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Publication numberUS3872650 A
Publication typeGrant
Publication dateMar 25, 1975
Filing dateFeb 27, 1974
Priority dateAug 31, 1972
Publication numberUS 3872650 A, US 3872650A, US-A-3872650, US3872650 A, US3872650A
InventorsVickers James L
Original AssigneeStone Container Corp
Export CitationBiBTeX, EndNote, RefMan
External Links: USPTO, USPTO Assignment, Espacenet
Packaging machine using two blank carton system
US 3872650 A
Abstract
A packaging machine for assembling a sealed carton from a pair of paperboard blanks. Each blank includes a center panel and alternate hinged side panels. One blank has flanges along opposite longitudinal, side and transverse end edges of the panels. The flanged blank is positioned with lading on the center panel thereof at a setup station of the machine and lowered past folding members to be folded into a generally "U" shape partially surrounding the lading. Concurrently, the side flanges are folded. Next, the blank and lading are moved in a bucket formation to an assembly station, during which movement the end flanges are folded. Prior to such movement, an unflanged blank is positioned at the assembly station with its center panel overlying the end flanges of the folded blank. An elevator mechanism moves the folded blank and lading upwardly against the unflanged blank past members which fold the unflanged blank into a "U" shape partially around the lading with the margin of the unflanged blank overlying the flanges to form the complete carton. Suitable adhesive coating of appropriate blank parts is provided either before or during folding operations. Then, the completed carton is moved into a compression chamber where the adhesive sets to seal the package.
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Description  (OCR text may contain errors)

United States Paten 1 Vickers [451 Mar. 25, 1975 1 PACKAGING MACHINE USlNG TWO 173] Assignec: Stone Container Corporation, Chicago, 111.

1221 Filed: Feb. 27, 1974 [21] Appl. No.: 446,124

Related US. Application Data [63] Continuation-in-part of Ser. No. 285,211, Aug. 31, 1972, Pat. No. 3,817,018, which is a continuation-in-part of Ser. No. 57,945, July 24, 1970, abandoned.

[52] US. Cl 53/207, 53/209, 53/231 [51} Int. Cl B65b 11/18 [58] Field of Search 53/140, 194, 207, 209,

156] References Cited UNITED STATES PATENTS 1,131,792 3/1915 Reifsnydcr 53/207 3,138,905 6/1964 Euingcr 53/207 3.332207 7/1967 Midnight 53/207 3,482,372 12/1969 Hottendorf.,. 53/207 X 3,530,640 9/1970 Hoffman 53/209 X 3,654,745 4/1972 Smith 53/164 X 3,665,675 5/1972 Johnson 53/223 3,782,071 l/l974 Hagcdorn 53/207 X Primary Eramiuer-Travis S. McGehcc Assistant Etaminer-John Sipos Attorney, Agent, or Firm-Silverman & Cass. Ltd.

[57] ABSTRACT A packaging machine for assembling a sealed carton from a pair of paperboard blanks. Each blank includes a center panel and alternate hinged side panels. One blanks has flanges along the opposite longitudinal side and transverse end edges of the panels. The flanged blank is positioned with lading on the center panel thereof at a setup station of the machine and lowered past folding members to be folded into a generally U shape partially surrounding the lading. Concurrently, the side flanges are folded. Next, the blank and lading are moved in a bucket formation to an assembly station, during which movement the end flanges are folded. Prior to such movement, an unflanged blank is positioned at theassembly station with its center panel overlying the end flanges ofthe folded blank. An elevator mechanism moves the folded blank and lading upwardly against the unflanged blank past members which fold the unflanged blank into a U shape partially around the lading with the margin of the unflanged blank overlying the flanges to form the complete carton. Suitable adhesive coating of appropriate blank parts is provided either before or during folding operations. Then, the completed carton is moved into a compression chamber where the adhesive sets to seal the package.

28 Claims, 7 Drawing Figures PATENTEUHARZS i975 sum. u gr 4 mm 2 2 3l|\ 2 2 v H 4 2 2i 2 2 3 4 2 v 2 6|\\ 5 O 2 2 Has FIG]

3 M 2 mm m 0 B 2 v #0 WWW PACKAGING MACHINE USING TWO BLANK CARTON SYSTEM CROSS-REFERENCES TO RELATED APPLICATIONS This application is a continuation-in-part of my earlier copending application, Ser. No. 285,211, filed Aug. 31, 1972, now patent No. 3,817,018, which in turn is a continuation-in-part of my earlier copending application, Ser. No. 57,945 filed on July 24, 1970, now abandoned. All of the applications mentioned are owned by the same assignee.

BACKGROUND OF THE INVENTION This invention relates to a machine and method for forming a sealed package containing lading from two generally rectangular sheets of material, one of which is unflanged and the other of which has flanges along both the longitudinal and end edges thereof. Typically, the sheets of material are blanks of double-faced corrugated paperboard.

A method of the general type with which this invention is concerned is disclosed in US. application Ser. No. 285,21 1 referred to above. According to that prior method, the flanged blank is positioned at a setup station of a machine and the lading is positioned on the center panel thereof. Then, the flanged blank is folded into a U-shape formation partially surrounding the lading. The longitudinal flanges are folded inwardly generally perpendicular to the associated panels and the end flanges are folded to a position generally perpendicular to the associated side panels. Next, an unflanged blank is positioned overlying the folded blank and lading with the center panel of the unflanged blank adjacent the folded end flanges of the folded blank. Then, the unflanged blank is folded into a generally U-shape around the exposed lading with the margin of the unflanged blank engaging the flanges of the folded flanged blank so that the entire lading is enclosed between the thusly folded blanks. The flanges of the folded blank are adhesively secured to the margin of the unflanged blank for sealing the package with the lading enclosed. Specific equipment structure for carrying out the method is not disclosed in said application.

