Note: Descriptions are shown in the official language in which they were submitted.
CA 02687847 2009-12-08
METHOD AND APPARATUS FOR FORMING CONTAINERS WITH
CORRUGATED MATERIAL
RELATED APPLICATIONS
[0001] This application is a continuation-in-part of international application
PCT/CA2009/001249, filed September 11, 2009, which claims the benefit of and
priority
from United States provisional patent application No. 61/136,542, filed on
September 12,
2008, the entire contents of both of which are incorporated herein by
reference.
FIELD OF THE INVENTION
[0002] The present invention relates generally to methods and systems for
forming
containers made from corrugated material, including corrugated fibreboard.
BACKGROUND OF THE INVENTION
[0003] Containers are used to package many different kinds of items. One form
of
container used in the packaging industry is a case that is used for shipping
items /
products. In the present application, the term "case" is used to refer to such
containers.
Cases come in many different configurations and are made from a wide variety
of
materials. However, many cases are foldable and are formed from a flattened
state
(commonly called a case blank). Cases may be made from an assortment of
foldable
materials, including cardboard, paperboard, plastic materials, composite
materials, and
the like and possibly even combinations thereof.
[0004] One particular type of case that is in widespread use in packaging a
wide
variety of items is a case made from a corrugated material, such as corrugated
fibreboard.
The use of corrugated fibreboard generally enhances the strength of the case.
Of those
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cases made from corrugated fibreboard, the most common type is known as
"Regular
Slotted Container" case or "RSC" case and it is particularly well suited for
packaging all
types of items such as by way of example only, glass and plastic bottles,
packaged goods,
or other smaller cases or cartons.
[0005] The process for making an RSC begins with the formation of a piece of
plain
corrugated sheet material that can be formed by a corrugator machine. An
example of a
corrugator machine is the BHS Corrugator machine made by BHS Corrugated
Maschinen- and Anlagenbau GmbH. The corrugator machine may produce a length of
corrugated material of a given width that can be used immediately or stored in
a roll until
it is ready to be utilized.
[0006] The next step in forming an RSC is to take a roll or sheet of such
corrugated
material that may have an approximate width that may be the same as the width
of the
desired blank that may be used to form the RSC. The roll or sheet is also cut
transversely
such as to create sections of cardboard generally rectangular in shape. The
corrugated
material is then fed through what is known as a flexo-folder gluer machine. In
passing
through such a machine, the corrugated sheet passes through a printer, which
prints
words or pictures on one or both sides of the sheet. Next, the material is
creased both
across and along the sheet material such that when the RSC is folded / erected
it may
easily bend along the crease lines to form the desired shape.
[0007] The creased and printed sheet is then "slotted" with a slotting device
which
cuts thin transversely oriented "slots" in the board in intervals along the
top and bottom.
These slots create the panels that may be folded over the top and bottom
openings of the
RSC when it is erected. Finally, the sheet material goes through a rotary die
cutter to
remove excess corrugated material along one end of the board and crush down a
portoin
along a fold line, to create a thin "hinge". The purpose of the hinge is to
later allow the
board to be doubled back on itself (i.e. glue one end of the board to the
other to create a
tube) and glued.
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[0008] The result of the flexo-folder gluer up to this point is to create a
flat RSC
blank such as, by way of example only, the blank 900 shown in Figure 27.
Thereafter the
flexo-folder gluer may apply glue to the hinge portion of the blank. The
panels on either
end of the blank are then folded over by a folding mechanism such that one end
of the
blank is now glued to the other in a flattened tube-shaped orientation to
create a flat
"knock down" RSC.
[0009] After the knock down RSC has been created, it is typically grouped with
other
RSCs and shipped to the factory of the customer where the knock-down RSCs are
to be
erected and packed.
[0010] When it is desired to fill an RSC with a product, a two step operation
is
required. First, the RSC must be erected from its knock-down configuration,
either by
hand or using a "case erector" machine such as is disclosed in U.S. Pat. No.
7,510,517,
the contents of which are hereby incorporated by reference. An example of a
commercially available RSC case erector is the WF 20 model distributed by
Wexxar
Packaging.
[0011] The second step is placing of the product into the formed case, either
by hand
or using a "case packer" machine as in U.S. Pat. No. 4,644,734. An example of
a
commercial case packer is the VCP-25 Vertical Case Packer by Schneider
Packaging.
[0012] There are a number of systems that are available that perform both the
case
erection and the case packing functions in a single apparatus.
[0013] There are however significant drawbacks to the process of forming and
packing the RSCs. For example, the pre-folded and pre-glued blanks are not
well
adapted to shipping in bulk from the location where the knock-downs are formed
to the
premises where the knock-downs are erected and packed, due to their asymmetric
shape -
being three layers thick on the glued seam area and only two layers thick
elsewhere.
Unstable stacking characteristic of such blanks requires the use of secondary
containers
and also reduces the number of blanks that can be shipped per unit volume.
These
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factors result in a significant increase in shipping costs compared to blanks
that can be
shipped in a completely flat arrangement.
[0014] Other problems associated with the formation of a RSC relate to the
creation
of the knock-down RSC. The alignment and gluing that is done to form the
"knock-
down" is often not very accurately performed and so the RSC that is eventually
formed
may not be properly and accurately constructed. This may cause problems in the
erection
of the case and in the loading and storage of items in the RSC.
[0015] Despite the foregoing drawbacks, the use of the RSC is widespread in
the
packaging of items. There may be several reasons for the continued prevalence
of the
RSC compared to cases formed from flat, die cut blanks (i.e. cases in
alternative
arrangements that are not folded over and glued into a "knock down" state
prior to
shipment to the place where the case is to be erected and/or packed). These
reasons
include the following: (1) RSC cases can be easily set up and sealed by hand
without a
machine. So in situations where case erecting and packing is done by hand, the
RSC case
is preferred. RSC cases may be preferred because hand packing can be easily
done if
problems with machinery arise; (2) The machinery traditionally used to form
and pack
die cut cases from flat, die cut blanks has been more expensive, complex, and
inflexible
when compared to RSC erectors and packers. Thus, at a location where the
packing of
the items into a case is accomplished, it is desirable to have relatively
technically
straightforward and inexpensive equipment. (3) The standard equipment and
process for
forming and loading an RSC has been established for many years. Businesses
that have
invested in RSC-type machinery have not see the need to invest the time and
money to
move to an alternate system based on a flat die cut blank, in the absence of
significant
cost savings and a viable alternate system for forming and packing such a
case.
[0016] However it would be desirable to create a new type of blank and
associated
case that performs like an RSC and looks like an RSC, if some of the drawbacks
of the
existing RSC can be overcome. It should be noted that even a slight reduction
in wastage
of corrugated fibreboard material in creating the blank, would be immensely
beneficial.
However, it would also be desirable to have methods and apparatuses to form
such RSC
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replacement cases from blanks that could be readily and efficiently employed
at customer
premises.
SUMMARY OF THE INVENTION
[0017] Accordingly, a new blank design, designated by the applicant as a dual
side
seam-regular slotted container blank ( the "DSS-RSC" (TradeMark) blank) has
been
devised along with new forming processes and systems suited to forming cases
from
DSS-RSC blanks. The DSS-RSC blank that has been conceived can be formed into a
DSS-RSC case that is functionally equivalent to an RSC case, but may be both
cheaper to
manufacture than an RSC, and may provide equivalent or better strength than an
RSC.
[0018] According to an aspect of the invention there is provided a case made
from a
corrugated material, the case comprising: i. a generally flat transversely
extending base
panel; ii. first and second transversely extending, generally parallel, side
wall panels
upstanding from, and being oriented generally orthogonal to, the base panel,
each of the
first and second side wall panels having respective first transverse edges
extending along
and joined with respective opposite transverse edges of the base panel; iii.
first and
second upstanding end panels positioned at opposed ends of the first side wall
panel and
oriented generally orthogonal to both said first side wall panel and the base
panel, each
the first and second ends panel having edges joined with and extending from
opposed end
edges of the first side wall panel; iv. third and fourth upstanding end panels
positioned at
opposed ends of second side wall panel and oriented generally orthogonal to
the second
side wall panel and the base panel, each of the third and fourth end panels
joined with and
extending from opposed end edges of the second side wall panel; wherein the
first and
third end wall panels meet at a first vertically extending seam extending
upwards from
one end of the base panel and the second and fourth end wall panels meet at a
second
vertically extending seam extending upwards from an opposite end of the base
panel.
[0019] According to an aspect of the invention there is provided a case
comprising: i.
a generally flat transversely extending base panel; ii. first and second
transversely
extending, generally parallel, side wall panels upstanding from, and being
oriented
generally orthogonal to, the base panel, each of the first and second side
wall panels
CA 02687847 2009-12-08
having respective first transverse edges extending along and joined with
respective
opposite transverse edges of the base panel; iii. first and second upstanding
end panels
positioned at opposed ends of the first side wall panel and oriented generally
orthogonal
to both the first side wall panel and the base panel, each the first and
second ends panel
having edges joined with and extending from opposed end edges of the first
side wall
panel; iv. third and fourth upstanding end panels positioned at opposed ends
of second
side wall panel and oriented generally orthogonal to the second side wall
panel and the
base panel, each of the third and fourth end panels joined with and extending
from
opposed end edges of the second side wall panel; wherein the first and third
end wall
panels meet at a first vertically extending seam extending upwards from one
end of the
base panel and the second and fourth end wall panels meet at a second
vertically
extending seam extending upwards from an opposite end of the base panel, and
wherein
the first and third end wall panels overlap to form the first vertically
extending seam and
the second and fourth end wall panels overlap to form the second vertically
extending
seam.
[0020] According to an aspect of the invention there is provided a case made
from a
corrugated material, the case comprising: i. a generally flat transversely
extending base
panel; ii. first and second transversely extending, generally parallel, side
wall panels
upstanding from, and being oriented generally orthogonal to, the base panel,
each of the
first and second side wall panels joined with and extending from the base
panel; iii. first
and second upstanding end panels positioned at opposed ends of the first side
wall panel
and oriented generally orthogonal to both the first side wall panel and the
base panel,
each the first and second ends panel joined with and extending from the first
side wall
panel; iv. third and fourth upstanding end panels positioned at opposed ends
of second
side wall panel and oriented generally orthogonal to the second side wall
panel and the
base panel, each of the third and fourth end panels joined with and extending
from the
second side wall panel; wherein the first and third end wall panels meet at a
first
vertically extending seam extending upwards from one end of the base panel and
the
second and fourth end wall panels meet at a second vertically extending seam
extending
upwards from an opposite end of the base panel.
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[0021] According to an aspect of the invention there is provided a single
piece blank
for forming a case, the blank comprising a continuous piece of generally flat
corrugated
material comprising: i. a base panel; ii. first and second side wall panels
meeting either
side of the base panel meeting either side of the base panel along respective
opposite fold
lines; iii. first and second end panels meeting at opposed ends of the first
side wall panel
along respective opposite fold lines; iv. third and fourth side end panels
meeting at
opposed ends of second side wall panel along respective opposite fold lines. A
width of
aid base and a length of the first and third side end wall panels being
selected such that
when blank is erected to form the case, the first and third side end walls
will meet at a
first vertically extending seam at one end of the base panel and the second
and fourth side
end wall panels meet at a second vertically extending seam at an opposite end
of the base
panel.
[0022] According to an aspect of the invention there is provided a method of
forming
and loading a case, the case made from a corrugated material and comprising:
i. a
generally flat transversely extending base panel; ii. first and second
transversely
extending, generally parallel, side wall panels upstanding from, and being
oriented
generally orthogonal to, the base panel, each of the first and second side
wall panels
having respective first transverse edges extending along and joined with
respective
opposite transverse edges of the base panel; iii. first and second upstanding
end panels
positioned at opposed ends of the first side wall panel and oriented generally
orthogonal
to both the first side wall panel and the base panel, each the first and
second ends panel
having edges joined with and extending from opposed end edges of the first
side wall
panel; iv. third and fourth upstanding end panels positioned at opposed ends
of second
side wall panel and oriented generally orthogonal to the second side wall
panel and the
base panel, each of the third and fourth end panels joined with and extending
from
opposed end edges of the second side wall panel; wherein the first and third
end wall
panels meet at a first vertically extending seam extending upwards from one
end of the
base panel and the second and fourth end wall panels meet at a second
vertically
extending seam extending upwards from an opposite end of the base panel; the
method
comprising: i. forming a sheet of corrugated fiberboard; ii. operating a die
cutting
apparatus to form a generally flat case blank from the sheet of corrugated
fiberboard at a
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first location; iii. transporting the flat case blank to a second location;
iv. operating a case
forming apparatus at the second location to fold the case blank to form the
case, v. after
the case has been formed by the case forming apparatus, operating a loading
apparatus to
load at least one item into the case; vi. sealing the opposed top panels of
the case with the
at least one item held in the case.
