of respective cartons 110B and 110A. This is to avoid inadvertent
reopening of the leading minor flaps 226 by slots 168 and 170.
[0098] It will be appreciated that, throughout the above-described
closure of the trailing minor flap 228 of carton 110B, the rail
portions 178 and/or 176 substantially abut, cover or block the open
loading end 218 of the carton 110A. Similarly, throughout the
above-described closure of the trailing minor flap 228 of carton
110A, the rail portions 180 and/or 178 substantially abut, cover or
block the open loading end 218 of the carton 110A (although there
may be a small transverse gap between the open ends 218 of the
cartons 110A and 110B and their respective adjacent rail
portion(s)). This abutment, coverage or blocking may advantageously
inhibit or preclude egress of product or other carton contents from
cartons 110B and 110A during closure of the trailing minor flaps
228. This advantage is not necessarily present in conventional
minor flap closure techniques. For example, in systems where a
trailing minor flap is closed by a kicker in the manner shown for
trailing minor flap 238 in FIGS. 37 and 38 for example, the arc
through which the minor flap is to swing about its fold line during
closure is typically intentionally kept open, precisely so that
closure of the minor flap is unimpeded. To the extent that any
product contained in a carton whose trailing minor flap is being so
closed is jostled (e.g. due to normal conveyor movement), the
jostled product may undesirably fall out of the carton through the
intentionally open area. The presently described approach may be
less prone to such difficulties and may be less complex or less
costly than alternative approaches for addressing the same problem,
such as top-loading systems.
[0099] It will also be appreciated that the above-described closure
of the leading and trailing minor flaps on the loading end 218 of a
carton 110 is achieved without the use of a kicker. The
above-described minor-flap closure technique may accordingly be
referred to as a kickerless minor flap closure technique. The
omission of kickers for minor flap closure may advantageously avoid
the aforementioned precision control requirements that may be
required to account for factors such as conveyor speed and carton
material resiliency for example and may thus reduce the sensitivity
of the box closing apparatus 106 to variations in such
parameters.
[0100] Referring to FIG. 30, the carton conveyor 114 resumes
downstream indexing (movement) of both cartons 110A and 110B. As
the cartons exit the minor flap closing station 130, product egress
from between the now-closed minor flaps 226 and 228 is prevented by
the rail portion 180 of the reciprocating rail 164 along which the
cartons are conveyed.
[0101] It will be appreciated that, when the trailing minor flaps
228 are conveyed past the slots 168 and 170 that were used to close
those flaps, the slots 168 and 170 do not catch and reopen the
flaps 228. In some embodiments, this may be facilitated by the fact
that the slots 168 and 170 are partially downstream facing. That
is, in some embodiments, the distal tips of the closed,
downstream-pointing trailing minor flaps 228 are not thrust through
the slots, at least in part because the upstream side of each slot
is inwardly offset relative to the downstream side of the slot.
Also, when the closed leading minor flap 226 of the upstream carton
110B is conveyed downstream past slot 170, the flap 226 is simply
dragged across the slot 1700 by virtue of the fact that it was
earlier closed and thus points upstream. Although not expressly
illustrated, as the upstream carton 110B exits the minor flap
closing station 130, the reciprocating rail 164 may reciprocate
longitudinally (i.e. move in the upstream direction) back to its
original starting position. This upstream resetting movement of the
reciprocating rail 164 may for example commence just as the
trailing minor flap 228 of the carton 110B passes downstream slot
170. It is possible that the resetting could occur even earlier in
alternative embodiments.
[0102] Still referring to FIG. 30, as the leading carton 110A is
conveyed further downstream, the lower major flap 224 on the
loading end 218 starts to ride up the stationary lower major flap
plough 266. Upon further downstream conveying of the carton 110A,
the contact with the plough 262 causes the lower major flap 224 to
close, resulting in the carton configuration of FIG. 68. As this is
being done, a sealing device 268 (FIG. 30) applies a sealing
material, such as glue or tape, to an exterior surface of the lower
major flap 224. A similar sealing device 270 similarly applies a
sealing material to the exterior surface of the lower major flap
234 on the non-loading side of the carton 110A.
[0103] Referring to FIGS. 31 and 56, subsequent conveyance
(indexing) of the carton 110A past opposing upper major flap
closing ploughs 272 and 274 causes the upper major flaps 222 and
232, respectively, to close, resulting in the carton configuration
of FIG. 69. Carton sealing is completed through conveyance of the
carton 110A between opposing compression rails 276 and 278 flanking
the conveyor 114 (see FIGS. 31 and 56), which apply pressure to the
sides of the cartons.
[0104] Referring to FIGS. 32 and 57, the second carton 110B is
closed and sealed in the same manner as carton 110A.
