Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
3~
The present invention relates generally -to carton
~orming apparatus and relates in particular to a carton ~ormer
that utilizes ~olded box blanXs and which opens the blank,
ins0rts a package into the opened blank, and closes and seals
the end ~laps
Modern pac~age manu~acturing and packaging techniques
have developed to a state whereby the package material is usual- :
ly manu~actured by a first company, and the package is manu~ac-
tured and printed by a second company. One type o~ package
which is usually made and ~illed in this manner is the conven-
tional paper box comprised of an outer light cardboard carton ;-
and an inner paper bag that contains the product being sold.
Potato chips, crackers, pretzels, and cookies are one type o~
product that is packaged in the a~orementioned manner. ~ ~:
Occasionally the manu~ac$urer o~ the product has pru-
chased the packaging machinery which conventionally consists ~ !
a ~irst type oi mach1nery ~or manu~acturing and ~illing the
so~t bags and a
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second type of macl~inery for manufacturing the outer card'board boxes
and insertillg the paper bags in -the boxes~ ~any of the conventional
machines are ex~remely expellsive, heavy, require a large amoun-t o~
floor space, atld are comprised of a large nwnber of interrelated
and complicated elements that are prone to frequent ~'ailure. In
addi-tion, the conventional packaying equipment has a relatively slow
package per minute rate and -those capable of higher packagcs per
minute rates llave relatively large down times.
One type of packaging equipment uses cardboard cartons that
~D are manufactured as folded kox blanlcs and which are purchased by
tlle producer of the contents being packaged. The folded box blanks
are purchasecl in stacks and, once opened, can be quickly and
efficiently filled with a previously filled bag. The use of folded
box blanks by the producer of the contents eliminates -the necessity
for having the expensive equipment for manufacturing the outer
carton. I-lowever, the folded box blanks'still must be opened so
that -the formed carton is ready to receive the filled bag. Many of
the prior art devices for opening the folded box blanks comprise a
plurality of mechanical fingers connected to a plurality of c~riers.
The carriers are moved through a series of complex motions in order
to select one folded box blank, open the box blank, and position it
for receipt OL the filled bag. These devices are prolle to freqllent
breakdowns and are often very di~ficult to interface with other
mechanical equipment. As a result, additional comp]cx apparatus is
often necessary for receiving the opened box blank and Eor
positioning it for receiviny the Eilled bag.
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~48394 :
Swllmary of t]le Invcn~ion
.. :
The present invelltion overcomes the aforementioned disadvan-
~ages and provides a versatile and efficient carton forming and
filling apparatus that can operate at high speeds. A device in ~ -
accordance with the present invention requires relatively little
floor space and has a high degree of realiability, integrity, and
flexibility. Such a device is completely au-tomatic and produces
a finished, sealed package having an outer cardboard carton and an
inner filled hag. The complex and expensive interfacing equipment
1~ which is comMon with conventional machines is no lonyer required.
~s a resul-t, the present invention provides a relatively inexpensive,
relatively maintanance-free and relatively simple device for forming
cartons from folded box blanks.
A device in accordance with the present invention can easily
be used in combination with a flexible bag type package forming
apparatus. Flexible bags can be formed and filled with conventional
package forming apparatus such as that disclosed in the following
United States Patents of ~illiam C. Leasure: 3,027,696; 3,543j467;
3,548,563; and 3,785,112. Thecombinatlon of a device ln accordance
with the present invention with the aforementioned flexible bag
forming apparatus provides a system for forming and filling flexible ;~
bags, placing the bags in opened boxes, scaling thc box, and
delivering a completed package.
The present invention provides a device for forming a carton
from folded box blanks and comprises a means for supplying a
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plurality of the rolded box blanks, a rotatable cam Illeans for
engacJinc3 and opening the box blanks, means ~or depositing a EilLed
flexible bag into the open box blank, and mealls for closing and
sealiny the end Elaps of the box blank thereby forminy a sealed
carton. In one embodiment of the invention, the cam means for
opening supplied folded box blanks includes a first cam means for
receiving the blanks and for opening the received blanks upon the
rotation thereof and a second cam means for cooperating with the
first cam mealls for opening the received blanks. In one example
D oE the invention, the first and second cam means each respectively
comprises a substa-ntially cylindrical cam, the firs-t cam having an
axially progressing spiral cam surface whereby a folded blank is
received at a first end of the first cam and is engaged along one
edge thereof by the cam surface. In anothcr embodiment of the
present invention, the means for supplying folded box blanks include
a storage magazine containing a vertical stack of folded box blanks,
a disc means for separating the bottom blank from the vertical
stack of blanks and a rotatably mounted feed roller for receiving
and advancing the separated box blank. In a further embodiment of
the present invention, the box closing and sealing means comprises
a carrier means for receiving a bag coritairring bo~ blank from the
depositing means, for securely holding the box blank, and for
delivering a sealed box blank; a conveyer means for conveying the ~ -
carrier means to a plurality of longitudinally spaced stations; a
dust flap closure means located at one station for closing the dust
1~4~35~4
flaps at each end of the box blanks; seal end flap closure mea315
located at another station for closing thc seal en~ flaps at each
end of the box blank; and sealing means located at still a further
station for sealing the seal end flaps.
Other details, features and objects of -the present invention
are set forth in, or apparant from, the accompanying clrawings and
detailed descxiptiorl of the preferred embodiment found hereinbelow.
Brief Descri~tion of the Drawinqs
Figure 1 is a perspective view with parts cut away of a carton
b ~orllling apparatus in accordance with one embodiment of the
invention.