[0023] According to an aspect of the invention there is provided a system for
forming
and loading a case, the case made from corrugated fibreboard, the case
comprising: i. a
generally flat transversely extending base panel; ii. first and second
transversely
extending, generally parallel, side wall panels upstanding from, and being
oriented
generally orthogonal to, the base panel, each of the first and second side
wall panels
having respective first transverse edges extending along and joined with
respective
opposite transverse edges of the base panel; iii. first and second upstanding
end panels
positioned at opposed ends of the first side wall panel and oriented generally
orthogonal
to both the first side wall panel and the base panel, each the first and
second ends panel
having edges joined with and extending from opposed end edges of the first
side wall
panel; iv. third and fourth upstanding end panels positioned at opposed ends
of second
side wall panel and oriented generally orthogonal to the second side wall
panel and the
base panel, each of the third and fourth end panels joined with and extending
from
opposed end edges of the second side wall panel; wherein the first and third
end wall
panels meet at a first vertically extending seam extending upwards from one
end of the
base panel and the second and fourth end wall panels meet at a second
vertically
extending seam extending upwards from an opposite end of the base panel; and
wherein
the system comprises: i. a corrugator for forming a sheet of corrugated
fiberboard; ii. a
die cutting apparatus located at a first location operable to form a generally
flat case
blank from the sheet of corrugated fiberboard at a first location; iii. a case
forming
apparatus located at a second location to fold the generally flat case blank
to form the
case, iv. a loading apparatus to load at least one item into the case; v. a
sealing apparatus
for sealing the opposed top panels of the case with the at least one item held
in the case.
[0024] According to an aspect of the invention there is provided a method for
forming a case from a case blank, the case blank comprising: i. a base panel;
ii. first and
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second side wall panels meeting either side of the base panel meeting either
side of the
base panel along respective opposite fold lines; iii. first and second end
panels meeting at
opposed ends of the first side wall panel along respective opposite fold
lines; iv. third and
fourth side end panels meeting at opposed ends of second side wall panel along
respective opposite fold lines; a width of aid base and a length of the first
and third side
end wall panels being selected such that when blank is erected to form the
case, the first
and third side end walls will meet at a first vertically extending seam at one
end of the
base panel and the second and fourth side end wall panels meet at a second
vertically
extending seam at an opposite end of the base panel; the method comprising:
(a) orienting
a case blank in a generally flat first orientation; (b) rotating a first
portion of the blank
from the first orientation to a second orientation that is generally
orthogonal to a second
portion of the case blank.
[0025] According to an aspect of the invention there is provided a method of
forming
a case from a case blank, the case blank comprising: i. a base panel; ii.
first and second
side wall panels meeting either side of the base panel meeting either side of
the base
panel along respective opposite fold lines; iii. first and second end panels
meeting at
opposed ends of the first side wall panel along respective opposite fold
lines; iv. third and
fourth side end panels meeting at opposed ends of second side wall panel along
respective opposite fold lines. A width of the base and a length of the first
and third side
end wall panels being selected such that when blank is erected to form the
case, the first
and third side end walls will meet at a first vertically extending seam at one
end of the
base panel and the second and fourth side end wall panels meet at a second
vertically
extending seam at an opposite end of the base panel; the method comprising:
(a)
providing a case blank in a first generally flat orientation, the case blank
having first and
second portions, the first portion of blank being generally adjacent and
parallel to a first
portion of a mandrel; (b) rotating the second portion of the case blank about
the mandrel
so the second portion is positioned at a second orientation that is generally
orthogonal to
the first portion.
[0026] According to an aspect of the invention there is provided a method of
forming
a plurality of case blanks from a single sheet of corrugated material, each of
the plurality
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of blanks comprising: i. a base panel; ii. first and second side wall panels
meeting either
side of the base panel meeting either side of the base panel along respective
opposite fold
lines; iii. first and second end panels meeting at opposed ends of the first
side wall panel
along respective opposite fold lines; iv. third and fourth side end panels
meeting at
opposed ends of second side wall panel along respective opposite fold lines. A
width of
the base and a length of the first and third side end wall panels being
selected such that
when blank is erected to form the case, the first and third side end walls
will meet at a
first vertically extending seam at one end of the base panel and the second
and fourth side
end wall panels meet at a second vertically extending seam at an opposite end
of the base
panel; the method comprising: i. forming a sheet of corrugated fiberboard; ii.
cutting a
plurality of the blanks from the sheet such that a plurality of blanks are cut
both laterally
and longitudinally from the sheet of corrugated fiberboard.
[0027] According to an aspect of the invention there is provided a plurality
of blanks
made from a single continuous sheet of generally flat corrugated material, a
plurality of
blanks being cut from a single sheet in both a lateral and longitudinal
direction, each the
blank comprising: i. a base panel; ii. first and second side wall panels
meeting either side
of the base panel meeting either side of the base panel along respective
opposite fold
lines; iii. first and second end panels meeting at opposed ends of the first
side wall panel
along respective opposite fold lines; iv. third and fourth side end panels
meeting at
opposed ends of second side wall panel along respective opposite fold lines. A
width of
the base and a length of the first and third side end wall panels being
selected such that
when blank is erected to form the case, the first and third side end walls
will meet at a
first vertically extending seam at one end of the base panel and the second
and fourth side
end wall panels meet at a second vertically extending seam at an opposite end
of the base
panel.
[0028] According to an aspect of the invention there is provided a method of
forming
and loading a plurality of cases, each of the plurality of case made from a
corrugated
material and comprising: i. a generally flat transversely extending base
panel; ii. first and
second transversely extending, generally parallel, side wall panels upstanding
from, and
being oriented generally orthogonal to, the base panel, each of the first and
second side
CA 02687847 2009-12-08
wall panels having respective first transverse edges extending along and
joined with
respective opposite transverse edges of the base panel; iii. first and second
upstanding
end panels positioned at opposed ends of the first side wall panel and
oriented generally
orthogonal to both the first side wall panel and the base panel, each the
first and second
ends panel having edges joined with and extending from opposed end edges of
the first
side wall panel; iv. third and fourth upstanding end panels positioned at
opposed ends of
second side wall panel and oriented generally orthogonal to the second side
wall panel
and the base panel, each of the third and fourth end panels joined with and
extending
from opposed end edges of the second side wall panel; wherein the first and
third end
wall panels meet at a first vertically extending seam extending upwards from
one end of
the base panel and the second and fourth end wall panels meet at a second
vertically
extending seam extending upwards from an opposite end of the base panel; the
method
comprising: i. forming a sheet of corrugated fiberboard; ii. operating a die
cutting
apparatus to cut a plurality of generally flat case blank from the sheet of
corrugated
fiberboard in both a longitudinal and transverse direction on the sheet, the
die cutting
apparatus located at a first location; iii. transporting the plurality of flat
case blanks to a
second location; iv. operating a case forming apparatus at the second location
to fold the
plurality of case blanks to form the case, v. after the plurality of cases has
been formed by
the case forming apparatus, operating a loading apparatus to load at least one
item into
each of the plurality of cases; vi. sealing the opposed top panels of the case
with the at
least one item held in the case.
[0029] According to an aspect of the invention there is provided a system for
forming
a case, the case made from a case blank made from a corrugated material, the
case
comprising: i. a generally flat transversely extending base panel; ii. first
and second
transversely extending, generally parallel, side wall panels upstanding from,
and being
oriented generally orthogonal to, the base panel, each of the first and second
side wall
panels having respective first transverse edges extending along and joined
with respective
opposite transverse edges of the base panel; iii. first and second upstanding
end panels
positioned at opposed ends of the first side wall panel and oriented generally
orthogonal
to both the first side wall panel and the base panel, each the first and
second ends panel
having edges joined with and extending from opposed end edges of the first
side wall
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panel; iv. third and fourth upstanding end panels positioned at opposed ends
of second
side wall panel and oriented generally orthogonal to the second side wall
panel and the
base panel, each of the third and fourth end panels joined with and extending
from
opposed end edges of the second side wall panel; wherein the first and third
end wall
panels meet at a first vertically extending seam extending upwards from one
end of the
base panel and the second and fourth end wall panels meet at a second
vertically
extending seam extending upwards from an opposite end of the base panel; and
wherein
the system comprises a case forming apparatus to fold and glue the generally
flat case
blank to form the case, and wherein the case forming apparatus comprises: (a)
a mandrel,
and wherein the case blank has a first portion that can be positioned
proximate a first
surface of the mandrel; (b) a folding and guide apparatus; (c) a movement
apparatus
operable for moving the mandrel towards and through the folding and guide
apparatus
while the first portion of the case blank is positioned proximate the first
surface of the
mandrel; (d) an adhesive applicator positioned to apply an amount of adhesive
to at least
one portion of the case blank; the system operable such that while the mandrel
is moved
towards and through the folding and guide apparatus by the moving apparatus,
the
adhesive applicator applies adhesive to the at least one portion of the blank.
[0030] Other aspects and features of the present invention will become
apparent to
those of ordinary skill in the art upon review of the following description of
specific
embodiments of the invention in conjunction with the accompanying figures.
BRIEF DESCRIPTION OF THE DRAWINGS
[0031] In the figures which illustrate by way of example only, embodiments of
the
present invention,
[0032] Figure 1 is a top, left front perspective view of a case forming system
in
accordance with an example embodiment of the present invention;
[0033] Figure 2 is a top, right rear side perspective view of the system of
Figure 1;
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[0034] Figure 3 is a top, right frontperspective view of the system of Figure
1;
[0035] Figure 4 is a top, left rear perspective view of the system of Figure
1;
[0036] Figure 5 is a bottom, right rear perspective view of the system of
Figure 1;
[0037] Figures 6 to 18 are various additional perspective views of the system
of
Figure 1, illustrating the sequential forming of a case from a blank using the
system of
Figures 1 to 5;
[0038] Figures 19 to 20 are perspective views of a first alternate system;
[0039] Figures 21 to 22 are perspective views of a second alternate system;
[0040] Figures 23 to 26 are perspective views of a third alternate system;
[0041] Figure 27 is a plan view of a known type of blank that may be used to
form a
known type of Regular Slotted Case;
[0042] Figure 28 is a schematic flow chart of a method of forming a case in
accordance with an embodiment of the present invention;
[0043] Figure 29 is a perspective view of part of a typical press and cutting
die
portion of a die cutting apparatus to form part of a system for forming a DSS-
RSC case
(as hereinafter defined and described) in accordance with an embodiment of the
invention;
[0044] Figure 30 is a plan view of an example of a blank for a DSS-RSC case in
accordance with an embodiment of the present invention;
[0045] Figure 31 is a plan view of a sheet of corrugated material from which
can
produce a plurality of the blanks of the type shown in Figure 30;
[0046] Figure 32 is a schematic perspective view illustrating an example
process by
which a DSS-RSC blank such as the blank in Figure 30 can be erected into DSS-
RSC
case;
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[0047] Figures 33 to 35 are a series of perspective views of a DSS-RSC blank
such
as a blank in Figure 30 shown in isolation as it progresses through the
process of Figure
32;
[0048] Figure 36 is a plan view of a blank for a DSS-RSC case in accordance
with an
alternate embodiment of the present invention;
[0049] Figure 37 is a plan view of a sheet of corrugated material that can be
used to
produce a plurality of the blanks such as the blanks of Figure 36;
[0050] Figure 38 is a schematic perspective view illustrating an example
process by
which a DSS-RSC blank such as the blank in Figure 36 can be erected into a
case;
[0051] Figures 39 to 42 are a series of perspective views of a blank such as a
blank
in Figure 36 as it progresses through the process of Figure 38;
[0052] Figure 43 is a schematic view of a system for forming, erecting and
packing a
DSS-RSC case.
DETAILED DESCRIPTION
[0053] With reference initially to Figure 28, a process for forming and
packing a
DSS-RSC case with items is illustrated schematically. The first step 1000 is
the formation
of a corrugated sheet of material (that may be formed into a roll of material)
from which
the DSS-RSC blank will be made. The roll or sheet of corrugated material does
not have
to be of the specific width or length of the desired width and length of the
DSS-RSC
blank such as blank 400 as illustrated in Figure 30. The corrugated roll or
sheet of
fibreboard can be formed using a known type of corrugator machine such as the
BHS
Corrugator machine made by BHS Corrugated Maschinen- and Anlagenbau GmbH. An
example of the type of corrugated sheet of material that may be produced is
described in
US patent no. 150,588 the entire contents of which are hereby incorporated
herein by
14
CA 02687847 2009-12-08
reference. Step 1000 will typically take place in a plant location that is
dedicated to
manufacturing sheets / rolls of corrugated materials.
[0054] Once the sheet has been formed, the next step 1010 is the formation of
the
DSS-RSC blanks. This step 1010 may or may not take place at the same general
geographic location and the same physical building as step 1000. However, in
many
situations the DSS-RSC blanks will be formed at the same location as where the
corrugated material is formed in step 1000. The DSS-RSC blank (such as by way
of
example only blank 400 in Figure 30) may be formed from the sheet or rolled
sheet of
corrugated material (eg. corrugated fibreboard) by using a die cutting
machine. A die
cutting machine may comprise a preliminary printing portion such that when the
corrugated sheet is fed into the machine, appropriate text and / or images can
be printed
onto one or possibly both sides of the corrugated sheet in appropriate
positions. Thus,
when the DSS-RSC case is eventually erected, the printed material may be
appropriately
displayed.
[0055] Once it has been passed through the printing portion of the die cutting
machine, the corrugated sheet can then be fed to the actual die cutting
portion of the
machine where one or more blanks are cut from the sheet of corrugated
material.
Typically this process involves the sheet being fed through and between a
press and
rotating cutting die. An example of a press and die cutting machine that might
be
adapted to form a suitable DSS-RSC blank is illustrated in U.S. Patent Number
4,466,320. An example of a part of a typical press and cutting die portion 800
of such a
machine is also illustrated schematically in Figure 29. Cutting die 800 may
have raised
portions 810 that have outer cutting edges having a perimeter shape that
corresponds with
the shape of the desired blank. When the sheet of corrugated material is fed
through the
press and die cutting portion of the machine, the press and die cutting
portion can thus cut
out shapes, make perforations or creases, and may even cut the sheet into
smaller parts to
create a desired shaped blank. A series of gears forces the die to rotate at
the same speed
as the rest of the press, ensuring that any cuts the die makes line up with
the printed
material that has been placed on the corrugated sheet. The die cutting
apparatus may be
CA 02687847 2009-12-08
appropriately configured to cut out a single DSS-RSC blank at a time from the
sheet of
material, such as the blank 400 illustrated in Figure 30 or the blank 500 in
Figure 36.
