U.S. patent number 3,879,253 [Application Number 05/294,647] was granted by the patent office on 1975-04-22 for apparatus for forming corner pads.
This patent grant is currently assigned to Cellu Products Company. Invention is credited to Brendan L. Doll.
United States Patent |
3,879,253 |
Doll |
April 22, 1975 |
APPARATUS FOR FORMING CORNER PADS
Abstract
An apparatus for forming corner pads utilizing a plurality of
plies, each of which is adapted to be folded into a trihedral angle
arrangement, wherein the plies are successively fed into juxtaposed
relation while adhesive is applied to predetermined surfaces of
certain of the plies, and the plies are successively formed into
trihedral angle arrangements while being successively placed in
contiguous, nesting relationship to secure the nested plies
together by the adhesive to maintain the same in a collective
trihedral angle arrangement.
Inventors: |
Doll; Brendan L. (Patterson,
NC) |
Assignee: |
Cellu Products Company
(Patterson, NC)
|
Family
ID: |
26713077 |
Appl.
No.: |
05/294,647 |
Filed: |
October 3, 1972 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
Issue Date |
|
|
36332 |
May 11, 1970 |
3725170 |
|
|
|
Current U.S.
Class: |
156/443; 493/152;
156/475 |
Current CPC
Class: |
B65D
59/00 (20130101); B65D 81/054 (20130101); B31D
1/0012 (20130101) |
Current International
Class: |
B31D
1/00 (20060101); B65D 59/00 (20060101); B32b
031/00 () |
Field of
Search: |
;156/226,227,228,221,222,223,443,475 ;93/36.05,51E,52,39 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Van Horn; Charles E.
Assistant Examiner: Simmons; David A.
Attorney, Agent or Firm: Parrott, Bell, Seltzer, Park &
Gibson
Parent Case Text
This application is a division of my copending application, Ser.
No. 36,332, filed May 11, 1970, entitled "Method of and Apparatus
for Forming Corner Pads, which is now U.S. Pat. No. 3,725,170."
Claims
That which is claimed is:
1. Apparatus for forming a corner pad for protecting the corners of
furniture or the like utilizing a plurality of plies, each of which
is adapted to be folded into a trihedral angle arrangement with two
edges being brought into abutting relation, said apparatus
comprising,
forming means adapted to receive the plies one at a time and for
successively forming the plies into trihedral angle arrangements
and for successively placing the formed plies in contiguous,
nesting relationship with the attitude of selected plies being
varied so that the abutting edges of the plies are out of registry,
and
means operatively associated with said forming means for applying
adhesive to at least one of the contiguous surfaces of adjacent
plies to secure the nested plies together to maintain the same in a
collective trihedral angle arrangement.
2. Apparatus according to claim 1 including feeding means adapted
to successively receive the plies and operatively associated with
said forming means for feeding the plies one at a time and in
succession to said forming means.
3. Apparatus according to claim 2 including storage means
positioned in spaced relation to said forming means and operatively
associated with said feeding means for storing a stack of the plies
and for delivering the same one at a time to said feeding
means.
4. Apparatus for forming a corner pad for protecting the corners of
furniture or the like utilizing a plurality of generally L-shaped
plies, each of which is adapted to be folded into a trihedral angle
arrangement in which the edges defining the included angle of the
L-shape are brought into abutting relation, said apparatus
comprising
storage means for storing a stack of the plies in juxtaposed
relation,
feeding means operatively associated with said storage means for
withdrawing the plies one at a time from said storage means and for
feeding the same in succession along a predetermined path of
travel,
means disposed adjacent said feeding means for applying adhesive to
predetermined surfaces of certain of the plies as they are being
fed by said feeding means, and
forming means operatively associated with said feeding means for
successively receiving the plies therefrom and for successively
forming the plies into trihedral angle arrangements and for
successively placing the formed plies in contiguous, nesting
relationship so that the adhesive on the surfaces of the certain
plies is brought into contact with the contiguous surfaces of the
adjacent plies to secure the plies together and maintain the same
in a collective trihedral angle arrangement.
5. Apparatus according to claim 4 whereinn said forming means
comprises male forming means adapted to strike each ply at a point
adjacent the juncture of the edges defining the included angle of
the L-shape, and female forming and nested ply receiving means
adapted to engage each ply adjacent its periphery for cooperating
with the male forming means in the forming of the ply into the
trihedral angle arrangement and for receiving the thusly formed ply
therein in contiguous, nesting relationship with previously formed
plies.