[0105] Referring to FIGS. 33, 58 and 59, the sealed cartons emerge
from between the compressing rails 276 and 278 for possible further
processing downstream. The cartons illustrated in FIGS. 33, 58 and
59 may be in a further dwell period. In some embodiments, side
belts that grip the cartons may be continuously running to
discharge cartons 110 from the box closing apparatus 106. This may
prevent lugs from marking the trailing minor panel 216 of the
cartons 110 as they go around a chain pulley for example.
[0106] Various modifications to the above-described system are
possible. For example, for example, it is not absolutely required
for the carton conveyor 114 to use period dwell periods. Rather, a
continuous motion conveyor could be used. In such an embodiment,
product loading could be achieved while the cartons 110 are in
motion on the conveyor through the use of a product loading station
wherein a reciprocating arm transversely loads product into a
carton while being indexed along with the carton for example. In
such embodiments, the configuration of the fixed rail 162 used for
closing leading minor flaps 226 could remain the same. The
reciprocating rail 164 should be configured to move in a downstream
direction at a speed that is faster than the conveyor speed, in
order to be able to overtake and close the trailing minor flaps 228
of cartons as they are indexed downstream.
[0107] As described above, it is not absolute required for cartons
to be loaded and to have their minor flaps closed in pairs, like
carton pair 110A and 110B. For example, in a continuous motion
conveyor system, it may be practical to load each carton
individually as the carton is indexed. Alternatively, in some
embodiments, it may be desired to handle more than two cartons
(i.e. during product loading and during loading-side minor flap
closure) at once.
[0108] As indicated above, in some embodiments, if material memory
alone is insufficient to reliably urge the leading minor flap 226
to slide along the interior of rail portion 172 and to thus be
readily received within the slot 166 for leading minor flap
closure, or similarly if the material memory alone is insufficient
to urge the trailing minor flap 228 to slide along the interior of
rail portion 178 or 180 to thus be readily received within slot 168
or 170 respectively for trailing minor flap closure, then it may be
possible to use another mechanism, such as an outward transverse
air blast for example, to facilitate such urging and to thereby
encourage proper reception and closure of the flaps by the relevant
slot 166, 168 or 170.
[0109] In some embodiments, the slot 166 that is used to close
leading minor flaps 226 could be a slot in a rail that is not fixed
in relation to the conveyor 114. It may for example be possible for
the slot 166 to be defined in a rail that moves upstream as a
carton 110 whose leading minor flap 226 is to be closed is conveyed
downstream past the slot 166. It is the downstream movement of the
leading minor flap 226 relative to the slot 166 (or conversely
upstream movement of the slot 166 relative to the flap 226) that is
what causes the flap to close. Thus, while the slot 166 may be
defined in a fixed rail due to simplicity (since cartons are being
conveyed downstream in any event), it is not absolutely required
for the rail in which the slot 166 is defined to be fixed in all
embodiments. Furthermore, it will be appreciated that other
variations are possible to provide for relative movement of the
cartons and their minor flaps on the one hand, and the guide rails
sections and their slots 116, 168 and 170 on the other hand, to
achieve the closing of the minor flaps. For example, it may in some
embodiments be possible to provide for a fully stationary rail 160
and move the cartons 110 in alternate upstream and downstream
movements on the conveyor 114 to achieve closure of the minor flaps
226, 228.
[0110] The illustrated embodiments show conveyance of cartons with
the open end facing horizontally sidewards. It is possible that, in
an alternative embodiment, the cartons could, at least temporarily
at some point during their conveyance, be conveyed with the open
end facing in another direction that is transverse to the
longitudinal conveyance direction of the conveyor, that is not
necessarily sidewards. For example, it may be possible in some
embodiments that the longitudinal movement of the boxes is in a
vertical direction, and the open end of the box open in a
horizontal direction.
[0111] Referring now to FIGS. 79-95, an alternative embodiment of a
box closing apparatus 300, which may be referred to as a
double-sided box closing apparatus 300, is illustrated. The
apparatus 300 is designed to close cartons 310 that are similar in
shape and structure to the cartons 110 described hereinabove. Many
aspects the box closing apparatus 300, such as the conveyor 314
that conveys cartons in a downstream direction D, the kicker 440
that opens the leading minor flap, the reciprocating arms 304,
product guides 348, and reciprocating gate 350 used in product
loading, minor flap closing device 359 comprising a longitudinal
rail 360 having fixed and reciprocating sections 362 and 364
respectively, stationary lower major flap plough 466, sealing
devices 468 and 470, stationary opposing upper major flap closing
ploughs 472 and 474, and compression rails 476 and 478 are
analogous to their counterparts in the preceding description,
namely conveyor 114, kicker 240, reciprocating arms 140, product
guides 148, reciprocating gate 150, minor flap closing device 159,
comprising a longitudinal rail 160 having fixed and reciprocating
sections 162 and 164 respectively, stationary lower major flap
plough 266, sealing devices 268 and 270, stationary opposing upper
major flap closing ploughs 272 and 274, and compression rails 276
and 278, respectively. The alternative box closing apparatus 300
also has various operational similarities to the box closing
apparatus 106, such as the simultaneous loading of two cartons
during a dwell period and the closing of the minor flaps of the
same pair of cartons using a longitudinally movable rail during a
subsequent dwell period of the same duration.