[0056] Depending on the size of the blank and the configuration of the die
cutting
machine, multiple blanks such as blanks 400 or blanks 500 can be cut across
the width of
the sheet of material simultaneously. Examples of sheets of corrugated
material showing
the outlines of where the die cutting apparatus can cut from the sheet a
plurality of blanks
is illustrated in Figure 31 with blanks 400a-400h, and in Figure 37 with a
plurality of
blanks 500a-500h.
[0057] In overview, very long rolls or sheets of corrugated material may be
provided
with a width that may be approximately the same as the die cutting device. In
the rotary
die cutting of the sheet or roll fibreboard material, a cookie cutter like
action, cuts and
scores the material to generate blanks such as the DSS-RSC blank 400 shown in
Figure
30. Depending on the size of the blank and the size of the particular die,
multiple blanks
can be cut across the die simultaneously. Figure 31 shows how several DSS-RSC
blanks
can be cut from a sheet of corrugated fibreboard using a rotary die cutter.
Reference is
also made to Figure 37, which shows how several of DSS-RSC blanks 500 of
Figure 36
can be cut from a sheet of corrugated fibreboard using a rotary die cutter.
[0058] Once a plurality of blanks such as blanks 400 or blanks 500 have been
formed
they may be placed into stacks of blanks that may be conveniently loaded onto
pallets.
Once loaded onto pallets, as indicated in step 1020 of Figure 28, the blanks
can be
shipped to a location where the DSS-RSC blanks 400 or 500 may be erected and
filled
with product(s) pursuant to steps 1030 and 1040. The shipping can occur by any
known
type of transportation such as by way of example only, truck, and/or plane,
and/or train
and/or by ship.
[0059] The location where steps 1030 and 1040 occurs may conveniently be at
the
customer premises, where for example a manufacturer of a product wishes to
load the
product it has manufactured into a case. By way of example only, a
manufacturer of soft
drinks may produce bottles of soft drinks that need to be loaded into
cardboard cases for
shipping to their customer. Instead of employing an RSC and the equipment
normally
16
CA 02687847 2009-12-08
used to erect and fill such cases, the manufacturer can instead employ a case
former
apparatus. By way of example only, the case formers illustrated in Figures 1
to 26 can be
utilized to transform the generally flat configured DSS-RSC blanks into DSS-
RSC open-
topped cases in step 1030. The dimensions of such DSS-RSC cases may be
substantially
identical to the RSC case, and may meet or exceed the desired functional
qualities of the
typical prior art RSC case.
[0060] The final steps 1040 and 1050 illustrated in Figure 28 are the
loading/filling of
each DSS-RSC case with one or more products/items and then the sealing of the
case to
fully enclose the products/items. This step 1050 may typically take place, at
the same
location, or proximate to, the location where step 1040 takes place. Examples
of known
machines that can be employed to fill and seal such cases include the DPI Drop
Packer by
Combi Packaging Systems LLC.
[0061] It should be noted that in some embodiments, the erection of the DSS-
RSC
blanks into cases and the subsequent loading and sealing of the cases may take
place on a
single apparatus.
[0062] A schematic view of a system 7000 for forming, erecting and packing a
DSS-
RSC case with one or more items is illustrated in Figure 43. System 7000 may
include a
corrugator machine (as referenced above) 7010, and a die cutting machine 7020
(also as
referenced above). Corrugator machine 7010 and die cutting machine 7020 may in
some
applications be co-located at the same plant and building or be otherwise
located near to
each other in close geographic proximity. Corrugator machine 7010 and die
cutting
machine 7020 may in other applications be remotely located from each other.
[0063] System 7000 may also include a case forming apparatus 7030 which may be
located remotely from corrugator 7010 and die cutting machine 7020. Case
forming
apparatus 7030 may be located at the premises of a manufacturer of products
that need to
be packed into a case. System 7000 may also include a case filling apparatus
7040 and a
case sealing apparatus 7050 and these may be co-located with the case forming
apparatus
7030.
17
CA 02687847 2009-12-08
[0064] With reference now to Figures 30 to 35, illustrated is an example DSS-
RSC
blank 400 in various stages of configuration progressing from the generally
flat blank 400
in Figure 30 to the erected DSS-RSC in Figure 35. By way of example only, a
typical
formed DSS-RSC case used to hold smaller cartons of various consumer products
would
have dimensions of 24 inches in length, 12 inches in width and 18 inches in
height.
Referring to blank 400, panels 410, 420, 430, 440 and 450 may thus have a
common
length of 24 inches. Panels 430, 431, 432, 420, 421, and 422 may have a common
height
of 18 inches. Panels 410, 411, and 412 may have a common width of 12 inches.
In order
to create an overlapping side seam, panels 421, 422, 431, 432, 441, 442, 451,
and 452
may extend out approximately 7 inches from panels 410, 420, and 430. Panels
440, 441,
442, 450, 451, and 452 may extend out approximately 6 inches or less from
panels 430,
431, 432, 420, 421, and 422 to create the top flaps of the case. Finally
panels 411 and
412 may extend out from panel 410 to a distance of approximately 6 inches.
Blank 400
may be made of creased corrugated fibreboard that may have been produced by
the steps
1000 and 1010 as described above using known types of machines. The direction
of
corrugation within the fibreboard may be as is shown in the broken out portion
of panel
440 in Figures 30 and 34 and may run continuously, along the length of the
blank to
panel 450. Corrugated fiberboard is a paper-based material consisting of two
or three
paper layers glued or otherwise fused together: a fluted corrugated sheet and
one or two
flat linerboards. The fluted material is bent in wave-like orientation and is
glued to a
single flat linerboard or sandwiched between two flat linerboards. Blank 400
may be
scored and cut to form a bottom panel 410, side wall panels 420 and 430, and
major top
cover panels 440 and 450. Panels 440, 430, 410, 420 and 450 are arranged in
series
along the direction of corrugation. Panels 440, 430, 410, 420 and 450 have
transverse
edges that are oriented generally orthogonally to the direction of
corrugation. Where the
edge of one panel is joined to another panel at adjacent transverse edges (eg.
the right
edge of panel 440 is joined to the left edge of panel 430) there are fold
lines about which
the panels may be folded / rotated relative to each other. It will be noted
that each panel
440, 430, 410, 420, and 450 also extends transversely (in the case of blank
400, this is
also orthogonal to the direction of corrugation).
18
CA 02687847 2009-12-08
[0065] Each of the bottom and side wall panels 410, 420 and 430 is provided
with a
side end panel extending from each longitudinal side edge of the bottom and
side wall
panels (see panels 411, 412, 421, 422, 431 and 432). Each of these end panels
is foldable
about a longitudinal fold line where it is joined to the side edge of the
bottom / side wall
panels. It will be noted that there are gaps between side end wall panel 411
and side wall
end panels 431, 421. There are also gaps between side end wall panel 412 and
side end
wall panels 432, 422. The side end panels 421, 422, 431 and 432 may be
configured to
extend out from each side wall 420 and 430 respectively to a distance that is
equal to
slightly more than 1/2 of the width of the bottom panel 410. This may create
an overlap
of dimension 0 in Figure 35 to provide vertical seams 499a, 499b, (see Figure
35) such
that the ends of the DSS-RSC can be sealed. An overlap of side panels 422 and
432 and
of side panels 421 and 431 at the ends of the DSS-RSC is not necessary but is
beneficial.
Indeed, there may be an overlap of size 0 in the range for example of 1/2 to 3
inches. It
will be appreciated from Figure 35 that the direction of corrugation in panels
432 and
422, 431 and 421 will be vertically oriented. This combination of features
(the
overlapping side seams and the vertical orientation of corrugation in the main
end
panels), both individually and particularly in combination provide a co-
operative effect to
enhance the overall vertical support strength of the DSS-RSC case and thus may
provide
an enhanced stacking load capacity when DSS-RSC cases filled with products are
stacked
on top of each other.
[0066] If there is no overlap at the seam, it is desirable that the side
panels are in
proximate abutment with each other or that any vertical gap between them at
the seam, if
any, should be quite small (eg. less than an inch in most if not all
applications).
However, providing an overlap may provide advantages including enhancing the
strength
of the DSS-RSC case.
[0067] The bottom panels 411 and 412 may also extend out from the bottom panel
410 such that when the DSS-RSC is erected, these bottom panels 411, 412 will
reinforce
their respective end walls and the seams 499a, 499b, at the bottom of the
ends. Each of
the side panel panels 421, 422, 431 and 432 have a minor top panel extending
from the
top of the respective side panel. These minor top panel panels are numbered
441, 442,
19
CA 02687847 2009-12-08
451, and 452 in Figures 30-35. Gaps are also provided as follows: between
panel 450
and minor panels 451 and 452; and between panel 440 and minor panels 441 and
442, all
as shown in Figure 30. Minor top minor panels 441, 442, 451, 452 may be used
to assist
top panels 440, 450 in closing the opening to the case. Thus top minor panels
may be
positioned underneath or on top of top panels 440, 450 and may be joined to
the top
panels such as by adhesive or by packing tape to close the opening.
[0068] In order to maximize the overall strength, and in particular the
stacking
strength of the DSS-RSC design, the blank 400 may, as discussed above, be
oriented on
the fibreboard such that the internal columns in the corrugation run
vertically up the side
wall panels 430 and 420 of the case.
[0069] With reference now to Figure 32, the progressive folding of a DSS-RSC
blank
400 is shown schematically. The blank 400 progresses from the flat
configuration
referenced as "30" (referring to Figure "30") to a folded position referenced
as "33"
(referring to Figure 33) to a further folded position "34" (referring to
Figure 34) to an
erected configuration referenced as "35" (referring to Figure 35).
[0070] Figures 32-35 illustrate the process by which the DSS-RSC case in
Figure 30
can be erected. The DSS-RSC case may be erected by formation around a mandrel
such
as by way of example a mandrel 489. Referring to Figure 32, the DSS-RSC blank
is
placed against a mandrel and commences a process by which the panels of the
DSS-RSC
blank are folded around the mandrel to form an erected case. The sequence
shown here
by which the panels are folded and affixed to one another is merely
illustrative and of
course various other iterations may be chosen to get an identical or similar
end result.
[0071] Referring to Figure 33 and reference 33 in Figure 32, panel 410 may be
rotated / folded - for example by approximately ninety (90) degrees - about a
pre-
determined fold line between panels 410 and 430. Thus panel 410 (and attached
panels
411, 412, 420, 421, 422, 450, 451 and 452) may be rotated /folded relative to
panels 430,
431, 432, 440, 441 and 442 from a generally flat orientation to a generally
angled
orientation, thus forming a generally L-shaped configuration. Next, either
subsequent to
or simultaneous with the folding of panel 410 relative to panel 430, panel 420
can be
CA 02687847 2009-12-08
rotated / folded - for example by approximately ninety (90) degrees - about a
pre-
determined fold line between panels 420 and 410. Thus panel 420 (and attached
panels
421, 422, 450, 451 and 452) is rotated from a generally flat orientation to a
generally
angled orientation relative to panel 410 such that the panels 410, 420 and 430
will form a
generally U-shaped configuration.
[0072] Figure 34 and reference 34 in Figure 32 illustrate the next step of the
process.
Bottom panels 411 and 412 may be rotated - for example by approximately ninety
(90)
degrees - about a pre-determined fold line between panels 411 and 410, and 412
and 410,
respectively. Thus bottom panels 411 and 412 may be rotated relative to panel
410 from
a generally flat orientation to a generally angled orientation, thus each
forming a
generally L-shaped configuration with panel 410. The panels 410, 411 and 412
will thus
form a generally U-shaped configuration. All four of panels 411, 412, 420 and
430 are to
be rotated in the same general direction vis-a-vis panel 410 such that the
panels 411, 412,
420 and 430 thus begin to form opposing side walls of a four-sided container.
The
folding of each of panels 411 and 412 may be either simultaneous to one
another or with
one panel being folded after the other.
[0073] Prior to the further progressive folding of panels of the DSS-RSC blank
400 to
the configuration shown in Figure 35, a suitable type of adhesive (such as hot
melt
adhesive) may be applied to the outward facing surface of panels 411, 412.
Glue may
also or alternatively be applied to the inward facing surface of panel 422 and
the outward
facing surface of panel 432 in the region of the seam overlap 499a shown in
Figure 35.
Likewise at the opposite end of the DSS-RSC, glue may also or alternatively be
applied
to the inward facing surface of panel 421 and the outward facing surface of
panel 431 in
the region of the seam overlap 499b shown in Figure 35.
[0074] With reference to Figure 35 and reference 35 in Figure 32, side end
panels
431 and 432 may be rotated - for example by about approximately ninety (90)
degrees -
about a pre-determined fold line between panels 431 and 430, and 432 and 430
respectively. Thus side end panels 431 and 432 can be rotated relative to
panel 430 from
a generally flat orientation to a generally angled orientation, thus each
forming a
21
CA 02687847 2009-12-08
generally L-shaped configuration with panel 430. The folding of each of panels
431 and
432 may be either simultaneous to one another or with one panel being folded
subsequently to the other.