6. Apparatus according to claim 5 including means mounting said
female forming and nested ply receiving means for rotation, and
means for rotating said female forming and nested ply receiving
means a fraction of a revolution in timed relation to the operation
of said male forming means to vary the attitude of at least one ply
in each corner pad relative to the other plies so that the abutting
edges thereof are out of registry with the abutting edges of the
other plies.
7. Apparatus according to claim 6 including means operatively
associated with said female forming and nested ply receiving means
for withdrawing completed corner pads therefrom.
8. An apparatus for continuously forming corner pads useful in
protecting the corners of furniture or the like and utilizing a
plurality of plies, each of which is adapted to be folded into a
trihedral angle arrangement, said apparatus comprising
a forming station,
means for sequentially feeding individual plies along a
predetermined path of travel and delivering the same to said
forming station,
means for applying adhesive to only certain selected plies while
the plies are being fed along saaid path of travel, and
means for successively forming the plies received at said forming
station into said trihedral angle arrangement and for successively
placing the formed plies into a contiguous nesting
relationship,
whereby those plies having adhesive applied thereto become
interconnected to the adjacent ply to maintain the same in such
contiguous nesting relationship and form a unitary corner pad, and
those plies not having adhesive applied thereto define the
interface between the formed corner pads.
Description
The present invention relates to an apparatus for forming corner
pads for protecting the corners of furniture or the like during
shipment or other handling, and more particularly to such an
apparatus for forming trihedral corner pads in a substantially
continuous, automated manner.
It is the usual practice in the shipment or other handling of
furniture and the like to utilize corner pads of suitable
shock-absorbent material over each of the corners thereof to
protect the same from damage. The most common corner pad utilized
for this purpose is formed by manually folding a unitary blank of
corrugated paperboard material which is suitably cut and scored to
facilitate its being folded into the corner pad. Such corner pads
are almost universally in the shape of a trihedral angle since this
shape has been found to provide the desired protection with a
minimum of material.
While providing adequate shock absorption and protection to the
corners of furniture and the like, conventional corner pads require
an excessive amount of paperboard material for a given amount of
shock absorption since there is considerable waste of the
paperboard material in the fabrication thereof. Further, no
automated apparatus has been found for forming trihedral corner
pads, and therefore only manual operations have been utilized in
the fabrication thereof. These manual operations are very time
consuming, and contribute materially, along with the aforementioned
waste of material, to an excessive cost of producing conventional
corner pads.
With the foregoing in mind, it is an object of the present
invention to provide an apparatus for forming corner pads which
obviates the deficiencies of the prior manual operations of forming
corner pads heretofore utilized.
It is a more specific object of the present invention to provide an
apparatus for forming corner pads which may be substantially
automated and thereby a significant reduction in the cost of
manufacture can be achieved.
It is still another object of the present invention to provide an
apparatus for forming corner pads wherein the production of corner
pads is substantially increased over the production of conventional
pads.
Some of the objects of the invention having been stated, other
objects will appear as the description proceeds when taken in
connection with the accompanying drawings in which
FIG. 1 is an illustrative flow diagram of the operation of the
apparatus of the present invention;
FIG. 2 is an exploded plan view of a blank suitably cut and scored
for the formation of a corner pad by the apparatus of the present
invention;
FIG. 3 is a perspective view of one portion of the blank shown in
FIG. 2;
FIG. 4 is an isometric view of a finished corner pad formed by the
apparatus of the present invention;
FIG. 5 is a fragmentary plan view of an apparatus illustrating the
features of the present invention;
FIG. 6 is a side elevational view of the apparatus shown in FIG.
5;
FIG. 7 is a front elevational view of the apparatus shown in FIGS.
5 and 6;
FIG. 8 is a vertical sectional view taken substantially along line
8--8 in FIG. 6;
FIG. 9 is a fragmentary, exploded isometric view of a portion of
the apparatus shown in FIGS. 5, 6 and 7 and illustrating the ply
feeding means and portions of the forming means; and
FIG. 10 is an enlarged vertical sectional view taken substantially
along line 10--10 in FIG. 6.
Referring now to the drawings, there is illustrated in FIG. 4 a
corner pad 20 which is also shown and described in my U.S. Pat. No.
3,511,464, issued May 12, 1970, entitled "Corner Pad and Blank." As
illustrated, corner pad 20 comprises a plurality of plies 21, 22,
23 and 24, each of which is arranged in a trihedral angle
arrangement, and then placed in contiguous, nesting relation with
another ply. The plies are secured together by suitable means, such
as by adhesive 25 (FIG. 3). One of the desirable characteristics of
corner pad 20 and of the apparatus of the present invention is that
the corner pad can be formed with a minimum waste of material and
in most instances can be formed without any waste of material.