Heretofore, various packages formed from two blanks and various methods and machines for forming packages from one or two blanks of paperboard material have been proposed. Examples of such proposals may be found in US. Pat. Nos. 3,138,905; 3,272,419; 3,500,609; 3,530,640; 3,622,063; 3,654,745; 3,665,675; and Canadian Letters Pat. No. 796,155.

In application, Ser. No. 285,211, it is noted that the previously proposed methods and machines did not disclose the folding of a flanged blank having flanges entirely around the periphery thereof and an unflanged blank about a quantity of lading to form a sealed package. There are disclosed various method steps for forming such a package. In the following description, there is disclosed a machine for carrying out at least one sequence of method steps disclosed in said copending application and a specific method of forming a two blank package.

SUMMARY OF THE INVENTION According to the invention, there is provided a machine for forming a sealed package which is constructed from a generally rectangular blank of paperboard material and a sheet of material, the blank including a center panel and alternate side panels and flanges along the longitudinal edges of the center and side panels and along the ends of the side panels, the lading being supported in position on ,the center panel of the blank. The apparatus includes a first mechanism for folding the blank into a generally U-shaped form ation partially surrounding the lading with the center panel forming an end wall and the side panels forming two side walls; a second mechanism for folding the flanges along each longitudinal edge of the blank to a position generally perpendicular to the associated side walls and end wall; a third mechanism for folding the end flanges to a position generally perpendicular to the associated side walls; a fourth mechanism for positioning the sheet in a posistion where the center area thereof will overlie the end flanges of the folded blank; a fifth mechanism for folding the sheet into a generally U-shaped formation surrounding the lading exposed in the first formation such that the margin of the sheet is positioned overlying the flanges of the blank; and a sixth mechanism for securing the flanges and the margin of the sheet together to seal the package with lading therein.

Also, according to the invention, there is provided a method for forming such a sealed package from a pair of blanks, as described herein, which includes the following'steps: positioning the first blank unfolded in a generally horizontal position at a first station; arranging lading on the center panel of the first blank; moving the first blank with the lading in a first direction downwardly to a second station during which movement the first blank is folded into a Ushaped formation partially surrounding the lading; simultaneously folding the flanges on the flanged blank along each longitudinal edge to a position generally perpendicular to the associated side walls and end walls of the blank, moving the folded first blank and lading in a second direction laterally of the first direction to a third station; folding the flanges located along the ends of the side panels of the first blank to a position generally perpendicular to the associated side wall forming panels thereof while moving the folded first blank in the second direction toward the third station; prior to such movement, positioning the second blank at the third station in a position where the center panel of the second blank will overlie the folded end flanges of the folded blank when it is moved thereunder; moving the folded first blank and lading thereon upwardly in a third direction transversely of the second direction against the second blank and toward the fourth station; folding the second blank into a generally U-shape surrounding the lading exposed on the first blank while the blanks and lading are being moved upwardly such that the center panel of the second blank engages the end flanges of the first blank and forms an end wall and each alternate side panel of the unflanged blank engages the longitudinally extending flanges on the sides of the first blank, the side panels of one blank being disposed at to the side walls of the other blank; and securing the flanges of the first blank to the margin of the second blank.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a flow diagram illustrating successive steps that are followed in practicing the packaging method of the invention;

FIG. 2 is a top plan view of the packaging machine of the invention;

FIG. 3 is a vertical sectional view taken along line 33 of FIG. 2;

FIG. 4 is an end elevational view taken along line 44 of FIG. 2;

FIG. 5 is a fragmentary perspective view of a bucket formation which receives the folded flanged blank and lading;

FIG. 6 is a fragmentary perspective view of a pusher mechanism for pushing an unflanged blank to a position juxtaposed the folded flanged blank and lading; and

FIG. 7 is a fragmentary perspective view of an assembly station of the machine where the unflanged blank is folded about the lading and the flanges of the flanged blank to complete the package.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to FIG. 1, a first or flanged blank 10 from a supply 11 of the blanks is positioned at a setup station 12. The blank 10 includes a center panel 13 and alternate side panels 14 and 16 hingedly connected along appropriate fold lines 15. Along the longitudinal edges of the blank 10 and connected to respective ones of the panels 13, 14 and 16 are flanges 17, 18 and 20. Also, along the end edges of the side panels 14 and 16 are connected end flanges 22.

At the setup station 12, a quantity of lading 24 is positioned on the center panel 13. Then, the first blank 10 with lading are moved downwardly in a first direction 26 to a holding station 28. During this downward movement, side panels 14 and 16 are folded partially around lading 24 into a generally U-shaped formation. Simultaneously, flanges 17, 18 and 20, are folded inwardly generally perpendicular to the associated panels 13, 14 and 16. As folded, center panel 13 forms an end wall and side panels 14 and 16 form side walls of the partially completed package illustrated at station 24.

The partially completed package is next moved in a second direction 30 which is laterally horizontal of the first direction 26 to an assembly station 32. During movement from holding station 28 to the assembly station 32, end flanges 22 are folded generally perpendicular to the associated side panels 14 and 16 so that by the time the blank 10 reaches assembly station 32, end flanges 22 are completely folded.

Adjacent assembly station 32 is located a magazine 34 of second or unflanged blanks 36 each of which includes a center panel 37 and alternate side panels 38 and 40. A pusher mechanism 41, part of which is shown in FIG. 1, is positioned beneath the magazine 34 and operative to move one of the blanks 36 to a position where it will be above the path of movement of the folded first blank and lading into the assembly station 32. The center panel 37 is depressed such that panels 38 and 40 incline slightly upwardly. In this way the panel 40 forms a lead in for the folded end flanges 22 as the folded blank 10 is moved into the assembly station 32. In this respect the panel 40 functions as a continuation of the means for folding over the end flanges 22 and maintains the flanges 22 folded as they are moved to a position beneath the center panel 37 of the blank 36 at the assembly station 32.