[0075] Next, either simultaneously with, prior to, or subsequent to the
folding of side
end panels 431 and 432, side end panels 421 and 422 may be rotated / folded -
preferably
approximately ninety (90) degrees - about a pre-determined fold line between
panels 421
and 420, and 422 and 420 respectively. Thus side panels 421 and 422 are
rotated / folded
relative to panel 420 from a generally flat orientation to a generally angled
orientation,
thus each forming a generally L-shaped configuration with panel 420. The
folding of
each of panels 421 and 422 may be either simultaneous to one another or with
one panel
being folded subsequently to the other.
[0076] As side panels 431 and 432 are folded, they may be compressed in such a
manner that the inside surface portions ("inside" referring to the direction
oriented
towards the inside of the case) of side panels 431 and 432 engage outer
surfaces portions
of bottom panel 411 and 412 respectively. Thus, with the assistance of
adhesive
positioned between the respective surfaces, side panels 431 and 432 may be
attached to
the outside surface portions of bottom panels 411 and 412 respectively.
Likewise, with
the assistance of appropriately positioned adhesive, as side panels 421 and
422 are
folded, they may be compressed in such a manner that the inside portions of
side panels
421 and 422 engage the outer surfaces of bottom panels 411 and 412
respectively. Thus,
with the assistance of adhesive positioned between the respective surfaces,
side panels
421 and 422 may also be attached to the outside of bottom panels 411 and 412
respectively. Also with the assistance of appropriately positioned adhesive,
side panels
421 and 422 may be also compressed in such a manner that the inside surfaces
of side
panels 421 and 422 may also engage portions of the outer surfaces of side
panels 431 and
432 respectively. With the assistance of adhesive positioned between the
respective
surfaces, side panels 421 and 422 may thus be attached to portions of the
outside of side
panels 431 and 432 respectively. Alternatively, side panels 421, 422, 431 and
432 might
be folded and compressed in such a sequence that side panels 421 and 422 might
be
attached to the inside of side panels 431 and 432 respectively. Other folding
sequences of
22
CA 02687847 2009-12-08
the foregoing panels are also possible. For example, panels 431, 432, 421, 422
may all
be folded upwards and may also be glued prior to folding upwards opposite
panels 411
and 412 so that panels 411 and 412 are on the outside of the case. However, in
this latter
configuration, panels 411, 412 may be more readily susceptible to being
dislodged during
use. Any suitable type of adhesive may be employed in bonding together panels
in the
construction of the DSS-RSC case, such as Cool-Lok adhesive made by Nacan
Products
Limited. This "hot-melt"-type glue is typically applied in a "bead" along a
particular first
panel. This bead may be applied at a temperature appreciably higher than the
ambient
room temperature. As a second panel is folded over the first panel with the
glue and
pressure applied to the joint, the glue is spread out over the surfaces of the
two panels.
As the glue is spread out, it cools down, forming an instant adhesive bond
between the
panels.
[0077] Figure 35 and reference 35 in Figure 32 show the DSS-RSC case 400 with
the
top open after it has been erected, ready to be loaded with product. Minor top
panels 441
and 451 overlap and form one end cover panel of the case. Similarly, minor top
panels
442 and 452 overlap to form the other end cover panel. After product is loaded
into the
DSS-RSC from the top, the two end cover panels may be folded over at each end.
Finally, the two major cover panels 440 and 450 may be folded over and secured
to the
end cover panels.
[0078] An additional feature that may be incorporated into the DSS-RSC box
design
is a "punch out" handle to allow persons to more easily carry the case from
one location
to another. Referring to Figure 30 and Figure 35, blank 400 may include lines
498a,
498b that may either be pre-cut lines or perforation lines that provide a
modified type of
DSS-RSC case such that when the case is formed and sealed with product (eg.
Beer
bottles), persons seeking to carry the case can push through and in the
portion of the case
partially encircled by lines 498a and 498b to create an opening in the case at
either end in
which a hand can be inserted to create a handle. Referring more specifically
to Figure 30
lines 498a and 498b can be cut or perforated into the corrugated fiberboard at
the same
time the case is being cut from a larger sheet of fiberboard as described
herein. The DSS-
RSC case, modified to include the handles, may be formed in the same way as
the case
23
CA 02687847 2009-12-08
without this additional feature. The positioning of the handles over the seam
created by
the overlap of panels 421 and 431, and panels 422 and 432 may also provide
additional
strength to the handle that would otherwise not exist had the handle been
placed on a
portion of the case that did not have overlapping panels.
[0079] An alternative to the DSS-RSC blank 400 of Figures 30-35 is illustrated
in
Figures 36-41. In this alternative embodiment, blank bottom panels 511 and 512
of blank
500 that extend from the bottom of the case are cut into a triangular-shaped
"wedge"
instead of remaining in a rectangular shape as in Figure 30. Side flaps 531
and 532 have
a rectangular portion cut out (a "notch") extending from the bottom of the
flap up a
distance at least equal to the length that the bottom flaps 511 and 512 extend
from the
bottom panel 510.
[0080] Referring to Figure 41, the process is the same in forming the
alternative
embodiment of Figure 36. With reference now to Figure 38, the progressive
folding of a
DSS-RSC blank 500 is shown schematically. The blank 500 progresses from the
flat
configuration referenced as "36" (referring to Figure "36") to a folded
position referenced
as "39" (referring to Figure 39) to a further folded position "40" (referring
to Figure 40)
to a erected configuration referenced as "41" (referring to Figure 41).
[0081] It will however be noted from Figure 41 in particular, that panels 511,
521 and
531 are to be folded and compressed in such a sequence that the outer facing
surface of
bottom flap 51.1 is folded and glued to the inside of both side flaps 521 and
531.
Similarly, panels 512, 522 and 532 are may be folded and compressed in such a
sequence
that bottom flap 512 is folded and glued to the inside of both side flaps 522
and 532.
Furthermore, side flaps 521 and 531 may be folded and compressed in such a
sequence
that side flap 531 is attached to the inside of side flap 521. Similarly, side
flaps 522, and
532 are to be folded and compressed in such a sequence that side flap 532 is
attached to
the inside of side flap 522. The "notch" cut out of panels 531 and 532 and the
"wedge"
shape of panels 511 and 512 act in such a way that when the case is erected,
the tips of
the bottom flaps 511 and 512 fit against the outer end flaps 521 and 522
rather than on
the inner end flaps 531 and 532. It may be appreciated that the effect of
adhesive on the
24
CA 02687847 2009-12-08
inner surface of flap 521 and /or glue on panel 511, will be to pull and hold
panel 511
outwards towards and against outer panel 521thus drawing the tip of panel
511into flush
relationship with the inner surface of panel 531. Likewise, the effect of
adhesive on the
inner surface of flap 522 and for glue on panel 512, will be to pull and hold
panel 512
outwards towards and against outer panel 521 thus drawing the tip of panel 512
into
flush relationship with inner surface of panel 522. As a result, the tips of
panels 511 and
512 have inside surfaces that are generally flush with the inside surfaces of
flaps 531 and
532. This makes it easier for product to be inserted inside the case flush
with the end
walls of the case (i.e. it acts to inhibit product being loaded into the case
500 from being
caught on the edge of the bottom flaps 511 and 512). The inside of the case
500 showing
the notch and wedge feature can be seen in Figure 42
[0082] With brief reference to Figures 1-2, a case forming system 100 is
disclosed
that may be used in the processes illustrated in Figures 32 or 38. System 100
may
include a magazine 110 adapted to hold a plurality of blanks 400 -that may
equally be
blanks 500- in a substantially flat orientation. System 100 may also include a
mandrel
apparatus 120, a panel rotating apparatus 124, and a panel folding and guide
apparatus
130. The operation of case forming system 100 may be controlled by a
programmable
logic controller ("PLC") 132 (only shown schematically in Figure 1). PLC 132
may for
example be a model from the Micrologix family made by Allen-Bradley.
[0083] Referring again to Figure 30, illustrating a top view of the dual side
seam-
regular slotted container ("DSS-RSC") blank 400 , the blank is scored and cut
to form
the bottom 410, side walls 420 and 430, and major cover panels 440 and 450.
Each of
the bottom and side walls is provided with a panel extending from each side of
the
bottom and side walls. The side panels 421, 422, 431 and 432 extend out from
each side
wall to a distance equal to slightly more than 1/2 of the width of the bottom
410. The
bottom panels 411 and 412 extend out from the bottom such that when the case
is
erected, these bottom panels may reinforce the end walls at the bottom. Each
of the side
panels 421, 422, 431 and 432 have a minor top panel extending from the top of
the side
panel. These minor top panels are numbered 441, 442, 451, and 452 in Figure
30.
CA 02687847 2009-12-08
However, in other embodiments, containers having other side panel
configurations can be
formed.
[0084] The panels are connected / joined to adjacent panels/panels by
predetermined
fold / crease lines. The effect of the fold line is such that when one panel
such as for
example panel 410 is folded relative to an adjacent panel such as 420 or 430,
the panels
may tend to rotate relative to each other along the fold lines separating the
two panels.
[0085] In the alternative DSS-RSC blank 500 of Figure 36, bottom panels 511
and
512 extending from the bottom of the case are cut into a triangular-shaped
"wedge"
instead of remaining in a rectangular shape as in Figure 30. Side panels 531
and 532
have a portion cut out (a "notch") extending from the bottom of the panel up a
distance at
least equal to the length that the bottom panels 511 and 512 extend from the
bottom panel
510.
[0086] As will be described hereinafter, the DSS-RSC blank 400 or 500 may be
folded to form the desired case configuration for a top loading case that can
be delivered
to a case loading conveyor. The various walls and panels provide material that
can, in
conjunction with a connection mechanism (such as for example with application
of an
adhesive or a mechanical connection) join or otherwise interconnect
walls/panels to
adjacent walls/panels, to hold the case in its desired configuration.
[0087] In a preferred embodiment, the DSS-RSC blank may be made of a suitable
corrugated material such as a corrugated fibreboard. In order to maximize the
stacking
strength of the DSS-RSC design, the blank may be oriented on the fiberboard
such that
the internal columns in the corrugation run vertically up the walls of the
case. This
orientation of the corrugation can be seen in Figure 30.
[0088] Referring back to Figure 28, while there may be other apparatus or
systems
that may be able to erect a DSS-RSC blank, such as a blank 400 or blank 500,
into an
erected DSS-RSC case pursuant to step 1030, the systems illustrated in Figures
1-26 are
well suited for such a purpose.
26
CA 02687847 2009-12-08
[0089] Returning to system 100 of Figures 1-2, magazine 110 may be configured
to
hold a plurality of case blanks 400 (or blanks 500) in a vertically stacked,
flat
configuration, and be operable to move the stack of case blanks 400
sequentially upwards
under the control of PLC 132, so that single case blanks 400 may be retrieved
from the
stack for processing by a panel retrieval and rotating apparatus generally
designated as
124 that forms part of mandrel apparatus 120. Various specific constructions
of a
suitable magazine that might be employed in system 100 would be evident to a
person
skilled in the art. The magazine may comprise a large number of case blanks
400 held in
a vertical stack by aluminium rails (the rails are not shown in the drawings).
In this
configuration where blanks are retrieved from the top of a stack, the stack of
blanks in the
magazine is moved upwards from the bottom by a PLC controlled motor (not shown
in
drawings). The purpose of moving the stack of blanks upwards as cases are
formed is so
that the top case is always close against the bottom of the mandrel. The front
panels of
the top blank are then rotated around the mandrel by the panel rotation
apparatus 124. As
cases are taken and formed, the PLC may move the entire stack up sequentially
so that
the top case is always maintained close to the mandrel 121.
[0090] The mandrel apparatus 120 may have several additional components
including
a mandrel 121, a mandrel support frame 123 and a mandrel movement and support
apparatus generally designated 125. With particular reference to Figures 1, 10
and 11,
mandrel 121 comprises a pair of opposed, spaced, vertically and longitudinally
oriented
side plates 140a, 140b interconnected to and joined by a horizontally oriented
top plate
140c. A mandrel 121 may be generally configured in a variety of different
sizes and
shapes, each selected for the particular case blank 400 that is being formed
into a case.
The dimensions of the outer surfaces of mandrel 121 may be selected so that
the specific
case blank that it is desired to fold has during the forming process, fold /
crease lines that
are located substantially at or along the opposite side edges and the upper
and lower front
edges of mandrel 121. Such a selection may improve the performance of system
100 in
creating a formed case that is ready for loading with items. System 100 may be
configured to permit for the easy interchange of mandrels 121 so that the
system can be
readily adapted to forming differently sized / shaped cases from differently
configured
blanks.
27
CA 02687847 2009-12-08
[0091] With particular reference to Figures 1, 8 and 9, mandrel 121 may be
supported
by mandrel support frame 123, which may include a pair of spaced opposed
elongated
and longitudinally extending side plate members 150a and 150b. Side plates
150a, 150b
may be interconnected by and joined to a lower horizontally oriented plate
150c. Side
plates 150a, 150b and lower plate 150c may be integrally formed together. Side
plates
150a, 150b may be interconnected to respective side plates 140a, 140b of
mandrel 121,
with mandrel mounting brackets 141a and 141b, thus providing support for
mandrel 121.
Mandrel side plates 140a and 140b may for example contain a groove or channel
on their
inner surface for receiving mandrel support brackets or rails 141 a, 141b
respectively (see
for example Fig. 18) so that the mandrel 121 can be supported by the mandrel
support
frame 123 and may be generally restrained from vertical and transverse motion.
To assist
in securing the vertical and transverse movement, as well as to select the
appropriate
longitudinal position and restrain the mandrel 121 from longitudinal movement,
mandrel
top plate 140c may be mounted to and above a mandrel support base 153.