Figure 2 is a side elevational view of part of the embodiment
of the invention shown in Figure 1.
Figures3 and 4 are a plan view and a side elevational view,
respectively, of a box blank separator for separatlng and advancing
the lower box blank in a stack of box blanks, each figure consist-
ing of five parts and each part showing the various stages of the
separator Figures 3A and 4A showing the separator at the initial
or 0 position; Figures 3B and 4B showing the separator at the 90
position1 Figures 3C and 4C showing the separator at the 180
position; Fiyures 3D and 4D showing the separator at thc 270
position; and Figures 3E and 4E showing the separator at the 360
position.
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1~483~
Figure 5 is a plan view of a box blank openincj cam oE the
embodiment of tlle invention shown in Fiyure 1 and consists of
five parts, each part showing various positions of the cam and of
the box blank being opened Figure 5A showing the cam in the
initial or 0 position; Figure 5B showing the cam in the 90
position; Fiyure 5C showing the cam in the 180 position; Figure `~ :
5D showing the cam in the 270 position; and Figure 5E showing the .
cam in the 360 position.
Figure 6 is a plan view of a box blank opening cam means
in accordance with a further embodi.ment of the inven-tion and
consists of five parts, each part showing various positions of the:
cam and of the box blank being opened; Figure 6A showing the cam
in the initial or 0 posltion; Figure 6B showing the cam in the 90
posi.tion; F~gure 6C showing the cam in the 180 position; Figure~ -
6D showing the cam in -the 270 position; and Fiyure 6E showing~the
CaJn in the 360 position. .
:
Figure 7 is a top plan view of part of the embodiment of the ~ :
invention using the cam means shown in Figure 6.
Figure 8 is a plan view of a further embodimellt of the box
blank opening cam means ln accordance with the~ present invention~
Figure 9 is a plan view o~ yet another embodiment of the ; :
box b].allk openillg cam means of the invention.
Figure 10 is a plan view of the means for closing and sealing
the ends of a filled bo~ blank in accordance with the embodiMent
of the invention shown in Figure 1.
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Figure 11 is a side elevationa]. view oE the parts of the
embodiment of tlle invention shown in Figure 10.
Figures 12, 13, 14, and 14A are a series of figures depictiny .
the relative locatlon of a plurality of elements shown in Fiyure 11;
Figure 12 being a plan view of a carrier tray shown in the open
position and ready for receiving an opened and filled box blank. ~ ;
Figure 13 is a plan view of a stationary elongate cam having a .. :~:
surface such that when the cam follower of the carrier tray shown ;
in Figure 12 is in engagement tllerewith, the carrier tray will be: :
rotated 90 as shown in Figure 14. Figure 14 is a plan vi.ew of the ~ :
~ . . . .
carrier tray depicted in Figure 12, (not shown) in the closed
~; position in whlch a box blank can be s0curely held ln positionl and
Figure 14A is a plan view of a cam for rotating the carrier tray
: ~ .
~ shown in Fig~-e 14 to the position shown in Figure 12.
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Figure 15 is a schematic plan view of the.carrier tray shown -~
in Figure 12 and consists of four parts, each part showing the `~
various positions of the carrier tray as i.t is being rota-ted;
Figure lSA showing the carrier tray in the initial or 0, opened
position; Figure 15B shows the carrier tray of Figure lSA with an
opened box blank positioned longitudinally therein; Figure lSC
` shows the carrier tray rotated 45; and Figure lSD shows the
carrier tray rotated 90. : .
~: Figure 16 is a schematic plan view of a means for tucking ln
i: , :
the dust flaps oL an open box blank and consists of four parts, each
part showing the various positions o~ the tucking operation; Figure
16A showing the relative position of the box blank and stationary
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guides for tucking in the leading dust flaps; Figure 16B showing
the leading dust flaps being tucked in; Figuxe 16C showing the
rear dust flaps being tucked in and Figure 16D showing both dust
flaps tucked in and held in position.
Figure 17 is a schematic plan view of a means for applying
glue to Lhe seal ends of a box blank and for closing the seal ends
and consists of four parts, each part showing various positions
of the means for applying glue and for closing the seal ends.
Figure 18 is a schematic p]an view showing means for apply-
I~ ing pressure to the ends of the closed and sealed box and consistsof three parts, each part showing various rela-tive positlons
between the pr~ssure means and the box.
Figure 19 is a schematic plan view consis-ting of three
parts showing the carrier tray~with a sealed box therein; Figure
l9A showing the box in a first position; Figure 19B showing the
~ox rotated 45; and Figure 19C showing the box rotated 90 and the
, . . .
carrier tray in the opened position.
Detailed Description of the Preferred Embodiments
With reEerence to the figures in which lIke numerals depict
like elements, a carton forming apparatus 20 in accordance with
one enl~odiment of the lnvention is shown in Figure 1. Apparatus
20 can be thougllt of as being comprised of four major components,
a supplying means 22 for supplying a plurality of folded box blanks
B, a forming means that includes a rotata~le caM means 24 for
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~048394
engaging folded box blanks B and ~or opening the box blank to form
an opelled box blank or carton ~', filliny or depositing means 26
for inserting a flexible package or bag P into opcned box blank B', ....
and means for closing and sealing the end flaps of'the opened box
blank B' and tl~ereby forming a sealed carton B" .
