Note: Descriptions are shown in the official language in which they were submitted.
CA 02640818 2015-02-02
PATENT
80006-00876
METHODS AND MACHINES FOR FORMING A
POLYGONAL CONTAINER
BACKGROUND OF THE INVENTION
[0001] The embodiments described herein relate generally to
packaging products and, more specifically, to methods and systems for forming
a
polygonal container from a knocked-down flat container made from cardboard,
corrugated paperboard, or other similar sheet material.
[0002] Containers are frequently utilized to store and aid in
transporting products. These containers can be square, hexagonal, or
octagonal. The
shape of the container can provide additional strength to the container and
can provide
a more secure fit of the product contained within the container. For example,
an
octagonal-shaped container oftentimes provides greater stacking strength and
greater
resistance to bulge over conventional rectangular or square containers.
[0003] Product manufacturers and packaging companies commonly
utilize containers in a knocked-down flat state when shipping the containers
to the
product manufacturers and when storing the containers at the product
manufacturer's
before loading the containers with the product to be shipped. Knocked-down
flats are
formed from a blank of sheet material and can be erected to form a container
for
packaging and shipping. In at least some known cases, such knocked-down flats
are
erected at the manufacturer of the product to be shipped using a case erector
machine
that individually erects each knocked-down flat from a stack of knocked-down
flats.
This process of erecting a shipping container from a knocked-down flat at a
location
where the shipping container is then loaded with the product for shipment is
typically
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efficient, but is typically only used for forming shipping containers having a
rectangular shape.
[0005] However, rectangular shaped containers are oftentimes not
suitable for a packaging application. Specifically, the item to be packed and
shipped
may not be rectangular and, therefore, a rectangular shaped package may lack
the
desired space efficiency. Furthermore, a rectangular shaped package may lack
sufficient strength for stacking or bulge resistance. In these types of
packaging
applications, a shipping container having a non-rectangular configuration is
better
suited. For example, packages having an octagonal shape including angled
corner
panels may be required for space efficiency, stacking strength and/or bulge
resistance.
However, many known methods and systems for erecting shipping containers from
a
knocked-down flat are insufficient for forming an octagonal container.
Moreover, the
known methods and systems capable of forming an octagonal container typically
include more complicated machinery and, therefore, are more expensive to
employ
and more complicated to operate.
BRIEF DESCRIPTION OF THE INVENTION
[0006] In one aspect, a machine for erecting a polygonal container
from a knocked-down flat container formed from a blank of sheet material is
provided.
The container includes four main side panels, at least one corner panel
extending
between two of the main side panels, and at least one bottom flap extending
from one
of the main side panels for forming a bottom of the container. The machine
includes a
body, a first erecting mechanism coupled to the body, and a second erecting
mechanism coupled to the body. The first erecting mechanism is configured to
receive
the knocked-down flat container and erect the knocked-down flat container into
a
partially erected container having a substantially rectangular configuration.
The
second erecting mechanism is configured to receive the partially erected
container in
the substantially rectangular configuration and erect the partially erected
container
from the rectangular configuration into the polygonal container by applying a
force to
an exterior surface of the partially erected container to erect the polygonal
container.
The polygonal container has more than four sides.
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[0007] In another aspect, a machine for erecting a polygonal
container
from a knocked-down flat container formed from a blank of sheet material is
provided. The
container includes four main side panels, at least one corner panel extending
between two of
the main side panels, and at least one bottom flap extending from one of the
main side panels
for forming a bottom of the container. The machine includes means for erecting
the
knocked-down flat container into a partially erected container having a
substantially
rectangular configuration and means for further erecting the partially erected
container from
the substantially rectangular configuration into the polygonal container by
applying a force to
an exterior surface of the at least one corner panel, wherein the polygonal
container has more
than four sides.
[0008] In still another aspect, a method for erecting a polygonal
container from a knocked-down flat container formed from a blank of sheet
material is
provided. The container includes four man side panels, at least one corner
panel extending
between two of the main side panels, and at least one bottom flaps extending
from one of the
main side panels for forming a bottom of the container. The polygonal
container is formed
using a machine that includes a body, a first erecting mechanism coupled to
the body, and a
second erecting mechanism couple to the body. The method includes receiving
the knocked-
down flat container at the first erecting mechanism, erecting the knocked-down
flat container
into a partially erected container having a substantially rectangular
configuration at the first
erecting mechanism, and transferring the partially erected container in the
substantially
rectangular configuration to the second erecting mechanism. A force is applied
to an exterior
surface the partially erected container in the substantially rectangular
configuration to erect
the polygonal container at the second erecting mechanism, wherein the
polygonal container
has more than four sides.