[0092] Mandrel support frame 123 may be interconnected and supported by a
vertical
frame support member 152 (see for example Figures 1 and 9). For example, with
reference to Figure 8, lower support plate 150c, may have screw holes 151
which may
enable screws (not shown) to pass upwards through plate 150c into threaded
holes (not
shown) in a lower horizontal surface of vertical support member 152. Vertical
support
member 152 may be conveniently formed from a light but relatively strong
material that
can be readily formed into a tube, such as for example aluminium. Vertical
support
member 152 may be formed as a hollow channel member that has a longitudinally
extending cavity that allows for electrical and communication cables and
pressurized/vacuum air hoses to pass through from an upper end to a lower end.
In this
way, electrical power/communication cable and air hoses can deliver power,
electrical
signals and air to the mandrel support frame 123 and the panel rotating
apparatus 124.
[0093] For example, with reference to Figure 9, mandrel support base 153 may
also
be interconnected and supported by vertical frame support member 152, with
support
base 153 being mounted to a lower, forward facing surface area of support
member 152
by for example bolts/screws.
28
CA 02687847 2009-12-08
[0094] Vertical member 152 also has an upper end portion that is
interconnected to a
horizontal connector member 154 for interconnecting the vertical member 152
(and the
mandrel apparatus attached thereto) to the mandrel moving apparatus 125.
Connector
member 154 may be configured as a plate that interconnects to a corresponding
slider
plate 160 on mandrel moving apparatus 125. Connector member 154 may be bolted
to
plate 160 and may be interconnected to vertical member 152 with bracket
support
member(see for example Figures 1, 4 and 6).
[0095] With particular reference to Fig. 9, mandrel support base 153 is
generally L-
shaped and has an upper horizontal support member plate 157 and a vertical
attachment
leg portion 165. A quick release key bolt member 159 is provided for securing
leg
portion 165 to a generally U-shaped bracket member 161 that is secured to
attachment
plate 155 located on a forward facing surface of vertical support member 152.
Key bolt
159 may pass through apertures in bracket member 161 and leg portion 165 of
support
base 153. Mandrel top plate 140c may be connected to support plate 157 using
bolts or
screws (not shown) that may pass through apertures 156 in mandrel top plate
140c (see
Figure 2), into longitudinally oriented slots 158 that pass through support
plate 157.
Thus, the longitudinal position of mandrel 121 relative to support frame 123
and rotating
apparatus 124 can be selected by the appropriate setting of the screws in
slots 158. Quick
release key bolt device 159 may be used to provide for the rapid and tool free
attachment
and release of mandrel 121 to and from vertical frame support member 152.
[0096] Attachment of the mandrel 121 to vertical support 152 via mandrel
support
base 153 generally restrains mandrel 121 from movement in the longitudinal
direction
relative to support frame 123 and rotating apparatus 124.
[0097] Mandrel support and moving apparatus 125 may be used to support and
move
in reciprocating forward and rearward longitudinal movement, mandrel 121,
rotating
apparatus 124, vertical support member 152 and mandrel support frame 123. The
mandrel moving apparatus 125 may be mounted to a support frame (not shown)
with a
plurality of mounting blocks 166 that are connected to a longitudinally
extending guide
rail support member 172 of moving apparatus 125. Also comprising part of
moving
29
CA 02687847 2009-12-08
apparatus 125, guide slide rails 164a, 164b may be mounted to opposite side
edge faces
172a, 172b respectively of support member 172. Slider plate 160 may have
mounted
thereto, opposed sets of slide blocks 162a, 163a, and 162b, 163b (see Figures
1 and 2).
Each of the slide blocks 162a, 163a, and 162b, 163b may have inwardly facing
arcuate
surfaces which may engage portions of their respective guide rails 164a, 164b.
Slide
blocks 162a and 163a may be supported by and slide along guide rail 164a.
Slide blocks
162b and 163b may be supported and slide along guide rail 164b. The slide
blocks and
guide rails may be made of complimentary materials that allow for smooth and
easy
sliding of the blocks along the guide rails. For example, slide blocks may be
made of
aluminium and guide rails 164a, 164b may be made of stainless steel.
[0098] Moving apparatus 125 also includes a mandrel drive device 174 which may
include a continuous horizontally oriented drive belt 178 that extends between
and rotates
around a pulley 176 and a drive wheel 180. Drive wheel 180 may be driven in
both
rotational directions and at varying speeds by the drive shaft of a servo
drive motor 170.
The operation of drive motor 170 may be controlled by PLC 132 in combination
with a
position sensing apparatus (not shown) so that PLC 132 can determine when and
how to
operate drive motor 170 to appropriately position the drive belt 178 and thus
moving
apparatus 125. Drive motor 170 may be mounted at an end portion of support
member
172 with a vertically oriented connector plate 171.
[0099] To interconnect the drive belt 178 to slider plate 160 and/or sliding
blocks
162a-b, 163 a-b known attachment apparatus or mechanisms can be provided. For
example, a clamp can be mounted to plate 160 and the belt 178 can be secured
between
clamp arms of the clamp. Thus, when the drive belt moves longitudinally, in
parallel
longitudinal, vertical and horizontal alignment with the guide rails 164a,
164b, the slide
plate 160 and sliding blocks 162a-b, 163a-b can also move in the same
direction. The
result is that the mandrel support frame 152 and thus mandrel 121 can also be
moved
longitudinally, in parallel longitudinal, vertical and horizontal alignment
with rails 164a,
164b.
CA 02687847 2009-12-08
[00100] Also associated with moving apparatus 125 is a caterpillar device 199.
Caterpillar 199 has a hollow cavity extending along its length. Within the
cavity of
caterpillar 199 hoses carrying pressurized air / vacuum and electrical /
communication
wires can be housed. Caterpillar 199 allows such hoses and wires to move
longitudinally
as the mandrel support member 152 and thus mandrel 121 and mandrel support
frame
123 are moved longitudinally by moving apparatus 125. The hoses and wires may
extend
from external sources to enter at an inlet 199a of caterpillar 199 and
emerging at an outlet
199b. Once leaving outlet 199b, the hoses and wires may pass into the internal
cavity of
vertical member 152 (see Figure 2). An example of a suitable caterpillar
device that
could be employed is the E-Chain Cable Carrier System made by Ignus Inc.
[00101] The next component of system 100 to be described in detail is the
panel
rotating apparatus 124. Panel rotating apparatus 124 may engage one blank 400
and may
be employed to rotate one or more panels of blank 400 relative to one or more
other
panels. For example, as illustrated in Figures 9-11, panels 410, 411, 412,
430, 431, 432,
440, 441 and 442 of a blank 400 are rotated approximately 90 degrees relative
to panels
420, 421, 422, 450, 451 and 452 from a generally flat orientation to a
generally vertical
orientation. Panel rotating apparatus 124 may include a panel rotation unit
129. The
movement of unit 129 can be controlled by PLC 132 in such a manner that it can
rotate so
as to move a panel 410 (and attached panels 411, 412, 430, 431, 432, 440, 441
and 442 )
of a case blank 400 through a rotation of approximately 90 degrees, in an
aligned manner,
at an appropriate time, as is illustrated for example in Figures 9, 10 and 11.
[00102] Unit 129 will be described in detail, and with particular reference to
Figures 8 and 9 which for simplicity depict system 100 without mandrel 121.
The unit
129 may include a longitudinally oriented piston device 202 which has piston
blocks
21 la, 21 lb that rest on bottom plate 150c. Piston block 21 lb has a vertical
attachment
leg portion 212. A mounting block 205 with opposed generally vertical
longitudinally
oriented plates 214a, 214b and generally horizontal transversely oriented
plate 215 is
positioned at and connected to a rear end of reciprocating piston 202 with a
screw (not
shown) that passes through an aperture in leg portion 212 (not shown) and
apertures
213a, 213b in vertical plates 214a, 214b respectively. Mounting block 205 is
also
31
CA 02687847 2009-12-08
mounted to plate 150c with screws (not shown) that pass through apertures 210
in
horizontal plate 215 into the plate 150c.
[00103] Piston 202 may be a conventional pneumatic reciprocating cylinder 204
and is operable to move in a reciprocal movement between a fully extended
position (not
shown) and a retracted position (not shown). This reciprocating motion can be
achieved
in known ways such as for example, by using a double acting cylinder, which
can for
example, channel compressed air to two different chambers which in turn
provides
interchanging forward and backward acting forces on the piston 202. Piston 202
may for
example be a DSNU made by Festo. Compressed air may be delivered to piston 202
by
hoses (not shown) passing from vertical support member 152 out to connect with
apertures 203a, 203b.
[00104] To channel the compressed air appropriately, valves (not shown) can be
driven between open and closed positions by solenoids responsive to signals
from PLC
132 (FIG. 1). The valves could be located proximate the piston 202 or be
disposed
elsewhere. Electrical lines carrying signals from PLC 132 could also pass
through
vertical member 152 to operate the valves.
[00105] A piston rod 206 of piston 202 is provided with an extended arm
portion
208 that provides for a hinge connection 207 for pivoting the panel rotating
apparatus 124
between a generally horizontal position and a generally vertical position.
[00106] Panel rotation apparatus 124 also comprises panel rotating plate 219
with
outer and inner face 219a and 219b respectively. Panel rotating plate 219 may
be
attached by way of piano hinge 209 to forward lower extension of lower support
plate
150c of mandrel support frame 123. As a result of the movement of piston 202
the
cylinder rod 206, may extend or retract allowing the arm 208 to pivot relative
to rotating
apparatus 124. The movement of piston rod 206 thus causes the panel rotating
plate 219
to rotate through a certain angular distance relative to mandrel 121 around
piano hinge
209.
32
CA 02687847 2009-12-08
[00107] Air suction cups 220a and 220b may be fixedly mounted to outer or
forward facing face 219a of panel rotating apparatus plate 219 with mounting
block units
218a, 218b respectively. Air suction cups 220a and 220b may be interconnected
through
block units 218a, 218b to a source of vacuum by providing for an air channel
linked to a
manifold unit 225. The manifold unit 225 may in turn may be interconnected by
air
vacuum supply hose (not shown) to a pressurized air distribution unit
generally
designated 227. Unit 227 may include a plurality of valves that may be
operated by PLC
132 and may also include a vacuum generator apparatus 221. If a vacuum
generator is
utilized, pressurized air may be delivered from an external source through
vertical
support member 152 to unit 227. The vacuum generator may then convert the
pressurized air to a vacuum that can then be delivered to suction cups 220a,
220b.
[00108] The air suction force that may be developed at the outer surfaces of
suction cups 220a and 220b of unit 124 may be sufficient so that when
activated they can
engage, hold and rotate panel 410 of a blank 400 from a generally horizontal
position to
the position shown in Fig. 11. The vacuum generated at suctions cups 220a and
220b can
also be de-activated by PLC 132.
[00109] The suction cups 220a and 220b of unit 124 may engage the surface of
panel 410. In other embodiments suction cups of rotation units may
alternatively, or in
combination also, engage panel 430. The particular arrangement of suction cups
on
rotating plate 219 can be designed based upon the configuration of the case
blank and the
particular panels that need to be rotated. It may also be appreciated that in
the panel
rotation apparatus 124, suction cups are used to apply a force to hold and/or
move a panel
of a case blank. However alternative engagement mechanisms to suction cups
could be
employed. It should also be noted that a second set of suction cup / suction
plates
mounted for movement, including pivoting movement, could be deployed to
perform
additional panel folding or movement and/or holding of the panel and blank.
[00110] More generally, other types of apparatus may be employed to transfer a
blank 400 to the mandrel apparatus 120, such that one portion of the blank may
be
33
CA 02687847 2009-12-08
rotated, preferably about ninety degrees, relative to another portion of the
panel, to set-up
the folding process using a folding apparatus.
[00111] With particular reference to Figures 12-18, system 100 may also
include a
panel folding and guide apparatus 130, that may be a rail and plough apparatus
generally
designated 300. Rail and plough apparatus 300 is configured to cause the
appropriate
panel and sealing panels of a blank 400 to be appropriately folded and sealed
to produce a
case configuration that is suitable for delivery to a case conveyor (not
shown). Apparatus
300 may, as shown in the figures, include a plurality of rails and plough
devices. Each of
the rails and plough devices of apparatus 300 may be supported by rods or bars
interconnected to a support frame (not shown for simplicity in the figures).
[00112] Apparatus 300 may include a pair of spaced, longitudinally extending
overhead rails 302a, 302b configured and positioned so that as blank 400 is
moved
longitudinally forward by mandrel apparatus 120, rails 302a, 302b may fold
panel 430
and attached panels 431, 432, 440, 441 and 442, from a generally vertical
orientation to a
generally horizontal orientation.
[00113] A pair of opposed inner side rails 304a, 304b are configured and
positioned to engage bottom panels 411 and 412 respectively and may fold and
maintain
the panels 411 and 412 in a rearward longitudinal direction, until side end
panels 421,
422, 431 and 432 and attached panels 451, 452, 441 and 442 have been brought
into an
upward vertical and overlapping relationship.
[00114] Apparatus 300 may also include a pair of opposed wedge plough devices
31 la, 31 lb that may be configured and positioned so that as blank 400 is
moved
longitudinally forward by mandrel apparatus 120, plough devices 311 a, 311b
can
commence the generally inward folding of side end panels 431 and 432 and
attached
panels 441 and 442 respectively from a generally horizontal orientation
towards a
generally vertical orientation. Likewise, apparatus 300 may also include a
pair of
opposed wedge plough devices 310a, 310b that may be configured and positioned
so that
as blank 400 is moved longitudinally forward by mandrel apparatus 120, plough
devices
31 Oa, 31Ob can commence the generally inward folding of side end panels 421
and 422
34
CA 02687847 2009-12-08
and attached panels 451 and 452 respectively from a generally horizontal
orientation
towards a generally vertical orientation.