One example of how the plies 21-24 of corner pad 20 can be formed
is illustrated in FIG. 2 and, as there shown, a sheet of any
suitable shock absorbent material which is sufficiently flexible to
be folded while still providing the required shock absorbency, is
suitably cut into four generally L-shaped portions 21', 22', 23'
and 24'. Due to the manner of cutting and the shape of these
portions, the entire area of the sheet is utilized in the portions
and there is no waste. Of course, there are other ways in which the
plies can be formed, as for example from a web of material instead
of a sheet, from a much larger sheet, or from a narrower sheet or
web of a width corresponding to the width of a single ply. Also,
due to its relatively high shock absorbency and low cost,
corrugated paperboard is preferred.
Preferably, the L-shaped portions 21' - 24' are suitably scored at
the same time that the sheet is cut to facilitate the folding of
the plies 21 - 24 into the trihedral angle arrangements. As
illustrated in FIG. 2, the portions are scored along lines 21a',
21b', 21c'; 22a', 22b', 22c'; 23a', 23b', 23c'; and 24a', 24b',
24c'. This cutting and scoring step is indicated at 26 in the flow
diagram of FIG. 1.
As stated above, one of the desirable characteristics of the
present invention is that the corner pad 20 can be formed in a
substantially continuous, automated manner. To this end, the
cutting and scoring of the plies and the forming of the cut and
scored plies into the corner pad 20 may proceed in one continuous
operation, but it is also contemplated by the present invention
that the plies can be cut and scored in a separate operation and
suitably stored until they are desired to be formed into corner
pads 20.
After the cutting and scoring of the plies, the same are
successively fed into juxtaposed relation, as indicated at 27 in
FIG. 1. Also, the adhesive 25 is applied to predetermined surfaces
of certain of the plies (indicated at 30 in FIG. 1) and preferably,
the adhesive is applied while the plies are being fed into
juxtaposed relation. Finally, the plies are formed into a corner
pad 20 (indicated at 31 in FIG. 1) by forming each of the plies
into a trihedral angle arrangement and then placing the thusly
formed plies into contiguous, nesting relation. These steps of the
method will be described in more detail in connection with the
description of the illustrated embodiment of the apparatus of the
present invention.
The apparatus, illustrated in FIGS. 5 - 10, is generally indicated
at 32 and includes a suitable base 33 and front, rear, and top
frame members 34, 35 and 36 (FIG. 6). A pair of storage means,
generally indicated at 40 and 41 in FIG. 5, are supported in spaced
apart relation by the frame members and are adapted to store a
suitable stack 42, 43 of the plies for formation into the corner
pads 20. The supply means 40, 41 are substantially identical in
construction and therefore only supply means 40 will be described
in detail.
Supply means 40 comprises a center support member 44 which is
adapted to be received within the included angle of the generally
L-shape of the plies and to support the plies thereby, and side
support members 45, 46 disposed on opposite sides of the center
support member 44 and at a slightly lower elevation. Side support
members 45, 46 are adapted to engage the ends of the legs of the
generally L-shaped plies when the same are positioned in the supply
means. A slide 47 is mounted on center support member 44 for
movement toward the forward end of the supply means 40 and is
suitably biased in this direction by a weight 50 (FIG. 6) connected
thereto by a line 51 which extends over a pulley 52. The stack of
plies 42 is thereby urged toward the forward end of the supply
means 40 so that the plies may be successively withdrawn and fed
into juxtaposed relation for formation into corner pads.
A plate 53 is mounted immediately in front of and extends between
the two supply means 40 and 41 and has openings 54, 55 therein at
the forward ends of these supply means, respectively, through which
the plies are successively delivered. Ply positioning means is
provided at each of the openings 54, 55 and includes a bar or plate
56 extending parallel to plate 53 and across the upper portions of
the openings 54, 55 to engage the top portion of each ply. A pair
of ply restraining pads 57, 58 are also mounted at openings 54, 55,
respectively, for engaging the lower portion of each ply. Bar 56
and pads 57, 58 are spaced from the forward surface of plate 53 a
distance corresponding substantially to the thickness of one ply
and are adjustably mounted to vary this spacing to accommodate
plies of varying thickness. The plies are successively delivered
through the openings 54, 55 until they engage the bar 56 and one
set of pads 57, 58 which position each successive ply for being fed
along the plate 53 with the top portion thereof between the plate
53 and bar 56 into position to be formed into a corner pad 20.