[0008a] In another aspect, a machine for erecting a polygonal container
from a knocked-down flat container formed from a blank of sheet material, the
knocked-
down flat container including opposing first and second portions, wherein the
first portion
includes a first side panel, and wherein the second portion includes a second
side panel and a
first corner panel extending from the second side panel, said machine
comprising: a first
erecting mechanism operable to couple to the first side panel and separate the
first and
second portions of the knocked-down flat container to form a partially erected
container; and
a second erecting mechanism comprising a coupling device and a miter bar
positioned with
respect to the coupling device, said coupling device operable to couple to the
second side
panel of the partially erected container and to further separate the first
side panel from the
second side panel such that said miter bar applies a force to an exterior
surface of the first
comer panel to form an oblique corner wall of the polygonal container.
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[0008b] In still another aspect, a machine for erecting a polygonal
container from a knocked-down flat container formed from a blank of sheet
material, the
knocked-down flat container including opposing first and second portions, said
machine
comprising: a first erecting mechanism operable to separate the first and
second portions of
the knocked-down flat container to form a partially erected container, wherein
the first
portion includes a first side panel, and wherein the second portion includes a
second side
panel and a first corner panel extending from the second side panel; and a
second erecting
mechanism comprising a coupling device and a miter bar, said coupling device
operable to
couple to the second side panel of the partially erected container and to
further separate the
first side panel from the second side panel, said miter bar positioned to
couple against an
exterior surface of the first corner panel to form an oblique corner wall of
the polygonal
container.
[0008c] In still yet another aspect, a method for erecting a polygonal
container from a knocked-down flat container formed from a blank of sheet
material, the
knocked-down flat container including opposing first and second portions,
wherein the first
portion includes a first side panel, and wherein the second portion includes a
second side
panel and a first corner panel extending from the second side panel, said
method comprising:
coupling a first erecting mechanism to the first side panel; separating the
first and second
portions of the knocked-down flat container using the first erecting mechanism
to form a
partially erected container; coupling a coupling device to the second side
panel of the
partially erected container, wherein a miter bar is positioned with respect to
the coupling
device; and further separating the first side panel from the second side panel
using the
coupling device, such that the miter bar applies a force to an exterior
surface of the first
corner panel to form an oblique corner wall of the polygonal container.
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure I is a
view of a blank that may be used to form an
octagonal container according to one embodiment of this invention.
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[0010] Figure 2 is a view of an octagonal container that is formed by
the blank shown in Figure 1.
[0011] Figure 3 is a view of a knocked-down flat container formed
from the blank shown in Figure 1 and configured to form the container shown in
Figure 2.
[0012] Figure 4 is a schematic view of a machine that is used to form
the octagonal container shown in Figure 2 from the knocked-down flat container
shown in Figure 3.
[0013] Figure 5 is a view of a pair of suction cups shown in Figure 4
attached to the knocked-down flat container shown in Figure 3.
[0014] Figure 6 is a view of the suction cups shown in Figure 5
attached to the rectangular configuration of the knocked-down flat container
shown in
Figure 3.
[0015] Figure 7 is a perspective view of the knocked-down flat
container erected into a rectangular configuration at a first erecting
mechanism shown
in Figure 4.
[0016] Figure 8 is a view of a bottom of the container in the
rectangular configuration shown in Figure 7 having hot melt applied thereto.
[0017] Figure 9 is a schematic side view of the container in the
rectangular configuration shown in Figures 7 and 8 positioned within the
second
erecting mechanism shown in Figure 4.
[0018] Figure 10 is a schematic side view of the orthogonal container
shown in Figure 2 being formed at the second erecting mechanism shown in
Figure 4.
[0019] Figure 11 is another schematic side view of the orthogonal
container shown in Figure 2 being formed at the second erecting mechanism
shown in
Figure 4.
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[0020] Figure 12 is a further schematic side view of the orthogonal
container shown in Figure 2 being formed at the second erecting mechanism
shown in
Figure 4.
[0021] Figure 13 is a schematic side view of the orthogonal container
shown in Figure 2 positioned within the second erecting mechanism shown in
Figure
4.
[0022] Figure 14 is a perspective view of the feed rolls shown in
Figure 4.
[0023] Figure 15 is a perspective view of the suction cups shown in
Figure 4 feeding the knocked-down flat container shown in Figure 3 to the feed
rolls
shown in Figure 4.