[00115] Also part of apparatus 300 are a pair of opposed, downwardly and
inwardly oriented guide rails 306a, 306b, that are configured and positioned
to take over
from plough devices 31 la, 31 lb, to engage the upper surfaces of panels 431
and 432 and
to complete the inward folding of side panels 431 and 432 respectively to a
vertical
position. Likewise, also part of apparatus 300 are a pair of opposed, upwardly
and
inwardly oriented guide rails 308a, 308b, that are configured and positioned
to take over
from plough devices 31Oa, 31Ob, to engage the lower surfaces of panels 421 and
422 and
to complete the inward folding of side panels 421 and 422 respectively to a
vertical
position.
[00116] A pair of lower support rails 312a and 312b are positioned to assist
in
supporting blank 400 once it has been removed from the support of the stack of
blanks
400 in the magazine 110. It should also be noted that during the forward
longitudinal
movement of blank 400 as it is pushed by mandrel apparatus 120 through the
positions
illustrated in Figures. 15-18, opposed adhesive compression rails 314a, 314b
which are
configured and positioned to apply pressure to the end panels of the formed
case, to
ensure appropriate sealing of the panels and panels with the adhesive.
[00117] Adhesive (i.e. glue) applicators such as applicators 600 can be
appropriately positioned and their operation may be controlled by PLC 132.
Applicators
600 can apply a suitable adhesive such as a hot melt adhesive to various
panels so that
when the panels are folded as described herein, the panels can be held in the
desired case
configuration. An example of a suitable applicator that can be employed is the
model
ProBlue 4 applicator made by Nordson Inc. An example of a suitable adhesive
that could
be employed with on a case blank 400 made of cardboard is Cool-Lok adhesive
made by
Nacan Products Limited.
[00118] As shown in Figures 14 and 15, one adhesive applicator 600 may be
positioned and configured so it can apply adhesive as described above
including to an
outer surface of panel 432 and inner surface of panel 422 so that the desired
overlap seam
CA 02687847 2009-12-08
499a depicted in Figure 35 can be created. Applicator 600 may also be
configured to
apply adhesive to the outer surface of panel 412 at a suitable location.
[00119] On the opposed side, a second applicator 600 may be positioned and
configured so it can apply adhesive as described above including to an outer
surface of
panel 431 and inner surface of panel 421 so that the desired overlap seam 499b
depicted
in Figure 35 can be created. Applicator 600 may also be configured to apply
adhesive to
the outer surface of panel 411 at a suitable location.
[00120] Also with particular reference to Figures 14 and 15, associated with
rail
apparatus 300 are opposed pairs of upper latch devices 316a, 316b and lower
latch
devices 318a, 318b. The latch devices 316a, 316b may be gravity driven or
spring loaded
finger latches which permit one way movement of configured cases. Top plate
140c of
mandrel 121 may be inscribed with grooves 319a and 319b, and similarly the
lower
facing surface of lower support plate 150c, may also be inscribed with
corresponding
grooves (not shown). As the case blank is pushed forward, the latches are
pushed by
panels 20 and 30 to positions allowing the case blanks to pass the upper latch
devices
316a, 316b and lower latch devices 318a, 318b. However, once the rear edges of
major
cover panels 40 and 50 have passed the upper and lower latches respectively,
the latches
may fall into the respective grooves. This may then prevent rearward movement
of the
configured blank 400a and allow for retraction of mandrel 121 without physical
impairment by upper latch devices 316a and 316b or lower latch devices 318a,
318b. It
may also be appreciated that other known types of mechanisms could be deployed
that
would restrain the blank from rearward movement, when the mandrel apparatus is
starts
to move backwards and disengages from the blank to return to its start
position where the
next blank can be retrieved from magazine 400. For example, additional suction
cups
could be used that are controlled by valves and PLC 132 and that are
positioned to
engage and hold the blank (which has become a formed case) in position during
disengagement of the mandrel 121 from the formed case.
[00121] Various components of system 100 such as mandrel 121, mandrel moving
apparatus 125, panel rotating apparatus 124 and mandrel support frame 123 may
be made
36
CA 02687847 2009-12-08
of suitable materials such as for example mandrel 121 may be made from
aluminium.
Also a least some of the various components of system 100 such as mandrel 121
and
support frame 123 may be integrally formed or interconnected to each other by
known
techniques. For example if the components are made of a suitable metal or
plastic,
welding techniques can be employed. Also, the use of screws and/or bolts may
be
employed.
[00122] The operation of system 100 will now be described in detail. First,
magazine 110 may be raised so that the upper generally horizontally oriented
surface of
the upper-most blank 400 (which may be blank 400 from Figure 30 or may be
blank 500
from Figure 36) is just in contact with, or is a very short distance spaced
from (e.g. within
1/4 inch) the bottom surfaces of mandrel support frame 123 and mandrel 121.
Next,
magazine 110 and panel rotating apparatus 124 may co-operate so that the
single blank
400 from the top of the stack of case blanks may be retrieved from the
magazine 110 and
be transferred to the mandrel apparatus 120. Thus, in this way the panel
rotating
apparatus 124 may also serve as a transfer mechanism for transferring case
blanks in
series from the magazine 110 to the mandrel 121. In other embodiments, a
separate
transfer mechanism may be provided to retrieve blanks serially from the
magazine and
transfer them to the mandrel so that a rotating apparatus may rotate a portion
of the blank
as hereinafter described.
[00123] As shown in Figures. 9, 10 and 11, under the control of PLC 132, panel
rotation unit 124 may extend reciprocating piston rod 206 so that the rotating
plate 219
and the suction cups 220a, 220b thereon are rotated to be in an orientation
that is
downward facing. Upon coming into close proximity or contact with panel 410, a
vacuum may be applied to suction cups 220a, 220b, whereby they engage the
upward
facing surface of panel 410 of the top blank 400 in the stack. Panels 420 and
450 of the
blank 400 are at the same time are maintained generally in position up against
or
proximate the lower surface of mandrel support frame 123. Suction cups or
another
additional holding mechanism (not shown) could also be employed to hold the
panels 420
and 450 horizontally against the bottom surfaces of the mandrel. Panels 420
and 450
may also continue to be supported underneath by physical contact with the
upper surface
37
CA 02687847 2009-12-08
of another underlying blank 400 in the stack.
[00124] With particular reference now to Figures 9, 10 and 11, panel rotating
apparatus 124 may be operated by PLC 132 to rotate rotating plate 219 about
hinge 209
so that panel 410 may be rotated - preferably approximately ninety (90)
degrees - about a
pre-determined fold line between panels 410 and 420. Thus panel 410 (and
attached
panels 411, 412, 430, 431, 432, 440, 441 and 442) is rotated relative to
panels 420, 421,
422, 450, 451 and 452 from a generally flat and horizontal orientation to a
generally
vertical and angled orientation, thus forming a generally L-shaped
configuration. It is
this step that makes the rest of the case forming process using system 100
possible.
[00125] Vacuum may also be applied to suction cups 220a, 220b through
operation
of PLC 132 during the rotation of the panel 410. The air suction force that
may be
developed at the outer surfaces of suction cups 220a, 220b of panel rotation
apparatus
124 may be sufficient so that panel 410 of a blank 400 can be rotated from the
position
shown in Fig. 9, through the intermediate position shown in Fig. 10, to the
position
shown in Fig. 11.
[00126] Once panel 410 reaches the position shown in Fig. 11, the suction cups
220a, 220b associated with panel rotating apparatus plate 124 hold panel 410
against the
forward facing surfaces of mandrel side plates 140a, 140b and the outer
surface of 219a
of panel rotating plate 219. The panel 410 with attached panels 411, 412, 430,
431, 432,
440, 441 and 442 generally remain in a vertical orientation. Folding of panel
410 relative
to panel 420 takes place about the fold line between panel 410 and panel 420.
While
there may be a predetermined fold line between the other panels, until one is
bent relative
to the other, they will tend to remain in the same general plane.
[00127] The rotation of panel 410 of the top blank 400 may also tend to pull
that
blank upwards and perhaps a very small distance forward, the effect of which
may be to
free the top blank from the blank beneath it that is still on the stack. The
result is that the
top blank 400 is now capable of being moved forward by the mandrel apparatus
120
towards the rail and plough apparatus 300.
38
CA 02687847 2009-12-08
[00128] It will be appreciated that in some embodiments, the system could be
configured so that magazine 110 may discharge blanks 400 to a mandrel
apparatus like
apparatus 120 from the top rather than the bottom. However, discharging blanks
from the
top may require inverting some or all of the aforementioned components.
[00129] Next, mandrel support and moving apparatus 125 may be used to move
mandrel apparatus 120 and mandrel support frame 123 longitudinally forward
towards
rail and plough apparatus 300, thus also moving blank 400 that is held to
mandrel 121.
To create this forward longitudinal movement of the mandrel apparatus 120, PLC
132
can operate servo drive motor 170, to move drive belt 178 longitudinally in a
direction
that causes slider plate 160 to slide forward on guide rails 172a, 172b. With
the
movement of slide plate 160, the vertical support 152, mandrel support frame
123, and
mandrel apparatus 120 that is attached to frame 123, also move longitudinally
towards
rail and plough apparatus 300.
[00130] With particular reference now to Figures. 12-18, mandrel 121 is moved
longitudinally forward, and thus blank 400 which may be held thereto by the
connection
of panel 410 to the front surface of the plate 219a, also moves longitudinally
with the
mandrel 121. As blank 400 is moved longitudinally by mandrel apparatus 120,
first rails
302a, 302b may engage a portion of panel 430, so that panel 430 and attached
panels 431,
432, 440, 441 and 442, are folded along a fold line between panel 410 and
panel 430
downward from a generally vertical orientation to a generally horizontal
orientation as
shown in Figure 13 whereby panel 430 is held against the upper surface of
mandrel plate
140c.
[00131] With continued longitudinal movement of blank 400, opposed inner side
rails 304a, 304b may engage panels 411 and 412 respectively and may fold and
maintain
the panels 411 and 412 in a generally rearwardly extending orientation. At
about the
same time, a pair of wedge plough devices 311 a, 31 lb may commence the
generally
inward and downward folding of side end panels 431 and 432 and attached panels
441
and 442 respectively from a generally horizontal orientation towards a
generally vertical
orientation. Likewise, slightly after the wedge plough devices 311a, 311b
engage side
39
CA 02687847 2009-12-08
end panels 431 and 432, a pair of wedge plough devices 310a, 310b may commence
the
generally inward and upward folding of side panels 421 and 422 and attached
panels 451
and 452 respectively from a generally horizontal orientation towards a
generally vertical
orientation.
[00132] As shown in Figures. 14 and 15, with continued longitudinal movement
of
mandrel 121 with blank 400 held thereto, next opposed, downwardly and inwardly
oriented guide rails 306a, 306b, may take over from plough devices 311a, 31
lb, to
engage the upper surfaces of panels 431 and 432 and attached panels 441 and
442 and to
complete the inward and downward folding of outer panels 431 and 432
respectively to a
vertical position as shown in Fig. 15. Likewise, slightly after guide rails
306a, 306b, take
over from plough devices 311 a, 31 lb, opposed, upwardly and inwardly oriented
guide
rails 308a, 308b, may take over from plough devices 31Oa, 310b, to engage the
lower
surfaces of panels 421 and 422 and attached panels 451 and 452 and to complete
the
inward and upward folding of outer panels 421 and 422 respectively to a
vertical position
as shown in Fig.15. At an appropriate time during which the foregoing folding
process
takes place, the adhesive applicators 600 can apply appropriate amounts of
adhesive in
locations as described above.
[00133] Lower support rails 312a, 312b may assist in supporting blank 400 once
it
has been removed from the support of the stack of blanks 400 in the magazine
110.
[00134] Also as shown in Figures 16, 17 and 18, as blank 400 moves
longitudinally, the side end panels 431 and 432 are compressed in such a
manner that
inside portions of side end panel 431 engage outer surfaces of bottom panel
411 and
inside portions of side end panel 432 engage outer surfaces of panel 412.
Likewise, the
side end panels 421 and 422 are compressed in such a manner that inside
portions of side
end panel 421 engage outer surfaces of bottom panel 411 and side end panel 431
and
inside portions of side end panel 422 engage outer surfaces of bottom panel
412 and side
end panel 432. With the assistance of adhesive positioned between the
respective
surfaces, compression rails 314a, 314b may help ensure appropriate sealing of
the panels
together.
CA 02687847 2009-12-08
[00135] Under the control of PLC 132, or pursuant to another control or
trigger,
adhesive applicators 600 can apply a suitable adhesive at appropriate
positions on the
panels and/or panels just prior to the folding of the panels, so that when the
panels and
panels are folded as just described, the panels can be held in the desired
case
configuration. This approach of folding and pressing together two panels
immediately
after applying adhesive at least one of the panels can reduce the amount of
adhesive
required. By way of example, under the control of PLC 132, or pursuant to
another
control or trigger, adhesive applicators 600 can apply a suitable adhesive at
appropriate
positions on the panels just prior to or during the process of folding of the
panels, so that
when the panels and panels are folded as just described, the panels can be
held in the
desired case configuration. With reference to Figure 1, in the preferred
embodiment,
lines or beads of glue may be applied by stationary glue applicators 600 to
the blank 400
as the blank is being moved by mandrel 121 through the rail and plough
apparatus 300.
Thus, the glue can be applied at a particular time during the folding process
just prior to
engaging two panels with each other to interconnect them. In this manner, the
gluing and
folding can be completed in a single in-line process while the blank is being
moved
longitudinally through the rail and plough apparatus 300, without the need to
have a
separate gluing stage prior to commencing the folding by the rail and plough
apparatus
300.