The successive feeding of the plies is accomplished by feeding
means 60 (FIG. 9) which comprises a slide 61 slidably mounted on a
track member 62 which in turn is mounted on the front frame member
34. The slide 61 includes a pair of upstanding feeding members 63,
64 which include first portions 63a, 64a extending upwardly at an
acute angle to the vertical, and second portions 63b, 64b extending
upwardly from the upper ends of first portions 63a, 64a and
generally perpendicular thereto. Second portions 63b, 64b extend
parallel to the distal, inclined upper edges of the plies in the
supply means 40 and 41. Feeding members 63, 64 also include third
portions 63c, 64c mounted on second portions 63b, 64b and extending
therealong. The proximal edges of third portions 63c, 64c are
recessed from the proximal edges of second portions 63b, 64b to
form ply receiving notches which receive and hold the edge portion
of the ply during feeding.
Ply hold back members 65, 66 are respectively carried by the
feeding members 63, 64 for holding the plies in the supply means
40, 41 rearwardly of the plate 53 during the inactive or rearward
stroke of each of the feeding members 63, 64 to prevent the feeding
member from striking and damaging the plies in the supply means.
Also, suitable guide rollers 67, 68 are carried by the upper ends
of the feeding members 63, 64 and are received between bar 56 and a
guide bar 69 mounted adjacent thereto.
The slide 61 is reciprocated by a suitable drive means illustrated
as including a slide block 70 conected to the slide 61 and mounted
for reciprocation on a track member 71. Slide block 70 is connected
by a suitable link 72 to one end of a crank arm 73 (FIG. 7) which
is pivotally mounted on the front frame member 34 and is connected
by a link 74 to an eccentric 75 (FIG. 7) mounted on a drive shaft
76. Therefore, upon rotation of the eccentric 75, the slide 61 is
reciprocated back and forth along the track member 62 and feeds
successive plies from each of the supply means 40, 41 in
alternation.
Plate 53 also has a medial opening 77 therein and forming means,
generally indicated at 80 in FIG. 6, is provided between the supply
means 40 and 41 at this medial opening. Forming means 80 defines a
forming station and includes a female forming and nested ply
receiving means 81, which is illustrated as including a cylinder 82
mounted for rotation about its longitudinal axis by mounting means
83. Mounting means 83 includes a pair of cradle members 84, 85
mounted on the top frame member 36 and having a plurality of
supporting rollers 86, 87 mounted thereon which are received in
grooves (not shown) in the cylinder 82 to hold the cylinder in
position and prevent axial movement thereof. Cylinder 82 is rotated
by drive means including a gear 90 mounted around cylinder 82, an
idler gear 91 meshing with gear 90 and a drive gear 92 mounted on
drive shaft 76.
Cylinder 82 has three plate members 93, 94, 95 mounted therein and
extending rearwardly therefrom a substantial distance. Plate
members 93, 94, 95 include forward portions 93a, 94a and 95a
extending perpendicular to the longitudinal axis of the cylinder 82
and defining restraining means adapted to engage the plies adjacent
the outer periphery thereof. The plate members 93, 94, 95 also
include portions 93b, 94b, 95b which extend generally parallel to
the longitudinal axis of cylinder 82, but which are arranged
relative to each other such that they collectively define a
triangle which corresponds in shape and size to the triangle of the
base of each of the trihedral angle arrangements into which the
plies are formed so that the thusly formed plies may be received
within the space bounded by the portions 93b, 94b and 95b within
cylinder 82.
Forming means 80 also includes male forming means 100 which
cooperates with the female forming means 81 for forming the plies
into the trihedral angle arrangements. Male forming means 100
includes a forming member 101 which is mounted for pivotal movement
by a shaft 102 mounted in spaced bearings 103. Member 101 is
generally C-shaped and has a lower end portion 101a which is
adapted to strike each of the plies at a point adjacent the
juncture of the edges defining the included angle of the L-shape
and to force the ply rearwardly against the portions 93a, 94a and
95a of the female forming means. Member 101 is biased upwardly and
away from the female forming means 81 by a suitable spring 104 and
is moved downwardly by a linkage 105 (FIG. 8) which is connected at
its lower end to a cam follower 106 cooperating with a cam 107
mounted on drive shaft 76.