[0024] Figure 16 is a perspective view of the feed rolls shown in
Figure 4 moving the knocked-down flat container shown in Figure 3 to the first
erecting mechanism shown in Figure 4.
[0025] Figure 17 is another perspective view of the feed rolls shown
in Figure 4 feeding the knocked-down flat container shown in Figure 3 to the
first
erecting mechanism shown in Figure 4.
[0026] Figure 18 is perspective view of the first erecting mechanism
shown in Figure 4 erecting a first knocked-down flat container shown in Figure
3, and
the feed rolls shown in Figure 4 feeding a second knocked-down flat container
to the
first erecting mechanism.
[0027] Figure 19 is a perspective view of a knocked-down flat
container shown in Figure 3 being fed to the first erecting mechanism shown in
Figure
4.
[0028] Figure 20 is a perspective view of the suction cups shown in
Figures 5 and 6 attaching to the knocked-down flat container shown in Figure 3
at the
first erecting mechanism shown in Figure 4.
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[0029] Figure 21 is a perspective view of the first erecting
mechanism shown in Figure 4 erecting the knocked-down flat container shown in
Figure 3 into the rectangular configuration shown in Figure 7.
[0030] Figure 22 is another perspective view of the first erecting
mechanism shown in Figure 4 erecting the knocked-down flat container shown in
Figure 3 into the rectangular configuration shown in Figure 7.
[0031] Figure 23 is a perspective view of the knocked-down flat
container in the rectangular configuration shown in Figure 7 as formed by the
first
erecting mechanism shown in Figure 4.
[0032] Figure 24 is another perspective view of the knocked-down
flat container in the rectangular configuration shown in Figure 7 as formed by
the first
erecting mechanism shown in Figure 4.
[0033] Figure 25 is a perspective view of the first and second folding
arms shown in Figure 4 folding the bottom flaps of the knocked-down flat
container
in the rectangular configuration shown in Figure 7.
[0034] Figure 26 is another perspective view of the first and second
folding arms shown in Figure 3 folding the bottom flaps of the knocked-down
flat
container in the rectangular configuration shown in Figure 7.
[0035] Figure 27 is a further perspective view of the first and second
folding arms shown in Figure 3 folding the bottom flaps of the knocked-down
flat
container in the rectangular configuration shown in Figure 7.
[0036] Figure 28 is yet another perspective view of the first and
second folding arms shown in Figure 3 folding the bottom flaps of the knocked-
down
flat container in the rectangular configuration shown in Figure 7.
[0037] Figure 29 is a perspective view of the upper suction cups of
the second erecting mechanism shown in Figure 4 attaching to the knocked-down
flat
container in the rectangular configuration shown in Figure 7.
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,
[0038] Figure 30 is a perspective view of the second erecting
mechanism shown in Figure 4 erecting the knocked-down flat container shown in
Figure 3 into the octagonal container shown in Figure 2.
[0039] Figure 31 is a perspective view of the miter bar shown in
Figure 4.
[0040] Figure 32 is another perspective view of the second erecting
mechanism shown in Figure 4 erecting the knocked-down flat container shown in
Figure 3 into the octagonal container shown in Figure 2.
[0041] Figure 33 is a perspective view of a miter bar shown in Figure
4 as the second erecting mechanism shown in Figure 4 erects the knocked-down
flat
container shown in Figure 3 into the octagonal container shown in Figure 2.
[0042] Figure 34 is a further perspective view of the second erecting
mechanism shown in Figure 4 erecting the knocked-down flat container shown in
Figure 3 into the octagonal container shown in Figure 2.
[0043] Figure 35 is another perspective view of a miter bar shown in
Figure 4 as the second erecting mechanism shown in Figure 4 erects the knocked-
down flat container shown in Figure 3 into the octagonal container shown in
Figure 2.
[0044] Figure 36 is yet another perspective view of the second
erecting mechanism shown in Figure 4 erecting the knocked-down flat container
shown in Figure 3 into the octagonal container shown in Figure 2.
[0045] Figure 37 is a perspective view of the second erecting
mechanism shown in Figure 4 erecting the knocked-down flat container shown in
Figure 3 into the octagonal container shown in Figure 2.
[0046] Figure 38 is a perspective view of the backing plate and
compression plate shown in Figure 11 closing the bottom of the knocked-down
flat
container shown in Figure 3.