As more fully described hereinafter, the second blank 36 is folded about the lading 24 and folded flanges 17, 18, 20 and 22 at the assembly station and the inwardly facing margin of the second blank 36 is secured to the folded flanges 17, 18, 20 and 22 of the first blank 10, such as by an adhesive. This can be accomplished by providing blanks which already have an adhesive applied thereto, either to one margin of the second blank 36 and/or to one side of the flanges 17, 28, 20 and 22 of the first blank 10. Such an adhesive could be a pressure-sensitive adhesive or a heat-sensitive adhesive. In the alternative, and as indicated in FIG. 1, adhesive applicators can be positioned to apply adhesive to either the margin of the second blank 36 or to the outer facing surfaces of the folded flanges 17, 18, 20 and 22. In FIG. 1 three pairs of adhesive applicators are illustrated. The first pair of adhesive applicators are identified by the reference numeral 42 and are located along the path of travel of the folded first blank between the holding station 28 and the assembly station 32. The applicators 42 are operative to apply an adhesive to the outer facing surfaces of the flanges 22. A second pair of adhesive applicators 44 is located on either side of and beneath the path of travel of the second blank 36 from the magazine 34 to the assembly station 32. Each of the applicators 44 is operable to apply adhesive to the margin of the second blank 36 adjacent each end of the blank 36. A third pair of applicators46, one of which is hidden from view and a fourth pair of applicators 48, one of which is also hidden from view are located at the assembly station 32 and is operative to apply adhesive to the outer facing surfaces of the flanges 18 and 20 when the folded first blank 10 and lading 24 are moved upwardly as described hereinafter. As shown, the applicators 48 are pivotable to and from an adhesive applying position after the folded first blank 10 and lading 24 have been moved to the assem bly station 32.

As a further alternative the magazine 34 can be located to the right of the position shown in FIG. 1 and the blank 36 can be first moved from the bottom of the magazine 34, from right to left past a pair of adhesive applicators which apply adhesive to the longitudinal margins of the blank 36 and then in te direction shown by the pusher 41 and past the applicators 44. In this modification adhesive is applied only to margin of the blank 36.

After a second blank 36 has been positioned over the folded first blank 10 and lading 24, the first blank and lading are moved upwardly against the second blank 36 and to a fourth station 52, the upward direction being indicated by the arrow 50. The fourth station 52 is a temporary resting place for a completed package and actually is both the upper end of the assembly station and the entrance end of a compression chamber. During this upward movement, the second blank 36 engages folding members which fold the second blank 36 about the lading 24 and the flanges 17, 18 20 and 22 to complete the package by the time the blanks I0 and 36 reach the fourth station 52. A completed package is identified by the numeral 54. From the fourth station 52, the completed package 54 is moved by a ram assembly 56 in a fourth direction indicated by the arrow 58, into the compression chamber. A completed package in the compression chamber is identified by the reference numeral 59. In the compression chamber, pressure is applied to the end wall and side wall forming panels 37, 38 and 40 of the completed package 59 to hold the margin of the panels 37, 38 and 40 against the adjacent surfaces of the flanges 17, 18, 20 and 22 while the adhesive therebetween sets. Also, in the compression chamber heat can be applied to the margin of the folded second blank 36 if desired. As successive packages are formed and moved into the compression chamber, the completed packages are moved intermittenly through and then out of the compression chamber.

Referring now to FIGS. 2 and 3, the machine of the invention is identified generally by the reference numeral 60. Same includes a framework 61 having an opening 62 defined between stationary folding members or baffles 64, 65, 66 and 68. The opening 62 and the space thereabove define the setup station 12.

Movable within the machine 60 to and from the opening 62 is a carriage 70. The carriage 70 includes four suction cups 72 through which a vacuum is drawn when the machine 60 is operative and the center panel 13 of a first blank is brought into engagement with the suction cups 72. The suction cups 72 are mounted on a carriage framework which includes an arm 74 extending between the carriage framework and a bracket 76 that extends horizontally between two continuous chains 78 and 80. The chains 78 and 80 are trained about vertically spaced sprockets and the lower sprockets are driven by a drive shaft 81 (FIG. 3). As best shown in FIG. 2, the bracket 76 extends beyond the chains 78 and 80 and has a bearing member 82, 83 mounted at each end thereof.

Each bearing member is received on a guide shaft 84, 85 and slides vertically thereon when the chains 78, 80 are to move the carriage 70 upwardly and downwardly. Structure of the type described above can be found in US. Pat. No. 3,665,675.

After the first blank 10 has been positioned at the set up station 12 with the center panel 13 overlying the opening 62, a quanity of lading is placed on the center panel 13 and the machine is energized and started. This results first in vacuum draw on the suction cups 72 to hold the center panel 13 to the carriage 70 and secondly, in movement of the carriage 70 downwardly. While the carriage is moving center panel 13 of the first blank 10 downwardly, the sidepanels 14 and 16 engage the stationary folding baffles 68. and 66 respectively. This engagement causes the panels 14 and 16 to be folded upwardly into a generally U-shaped formation partially around the lading. At the same time, the flanges 17, 18 and engage the stationary folding baffles 64 and 65 and are folded inwardly of the associated panel. In this respect the baffles 64 and 65 engage and fold the flanges 17 upwardly. The baffles 64 also engage the flanges 20 and fold the same inwardly as the panel 16 is being folded upwardly. Likewise, the baffle 65 engages the flanges 18 and folds the same inwardly as the panel 14 is being folded upwardly.