SUPPLYING MEANS : ,
Wlth reference to Figures 1 and 2, supplylng means 22 com- ~ :
prises a storage means for magazine 30 for storing a vertical stack
of folded box blanks B, a transportlng mea:ns 32 for transporting ~ ~ '
.box blanks B to cam means 24, and transfer means 34 for transferring .- .'
folded box blanks s from magazine 30 to transportlng means 32.
Magazine 30 is a hopper-type magazine for storlng a plura],i~ty~of
folded~box blan~ks B ln a ver~tical stack or plle and~for providlng ~
for,the feeding of one box blank at a tlme~ from the bottom.~ Magazlne
30 compr~ises~ a slanted~back ~36 and a vlbraLor~38 dlrectly mounted :; ~
onto,-back 36. Vlbrator 38 ensures~:that the plurality of stacked : :
box blanks~ B are advanced downwardly as the bottom blank is fed ' ~ -~
from magazine 30.
Transfer means 34 comprlse~s a~rotatable disc means 40 for :~
.
separating the bottom folded box blank B from the vertlcal stack
and a mealls for advanciny and Eeeding the separated box: blank from
,
; ~; magazine 30 complising a rotata~ly mounted fced roller 42. IYith ~ ~
i
further re:Eerence to Figures 3 and 4, the feed roller ~2 ls a : 1 ~
.
cylindrical roller ~hich extends substantially the transverse width 1l
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L8394 ;~
of magazine 30 and is rotatably mounted at the rearward part of the
bottom o~ macJaæine 30. Disc nleans 40 is com~rised of two sets of
cliscs, each s~t of discs including a rotatably mounted vertical
axle 44,agenerally oval-shaped top disc 46 and a generally oval-
shapecl bottom disc 48. Discs 46 and 48 have a shape and are mounted
on axle 44 such that, as shown in plan view in E`ig~re 3, tlle outer-
most edges of the combined discs substantially for~ a vir~ual circle.
Ilowever, at one of the ends 50 of bottom disc 48, a section 52
protrudes beyond -tlle virtual circle and is for supporting the bottom-
most box blank as the bottommost box blank is being separated from
the next box blank in the stack. The corresponding end section of
top disc 46 to end section 52 (denoted 54) has a reduced thickness
so as to form a knife-like edge thereby permitting easïer separation
of the bottommost box blank from the next box blank in the stack.
, .
Below disc means 40 is a guide plate 56 for guidiny a separa-ted box
blank as the box blank is advanced by the rotating feed roller 42.
.
Transfer means 34 further comprises a pair of loader rollers
58 and 60 and a pivotable loading plate 62 whlch Is positionable ~ -
between a first, horizontal position and a second, vertical positlon.
Loader rollers 58 and 60 are rotatably mounted horizontal rollers
with loader roller 58 being smaller than loader roller 60 and
located vertically thereabove forming a nip therebetween. The
vertical height of the nip between loader rollers 58 and G0 is ~he
the vertical hei~ht of the
same as the/top of guide plate 56 so that a box blank advanced by
feed roller 4Z and positioned by guide plate 56 can be fed into the
nip between loader rollers 58 and 60 and further advanced by the
rotating leader rollers.
1 1
B399L
In a ~reselltly ~referred embodiment of the inventioll, loader rollers
58 and 60 are continuously turning, but Eee~ roller 42 rotates
intermittently, the rota-tion being controlled by a pair of micro-
switches (not shown) -tripped by a separated and advanced box blank
B. Loading plate 62 lS positioned in a 90 arc by a means (not
shown) that is also in-termittently operated i.n a timed sequence so
that loading pl.ate 62 is in a horizontal position to receive a box
blank fed by loader rollers 58 and 60 and is rotated into a vertical
position once the box blank has been recelved.
Transporting means 32 comprises a plurality of transport
screws, the~ number of transport screws depending upon the particular
embodiment of the invention, and a means for synchronously rota-ting
the plurality of transport screws (the rotating means not being
shown). In the present embodiment of the invention shown in Fiyure
2, two pairs of transport screws are depicted, an upper pa~r of
transport screws 64 and a lower pair of~transport screws~66. .The
individual transport screws in the upper and lower pairs are spaced : .
an equal distance apart in a horizontal transverse direction a
sufficient distance such that folded box blanks B can fit between
the threads, designated by numeral 68, of the correspondlng transport
screw. The form of thread 68 should be such that box blanks B can .-
be mailltairled in a substanti.a:Lly perpend.icul.ar posi.tion to the
axis of the respective transport screws.
The operation of the supplying means 22 of carton forming
apparatus 20 provides a continuous supply of folded box blanks B ~ :
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~LQ4839g~ :
one at a time to cam means 24. ~ continuous supply of folded box
blanks B is kept in magazine 30 whicll ac-ts as a temporary storage
area and which initially aligns the folded box blanks. Irhe vibrating
~ack 3G of magazine 30 ensures that the stack of box blanks moves
slowly down the angled back 36 as the individual box blanks are
fed from magazine 30. In addition the vibrating back 36 of
mayazine 30 ens~res that -the bottom box blank B in the stack is
kept in contact wi-th dlsc means 40. When a box blank is needed
discs 46 and 48 are rota-ted. As clearly shown in Figures 3 and 4
the stack of box blanks B is initially supported by the middle
portion of the pair of bottom discs 48. As axle 44 is rotated
end section $4 of the pair of -top discs 46 move bet~een the two
bottommost box blanks B. Because the spacing between discs 46 and
48 is substan-tially equal to the thickness of a folded box blank
and because end section 54 is inclined top disc 46 can easily
separate the bottommost box blank from the next box blank in the .