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[0047] Figure 39 is another perspective view of the backing plate and
compression plate shown in Figure 11 closing the bottom of the knocked-down
flat
container shown in Figure 3.
[0048] Figure 40 is a further perspective view of the backing plate
and compression plate shown in Figure 11 closing the bottom of the knocked-
down
flat container shown in Figure 3.
[0049] Figure 41 is a view of the octagonal container shown in
Figure 2 at the second erecting mechanism shown in Figure 4.
[0050] Figure 42 is a perspective view of the machine shown in
Figures 14-41.
DETAILED DESCRIPTION OF THE INVENTION
[0051] In one aspect, a machine is provided for erecting an octagonal
container from a knocked-down flat container. The knocked-down flat container
is
formed from a blank of sheet material. The container includes four main side
panels
and four corner panels extending between each of the main side panels. The
container
also includes a plurality of bottom flaps extending from the main side panels
for
forming a bottom of the container, and includes a plurality of top flaps
extending from
the main side panels for forming a top of the container. The machine includes
a body,
a first erecting mechanism coupled to the body, a gluing mechanism, and a
second
erecting mechanism coupled to the body. The first erecting mechanism is
configured
to receive the knocked-down flat container and erect the knocked-down flat
container
into a container having a rectangular configuration. The first erecting
mechanism
includes a first erecting arm rotatably coupled to the body having at least
one suction
cup attached thereto, and a lower holding mechanism. The lower holding
mechanism
is configured to hold a lower side panel of the knocked-down flat container
while the
first erecting arm couples the suction cup to an upper side panel of the
knocked-down
flat container and rotates a portion of the knocked-down flat container into
the
rectangular configuration, also known as the partially erected container.
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[0052] The partially erected container is then transferred in the
rectangular configuration proximate the gluing mechanism to the second
erecting
mechanism. The second erecting mechanism includes at least one upper suction
cup
for attaching to an upper side panel of the partially erected container in the
rectangular
configuration, and at least one lower suction cup for attaching to a lower
side panel of
the partially erected container in the rectangular configuration. The at least
one upper
suction cup and the at least one lower suction cup move the upper side panel
and the
lower side panel apart in opposite directions, such that a leading side panel
and a
trailing side panel of the partially erected container move toward one another
to form
the octagonal container, also known as the fully erected container. The second
erecting mechanism also includes at least one miter bar that is configured to
position
the corner panels of the octagonal container, and a pressing plate for
pressing the
glued bottom flaps together for forming the bottom of the octagonal container.
[0053] In another aspect, a method is provided for erecting an
octagonal container from a knocked-down flat container. The knocked-down flat
container is formed from a blank of sheet material. The container includes
four main
side panels and four corner panels extending between each of the main side
panels.
The container also includes a plurality of bottom flaps each extending from
each of
the main side panels for forming a bottom of the container, and includes a
plurality of
top flaps extending from the main side panels for forming a top of the
container. The
octagonal container is formed by a machine that includes a body, a first
erecting
mechanism coupled to the body, a gluing mechanism, and a second erecting
mechanism coupled to the body. The method includes receiving the knocked-down
flat container at the first erecting mechanism and erecting the knocked-down
flat
container into a container having a rectangular configuration, also known as
the
partially erected container.
[0054] Specifically, a lower holding mechanism of the first erecting
mechanism holds a lower side panel of the knocked-down flat container while a
first
erecting arm of the first erecting mechanism couples a suction cup to an upper
side
panel of the knocked-down flat container and rotates a portion of the knocked-
down
flat container into the rectangular configuration. The partially erected
container is
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transferred in the rectangular configuration proximate the gluing mechanism
for
applying glue and then to the second erecting mechanism. The method includes
attaching at least one upper suction cup and the at least one lower suction
cup to the
upper side panel and the lower side panel, respectively, of the partially
erected
container, and moving the upper side panel and the lower side panel apart in
opposite
directions, such that a leading side panel and a trailing side panel of the
partially
erected container move toward one another to form the octagonal container,
also
known as the fully erected container. The method also includes positioning the
corner
panels of the octagonal container using at least one miter bar of the second
erecting
mechanism, and applying a pressing plate for pressing the glued bottom flaps
together
for forming the bottom of the octagonal container.
[0055] Figure 1 is a view of a blank that may be used to form an
octagonal container according to one embodiment of this invention. Figure 2 is
a
view of an octagonal container that is formed by the blank shown in Figure 1.