[00136] In particular, with reference to Figure 15, glue may be applied to the
outward facing surface of panels 432 and 442 in a bead 601 extending up the
walls of the
case along the portion of panels 432 and 442 that will overlap with panels 422
and 452.
Thus when panels 422 and 452 are folded and compressed against the outside
surface of
panels 432 and 442, a seam may be formed by the bond between panels 422 and
432, and
452 and 442. In a similar method, a bead may be applied extending up the walls
of the
case along the portion of panels 422 and 452 that will overlap with panels 421
and 451.
Thus when panels 421 and 451 are folded and compressed against the outside
surface of
panels 431 and 441 another seam may created on the opposite side of the case
as panel
421 is bonded to panel 431 and panel 441 is bonded to panel 451.
41
CA 02687847 2009-12-08
[00137] This approach of folding and adhesively connecting two panels together
immediately after applying adhesive to at least one of the panels may reduce
the amount
of adhesive required. As stated above, in the preferred embodiment, the
adhesive may be
"hot-melt"-type glue such as Cool-Lok adhesive made by Nacan Products Limited.
A
bead of hot-melt glue may be applied by applicators 600 to the surfaces of the
appropriate
panels at a temperature appreciably higher than the ambient room temperature.
The bead
of glue may be approximately cylindrical in shape and as the second panel is
folded over
the first panel and compressed by the rail and plough apparatus 300, the bead
of glue
becomes flattened and spreads out over the seam. As the glue is spread out, it
cools
down, forming an instant adhesive bond between the panels. When gluing and
folding is
done in a single in-line process, as in the preferred embodiment, the glue has
little time to
cool down between glue application and panel compression. Because there is
little time
between glue application and compression, the bead of glue is not required to
retain heat
for a significant amount of time and a bead with a smaller radius (and
consequently a
reduced amount of glue) may be used as compared to a system where the glue is
applied
in a separate process prior to folding.
[00138] As is shown in Figures 16, 17 and 18, as blank 400 moves further in a
longitudinal direction, the folded blank, with panels secured appropriately
with for
example adhesive, may move past the end of overhead rails 302a, 302b and
upward rails
308a, 308b. Also, as shown in Fig. 17, the rear edge of rear panel 450 may
pass lower
latch devices 318a, 318b, and the rearward edge of panel 440 may pass upper
latch
devices 316a, 316b. This longitudinal positioning of blank 400 may cause latch
devices
316a, 316b, 318a, 318b to be activated.
[00139] Once activated, the latch devices may restrict the case from moving
longitudinally backwards, when the mandrel apparatus 120 is withdrawn.
[00140] Additionally, upon receiving the signal from the position sensor that
the
blank has reached the release position as shown in Figure 18 (i.e. the mandrel
has
reached the end of its stroke cycle), PLC 132 may send a signal to servo motor
170
causing it to reverse its rotational direction, which in turn causes drive
belt 178 to move
42
CA 02687847 2009-12-08
in the opposite direction. This movement of belt 178 causes slider plate 160
and thus
mandrel support frame 123 and mandrel apparatus 120 to also move in a reverse
or
rearward direction (not shown). Additionally, PLC 132 may send appropriate
signals to
deactivate the vacuum force provided at suction cups 220a and 220b in panel
rotating
apparatus plate 219 so that the container is no longer held on the mandrel by
the suction
cup forces.
[00141] Once the mandrel 121 has been withdrawn from the blank (which has now
been formed into a container - case -400a), the container 400a may no longer
be
supported, except possibly at least to some extent by compression rails 314a,
314b. Thus,
container 400a may be transferred to a case conveyor (not shown) that is
configured to
receive the container and the container is then carried away by the case
conveyor to be
loaded and/or processed further. Case conveyors are well known in the art and
any
suitable known case conveyor may be utilized.
[00142] A device may be employed to push the container 400a (e.g. the formed
DSS-RSC case) out from between rails 314a, 314b. For example, a simple push
down
cylinder device that may also be controlled by PLC 132 may be used. Other
examples of
transfer devices that might be employed to transfer the case from the end of
guide
apparatus 130 to a case conveyor include a "blow-off' system that may use one
or more
jets of compressed air, a suction cup system, the use of pushing arm or simply
allowing
for freefall of the formed case.
[00143] While the container 400a is being transferred to the case conveyor,
the
mandrel apparatus 120 can be returned to its start position (not shown), ready
to
recommence the process that has just been described above to form another
case.
[00144] It is anticipated that cases may be formed at a rate of in the range
of about
1 to about 60 cases per minute.
[00145] Many variations of the embodiments described above are possible. By
way of example only, one portion of the blank may not have to be rotated from
a
generally flat configuration with the rest of the case blank, ninety degrees
relative to
43
CA 02687847 2009-12-08
remaining portions of the panel, to set-up the folding process. In some other
embodiments, the initial rotation of one portion of the blank from a generally
flat
configuration of the entire blank, may for example be only in the range of
from forty-five
degrees to ninety degrees. Once the first portion has been rotated from the
flat
configuration to the angled position, the blank is then more readily capable
of being
engaged by other mechanisms such that a further rotation of the first portion
and other
portions of the blank can be carried out to bring the first portion to a
vertical position
against the front face of the mandrel. Alternatively, in some applications a
mandrel
might be employed which has outer surfaces that are not completely at right
angles to
each other. A case blank could then be utilized in the system such that when
folded, the
blank may not form a cuboid shape.
[00146] The system could, with some other modifications, be provided in other
spatial orientations such as in a vertically inverted configuration. In such a
vertically
inverted configuration, a magazine may hold blanks in a stack but be
configured to
dispense the blanks from the bottom of the stack. A blank could then be
retrieved from
the bottom of the stack and the front panels could be rotated ninety degrees
downwards
(instead of upwards) to engage a mandrel, so that like in the embodiment
described
above, an L-shaped configuration is formed around the mandrel. In some such
embodiments, a separate rotation device may not be required to rotate the
front panels
ninety degrees to engage the mandrel. Once released from the magazine, the
front panels
may rotate and pivot downwards. Suction cups or another holding mechanism
could then
be employed to hold the front panels vertically against the front surface of
the mandrel.
An additional holding mechanism could also be employed at a top plate of the
mandrel so
that the L-shaped blank is held to the mandrel before and during its passage
through a
holding apparatus. Such a holding apparatus may be simply the inverted
configuration to
the holding apparatus described above. An example of such an embodiment is
illustrated
in Figures 19 and 20.
[00147] With reference to Figures 19 and 20, system 1100 is constructed
substantially the same way as system 100 as illustrated in Figures 1 to 18
with generally
all the same components. However, the orientation of system 1100 is vertically
inverted
44
CA 02687847 2009-12-08
in its orientation compared to system 100. Therefore, while each blank 4001 of
system
1100 (each of which may be like blank 400) is moved longitudinally in a
generally
horizontal direction, the process and components are vertically inverted about
a
horizontal longitudinal axis.
[00148] System 1100 therefore may have a magazine 4000 holding blanks 4001
(which may be of the type blank 400 of Figure 30 or blank 500 of Figure 36)
vertically
above mandrel apparatus 1120, panel rotating apparatus 1124 and mandrel
movement and
support apparatus 1125. Mandrel apparatus 1120 may be constructed like mandrel
apparatus 120 with a mandrel 1121, but may be oriented in a vertically
inverted
configuration compared to apparatus 120. Likewise panel rotating apparatus
1124 and
mandrel movement and support apparatus 1125 may be constructed like panel
rotating
apparatus 124 and mandrel movement and support apparatus 125 respectively, but
each is
also oriented, vertically inverted. System 1100 may also include a panel
folding and
guide apparatus 1300 that may be a rail and plough constructed like apparatus
300, but
again it may be vertically inverted.
[00149] In operation of system 1100, magazine 4000 may provide blanks 4001 in
a
stack such that there is a downwardly facing, but generally horizontally
oriented surface
of panel 20 in the bottom-most blank in the stack that is just in contact
with, or is a very
short distance spaced from the bottom surfaces of mandrel 1121. Next, magazine
4000
and panel rotating apparatus 1124 may co-operate so that the single blank 4001
from the
"bottom" of the stack of blanks may be retrieved from the magazine 4000 and be
transferred to the mandrel apparatus 1120. It should be noted that in this
embodiment,
gravity may assist in releasing a blank 4001 from magazine 4000 and securing
it to
mandrel 1121.
[00150] As with the embodiment of Figures 1-18 described above, a PLC like
PLC 132 may cause panel rotation unit 1124 to extend so that a rotating plate
1219 and
the suction cups thereon are rotated to be in an orientation that is upward
facing. Upon
coming into close proximity or contact with a panel 410, suction cups may
engage the
downward facing surface of panel 410 of the bottom blank 4001 in the stack.
The blank
CA 02687847 2009-12-08
4001 may also at the same time be supported proximate the upper surface of the
mandrel
support frame 1123.
[001511 Thereafter panel rotating apparatus 1124 may be operated to rotate
plate
1219 so that panel 410 may be rotated - preferably approximately ninety (90)
degrees -
downwards, but otherwise generally as described above, to form a generally L-
shaped
configuration. Vacuum may also be applied to suction cups through operation of
the
PLC during the rotation of the panel 410. The air suction force that may be
developed at
the outer surfaces of suction cups of panel rotation apparatus 1124 may be
sufficient so
that panel 410 of a blank 4001 can be rotated from the position shown in Fig.
19 to a
vertical position.
[00152] Once panel 410 reaches the vertical downward position, the suction
cups
associated with panel rotating apparatus plate 1124 hold panel 410 against the
forward
facing surfaces of mandrel 1121 with attached panels 411, 412, 430, 431, 432,
440, 441
and 442 also generally remaining in a vertically downward orientation.
[00153] The rotation of panel 410 may also tend to pull that blank downwards
and
perhaps a very small distance forward direction, the effect of which may be to
free the
blank from magazine 4000. The result is that the "bottom" blank is now capable
of being
moved forward by the mandrel apparatus 1120 towards the panel folding and
guide
apparatus 1300. The magazine may again comprise a stack of blanks held in
position by
vertical rails (not shown). Here, where the case former takes blanks from the
bottom of
the stack, gravity may bring the cases to the bottom of the magazine. At the
bottom of
the stack, there may be small metal tabs attached to the rails (not shown)
that protrude out
into the plane of the stack such that the stack may rest on the tabs. In
essence, the stack
is held up by the tabs against or closely proximate to the top of the mandrel.
When the
panel rotation device 1124 engages the bottom case blank and rotates the front
panel
downwards, the bottom case blank may be pulled through the tabs and out of the
magazine. The tabs themselves may remain stationary, but because the case
blank may be
flexible, so that the case blank may bend from the force of the rotation
device and pull
out of the magazine. In this way, the system may prevent more than one blank
at a time
46
CA 02687847 2009-12-08
from being taken. Of course various other embodiments of how a magazine can be
set up
and how a case can be taken from a magazine.
[00154] Thereafter, the panel folding and guide apparatus 1300 may cause the
blank to be folded in the same manner as described above in relation to rail
and plough
apparatus 300, but in an orientation that is vertically inverted.
[00155] It may be appreciated that in some embodiments, the system could be
also
configured so that a magazine may discharge blanks to a mandrel apparatus from
the side
rather than the top or bottom whereby the general orientation of the movement
of the
blank and the mandrel apparatus through a rail and plough apparatus is
generally
vertically upwards or downwards. One example of such a configuration is
illustrated in
Figures 21 and 22. System 2100 is also constructed substantially the same way
as system
100 with generally all the same components. However, the orientation of system
2100
rotated by about 90 degrees to generally vertically orientation compared to
system 100.
Therefore, each blank 2400 of system 2100 (each of which may be like blank 400
of
Figure 30 or blank 500 of Figure 36) is moved generally longitudinally in a
generally
vertically downwards direction.
[00156] System 2100 therefore may have a magazine 211.0 holding blanks 2400
that is positioned to hold blanks 2400 in a generally vertical orientation and
horizontally
spaced from mandrel apparatus 2120, panel rotating apparatus 2124 and mandrel
movement and support apparatus 2125. Mandrel apparatus 2120 may thus be
constructed
like mandrel apparatus 120 with a mandrel 121, but may be oriented in a
generally 90
degree rotated configuration compared to mandrel apparatus 120. Likewise panel
rotating apparatus 2124 and mandrel movement and support apparatus 2125 may be
constructed like panel rotating apparatus 124 and mandrel movement and support
apparatus 125 respectively, but each is also oriented in a generally 90 degree
rotated
configuration. System 2100 may also include a panel folding and guide
apparatus 2300
that may be a rail and plough constructed like apparatus 300, but again can be
oriented in
a generally 90 degree rotated position compared to apparatus 300.
47
CA 02687847 2009-12-08
[00157] In operation of system 2100, magazine 2110 may provide blanks in a
stack
such that there is a vertically oriented outward facing, surface of the
"bottom" blank in
the stack that is just in contact with, or is a very short distance spaced
from, the outward
facing surfaces of mandrel 2121. Next, magazine 2110 and panel rotating
apparatus 2124
may co-operate so that the single blank 2400 from the "bottom" of the stack of
blanks
may be retrieved from the magazine 2110 and be transferred to the mandrel
apparatus
2120.