s-tack. As shown in Figure 3s discs 46 and 48 have been ro-tated
90 and the bottommost box blank B is supported by end section 52
of bottom disc 48 and the remainder of the stack of box blanks is
supported by end section 54 of top disc 46. It is noted that the
separating process is further aided by the fact that back 36 of ~
mayazine 30 is slanted and hence the weight of the entire stack is ~-
not placed dire~ctly above discs 46 and 48. Figures 3C and 4C show
discs ~6 and 48 in the 180D position whereby the botton!most box
blank B has been released and lowered onto feed roller 42. The
stack of box blanks are still supported by top disc 46. Upon the
loweriny of the former bottommost box blank B onto feed roller 42
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the drive means (not shown) for fced roller 42 is encrgized and the
box blank is advanced away from magazine 30 as shown in Fiyures 3D
and 4D. ~'igures 3~ and 4~ depict the disc means 40 back in its
initlal startillcJ position with tlle stack of folded box blanks ayain
being s~pported by bottom discs 48. Thus, the bottommost box blank
B in -the stack is separated and advanced from magazine 30 with only
one complete revolution of disc means 40. -~
The advanced box blank B is positioned by guide plate 56
into the nip between continuously rotating loader rollers 58 and
:
~D 60. A microswitch (not shown) which has been tripped by the advanc~ ; ;
ing box blank B provides a signal for the stopping o~ feed roller 42.
The advancing box blank is further advanced by rollers 58 and 60
,
onto loading plate 62 which has been previously positioned into the
first, horizontal position. As box blank B is beiny loaded onto
loadiny plate 62, the box blank B trips a microswitch or (not shown)
other~detectiny means which in turn provides a~slgnal for causiny
tlle activation of the loadiny plate positioning means (not shown~). ;
Loading plate 62 is then positioned into the second, vertical
position where the box blank is received by transport screws 64 and
66. The transport screws 64 and 66 are then rotated one revolution
and the loaded box blank B is received by threads 68 of the~transport
screws. Loading plate 62 is then returned to the first, horizon-tal
position for accep-ting another box blank. Transport screws 64 and
: ~ ~ - ,.
6G advance the loaded box blanks B into the box opening cam means
24.
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A means-~or opening a ~olded box blank is in general
comprised o~ at least one cylindrical cam having a spiral cam
sur~ace ~or engaglng one o~ the sides o~ Polded box blank B.
Four embodiments o~ cams in accordance with the present invention
are disclosed in Figures 5 through 9 and are described in greater
detail hereinbelow.
With respect to Figure 5, cam means 24 is comprised o~
a single elongated disc cam 70 having an axially progressing,
spiral cam sur~ace 72 having a radial distance ~rom the axis o~
rotation o~ cam 70 that increases as a function of an increasing
distance along the axis o~ rotation. Cam 70 is described in
greater detail in U,S. Patent 4,207,579, issued June 7, 1977.
As folded box blank B is being opened, the side o~ the box
blank in engagement with cam sur~ace 72 moves axially along cam
surface 72 as cam 70 is rotated. The other side of the ~olded
box blank B is retained in the same axial location at the end
of the corresponding transport screw.
The opening of a ~olded box blank B by cam 70 is shown ~ -
at various stages in Figures ~A through 5E wherein cam 70 is
:
20 shown at positions o~ 0, 90~, 180, 270, and 360 respectively.
The transport screws 64 and 66 axially and longitudinally trans-
port the folded box blands B and supply them one at a time to
cam 70 located at the end of one o~ the upper transport screws
64, when cam 70 is in the 0 position. The edge of box blank B
in contact with the tran~port screw 64 having cam 70 attached
thereto can continue to move in a longitudinal direction on cam
sur~ace 72,
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On t~e otller hand, the opposite side of box blank B, whi.cll is
in contact with the other upper transport screw 64, is retained and
held at tlle end thereof where threads 68 -terminate. Cam surface 72
has a shape so that folded box blank B is completely opened upon
one revolution of cam 70. As can be seen in Figures 5A -through 5E,
as cam 70 rotates, the distance between cam surface 72 and thé other
upper transpor-t screw 64 diminishes. Consecluently, box blank B
~s beiny slowly compressed at the two opposite folded edyes thereof.
Since cam surface 72 also proyresses in an axiaL direction as the
radial dis-tance of cam surface 72 from the axls of rotation
ncreases, the edye of box blank B in contact with cam surface 72
lS forced in an axlal direction and lS malntained in contac-t with
cam 70 a-t the vertex between cam surface 72 and the radial edye of
cam 70 that defines the end of cam surface 72 As stated above,
the~opposite side of box blank B in contact wi~tll the other transport
screw 64 is retained at the same axial position located at the end
of the other transport screw 64. Finally, as shown in Fiyure 5F,
: ~ ~ : . .
box blank B' has been completely opened and a second folded box
blank B has been suppl~ied by the transport screws 64 and 66 to cam
~ 70.