Although, the present invention is described with respect to a blank for
forming an
octagonal container, as would be appreciated by one of ordinary skill in the
art, the
present invention, with modification, may also apply to a blank for forming
any
polygonal-shaped container. In the exemplary embodiment, blank 100 is
fabricated
from at least one of paperboard, cardboard, corrugated board, and/or plastic.
Blank
100 has an exterior surface 310 and an interior surface 312 and includes eight
aligned
rectangular panels 102, 104, 106, 108, 110, 112, 114, and 116, joined together
by
preformed parallel fold lines 120, 122, 124, 126, 128, 130, and 132.
Specifically,
panels 102 and 104 are connected along fold line 120; panels 104 and 106 are
connected along fold line 122; panels 106 and 108 are connected along fold
line 124;
panels 108 and 110 are connected along fold line 126; panels 110 and 112 are
connected along fold line 128; panels 112 and 114 are connected along fold
line 130;
and panels 114 and 116 are connected along fold line 132. A tongue 140 is
connected
along a free edge 142 of panel 102 by a fold line 144 that is parallel to fold
lines 120,
122, 124, 126, 128, 130, and 132.
[0056] Furthermore, each panel 102, 106, 110, and 114 includes a
top flap 150, 152, 154, and 156, respectively. Specifically, top flap 150 is
connected
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to panel 102 by a fold line 160; top flap 152 is connected to panel 106 by a
fold line
162; top flap 154 is connected to panel 110 by a fold line 164; and top flap
156 is
connected to panel 114 by a fold line 166. Fold lines 160, 162, 164, and 166
are
aligned perpendicular to fold lines 120, 122, 124, 126, 128, 130, 132, and
144.
Similarly, each panel 102, 106, 110, and 114 includes a bottom flap 170, 172,
174,
and 176, respectively. Specifically, bottom flap 170 is connected to panel 102
by a
fold line 180; bottom flap 172 is connected to panel 106 by a fold line 182;
bottom
flap 174 is connected to panel 110 by a fold line 184; and bottom flap 176 is
connected to panel 114 by a fold line 186. Fold lines 180, 182, 184, and 186
are
aligned perpendicular to fold lines 120, 122, 124, 126, 128, 130, 132, and
144.
[0057] In the exemplary embodiment, rectangular panels 102, 104,
106, 108, 110, 112, 114, and 116 and tongue 140 each have the same height HI.
Panels 102 and 110 each have a width Wi. Panels 106 and 114 each have a width
W2
that is greater than width W1. Panels 104, 108, 112, and 116 each have a W3
that is
less than width WI.
[0058] Blank 100 is configured to form, by wrapping and fastening
panels 102, 104, 106, 108, 110, 112, 114, and 116, tongue 140, and flaps 150,
152,
154, 156, 170, 172, 174, and 176, as described below, a container 200, as
shown in
Figure 2. Container 200 has a height equal to height Hi, a length Li and a
width W4.
Container 200 has a rectangular cross section and four cut corners. In the
exemplary
embodiment, the large lateral faces 202 and 204 of container 200 are formed by
panels 106 and 114, respectively, whereas the small lateral faces 206 and 208
are
formed by panels 102 and 110, respectively. Further, panels 104, 108, 112, and
116
form the cut corners 210, 212, 214, and 216 of container 200. Moreover, bottom
flaps
170, 172, 174, and 176 form the bottom 220 of container 200; and top flaps
150, 152,
154, and 156 form the top 222 of container 200.
[0059] Figure 3 is a view of a knocked-down flat container 300
formed from blank 100 and configured to form container 200. Knocked-down flat
container 300 is formed by folding panel 102 into a face-to face relationship
with at
least a portion of panel 106, and folding at least a portion of panel 114 into
a face-to-
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face relationship with panel 110. Accordingly, panel 114 forms an upper side
panel
302 of knocked-down flat container 300 and panel 102 forms a leading panel 304
of
knocked-down flat container 300. Further, panel 106 forms a lower side panel
306 of
knocked-down flat container 300 and panel 110 forms a trailing panel 308 of
knocked-down flat container 300. Knocked-down flat container 300 has exterior
surface 310 of blank 100 exposed, and a minimal area of interior surface 312
exposed.