At the end of its downward stroke of movement, the carriage 70 reaches the holding station 28 where the blank 10 and lading 24 are received in a blank holding structure or bucket formation 90 including four spaced-apart corner frame members 91 94 which are best shown in FIG. 5. The corner members 91 and 94 each have the same general configuration and are substantially identical and mirror images of the members 92 and 93. Since the frame members 91 94 are similar in configuration, only one of them, frame member 92, will be described in detail with reference to FIG. 5. Frame member 92 includes a broad end plate 95, a narrow side plate 96 and a narrow bottom plate 97. The bottom plate 97 is integral with the end plate 95. The plates 97 are connected to and lie in planes perpendicular to each other so as to form a corner at the junction of the three plates 95 97. One important feature of the configuration of the corner frame members 91 94 is the provision of a strip secured to the end plate 95 having an edge 98a thereof spaced from and parallel to the junction between the end plate 95 and the side plate 96. The strip 98 also has a bottom edge 98b which is spaced from and parallel to the bottom plate 97. The distance between the side edge 98a of the strip 98 and the side plate 96 is substantially equal to the width of either of the flanges 18 and 20, likewise, the space between the bottom edge of strip 98 and the bottom plate 97 is substantially equal to the width of the flange 17. With this structural arrangement, after the carriage 70 has moved to the holding station 28 and through an open center space 100 defined between the corner members 91 94 of the bucket formation 90, the strip 98 secured to the end plate 95 of each corner frame member 91 94, forms a locating or abutment means for seating the flanges 17, 18 and 20 and in this way, hold the flanges 17, 18 and 20 in place after the first blank 10 has been folded about the lading. A portion of a folded blank 10 including flanges 17 and 18 is shown in phantom in FIG. 5.

As shown in FIG. 5, the plate 96 of each of the corner frame members 91 94 is secured to a bracket which is slidably mounted on one of two rods 101 and 102, with corner frame members 91 and 93 being slidably mounted on the rod 101 and the corner frame members 92 and 94 being slidably mounted on the rod 102. Also the plate 96 of the corner frame members 91 and 92 each extend downwardly from the corner frame members 91 and 92 for connection to a continuous chaindriving assembly 104 (FIG. 3).

After a blank 10 has been folded about the lading and received in the bucket formation 90, the chain assembly 104 is operated to move the bucket formation 90 horizontally to the assembly station 32, as shown in phantom lines at the assembly station 32. This position at the assembly station 32 can be referred to as the forward position of the bucket formation 90.

Situated along the path of movement of the bucket formation 28 are two elongate spaced apart folding bars 111 and 112 (best shown in FIG. 5) which extend from a point adjacent the path of travel of the bucket formation 90, in the direction of the forward path of travel of the bucket formation 90, slightly toward each other and slightly into the path of travel of the bucket formation 90. The bars 111 and 112 are positioned to engage the end flanges 22 and fold the same over to a position generally perpendicular to the associated side panel 14 or 16. In addition to and cooperating with the rods 111 and 112 are a pair of spaced apart guide plates 115 and 116. Each of the plates 115 and 116 is disposed in a plane slightly below the plane of the bars 111 and 112 and has an outer edge 117, 118 which is rounded at one end and which is positioned to engage one of the side panels 14, 16 at the junction between the panel 14 or 16 and the flange 22. In this way, the guide plates 115 and 116 serve to hold the panel 14 or 16 in place while the associated connected end flange 22 is folded over the plates 115, 116. As shown in FIG. 5, the bars 111 and 112 and the plates 115,116 depend from brackets 119 extending from adjustable side rails 119a (FIG. 2) located above and to the side of the path of movement of the bucket formation 90.

Referring now to FIGS. 2, 4 and 6, the pusher mechanism 41 is located adjacent the assembly station 32 and beneath and perhaps to the side of a magazine (FIG. 1) containing the second blanks 36. The pusher mechanism 41 includes a fork assembly 120 having two spaced-apart tines 121 and 122. Each tine 121 and 122 has a lip 123, 124 and the fork assembly 120 is driven by a fluid-operated piston and cylinder mechanism 128 and slidably supported on a pair of bars 129, 130. A pair of parallel-spaced guide rails 131 and 132 (FIGS. 2 & 7) are situated on either side of the fork assembly 120, each rail 131 and 132 having a generally L-shaped cross section with one leg of the L extending horizontally toward the other rail and the other leg of the L extending upwardly. Together the rails 131 and 132 provide a guideway 133 for receiving and holding a second blank 36 in a desired position while the pusher mechanism 41 moves the blank 36 to the assembly station 32. In this respect, one of the second blanks 36 is shown in phantom lines in FIG. 6 with the transverse ends thereof supported on the horizontally extending legs of the L cross section of the rails 131 and 132. It will be noted that the forward edges of the tines 121 and 122 engage one side edge of the blank 36 and that the lips 123 and 124 are positioned to engage the underside of the blank 36 and in this way, support the central portion of the second blank 36 as the pusher mechanism 41 moves the second blank 36 to the assembly station 32. As will be described in greater detail below a pair of rods (181, 182 FIG. 7) are positioned at the assembly station 32 to engage, and to defect downwardly, the center panel 37 so that panels 38 and 40 incline upwardly and panel 40 can form a lead in for folded end flanges 22. The lead in or inclined position is shown in phantom lines in FIG. 3.

As shown in FIGS. 6 and 7, a portion of each of the horizontal legs of the L cross section of the guide rails 131 and 132 is cut away or recessed in the area of the assembly station 32 such that the guide rail has a smaller cross section in the area of the assembly station 32. The recesses are identified with reference numerals 133 and 134 and facilitate movement of the transverse end edges of the second blank 36 in an arcuate path downwardly and then upwardly when a folded first blank 10 and lading 24 are moved upwardly against the second blank 36 at the assembly station 32 as indicated by the position of a partially folded blank 36 shown in phantom lines in FIG. 3.