;; A second embodiment of cam~means 24 is shown in Figures
6 and 7. In the second embodimen-t, cam means 24 comprises a first
cam means for receiving the folded box blanks B and for openiny
tlle reccived box blanks upon the rotation -thereof about an axis of
rotation and a second cam means for cooperatiny with the first
cam means for openin~ the received box blanks B one at a time. First
cam means comprises a generally cylindrical cam 74 integrally mounted
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~L~4839~L :
orl thc end of a first upper transport: screw 7G. F~rst cam 74 has
an axially progressing spiral cam surface 78U at increases in the
radial dimension -thereof from -the axis of rotation as a function :
of the angle of rota-tion of first cam 74. The secand cam means
comprises a substantially cylindrical cam 80 in-tegrally mounted
at the end o:f the other or second upper transport screw 82. Second
cam ûO has an axially progressing spiral cam surface 84 wl:ich is
constant in tlle axial direction, but which increases in the radial
dimension from the axis of rotation as a function of the angle of
rotation of second cam 80. 1~ folded box blank B is received at the
endsof cams 74 and 80 in con-tact with transport screws 76 and 82 .
respectively. Folded box blank B is engaged along both sides
thereof by cam surfaces 78 and 84 and is fully opened in one, 3600
revolution of cams 74 and 80. Another way of describing cam surfaces .
78 and 84 is that the root of first cam 74 moves axially and the ~.
root diameter thereof increases radially and the root of second :
cam 80 does not move axially thereon, but does increase radially. ~`
Means, ~not shown) is provided for synchronously rotatlng cams 74
and 80 in a c].ockwize and counterclockwise direction respectively,
when viewed from the rearward or distal end of -the cams and as
shown by arrows 86 and 88 respectively.
Figure 8 depicts a third embodiment of cam means 24 whlch
comprises two mul-tiple revolution box opening cams 90 and 92.
Several lntegral number of revolutions are required to open a
folded box blank B using cams 90 and 92 and the entire box blank
is advanced longitudinally and axially along cams 90 and 92 as
-the box blanks are being opened. Cams 90 and 92 comprise axially
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~l0~83~ :
progressing spiral cam surfaces 94 and 96, respectively. Cam
surfaces 94 and 96 are similar and each cam surface increases
in the radial dimension from the axis of rota-tion (shown at 98 ;~ -
and 99 respectively) as a function of the angle o-~ rotation and
the axial length of the respective cams, Cam sur~aces 94 and 96
have the same radial dimension for the same axial distance along
and angular position of the respective cam, Thus cams 90 and
92 -function essentially as an extension of their respective trans-
port screws 100 and 102, In the embodiment of the invention
shown in Figure 8, seven complete revolutions of cams 90 and 02
are required to form an opened box blank B'. Cam sur~aces 9g
and 96 can also be described as having the root of the cam
moving axially as the root diameter increases radially.
With reference to Figure 9, a ~ourth embodiment of cam ;~
means 24 is depicted. In -this embodiment, cam means 24 comprises
a generally truncated conical cam 104 -for engaging one edge of ;
the box blank B and a cylindrical cam-like transport screw 106
for engaging the other edge of box blank B, Cam lOg has an
axially progressing spiral cam surface 108 that increases in
the radial direction from the axis o~ rotation 110 as a function
of the angle of rotation and of the axial distance along cam 104.
Cam surface 108 generally conforms to the shape of the side of
box blank B as opened box blank B' is being formed. Another way
of describing cam surface 108 is that -the root of cam 104 moves
axially as the root diameter o~ the cam increases radially.
Conical cam 104 essentially forms an extension of and is integral ~
with transport screw 112. Cam-like screw 106 engages the other ~-;
edge of the folded box blank B and includes threads 114 having a
pitch that increases in a first axial portion 116 and then is
constant in a second axial portion 118 of cam-like screw 106.
Cam-like screw 106 has a thread surface 120 which spirally in-
creases in the axial direction and is constant in the radial dis~
- 18 -
~ ~341~394 ~
tance from an axis o~ rotation 122 o~ cam like transport screw
106 so as to con~orm to and engage the side of the box blank B :~
during the opening of the box blank. Cam-like screw 106 is in-
tegrally mounted to and essentially forms an extension of its :
respect.tve transport screw 124 and has substantially the same
diameter as the diameter as transport screw 124. Threads 114
o~ cam-like screw 106 can also be described as having a root .~ .
diameter which remains constant and a thread profile that changes
with the axial distance along screw 106. In this embodiment of ~ ;
cam means 24, several revolutions of cam 104 and screw 106 are
required to open a box blank B. In the embodiment shown in
Figure 9, a box blank is fully opened in seven complete revolu-
tions of cam 104 and cam--like screw 1060
DEP0~ITING MEANS ~ :
. ;
Depositing means 26 deposits a flexible bag or package
P into an opened box blank B' and is depicted in Figures l, 2, 7, .:
and 11. The depositing means 26' comprises lifting means 130 for
receiving an open box blank B' from cam means 24 and lifting box
blank B' into position under a bag forming and filling apparatus
132, ~lap spreader means 134 for opening and holding open the end
flaps of box blank B', and rotating means 136 for rotating the -
bag-filled box blank B' to a horizontal position and for deposit~
ing the box blank on the box closing and sealing means 28.
~ typical opened box blank B' is shown in Figure 1.
Opened box blank B' is a hollow rectangular parallelpiped having
front and back panels 140 and 141, respectively, side panels 142,
and foldable end flaps, generally designa-ted 143, at both endsO ;
End flaps 143 include -two dust flaps 144, which are extensions `~
at each end of both side panels 142, and include seal end flaps :
145, which are extensions at each end of front and back panels
140 and 1410 When an opened box blank B' is presented to bag
forming apparatus 132 for receiving a formed, flexible bag P, it ;~
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` ~(141!~3~3~
is necessary to ensure that end flaps 143 do not block the path
o~' travel of the bag P being inserted into box blank B'.