[0060] Figure 4 is a schematic view of a machine 350 that may be
used to form container 200 from knocked-down flat container 300. Although, the
present invention is described with respect to a machine for forming an
octagonal
container, as would be appreciated by one of ordinary skill in the art, the
present
invention, with modification, may also apply to a machine for forming any
polygonal-
shaped container. For example, a polygonal container formed by machine 350 may
includes zero, one, two, or three corners to form a four, five, six, or seven-
sided
container. Machine 350 includes a body 351, a feeding mechanism or assembly
352,
a first erecting mechanism or assembly 354, a glue mechanism or assembly 356,
and a
second erecting mechanism or assembly 358. Feeding mechanism 352, first
erecting
mechanism 354, glue mechanism 356, and second erecting mechanism 358 are each
coupled to machine body 351. Exemplary means for erecting the knocked-down
flat
container into a partially erect container having a substantially rectangular
configuration include, for example, first erecting mechanism 354, although any
suitable means for erecting may be used. Exemplary means for further erecting
the
partially erected container into a polygonal container include, for example,
second
erecting mechanism 358, although any suitable means for further erecting may
be
used. Exemplary means for applying adhesive include, for example, glue
mechanism
356, although any suitable means for applying adhesive may be used.
[0061] A plurality of knocked-down flats 300 are placed in a stack
400 adjacent feeding mechanism 352. Specifically, the knocked-down flats 300
are
positioned such that the leading panel 304 (shown in Figure 3) is positioned
adjacent a
feed band 402 of feeding mechanism 352.
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[0062] Feeding mechanism 352 includes at least one suction cup 404
that is configured to remove a top knocked-down flat container 300 from stack
400.
Specifically, suction cup 404 attaches to upper side panel 302 (shown in
Figure 3) and
moves knocked-down flat container 300 to feed band 402. The lower side panel
306
(shown in Figure 3) of knocked-down flat container 300 is positioned on feed
band
402, and at least one feed roll 406 is positioned in contact with leading
panel 304 and
upper side panel 302. Feed roll 406 and feed band 402 move knocked-down flat
container 300 to first erecting mechanism 354.
[0063] First erecting mechanism 354 includes a lower holding
mechanism or assembly 450 that locks to lower side panel 306 of knocked-down
flat
container 300. In the exemplary embodiment, lower holding mechanism 450 is a
vacuum that locks to lower side panel 306 via suction. First erecting
mechanism 354
also includes a rotatable erector arm 452 that includes at least one suction
cup 454
that attaches to upper side panel 302 of knocked-down flat container 300, as
shown in
Figure 5. Erector arm 452 rotates such that knocked-down flat container 300 is
formed into a partially erected container having a substantially rectangular
configuration. Figure 6 is a top view of knocked-down flat container 300
partially
erected into the rectangular configuration and having a pair of suction cups
454
attached thereto. Exemplary means for holding a lower side panel of the
knocked-
down flat container include, for example, lower holding mechanism 450,
although any
suitable means for holding may be used. Further, exemplary means for attaching
to
an upper side panel of the knocked-down flat container include, for example,
erector
arm 452 and/or suction cup 454, although any suitable means for attaching may
be
used.
[0064] Referring again to Figure 4, after knocked-down flat
container 300 is formed into the partially erected container, bottom flaps 170
(shown
in Figure 1) and 174 (shown in Figure 1) are folded with a first folding arm
456 to a
substantially ninety degree angle with respect to leading panel 304 and
trailing panel
308 as shown in Figure 7. Further, a second folding arm 458 folds bottom flaps
172
(shown in Figure 1) and 176 (shown in Figure 1) to a substantially 45 degree
angle
with respect to upper side panel 302 and lower side panels 306. First erecting
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,
,
mechanism 354 also includes a walking stick 460 that is moved along a pulley
system
462 to move knocked-down flat container 300 in the partially erected,
rectangular
configuration to second erecting mechanism 358. As partially erected, knocked-
down
flat container 300 is moved toward second erecting mechanism 358 a position of
knocked-down flat container 300 is detected by a photoeye 464. As shown in
Figure
8, when partially erected, knocked-down flat container 300 reaches a
predetermined
position gluing mechanism 356 applies hot melt 466 to bottom flaps 170 and
174.
Exemplary means for folding a first pair of opposing bottom flaps include, for
example, first folding arm 456, although any suitable means for folding may be
used.
Further, exemplary means for folding a second pair of opposing bottom flaps
include,
for example, second folding arm 458, although any suitable means for folding
may be
used.
[0065] Figure 9 is a schematic side view of knocked-down flat
container 300 in the partially erected, substantially rectangular
configuration shown in
Figures 7 and 8 positioned within the second erecting mechanism shown in
Figure 4.