[00158] As with the embodiment of Figures 1-18 described above, a PLC like PLC
132 may cause panel rotation apparatus 2124 to extend so that a rotating plate
2219 and
suction cups thereon are rotated to be in an orientation that is generally
vertical. Upon
coming into close proximity or contact with a panel 410, suction cups may
engage the
vertically oriented and outward facing surface of panel 410 of the bottom
blank 2400 in
the stack. The blank 2400 may also at the same time be supported proximate the
vertical
surface of the mandrel support frame by the magazine until the blank has been
engaged
by the panel rotation apparatus 2124.
[00159] Thereafter panel rotating apparatus 2124 may be operated by rotating
plate
2219 so that panel 410 may be rotated - preferably approximately ninety (90)
degrees to
a generally horizontal position, but otherwise generally as describe above, to
form a
generally L-shaped configuration. Vacuum may also be applied to suction cups
through
operation of the PLC during the rotation of the panel 410. The air suction
force that may
be developed at the outer surfaces of suction cups of panel rotation apparatus
2124 may
be sufficient so that panel 410 of a blank can be rotated approximately 90
degrees.
[00160] Once panel 410 reaches the horizontal position, the suction cups
associated with panel rotating apparatus plate 2219 hold panel 410 against the
forward
facing surfaces of mandrel 2121 with attached panels 411, 412, 430, 431, 432,
440, 441
and 442 also generally remaining in a horizontal orientation.
[001611 The rotation of panel 410 may also tend to pull that blank
horizontally and
perhaps a very small distance downward direction, the effect of which may be
to free the
top blank from magazine 2110. The result is that the bottom blank is now
capable of
48
CA 02687847 2009-12-08
being moved forward by the mandrel apparatus 2120 towards the panel folding
and guide
apparatus 2300. As in the other two systems 100 and 1100 described above, the
magazine employed in system 2100 may be just a stack of case blanks held in
position by
horizontal rails (not shown). The magazine may operate using a combination of
the other
two types of magazines described above (e.g. the orientations in figures 1 and
19).
Because gravity would not pull the case blanks to the "bottom" of the stack,
it may utilize
a PLC controlled motor to push the whole stack sequentially towards the
mandrel as case
blanks are taken from the bottom of the stack and formed. In addition, to
prevent the
case blanks from tipping over and falling out of the magazine 2110, at the
bottom of the
stack, there may be small metal tabs attached to the rails (not shown in the
drawings) that
may protrude out into the plane of the stack such that the stack may rest on
the tabs after
being advanced by the PLC controlled motor. In general, the stack may be held
up by the
tabs against or closely proximate to the top of the mandrel. When the panel
rotation
apparatus 2124 engages the bottom case blank and rotates the front panel
towards the
horizontal, the bottom case blank may be pulled through the tabs and out of
the magazine
2110. The tabs themselves may remain stationary, but because the case blank is
slightly
flexible, the case blank may bend from the force of the rotation device and
pull out of the
magazine. In this way, the system 2100 prevents more than one blank at a time
from
being taken. Of course other embodiments for a magazine set-up could be
employed in
system 2100.
[00162] Thereafter, the panel folding and guide apparatus 2300 may cause the
blank to be folded in the same manner as described above in relation to rail
and plough
apparatus 300, but in an orientation that is vertically inverted.
[00163] In yet another embodiment as depicted in Figures 23 to 26, a system
3100
is illustrated in which the mandrel may be de-coupled from the panel rotating
apparatus
and support frame. In such a configuration, the panel rotation apparatus and
support
frame may remain in a fixed position and not move with the mandrel and
partially folded
blank in a longitudinal direction towards the rail and plough apparatus.
49
CA 02687847 2009-12-08
[00164] System 3100 may for the most part be constructed substantially the
same
way as system 100 with generally most of the same components. System 3100
therefore
may have a magazine 3110 holding blanks 3400 (which may be of the type of
blank 400
or Figure 30 or blank 500 of Figure 36) below a mandrel apparatus 3120, a
panel rotating
apparatus 3124 and a mandrel movement and support apparatus (not shown).
Mandrel
apparatus 3120 may be constructed in a similar manner to mandrel apparatus 120
with a
mandrel 3121. Likewise panel rotating apparatus 3124 and mandrel movement and
support apparatus may be constructed like panel rotating apparatus 124 and
mandrel
movement and support apparatus 125 respectively. However, panel rotating
apparatus
3124 is decoupled from mandrel movement and support apparatus. System 3100 may
also include a panel folding and guide apparatus 3300 that may be a rail and
plough
constructed like apparatus 300.
[00165] Mandrel 3121 may include a pair of spaced opposed elongated and
longitudinally extending side plate members 3140a and 3140b. Side plates
3140a, 3140b
may be interconnected by and joined to an upper horizontally oriented plate
3140c. Side
plates 3140a, 3140b and upper plate 3140c may be integrally formed together.
Mandrel
side plates 3140a and 3140b may contain a groove or channel (not shown) on
their inner
surfaces for receiving mandrel support rails 3141a, 3141b respectively so that
the during
extraction of a blank 3400 from magazine 3110, mandrel 3121 can be supported
by the
support frame 3123 and may be generally restrained from vertical and
transverse motion.
However, it should be noted that during longitudinal movement of mandrel 3121
caused
by movement and support apparatus (not shown), mandrel side plates 3140a and
3140b
may slide longitudinally relative to rails 3141a, 3141b respectively. The
result may be
that after extraction of a blank 3400 from magazine 3110, and the initial
folding of the
blank 3400 on mandrel 3121, mandrel 3121 can move away with the extracted
blank
3400 longitudinally from rotating apparatus 3124 and support frame 3123.
[00166] Mandrel 3121 may be interconnected to and supported by a vertical
frame
support member 3152 having a connection plate 3153 extending horizontally at
the lower
surface of vertical member 3152. Plate 3153 may have screw holes 3155 which
may
enable screws (not shown) to pass down into threaded holes (not shown) in an
upper
CA 02687847 2009-12-08
horizontal surface of mandrel plate 3140c. Vertical support member 3152 may be
conveniently formed from a light but relatively strong material that can be
readily formed
into a tube, such as for example aluminium. Vertical support member 3152 may
be
formed as a hollow channel member that has a longitudinally extending cavity
that allows
for electrical and communication cables and pressurized/vacuum air hoses to
pass
through from an upper end to a lower end. In this way, electrical
power/communication
cable and air hoses can deliver power, electrical signals and air to the
suction cups 3199a,
3199b that are positioned to face outwards in a generally horizontal
orientation. Suction
cups can be mounted in the end faces of side plates 3140a, 3140b respectively.
The
supply of vacuum to suction cups 3199a, 3199b may be controlled by a PLC like
PLC 32.
[00167] Vertical member 3152 also has an upper end portion that is
interconnected
to the mandrel moving apparatus (not shown). Mandrel support and moving
apparatus
may be used to support and move in reciprocating forward and rearward
longitudinal
movement mandrel 3121.
[00168] Panel rotating apparatus 3124 may engage one blank 3400 and may be
employed to rotate a blank 3400 panel 410 relative to one or more other
panels. The
movement of unit 3124 can be controlled by the PLC in such a manner that it
can rotate
so as to move a panel 410 (and attached panels 411, 412, 430, 431, 422, 440,
441 and
442) of a case blank 3400 through a rotation of approximately 90 degrees, in
an aligned
manner, at an appropriate time.
[00169] Unit 3124 may be described in overview and with particular reference
to
Figures 24 and 25. Like unit 124 in the previous system 100, unit 3124 may
include a
longitudinally oriented piston device 3202 which has piston blocks that rest
on bottom
plate 3150c of support frame 3123. Piston 3202 may be a conventional pneumatic
reciprocating cylinder and is operable to move in a reciprocal movement
between a fully
extended position (not shown) and a retracted position. To channel the
compressed air
appropriately, valves (not shown) can be driven between open and closed
positions by
solenoids responsive to signals from PLC 132. The valves could be located
proximate
51
CA 02687847 2009-12-08
the piston 3202 or be disposed elsewhere. Electrical lines carrying signals
from PLC
could also pass through vertical member 3152 to operate the valves.
[00170] A piston rod of piston 3202 is provided with an extended arm portion
that
provides for a hinge connection for pivoting the panel rotating apparatus 3124
between a
generally horizontal position and a generally vertical position.
[00171] Panel rotation apparatus 3124 also comprises panel rotating plate 3219
Panel rotating plate 3219 may be attached by way of piano hinge to forward
lower
extension of bottom plate 3150cof support frame 3123. As a result of the
movement of
piston the cylinder rod may extend or retract allowing the arm to pivot
relative to rotating
apparatus 3124. The movement of piston rod thus causes the panel rotating
plate 3219 to
rotate through a certain angular distance relative to mandrel 3121.
[00172] Air suction cups 3220a and 3220b may be interconnected through block
units to a source of vacuum. A plurality of valves that may be operated by the
PLC and
may also include a vacuum generator apparatus such as apparatus 221 in the
previous
system 100. If a vacuum generator is utilized, pressurized air may be
delivered from an
external source through vertical support member 3152. The vacuum generator may
then
convert the pressurized air to a vacuum that can then be delivered to suction
cups 3220a,
3220b.
[00173] In operation of system 3100, magazine 3110 may be raised so that the
upper generally horizontally oriented surface of the upper-most blank 3400 is
just in
contact with, or is a very short distance spaced from (e.g. within 1% inch)
the bottom
surfaces of frame 3123 and mandrel 3121. Next, magazine 3110 and panel
rotating
apparatus 3124 may co-operate so that the single blank 3400 from the top of
the stack of
case blanks may be retrieved from the magazine 3110 and be transferred to the
mandrel
apparatus 3120. Thus, in this way the panel rotating apparatus 3124 may also
serve as a
transfer mechanism for transferring case blanks in series from the magazine
3110 to the
mandrel 3121.
52
CA 02687847 2009-12-08
[00174] Under the control of the PLC, panel rotation apparatus 3124 may extend
reciprocating piston rod so that the rotating plate 3219 and the suction cups
3220a, 3220b
thereon are rotated to be in an orientation that is downward facing. Upon
coming into
close proximity or contact with panel 410, suction cups 3220a, 3220b, may
engage the
upward facing surface of panel 410 of the top blank 3400 in the stack. Panels
420 and
450 of the blank 3400 are at the same time are maintained generally in
position up against
or proximate the lower surface of support frame 3123 and mandrel side plates
3140a,
3140b. Blank 3400 continues to be supported underneath by physical contact
with the
upper surface of another underlying blank 400 in the stack.
[00175] Panel rotating apparatus 3124 may be operated by the PLC to rotate
rotating plate 3219 about hinge so that panel 410 may be rotated - preferably
approximately ninety (90) degrees - about a pre-determined fold line between
panels 410
and 420. Thus panel 410 is rotated relative to panels 420 and 450 from a
generally flat
and horizontal orientation to a generally vertical and angled orientation,
thus forming a
generally L-shaped configuration.
[00176] Vacuum may also be applied to suction cups 3220a, 3220b through
operation of PLC 132 during the rotation of the panel 410. The air suction
force that may
be developed at the outer surfaces of suction cups 3220a, 3220b of panel
rotation
apparatus 3124 may be sufficient so that panel 410 of a blank 3400 can be
rotated from
the flat position shown in Figure 23 to an angled configuration.
[00177] Once panel 410 reaches the vertical position, the suction cups 3220a,
3220b associated with panel rotating apparatus plate 3129 may hold panel 410
against the
forward facing surfaces of mandrel side plates 3140a, 3140b and the outer
surface of
3219a of panel rotating plate 3219 with attached panels 411, 412, 430, 431,
432, 440, 441
and 442 also generally remaining in a vertical orientation until suction cups
3199a,
3199b of mandrel 3121 are activated by PLC and can then engage panel 410 of
blank
3400. Once suction cups 3199a, 3199b of mandrel 3121 are activated and engage
panel
410 of blank 3400, cups 3220a and 3220b of rotation apparatus 3124 can be de-
activated.
The rotation of panel 410 may also tend to pull that blank upwards and perhaps
a very
53
CA 02687847 2009-12-08
small distance forward, the effect of which may be to free the top blank from
the blank
beneath it that is still on the stack. The result is that the blank 3400 now
held by suction
cups 3199a and 3199b, is now capable of being moved forward by the mandrel
apparatus
3120 towards the panel folding and guide apparatus 3300.
[00178] Next, mandrel support and moving apparatus (not shown) may be used to
move mandrel apparatus 3120 longitudinally forward towards panel folding and
guide
apparatus 3300, thus also moving blank 3400 that is held to mandrel 3121.
[00179] System 3100 may have the advantage of allowing for faster operation of
the case former relative to system 100 shown in Figure 1. This is because as
the mandrel
apparatus 3120 is being moved longitudinally forward with a first blank to
form a case,
the panel rotation apparatus 3124 can be rotated to engage the surface of a
second blank
from the magazine. Once the mandrel apparatus 3120 has moved the first blank
through
the panel folding and guide apparatus 3300 to form a case and the mandrel
apparatus
3120 is reversed to its original position, the panel rotation apparatus 3124
may rotate the
front panels of the second blank in an L-shaped configuration around the
mandrel 3121.
The mandrel 3121 can now move forward longitudinally with the second blank to
repeat
the process.
[00180] Of course, the above described embodiments are intended to be
illustrative
only and in no way limiting. The described embodiments of carrying out the
invention
are susceptible to many modifications of form, arrangement of parts, details
and order of
operation. The invention, rather, is intended to encompass all such
modification within
its scope, as defined by the claims.
[00181] When introducing elements of the present invention or the embodiments
thereof, the articles "a," "an," "the," and "said" are intended to mean that
there are one or
more of the elements. The terms "comprising," "including," and "having" are
intended to
be inclusive and mean that there may be additional elements.
54