Bag ~orming apparatuses are conventional and in general
~orm a ~lexible pillow-type bag from a continuous roll of sheet
material (not shown)0 The sheet material is usually formed into
a cylinder by overlapping and sealing together the two side edges.
A sealing jaw, depicted at 146 in Figure 1, flattens out and
seals one end o~ the formed cylinder to make a container. The
container is then filled with a product, the formed cylinder is
advanced downward relative to sealing jaws 146 and sealing jaws
146 flatten out and seal a top portion of the container to com-
plete the bag forming process. Examples of a bag forming appa~
ratus 132 usable with the present invention are disclosed in the
Leasure U.S. patents, 3,027,696; 3,543,467; 39548,563 and
3,785,112.
With reference to Figures 2, 7 and 11, lifting means
130 comprises fluid operated, transversely movable clamps 150
slidably mounted in a housing 152, means (not shown) located in
housing 152 for positioning clamps 150 into and out of engagement
with side panels 142 of box blank B' near the top thereof, and
means (not shown) ior positioning clamps 150 to a first lower
position (shown in phantom in Figure 2) for receiving the opened
box blan~ B~ from cam means 24 and for lifting box blank B' to a
second upper position under bag forming apparatus 132. In the
presently preferred embodiment of the invention, housing 152
travels at an angle upwardly and downwardly between its two posi-
tions so that both vertical translation and longitudinal transla-
tion of housing 152 can be easily accomplished by a simplified
moving means.
Flap spreader means 134 comprises a mounting frame 154,
flexibly mounted guides 156 mounted at opposite transverse sides
of frame 154 for spreading dust flaps 144, and ~lexure mounted, ;;
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9 ~4~33~34
fluid operated guides 158 mounted on irame 154 for spreading the
top seal end flaps 145. :~
Rotating means 136 grasps the opened box blank B' after ~ ;
the positioning thereof to the second position under the bag
forming apparatus 132 by lifting means 130. Rotating means 136
is comprised of an expansible U-shaped support collar 160, a
mounting frame (not shown), a means for expanding support collar ~
160 (not shown) and a means for rotating support collar 160 from ~ ; :
a vertical position to a horizontal position (not shown)O Support ~ : -
collar 160 is comprised of a lower support bar 162 and two, trans- ~:
versely movable grasping arms 164 for grasping box blank B' along ` ~:~
the lower portions of side panels 142. Support bar 162 of support
collar 160 also holds the bottom of box blank B' to retain the
received bag P within the box blank.
In operation, lifting means 130 travels down an angle
and picks up the formed box blank B' with ~luid operated clamps .
150. Lifting means 130 together with box blank B' is then lifted
upwardly at an angle into position under bag forming apparatus
132. As box blan~ B' is lifted upwardly to the uppermost posi- ;~
tion thereof, the end flaps 143 of box blank Bl come into engage~
ment with guides 156 and guides 158 of flap spreader means 134.
Guides 158 are then rotated outwardly a small amount to spread
apart seal end flaps 145 and to present an inner surface thereof
to a bag P being dropped downwardly, the inner surfaces of guides -:~
158 guiding the dropped bag P into box blank Blo Just prior to .~ -~
the dropping of bag P, rotating means 136 travels upwardly
whereupon support bar 162 thereof engages the bottom of box i~
blank Bl. Grasping arms 164 are then moved into engagement with .;.
the bottom sections of side panels 142 of box blank B'~ When bag
P is in box blank B', clamps 150 of lifting means 130 are dis~
engaged and the rotating means 136 is lowered to its bottommost ~ .
position. Upon reaching its bottommost position, rota~ing means
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3~9~
136 is rotated until it is in a horizontal position whereupon
grasping arms 164 are moved outwardly to disengage from the bag-
filled box blank B'. The box closing and sealing means 28 now
receive box blank B~ and close and seal end flaps 143 to produce
the final sealed carton Bb'~
BOX SEALING AND CLOSING MEANS
Box closing and forming means, as shown in Figures 1,
10, and 11, is comprised of a carrier means 170 for receiving
the bag-filled box blank B' from depositing means 26, for securely
holding box blank B', and for delivering a sealed box blank B" and
a conveyor means 172 for conveying carrier means 170 to a plurality
of longitudinally spaced, in-line stations, including a receiving
station 174 for receiving box blank Bl and a delivering station
176 for delivering a sealed box blank B~o Box closing and forming ~ :
means 28 further comprises dust flap closure means 178 located at ;.
a second station 180, a seal end flap closure means 182 located ~ :
at a third station 184, and a sealing means 186 located at a ~ `
fourth station 1~8. The various components of box closing and
forming means 28 are mounted on a single elongated frame 190 which `~
is in turn mounted on four legs 1920
Conveyor means 172 comprises a rotatable endless con-
veyor 200 that is in turn comprised of two endless chains 202, a
rotatable end sprocket 204 with sprocket wheels 206 and 208 for ~ .
engagement with corresponding chains 202, and a driving end ~ : :
sprocket 210 for rotating and supporting chains 202 at the other
end thereof, Conveyor 200 is continuously operated by a drive ~::
means (not shown)O
Carrier means 170 is comprised of a plurality of iden~
tical carriers212 that are e~ually spaced around and rigidly
attached to endless conveyor 200, In the embodiment shown in
the drawings, carrier means 170 is comprised of eight identical
carriers 212 and thus eight sealed box blank B" can be produced
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394
for each complete revolution of conveyor 200. Carrler 212 is
depicted in greater detail i~ Figures 12 and 14. In general,
carrier 212 comprises a non-rotatable frame 214 rigidly mounted ~ :
.. . .