At the assembly station 32 above the forward position of the bucket formation 90 are positioned three pairs 141, 142, 143 of spaced apart rods (FIGS. 3 and 7). As a folded blank 10 is moved upwardly into engagement with a second blank 36, the center panel 37 of the blank 36 engaging the second blank 36 is carried upwardly past the pairs of rods 14] 143 which engage the side panels 38 and 40 to fold the same against the folded flanges 18 and 20 and into a generally U-shape partially about the lading 24. An elevator mechanism 150 (FIGS. 2, 3 & 7) for moving the folded first blank 10 and lading 24 upwardly against the second blank 36 and past the spaced-apart pairs of rods 141 143 is located at the assembly station 32. The elevator mechanism 150 includes a plate 152 disposed centrally of the station 32 and its at rest position is above the forward position of the bucket formation 90 as shown in FIG. 2. The plate 152 is configured to move through the open center space defined between the corner frame members 91 95 and is connected to an arm 154 which extends, and is movable, between the corner frame members 93 and 94. As best shown in FIG. 2, the arm 154 is connected to a journal block 155 and to a bracket 156 which is secured to and between a pair of chains 158 and 160. The chains 158 and 160 are trained about upper and lower sprockets and the lower sprockets are connected to a shaft 163 (FIGS. 3 & 4) which is driven by the drive shaft 81. The drive shaft 81 in turn is driven by a counter-shaft 165 (FIG. 3). Accordingly, when the counter-shaft 165 rotates the shaft 81 to move the carriage 70 downwardly, it also operates the elevator mechanism 150 to move the plate 152 downwardly to a position beneath the path of movement of the bucket formation 90. Then, after the bucket formation 90 has been moved to its forward position over the plate 152, the counter shaft 165 is rotated to rotate the shaft 82 to cause movement of the plate 152 and the carriage 70 upwardly. At that point, the plate.l52 will move the folded first blank 10 and lading 24 out of the bucket formation 90 and upwardly into engagement with the second blank, and then past the parallel spaced pairs of rods 141 143 which engage and fold the second blank 36 over the first blank 10 and lading 24.

To prevent the center panel 37 of the second blank 36 from buckling upwardly when the blanks are moved upwardly at the assembly station 32, and to deflect the center panel 37 downwardly so that panels 38 and 40 are inclined upwardly as shown in phantom lines in FIG. 3, a panel deflecting and retaining assembly is connected to and movable with the elevator mechanism 150 and positioned to engage the center panel 37. The retaining assembly 180 includes a pair of parallelspaced rods 181 and 182 which are turned upwardly at one end and which are secured together by a bar 183 which in turn is secured to the lower end ofone leg 184 of a U-shaped framework 186, the other leg 188 of which is secured to the bracket 156. The block 155 is journaled on a vertical guide shaft 190 and to minimize horizontal wobbling of the assembly 180, a pair of guide fingers 191, 192 are mounted to the leg 188 and straddle the guide shaft 190.

As best shown in FIGS. 2, 3 and 7, the panel deflecting and retaining assembly 180 is initially positioned at the upper end of the assembly station 32 above the 7 plate 152. When the elevator mechanism 150 is operated to move the plate 152 downwardly, the rods 181 and 182 of the assembly 180 also are moved downwardly to a position just above the path of movement of the second blank 36. As best shown in FIG. 7, the distal ends of the rods 181 and 182 are bent slightly upwardly to facilitate movement of the second blank 36 thereunder. The rods 181 and 182 then deflect the panel 37 downwardly and hold the center panel 37 in position to receive the folded end flanges thereunder. The panel 37 will then hold the flanges 22 folded over when the blanks 10 and 36 are moved upwardly and the side panels 38 and 40 of the blank 36 are folded about the folded flanges 17, 18, 20, 22 of the first blank 10 upon engaging the pairs of rods 141 143.

From the foregoing description, it will be apparent that the panel-retaining assembly 180 and the moving plate 152 move between a lower position straddling the path of movement of the bucket formation 90 and an upper position position where the completed package 54 (shown in phantom line in FIG. 7) is formed. The upper position can be referred to as the temporary holding station or fourth station 52 described in connection with the flow diagram shown in FIG. 1. This temporary holding station 52 is defined between the pairs of rods 141 143, the plate 152 and the pair of rods 181 182. Also, the pairs of rods 141 143 form part of a compression chamber 200 which is located laterally of the fourth station 52. In this respect, the compression chamber 200 is defined by extensions of the rods 141 143, these extensions extending to the left from the fourth station 52 as viewed in FIG. 7 The compression chamber 200 also is defined by two upper rods 201, 202, which are positioned in a plane generally perpendicular to the planes containing the pairs of rods 14] 143. The rods 201 and 202 are generally in line with the rods 18] and 182 of the retaining assembly. The chamber 200 is further defined by two bottom rods 211 and 212 which extend outwardly with the other rods 141 143, 201, 202 from the framework 61 and straddle one end of the upper position of the plate 152.

The rods 141 143 and 201, 202, are arranged and positioned to define a slightly smaller envelope than defined by the dimensions of a completed package 56 thereby to apply pressure on the panels 37 40 defining three walls of the completed package 54 to hold these panels in place against the folded flanges 17, 18, 20 and 22 while the adhesive between the margin of these panels 37 40 and the flanges 17 22 sets after the completed package 54 has been moved into the chamber 200 by the ram assembly 56.