Referring to Figures 4 and 9, second erecting mechanism 358 includes at least
one
upper suction cup 500 and at least one lower suction cup 502. Second erecting
mechanism 358 also includes at least one fixed miter 504 positioned at a
corner of the
rectangular configuration of knocked-down flat container 300. Upper suction
cup 500
is configured to attach to upper side panel 302, and lower suction cup 502 is
configured to attach to lower side panel 306. Exemplary means for means for
attaching to an upper side panel of the partially erected container in the
substantially
rectangular configuration include, for example, upper suction cup 500,
although any
suitable means for attaching may be used. Further, exemplary means for
attaching to
a lower side panel of the partially erected container in the substantially
rectangular
configuration include, for example, lower suction cup 502, although any
suitable
means for attaching may be used.
[0066] As seen in Figure 10, suction cups 500 and 502 pull upper
side panel 302 and lower side panel 306 apart in opposite directions, such
that leading
panel 304 and trailing panel 308 are pulled toward on another to form
octagonal
container 200. Further, panels 104, 108, 112, and 116 are repositioned at an
angle to
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form the corners 210, 212, 214, and 216 of container 200. The formation of
corners
210, 212, 214, and 216 is aided by at least one fixed miter 504. More
specifically,
fixed miter 504 applies a force and/or a pressure to exterior surface 310 of a
respective corner 210, 212, 214, and/or 216 when partially erected, knocked-
down flat
container 300 is positioned against miter 504. Accordingly, miter 504
facilitates
erecting container 200 from partially erected, knocked-down flat container 300
by
applying pressure to exterior surface 310 of container 300, and more
specifically,
exterior surface 310 of a corner 210, 212, 214, or 216.
[0067] In the exemplary embodiment, as shown in Figure 10, second
erecting mechanism 358 includes a first bottom fixed miter 506, a second
bottom
fixed miter 508, and a top fixed miter 510. In the exemplary embodiment, first
bottom fixed miter 506 positions panel 104 to form corner 210, second bottom
fixed
miter 508 positions panel 108 to form corner 212, and top fixed miter 510
positions
panel 112 to form corner 214. In an alternative embodiment, second erecting
mechanism 358 may be modified to include any suitable number of fixed miters
504
capable of forming container corners, as described herein. Further, second
erecting
mechanism 358 includes a top plate 512 that positions panel 114/upper side
panel
302, and a bottom plate 514 that positions panel 106/lower side panel 306.
Moreover,
in the exemplary embodiment, panel 116 forms corner 216 by virtue of the
positioning of panels 104, 106, 108, 112, and 114. Miter bar 504 is an example
of a
means for applying a force to the exterior surface of at least one corner
panel,
although any suitable means for applying a force may be used.
[0068] Figure 11 is a side view of octagonal container 200 at second
erecting mechanism 358. As illustrated in Figure 11, after octagonal container
200 is
formed, bottom flaps 172 and 176 are still positioned at a 45 degree angle
with respect
to upper side panel 302 and lower side panels 306. Further, bottom flaps 170
and 174
are positioned at a substantially ninety degree angle with respect to leading
panel 304
and trailing panel 308. Moreover, panels 170 and 174 have hot melt 466 (shown
in
Figure 8) applied thereon, as described above. In the exemplary embodiment,
second
erecting mechanism 358 includes a compression plate 550 and a backing plate
552
that are configured to seal flaps 172 and 176 to flaps 170 and 174. In the
exemplary
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embodiment, compression plate 550 and backing plate 552 are driven by at least
one
of a servo mechanism, a pneumatic mechanism, a hydraulic mechanism, a
computer,
and/or any other suitable mechanism or assembly capable of driving compression
plate 550 and backing plate 552, as described herein. Exemplary means for
applying
a force to an exterior surface of the bottom flaps include, for example,
backing plate
552, although any suitable means for applying a force may be used. Further,
exemplary means for applying a force to an interior surface of the bottom
flaps
include, for example, compression plate 550, although any suitable means for
applying a force may be used.
[0069] As seen in Figure 12, compression plate 550 moves through
octagonal container 200 and toward backing plate 552. Compression plate 550 is
positioned substantially flush with bottom flaps 170 and 174. Backing plate
552
moves toward compression plate 550 and is positioned substantially flush
against
bottom flaps 172 and 176. As plate 550 moves toward plate 552, backing plate
552
applies a force and/or pressure to exterior surface 310 of bottom flaps 170,
172, 174,
and/or 176, and compression plate 552 applies a force and/or pressure to
interior
surface 312 of bottom flaps 170, 172, 174, and/or 176. Accordingly, the
movement of
compression plate 550 and backing plate 552 compresses flaps 170 and 174
against
flaps 172 and 176 thereby, sealing the bottom 220 of container 200 by virtue
of the
hot melt 466. Figure 13 is a view of the bottom 220 of container 200 after
being fully
erected at second erecting mechanism 358. After being fully erected, octagonal
container 200 is discharged from machine 350 and a second knocked-down flat
container 300 is fed through machine 350, as described herein.