to and supported by conveyor 200, a carrier tray 216 rotatably :
mounted on frame 214 for receiving the bag-filled box blank B',
and a means 218 for rotating carrier tray 216. Carrier tray 216 ;
is positioned longitudinally parallel to conveyor 200 for re-
ceiving a bag-filled box blank B' and for delivering a sealed
box blank B", and is positioned transversely for presenting end .` :
flaps 143 to the various stations for closing and sealing the
end flaps. .; i~
With particular reference to Figures 12 and 14, carrier ~ :
tray 216 comprises two generally horizontal tray sections 220 and
222, elongated cylindrical support rods 224 and 226, bearing
blocks 228 and 230 for slidably mounting tray sections 220 and
222, respectively, on support rods 224 and 226, and a central
bearing member 232 for rotatably mounting carrier tray 216 onto
frame 2140 Each tray section 220 and 222 includes a horizontal ;~
plate 234 and a vertical back 236. Bearing blocks 228 and 230 are `~
2Q rigidly mounted to the bottom of the corresponding plate 234 of :~
tray sections 220 and 222 with securing means such as screws 238.
Rigidly mounted onto the ends of support rods 224 and 226 are two
end plates 240 and 242 for keeping the support rods in proper
alignment and further for providing a backing surface for two :.
pairs of coil springs 244 and 246 concentrically mounted, res-
pectively, around each end of support rods 224 and 226. The other
ends of springs 244 and 246 bear against the end of bearing blocks
228 and 230 for resiliently urging tray sections 220 and 222 toward :~
each other. Thus, when a bag-filled box blank B' has been deli-
30 vered to carrier 212, the box blank B' can be securely held in .
place on top of carrier tray 216 by tray section backs 236 which
resiliently engage corresponding side panels 142 of the box blank :
B~
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:
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39~ ~
frame 190 between conveyor chains 202, Thus, as a carrier 212 `~
enters receiving station 174, carrier tray 216 is in the first,
opened position with tray sections 220 and 222 aligned parallel
to conveyor chains 202. As carri0r 212 is moved through receiving
station 17~, a box blan~ B' is placed on carrier tray 216 by
depositing means 260 As carrier 212 is conveyed out of receiving
station 174, cam follower 256 engages elongate cam 258 and upon ;
further longitudinal movement of carrier 212 with respect to
elongate cam 258, cam follower 256 is guided along cam surface -
260, thereby rotating carrier tray 90 to the second, closed -~
position. Hence, as carrier 212 is conveyed to second station
180, carrier tray 216 has been rotated such that tray sections220
and 222 are positioned in a transverse direction with the tray
sections being forced closer together by springs 244 and 2~6. ~ -
A second elongate cam 262 is rigidly mounted to frame ;~
190 at delivery station 176. Elongate cam 262, shown in Figure
14A, has a cam surface 264 that is the functional opposite of cam
surface 260 so that elongate cam 262 rotates carrier tray 216 in
the counterclockwise direction back to the position of carrier
tray 216 shown in Figure 120 The interaction of cam follower 256
with cam 262 and the resultant rotation of carrier 212 is similar
to that described above regarding elongate cam 258D Obvious means
such as springs and engaging disc camscan be further employed t~
ensure the positive rotation of carrier tray 216 between the first ~ ,
and second positions thereof. Furthermore, stop means can be used ;~
to ensure that carrier tray 216 does no-t overshoot the desired
rotational position thereof. These and other means to ensure
effective positioning of carrier tray 216 are conventional and
well known and need not be described in further detail herein. ~ ;~
A sealed box blank B" is produced in the second through
fourth stations o~ box closing and forming means 28. At second
station 180, dust flap closure means 178 tuck in and close dust
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': i : . :, . . .
394
flaps 14~ of box blank B'. Dust flap closure means 17~ comprises
a first pair of stationery tucking members 270 and 272 for tucking
in the leading dust flaps of box blank B'. Tucking members 270
and 272 are rigidly mounted onto -frame 190 on either side of end-
less conveyor 200. In the embodiment of the invention depicted ; :~
in Figures 10 and 11, tucking members 270 and 272 include a plate-
like main body 274 and an integrally attached, triangularly shaped ~ .
in elevation forward section 276, In plan view as shown in Figure ~
10, it could also be seen that forward section 276 is comprised of ;
an inclined ramp for gradually engaging dust flaps 144. A pair of ~.
parallelly spaced, horizontally extending guide rails 278 having
outwardly slanted forward guide rail extensions 279 are mounted
on frame 190 just inside first tucking members 270 and 272. Guide -~
rail extensions 279 initially engage box blank B' and center the
box blank on carrier tray 216 as carrier 212 is conveyed through ~ ~ :
station 1800 Dust flap closure means 178 further comprises a
second pair of dust flap tucking members 280 and 282. Tucking ~ :
members 280 and 2~2 each comprises an inverted L-shaped member . :
pivotably mounted at the lower end thereof ~o frame 190~ Tucking
members 280 and 282 are automatically rotated by fluid means (not
shown) when carrier 212 reaches a certain location in second
station 184. In one embodiment, the rotation of tucking members ;
280 and 282 is initiated by a microswitch (not shown) that is
tripped by carrier 212, The longitudinal position of carrier 212
when second tucking members 280 and 282 are rotated, is such that
the bases of the members engage (as shown in Figure 16C) the rear
dust flaps 144 of box blank Bl and hold the rear dust flaps in
place until box blank B' has been advanced sufficiently that the ,~
tucked in dust ~lap is also engaged by guide rail extensions 279
of guide rails 278, The main section of guide rails 278 engage .:~
the corresponding ends of box blank B' between the open seal end
flaps 145 and hold dust flaps 144 in the tucked in position as box
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, . . . .