As shown in FIGS. 2 and 7, the ram assembly 56 is operable to move a completed package 54 from the fourth station 52 into the compression chamber 200 and to the position of the package 59 shown in phantom lines in FIG. 7. The ram assembly 56 includes a guide rod 220 mounting a bearing member 222 to which is connected a bracket 224. Two bars 225 and 226 extend outwardly from the bracket 224 and laterally of the rod 220 to form a ram. The bars 225 and 226 are positioned one above the other and arranged to move through the spaces defined respectively between the rods 141 and 142 and between the rods 142 and 143. In other words, the bars 225 and 226 straddle the rods 142 on either side of the fourth station 52 and the compression chamber 200. The ram assembly 56 further includes a piston rod 230 which extends from a piston and cylinder mechanism 232 and is connected to the bracket 224. Operation of the mechanism 232 causes movement of the rod 230 for moving the bars 225, 226 against a completed package for moving the same from the station 52 into the compression chamber 200 and then back to the position shown in FIG. 7.

If adhesive had not been initially applied to the flanges of the blank or to the margin of one side of the blank 36 prior to insertion of the blanks in the machine 60, then it is understood that adhesive is applied by means of the adhesive applicators 42, 44, 46 and 48 shown schematically in FIG. 1 and omitted from the remaining figures for the sake of clarity. These adhesive applicators 42 48 will, of course, be mounted to the framework 61 and/or rails 119a.

In the operation of the machine 60, a blank 10 is first positioned at the setup station 12 as shown in FIGS. 2 and 3. Then a quantity of lading 24 is positioned on the center panel 31 of the blank 10 and the suction cups 72 are rendered operative to hold the center panel 13 of the blank 10 to the carriage 70. Next, the shaft 165 is rotated to cause the carriage 70 (and the elevator mechanism 150 and associated panel-retaining assembly 180) to move downwardly and in this way, bring the first blank 10 and lading with the panels 14, 16 and longitudinal flanges 17, 18, 20 thereof folded into the bucket formation 90 at the holding station 28. Next, the bucket formation 90 is moved from the holding station 28 to the assembly station 32 while at the same time a second blank 36 is dropped from the magazine 34 (shown only schematically in FIG. 1) and the pusher mechanism 41 is operated to move the second blank 36 into proper position at the assembly station 32. The end flanges 22 of the first blank 10 are folded by bars 111, H2 and plates 115 and 116 and are moved under, and maintained folded by, panels 40 and 37 during the movement between the the holding station 28 and the assembly station 32. Then, the drive shaft 165 is rotated to cause the elevator mechanism 150 to move upwardly and raise the folded first blank 10 and lading 24 against the second blank 36 and the second blank 36 into contact with the pairs 141 143 of rods to cause folding of the second blank 36 about the first blank 10 and lading 24, so that a completed package 54 is formed by the time the blanks 10 and 36 and lading 24 reach the fourth station 52. Next, the ram assembly 56 is operated to move the completed package 54 into the compression chamber 200 where pressure is applied to the outer surfaces of the panels of the second blank 36.

It will be understood that the compression chamber 200 can have any desired length and that an end of a conveyor can be situated at the outer end of the compression chamber 200 so that completed packages 59 pushed out of the compression chamber 200 as a result of a newly completed package being moved into the compression chamber, will fall onto the conveyor and be carried away for further handling or storage.

The design of the bucket formation with spaced apart corner members 91 94 provides a number of advanges. First of all, as described above, it permits the arms 74 and 154 to move between two of the corner members when raising or lowering the respective carriage or elevator. Also it permits the bucket formation 90 to be enlarged in two directions. In this respect, the rods 101 and 102 (supporting the corner members 91 94) and the baffles 64, 65, 66 and 68 as well as the brackets 119 are mounted to the movable side rails 119a. The rails 119a are supported on threaded rods 240, and movable toward and away from the centerline of the path of movement of the bucket formation 90, when it is desired to adjust the machine 60 for handling a different size package made from smaller or larger blanks 10 and 36.

When the rods 240 are rotated to effect such adjustments for a shorter or longer blank 10, other adjustments are usually necessary for changes in the width of the blank 10 and for corresponding changes in the size of the blank 36. Accordingly, it will be understood that the spacing between corner members 91 and 93 and between 92 and 94, the spacing between the two baffles 66 and between the two baffles 68, the horizontal spacing between the pairs of rods 141 143, the height of rods 201 and 202, the spacing between guide rails 131' and 132 and the spacing between plate 152 and rods 181 and 182 also will have to be adjusted and suitable adjustable mountings and interconnections are provided for this purpose. Preferably, some of these elements are interconnected so that adjustment of the spacing of one set of elements results in an automatic corresponding adjustment of another set of elements.

Although the specific structure of the various mechanisms and devices for folding the two blanks about a quantity of lading to form a package have been illustrated in the accompanying drawings and described in the foregoing description, it is to be understood that various minor modifications can be made to such structure without departing from the scope of the invention, as determined from the claims appended hereto.

What it is desired to secure by Letters Patent of the United States is:

l. A machine for forming a sealed package containing lading from a generally rectangular blank of paperboard material and a sheet of material, the blank including a center panel and alternate hingedly connected side panels and flanges hinged along the longitudinal edges of the center and side panels and along the ends of the side panels, said apparatus having a setup station for a blank having the lading supported adjacent the center panel ofthe blank, first means for folding the blank into a generally U-shaped formation partially surrounding the lading with the center panel forming an end wall and the side panels forming two side walls of the formation, second means for folding the flanges along each longitudinal edge of the blank to a position generally perpendicular to the associated side walls and end wall, third means for folding the end flanges to a position generally perpendicular to the associated side walls, fourth means for positioning the sheet, fifth means for folding the sheet of material into a U-shaped formation partially around the lading with the margin of the sheet positioned overlying the flanges of the blank and sixth means for securing the flanges of the blank to the margin of the sheet.