[0112] However, the box closing apparatus 300 differs from the
above-described box closing apparatus 106 primarily in four
respects.
[0113] Firstly, the apparatus 300 is designed to open, not close,
the minor flaps on the non-loading ends of cartons 310A and 310B,
i.e. on the non-loading side 306 of the conveyor 314, upstream of
the product loading station 320. In the illustrated embodiment,
this is done using a mechanism similar to what was used for opening
the minor flaps 226 and 228 on the loading end 218 of the cartons
110A and 110B on the loading side of the conveyor 114 described
above. The reason for this opening of the flaps on the non-loading
end of the cartons is to support the use of reverse reciprocating
arms 302, described immediately following.
[0114] Secondly, the apparatus 300 has an additional set of
reciprocating arms 302--referred to as reverse reciprocating arms
302--on the non-loading side of the carton conveyor 314. Arms 302
may be actuated and controlled like arms 140 as described above,
using a double acting pneumatic cylinder having a supply of
compressed air controlled by electronic valves that are themselves
controlled by controller 108. The reverse reciprocating arms 302
are designed to cooperate with a set of reciprocating arms 304 that
are similar to the reciprocating arms 140 described earlier, during
product loading. More particularly, the reverse reciprocating arms
302 are designed to extend transversely, from the non-loading side
306 of the conveyor 314, fully through a pair of cartons 310A and
310B whose loading and non-loading ends have both been opened,
towards the reciprocating arms 304 on the loading side of the
conveyor 314, until a to-be-loaded product 344 becomes cradled
between the ends 303 of the reverse reciprocating arms 302 and the
pusher ends 342 of reciprocating arms 304. The reverse
reciprocating arms 302 are further intended to be retracted
transversely in synchronicity with the transverse extension of the
reciprocating arms 304, so that the product 344 that is being
pushed into the cartons 310A and 310B continues to be cradled
between the ends 303 of the reverse reciprocating arms 302 and the
pusher ends 342 of the reciprocating arms 304 during product
loading, which ends 303 and 342 remain separated by substantially
the same transverse extent as the product is being transversely
loaded. The cradling of the product may inhibit product scattering
or dispersal, which could possibly otherwise be caused by jostling
or by friction with the bottom or upstanding sides of the product
guides 348 for example, as the product is pushed into the carton
310. Such scattering or dispersal could risk product damage (e.g.
due to impact with an edge of a carton wall or sandwiching of the
product between a carton wall and a pusher end 342) during loading
or, alternatively or additionally, could result in undesirable
disarray of the loaded product. Such operation of the reverse
reciprocating arms 302 and reciprocating arms 304 is illustrated in
FIGS. 80-83.
[0115] Thirdly, the apparatus 300 has another reciprocating gate
351, analogous to reciprocating gate 350, on the non-loading side
of the carton conveyor 314, opposite reciprocating gate 350. The
second gate 351 may operate substantially in synchronicity with the
reciprocating gate 350, whose operation is analogous to the
operation of reciprocating gate 150, described above. A
reciprocating gate 351 is used on the non-loading side in this
embodiment in order to hold the minor flaps on the non-loading side
open during loading (to allow the reverse reciprocating arms 302 to
"reach through" the cartons 310 unimpeded) and to keep the flaps
open upon conveying of the carton, with opened minor flaps, into
and out of the product loading station. The lowering and raising of
the reciprocating gate 351 is shown in FIGS. 80 and 83,
respectively.
[0116] Fourthly, the apparatus 300 has a second minor flap closing
device 389 on the non-loading side of the conveyor 314 that is
essentially a mirror image of the minor flap closing device 359 on
the loading side of the conveyor 314. The device 389 comprises a
longitudinal rail 390, with similar fixed and reciprocating
sections 392 and 394 respectively as longitudinal rail 360. The
second minor flap closing device 389 is used to close the leading
and trailing minor flaps on the non-loading ends of the cartons
310A and 310B during the same dwell period in which the leading and
trailing minor flaps of the same cartons are closed on the loading
ends of the cartons.