1~4~33~
blank B' is conveyed to the third station 184, Located at the -
beginning of the third station 184 are a pair o~ hot melt glue
applicators 284 and 286, Glue applicators 284 and 286 apply a
string of glue to the bottom seal end flap and apply a dot of glue
to each end of the top seal end flap respectively. If desired,
additional glue applicators can be provided to apply glue to both
inside and outside seal end ~laps lg5.
Seal end flap closure means 182 comprise upper and lower .;~
sheet metal guides 288 and 290, Guides 288 and 290 are mounted
onto frame 190 at either side of conveyor 200 and engage first ; :
the uppermost seal end flap Pirst and then the bottommost seal .
end flap for closing the respective flaps in the desired orderO :;-
Guide 288 comprises a blade section 292 having a blunt, downwardly
curved, convex leading edge 294, The lower guide 290 has a simi~
lar blade section 296, but with an upwardly curved, blunt, convex
leading edge 298, Guides 288 and 290 each respectively comprise -~
elongate guide bars 300 and 302 mounted at the rearward ends
thereof to frame 190 and rigidly attached to and supporting blade
sections 292 and 296, respectively, at the other end thereofO As
can be seen in Figure 10, guides 288 and 290 are located on either
side of conveyor 200 and are positioned so as to engage the out~
wardly extending seal end flaps at the top and bottom of box blank
B'. Guide bars 300 and 302 finish closing seal end flaps 145 of
box blank Bt and apply pressure to compress and set the hot melt .
glue, :
Sealing means 186 located at third s-tation 184 thus can ,; ~;r~
be thought of as comprising guide bars 300 and 3020 In addition,
sealing means 186 comprises a pair of based elongate parallel
pressure bars 304 and 306 which are rigidly mounted on frame 190
on either side of conveyor 200 and just rearwardly of the rearward
ends of guide bars 300 and 302, Pressure bars 304 and 306 engage ~
the closed ends of the sealed box blank B" and hold the sealed end ~ : :
.
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,. . .. .. . . .
1~41~3~
flaps 145 thereof in position for a longer period of time as box
blank B" is conveyed therealong to ensure the setting of the glue. ;
As mentioned above, elongate cam 262 is mounted at
delivery station 176 for engaging cam follower 256 and for ro-
tating carrier tray 216. As carrier tray 216 is rotated, tray
sections 220 and 222 are urged apart by the interaction of cam ~
-followers 250 and 252 with disc cam 248, Thus, as carrier 212 is ``
conveyed to the end of delivery station 176 and around end sprock-
, . . .
et 204, sealed box blank B" is released from carrier 212 and deli-
verçd to any desired supporting structure (not shown).
The operation of box closing and forming means 28 is
schematically shown in Figures 15 through 19, In Figure 15A,
carrier tray 216 is shown in the open, loading position with tray
sections 220 and 222 spaced apart so that a box blank B' can be
inserted in between backs 236, as shown in Figure 15B, Carrier
tray 216 is then rotated 90 and during the rotation thereo-f, as
described hereinabove, tray sections 222 and 224 are urged toward
each other with backs 236 engaging the sides of box blank Bl,
Thus, carrier tray 216 clamps box blank B' as carrier tray 216
is rotated by the camming action between elongate cam 258 and
cam follower 256. Figure 16 depicts the operation of dust flap
closure means 1780 As box blank B' engages dust flap closure
means 178, box blank Bl is posltioned on carrier tray 216 by guide
rail extensions 279 and the leading dust flaps 144 are folded in~
wardly. The folding operation of the leading dust flaps 144 con-
tinues as box blank B' is moved longitudinally into tucking members
270 and 272 shown in Figure 16C. The rear dust flaps are then
. ..: .,
tucked in by the operation of pivotable second, tucking members ;~
280 and 282, The tucking of the rear dust flaps is timed so as
to tuck the dust -flaps under the guide rail extensions 279, which
then holds both tucked in dust flaps 144 in place, as shown in
Figure 16B, As shown in Figure 17, with front and rear dust flaps
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1q~4~39~
tucked in and seal end flaps extended, box blank B~ is advanced
toward glue applicators 284 and 286. Hot melt glue is then ~;
applied to the insides of the seal ends and the seal ends are
folded down by seal end flap closure means 182, shown in Figures
17B, and 17C.
Finally, with reference to Figures 18 and 19, the ends
of the sealed box blank B" are compressed by pressure bars 304
and 306 so that the seal end flaps 145 are held down giving the
adhesive time to set. Thus, the length of pressure bars 304 and
the rotational rate of conveyor 200 determine the additional time
provided for setting the glue. Finally, as shown in Figure 19, -
after sealed box blank B" has been conveyed a sufficient distance
away from pressure bars 304 and 306, carrier tray 216 is inde~ed
90 back to its initial position, thereby opening tray sections
220 and 222 from another. The sealed box blank B" is then dis~
charged from carrier tray 216 which completes one complete cycle
of box closing and forming means 28.
Although the invention has been described in detail ;~ ~-
with respect of its exemplary embodiments thereof, it will be
understoo~ of those of ordinary skill in the art that variations
and modifications may be effected within the scope and spirit of
the inventlon.
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