2. The machine according to claim 1 which includes a framework having an opening defining said setup station, a holding station within said framework, means for moving said blank from said setup station to said holding station and said first means including, adjustably mounted stationary folding means positioned within said framework between said setup station and said holding station for engaging and folding the blank when the blank is moved from said setup station to said holding station.

3. The machine according to claim 2 wherein said second means for folding the flanges along each longitudinal edge of the blank includes adjustably mounted stationary folding means positioned within said framework adjacent the path of movement of the blank for engaging and folding the flanges along the longitudinal edges of the blank as the blank is moved from said setup station to said holding station.

4. The machine according to claim 1 including a holding station, an assembly station, holding means situated at said holding station normally for holding the blank in place against the lading after the blank has been folded partially about the lading and means for moving said holding means between said holding station and said assembly station.

5. The machine according to claim 4 wherein said holding means includes four spaced-apart, adjustably mounted corner brackets mounted to a movable framework and arranged to form a generally rectangular shaped bucket formation which receives the first blank and lading after the first blank has been folded about the lading.

6. The machine according to claim 5 wherein each of said corner brackets includes two side plate portions and an end plate portion all of which are disposed, respectively, generally perpendicular to each other, said two side plate portions being joined together and one of said side plate portions having abutment means for locating the longitudinal flanges and retaining them in place.

7. The machine according to claim 6 wherein said abutment means includes a piece of material secured to one of said side plate portions with one edge of said piece being parallel to and spaced from the junction of said two side plate portions a distance at least equal to the width of one of the flanges extending along the longitudinal edge of the blank, the piece also terminating at a distance above said end plate portion equal to the width of the flange connected to the center panel.

8. The machine according to claim 4 wherein said holding means has an open space in the center thereof to permit a blank moving means to move through said holding means.

9. The machine according to claim 4 wherein said third means for folding the end flanges is located along the path of travel of said holding means between said holding station and said assembly station and is positioned during movement of the folded blank and lading between said stations to fold the end flanges to a position generally perpendicular to the associated side walls.

10. The machine according to claim 9 wherein said third means for folding the end flanges is defined by adjustably mounted stationary folding means.

11. The machine according to claim 10 wherein said adjustably mounted stationary folding means includes two bars each located on one side of the path of travel of the folded blank between said holding station and said assembly station, each bar being arranged to engage and fold over one of the end flanges as the folded blank is moved past said bars toward said assembly station.

12. The machine according to claim 11 including two guide plates, each guide plate being parallel spaced from one of said bars, an edge of each said guide plate being arranged to engage the margin of one side panel adjacent the junction between the side panel and the end flange so that, when the folded blank is moved past said folding bars and said guide plates, said edge of each said plate engages the inner surface of one of the side panels and holds the same in place while the adjacent one of said folding bars engages and folds the adjacent end flange over said guide plate.

13. The machine according to claim 1 wherein the sheet of material is an unflanged blank of paperboard material and wherein said apparatus includes an assembly station and said fourth means for positioning said unflanged blank adjacent the end flanges of the folded blank includes pusher means for pushing the unflanged blank from a magazine to a position at said assembly station and adjacent to the end flanges of the folded blank.

14. The machine according to claim 13 wherein said fourth means includes guide means for engaging the ends of the unflanged blank and retaining the ends of the unflanged blank in a desired alignment while the blank is moved to said assembly station and said pusher means includes a fork arranged for movement in a direction parallel to said guide means for engaging one side edge of an unflanged blank and moving the same to the assembly station and power means for moving said fork, said fork having at least two spaced apart tines, each tine having a head and a lip, the head being adapted to engage a side edge of the unflanged blank and the lip being adapted to engage a small marginal area on one side of the unflanged blank.

15. The machine according to claim 14 wherein said guide means includes a pair of adjustably mounted spaced apart guiderails each of which has an L-shaped cross section, each guiderail having a reduced crosssection in the area where said guiderails extend across said assembly station so that when one of the unflanged blanks is moved transversely of said guiderails in one direction and folded into a generally U-shape about the lading the end edges of the unflanged blank can move arcuately in the opposite direction transversely of the guiderails.

16. The machine according to claim 1 including an assembly station and wherein said fifth means includes elevator means at said assembly station for moving the folded blank and lading against the sheet and stationary folding members which are arranged in the path of movement of the sheet and in position to engage side portions of the sheet whereby when the lading and folded first blank are moved into engagement with the sheet the sheet is moved past the folding members into a generally U-shape partially about the lading with the margin of one side of the sheet engaging the outer facing surfaces of the folded flanges of the blank.

17. The machine according to claim 16 including retaining means positioned to engage and retain the central portion of the sheet in place and prevent buckling of the central portion of the sheet while the folded blank, the lading and the sheet are being moved past said stationary folding members, said retaining means being movable with said elevator means.

18. The machine according to claim 16 wherein said stationary folding members past which the sheet is moved comprises at least two pairs of adjustably mounted rods extending on either side of and transversely of the path of movement of the blank and sheet at said assembly station.

19. The machine according to claim 18 including means for holding the sheet against buckling while the blank and sheet are being moved past said rods at said assembly station, said sheet holding means being movable with said elevator means for moving the folded blank and lading into engagement with the sheet.

20. The machine according to claim 19 wherein said sheet holding means includes a pair of spaced apart rods which lie in a plane generally perpendicular to the planes containing said pairs of rods on either side of said assembly station, and which are in a plane above a plane extending between sheet support means and which are bent upwardly at the ends thereof to facilitate movement of a sheet thereunder and so that the center area of the sheet is deflected below the ends of the sheet.