[0117] Select aspects of the operation of box closing apparatus 300
that is further shown in FIGS. 84-95 will now be described.
[0118] In FIGS. 84 and 85, closure of a leading minor flap 436 by
the minor flap closing device 389 on the non-loading side of the
carton 310A is shown. As the carton 310A is conveyed past slot 396
in fixed rail section 392, the leading minor flap 436 is closed by
the slot 396, in the same manner (except in mirror image) as
leading minor flap 226 was closed by slot 166 in fixed rail section
162 of the above-described embodiment. The closing of the leading
minor flap 436 on the non-loading end may be done simultaneously
with the closing of the leading minor flap of the carton 310A on
the opposite, loading end of the carton by the minor flap closing
device 360 (not expressly shown).
[0119] In FIGS. 86 and 87, the downstream carton 310A is conveyed
further downstream towards the reciprocating rail portions 364 and
394 of the minor flap closing devices 359 and 389 respectively.
[0120] In FIGS. 88 and 89, closure of a leading minor flap 436 on
the non-loading side of the other carton 310B is shown. The flap
436 on carton 310B is closed in the same manner as the leading
minor flap 436 of carton 310A was closed.
[0121] In FIGS. 90-92, the pair of cartons 310A and 310B is
conveyed until their trailing minor flaps 438 are just downstream
of slots 399 and 398, respectively, in the reciprocating rail 394,
at which time the conveyor 314 enters a dwell period and indexing
of the cartons 310A and 310B ceases.
[0122] In FIGS. 93-95, the trailing minor flaps 438 of cartons 310A
and 310B are closed by slots 399 and 398, respectively, in the
reciprocating rail section 394 of the minor flap closing device
389, as the rail 394 is moved longitudinally downstream past the
flaps 438. This is done much in the same way (except in mirror
image) to the closing of the trailing minor flaps 228 of cartons
110A and 110B by the reciprocating rail 164, described above. The
trailing minor flaps on the non-loading end of the cartons 310A and
310B may be done simultaneously with the closing of the trailing
minor flaps 428 of cartons 310A and 310B on the loading end of the
cartons by slots 370 and 368, respectively, of the opposing
reciprocating rail 364 of minor flap closing device 359.
[0123] FIG. 96 is a perspective view of an alternative form of
reverse reciprocating arms 502 and reciprocating arms 504 that may
be used in some box closing apparatus embodiments. A pair of
interconnected reverse reciprocating arms 502 each has a clawed end
506. In the present embodiment, each end 506 has four tapered claws
508 equally spaced about a periphery of the end 506. The number of
claws can vary in other embodiments but will typically be at least
two. The profile of each end is substantially square and slightly
smaller than a transverse square interior profile of each a pair of
cartons 510 with which the arms 502 are aligned. The cartons are
opened on their loading ends 512 and non-loading ends 514, to
accommodate extension of the reverse reciprocating arms 502 through
the cartons 510 in the manner described above with respect to FIGS.
80-83. A pair of cylindrical rolled products 516, each of which may
be a roll of plastic bags for example, is positioned for loading
into respective cartons 510 within respective buckets 518 of a
product conveyor 520, which may be driven using gearing 522. The
reciprocating arms 504 have respective clawed pusher ends 524. In
the present embodiment, each end 524 has four tapered claws 526,
similar to claws 508, equally spaced about a periphery of the end
524. The number of claws can vary in other embodiments but will
typically be at least two. The profile of each end 524 is similar
to that of end 508 and may permit the end 524 to be partially
inserted into the carton 510 during product loading.
[0124] Loading of the product 516 may be done using a similar
cradling approach to what is described above with respect to FIGS.
80-83. When opposing clawed ends 506 and 524 cooperate to cradle
the product 516, the ends of cylindrical products 516 tend to be
pinched or squeezed inwardly (i.e. some pressure is applied from
the circumferential exterior of the roll ends towards the axial
center of the rolled products 516) by the tapered claws 508 and
526. This may advantageously discourage unrolling of the products
516 during product loading, as might otherwise occur due to
friction of the exterior surface of the rolled products against the
interior walls of the cartons 510 or possibly even due to the
effects of inertia for example.
[0125] Of course, the above described embodiments are intended to
be illustrative only and in no way limiting. The described
embodiments of carrying out the invention are susceptible to many
modifications of form, arrangement of parts, details and order of
operation. The invention, rather, is intended to encompass all such
modification within its scope, as defined by the claims.
[0126] When introducing elements of the present invention or the
embodiments thereof, the articles "a," "an," "the," and "said" are
intended to mean that there are one or more of the elements. The
terms "comprising," "including," and "having" are intended to be
inclusive and mean that there may be additional elements other than
the listed elements.
* * * * *