As a ply is moved into position by the feeding means 60, the same
is positioned between the male forming means 100 and the female
forming means 81 with the included angle facing downwardly. In
timed relation to the operation of the feeding means 60, the male
forming member 101 is moved downwardly about the axis of the shaft
102 to bring the portion 101a into sharp contact with the ply and
to force the ply rearwardly against the portions 93a, 94a and 95a
which restrain rearward movement of the peripheral portions of the
ply while the male forming member continues to force the central
portion of the ply rearwardly which folds the ply along the score
lines therein into a trihedral angle arrangement. Once the ply has
been folded into the trihedral angle arrangement, the same will
slide into the area bounded by the portions 93b, 94b and 95b within
the cylinder 82 and will be forced rearwardly within this area
until the same is brought into contiguous nesting relationship with
the previously formed ply. The male forming member 101 is then
withdrawn by the spring 104 to permit the next ply to be moved into
position for formation.
The attitude of at least one ply in each corner pad is varied
relative to the other plies so that the edges of this L-shaped ply
which abut when the ply is formed into a trihedral angle
arrangement will be out of registry with the abutting edges of the
other plies. In the illustrated embodiment, this is accomplished by
rotating cylinder 82 a fraction of a revolution for certain plies
being formed. More specifically, the cylinder 82 is rotated
one-third of a revolution during the formation of each ply so that
the abutting edges of adjacent plies are out of registry.
Preferably, adhesive is applied to predetermined surfaces of
certain of the plies to secure the plies together to maintain the
same in contiguous nesting relationship and so that they define a
collective trihedral angle arrangement. To this end, adhesive
applying means 110 and 111 are disposed between the respective
supply means 40 and 41 and the forming means 80. As illustrated,
adhesive applying means 110 and 111 include spraying heads 112, 113
for spraying adhesive of a suitable type, preferably hot melt
adhesive but other types may be used, onto the forwardly facing
surfaces of certain of the plies. The spraying heads 112, 113 are
connected by suitable pipes 114, 115 to a suitable pressurized
source of adhesive, and are preferably constructed so as to spray
adhesive onto the plies in two vertically spaced lines (as seen in
FIG. 3) as the plies are fed past the spraying heads.
The spraying heads 112, 113 are controlled by means of solenoids
116, 117 which have suitable wiring extending to a control means.
Preferably, this control means controls the application of adhesive
to the plies in such a manner that the application of adhesive
controls the number of plies in the corner pad being formed. For
example, if the corner pad is to be of two-ply construction,
adhesive would be applied only to alternate plies fed past the
spraying heads 112, 113. If the corner pad is to be of three-ply
construction, adhesive would be applied to two successive plies and
the third ply would not have any adhesive applied thereto. This
would be true for any number of plies, with adhesive being applied
to a number of successive plies equal to one less than the number
of plies desired to be included in the corner pad. Of course, the
foregoing statements apply only to the application of adhesive to
one surface of the ply, but a suitable sequence of adhesive
application to both sides or the like and controls therefor will be
readily apparent to a workman in this field.
The control means for the spraying heads 112, 113 includes a
control panel 120 (FIG. 7) having a selector knob 121 having four
(4) illustrated positions 121a, 121b, 121c and 121d. The control
means also includes control switches 122, 123, 124, 125, 126, 127
and 128 (FIG. 10) which are selected by rotation of the knob 121
and which are controlled by suitable cams 130 - 134 which are
driven by a chain and sprocket drive system from the drive shaft
76. By rotating the cams at different speeds, by utilizing
sprockets of different sizes and by having different configurations
therefor, the timing and interval of actuation of the various
switches and hence the spraying heads 112, 113 can be controlled
relative to the feed of the plies to control the adhesive
application in the desired manner set forth above.
After formation into the trihedral angle arrangements and the
placement into contiguous, nesting relationship, the nested plies
are forced rearwardly within the space between the portions 93b,
94b, 95b of plate members 93, 94, 95 by the addition of newly
formed plies to the forward end of the space. The time interval
required for the nested plies to move from the forward end of this
space to the rearward end thereof is ample for the adhesive to
become set, or dry as the case may be, and the nested plies exit
from this space as finished corner pads 20 (FIG. 5). Preferably,
conveyor means 135 (FIGS. 5 and 6) is provided beneath the rearward
end of plate members 93, 94 and 95 for receiving and conveying the
finished corner pads away from the machine for use or
packaging.
It is therefore believed apparent that the present invention
provides a novel apparatus for forming corner pads whereby the
corner pads may be formed in a substantially continuous, automated
manner and with little or no waste of material and at a
considerably higher rate of production than has heretofore been
possible.
In the drawings and specification there have been set forth the
preferred embodiments of the invention, and although specific terms
are employed, they are used in a generic and descriptive sense only
and not for purposes of limitation.
* * * * *