21. The machine according to claim 16 wherein the sheet of material is a generally rectangular unflanged blank of paperboard material and wherein said fourth means for positioning the unflanged blank adjacent the end flanges of the folded blank comprises two, spaced apart, elongate guide rails and pusher means for pushing an unflanged blank received on and between said guiderails to a position at said assembly station, each of said guiderails having a smaller cross section in the area of said assembly station to permit the ends of the unflanged blank to move arcuately in one direction as the folded blank and lading are moved against the unflanged blank and carry the unflanged blank in the opposite direction.

22. The machine according to claim 16 wherein said sixth means for securing the flanges of the blank to the margin of the sheet includes adhesive applying means for applying adhesive to at least a portion of the flanges of the folded blank or to the margin of the sheet before the sheet and folded blank are brought into engagement at said assembly station.

23. The machine according to claim 22 wherein said sixth means includes a compression chamber located adjacent one end of said assembly station and means for moving the completed package from said one end of said assembly station transversely of the direction of movement of said other moving means at said assembly station and into said compression chamber.

24. The machine according to claim 21 wherein said folding means includes at least two pairs of spaced apart rods which lie in parallel spaced planes and extend transversely of the direction of movement of said folded blank and lading and parallel to said completed package moving means, said compression chamber being defined on two sides by extensions of said pairs of rods, a third side of said compression chamber being defined by two additional rods situated in a plane perpendicular to the planes containing said two pairs of rods and said completed package moving means is operative to push the completed package in a direction parallel to said rods into the compression chamber where said rods exert pressure on the side walls formed by side panels of the sheet of material and on the end wall defined by a center panel of the sheet of material.

25. The machine according to claim 1 wherein said sixth means for securing the flanges of the blank to the margin of the sheet include adhesive applying means for applying adhesive to either the outer facing surfaces of the folded flanges or to the margin of the sheet positioned to come in contact with the flanges before the sheet is folded about the lading and the folded flanges of the folded blank.

26. The machine according to claim 25 wherein said securing means also includes a compression chamber and seventh means for moving the completed package into said compression chamber so that pressure is applied to the side walls and end wall defined by the panels of the sheet to hold the margin of the sheet in engagement with the folded flanges of the blank while the adhesive sets therebetween.

27. A machine for forming a sealed package containing lading using first and second generally rectangular blanks of paperboard material, each blank including a center panel and alternate side panels and the first blank including flanges along the longitudinal edges of the center and side panels and flanges along the ends of the side panels, said apparatus comprising:

a framework, said framework having an opening at the top thereof defining a setup station where the first blank is positioned with the center panel thereof over said opening and lading to be packaged is arranged on the center panel of the first blank; a holding station located within said framework beneath said setup station; carriage means for moving the first blank and lading downwardly in a first direction to said holding station; stationary folding means positioned adjacent the path of movement of the first blank and lading from said setup station to said holding station and arranged to engage and fold the first blank into a generally U-shape partially about the lading; additional stationary folding means located along the path of travel of the first blank and lading and arranged to engage and fold the flanges along each longitudianl edge of the first blank to a position generally perpendicular to the associated side walls and end wall formed from the panels of the first blank; an assembly station positioned laterally of the holding station; holding means situated at the holding station for holding the first blank against the lading after holding thereof; means for moving said holding means holding said folded first blank and lading to said assembly station; stationary folding means situated adjacent the path of travel of said holding means for folding said end flanges to a position generally perpendicular to the side walls formed from the first blank while the folded first blank and lading are being moved from said holding station to said assembly station; pusher means movable from a position adjacent said assembly station and operative to move a second blank from said magazine to a position at said assembly station; means for applying adhesive to either the folded flanges of the first blank or to the margin of the second blank; means at said assembly station for moving said folded first blank and lading upwardly against the second blank; stationary folding means at said assembly station adjacent the path of travel of said moving means and arranged to engage the side panels of the second blank as the lading and folded first blank are moved upwardly into engagement with the second blank thereby to fold the second blank into a generally U-shape partially about the lading and in such a way that the center panel of the second blank engages the end flanges of the first blank and forms an end wall of the package and each alternate side panel engages the longitudinally extending flanges on one side of the first blank and form side walls of the package.

28. The apparatus according to claim 27 wherein said holding means comprises a bucket formation defined by adjustable mounted spaced-apart corner frame members with an open center space being defined between s aid frame members, said carriage means and said assembly station moving means being movable through said open center space, an arm forming part of said carriage means being movable between two of said corner frame members, and an arm forming part of said moving means being movable between the other two of said corner frame members.

l l= i

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Referenced by
Citing PatentFiling datePublication dateApplicantTitle
US4463541 *Jul 13, 1981Aug 7, 1984International Paper CompanyApparatus and method for automatically packing articles in catons
US4631896 *Apr 12, 1985Dec 30, 1986Internationale Octrooi Maatschaapij "Octropa" B.V.Method, apparatus and blank for packing at least one article in a self-supporting wrapping having the shape of a rectangular parallelepiped
US4871068 *Jun 15, 1988Oct 3, 1989I.C.P., S.A.Packaging arrangement for a group of containers including a handle on a tying strap
US5131208 *Jan 31, 1991Jul 21, 1992Radco Industries, Inc.Method and apparatus for forming cartons
US5433062 *Aug 4, 1994Jul 18, 1995Focke & Co. (Gmbh & Co.)Packaging container (display pack) and process and apparatus for producing it
US7017852 *Apr 1, 2004Mar 28, 2006Davis-Standard CorporationMultiple fixed-position film centerwinder and method for winding web material
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Classifications
U.S. Classification53/207, 53/209, 53/231
International ClassificationB65B49/02, B65B11/00, B65B11/58
Cooperative ClassificationB65B49/02, B65B11/004, B65B11/58
European ClassificationB65B11/00D, B65B49/02, B65B11/58