[0070] Figures 14-41 are views of a knocked-down flat container 300
being formed into an octagonal container 200 using machine 350 shown in Figure
4.
An arrow A indicates the direction of movement of container 300 and/or 200
through
machine 350. More specifically, Figures 14-16 show knocked-down flat container
300 being feed into the machine 350 by the feeding mechanism 352. Figure 14
shows
the feed rolls 406 of the feeding mechanism 352. Figure 15 shows the suction
cups
404 of the feeding mechanism 352 feeding the knocked-down flat container 300
to the
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feed rolls 406 of the feeding mechanism 352. Figure 16 shows the feed rolls
406 of
the feeding mechanism 352 moving the knocked-down flat container 300.
[0071] Figures 17-19 show the feeding mechanism 352 feeding the
knocked-down flat container 300 to the first erecting mechanism 354. Figure 18
shows the first erecting mechanism 354 erecting a first knocked-down flat
container
300 in a partially erected container 300, while the feed rolls 406 of the
feeding
mechanism 352 feed a second knocked-down flat container 300 to the first
erecting
mechanism 354.
[0072] Figures 20-24 show the knocked-down flat container 300
being erected into the partially erected container having a substantially
rectangular
configuration. Figure 20 shows the suction cups 454 of the first erecting
mechanism
354 attaching to the upper side panel 302 of the knocked-down flat container
300.
Figures 21 and 22 show the first erecting mechanism 354 erecting the knocked-
down
flat container 300 into the partially erected container. Figures 23 and 24
show the
rectangular configuration of the partially erected, knocked-down flat
container 300 as
formed by the first erecting mechanism 354.
[0073] Figures 25-28 show the first and second folding arms 456 and
458 of the first erecting mechanism 354 folding the bottom flaps 170, 172,
174, and
176 of the partially erected, knocked-down flat container 300.
[0074] Figures 29-37 show the rectangular configuration of the
partially erected, knocked-down container 300 being formed into the octagonal
container 200 by the second erecting mechanism 358. Figure 29 shows the upper
suction cups 500 of the second erecting mechanism 358 attaching to the
rectangular
configuration of the knocked-down flat container 300. Figures 30, 32, 34, 36,
and 37
show the second erecting mechanism 358 erecting the octagonal container 200.
Figures 31 and 33 show a miter bar 504 of the second erecting mechanism 358.
Figure 35 show a miter bar 504 shown of the second erecting mechanism 358
forming
the corners of the octagonal container 200.
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[0074] Figures 38-41 show the bottom 220 of the octagonal container
200 being closed at the second erecting mechanism 358. Figures 38-40 show the
backing plate 552 and compression plate 550 of the second erecting mechanism
358
closing the bottom 220 of the octagonal container 200. Figure 41 shows a
completed
octagonal container 200 at the second erecting mechanism 358. Figure 42 is a
perspective view of machine 350 as shown in Figures 14-41.
[0075] Accordingly, the above-described machines and methods
facilitate quickly and continuously forming polygonal containers, such as
octagonal
containers, from a stack of knocked-down flats. As such, time and/or costs
associated
with forming polygonal containers are facilitated to be reduced, thereby,
reducing
time and/or costs associated with manufacturing and packaging.
[0076] As used herein, an element or step recited in the singular and
proceeded with the word "a" or "an" should be understood as not excluding
plural
elements or steps, unless such exclusion is explicitly recited. Furthermore,
references
to "one embodiment" of the present invention are not intended to be
interpreted as
excluding the existence of additional embodiments that also incorporate the
recited
features.
[0077] Exemplary embodiments of machines and methods for
erecting a polygonal container are described above in detail. The machines and
methods illustrated are not limited to the specific embodiments described
herein, but
rather, components of the machines may be utilized independently and
separately
from other components described herein. Further, steps described in the method
may
be utilized independently and separately from other steps described herein.
[0078] While the invention has been described in terms of various
specific embodiments, those skilled in the art will recognize that the
invention can be
practiced with modification.
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