Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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REINFORCED POLYGONAL CONTAINERS AND
BLANKS FOR MAKING THE SAME
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This patent application claims priority to U.S. Provisional Patent
Application Serial No. 61/822,094, filed on May 10, 2013.
BACKGROUND
[0002] The embodiments described herein relate generally to a blank and
a reinforced polygonal container formed from the blank and more particularly,
to a blank
of sheet material for forming a reinforced polygonal container having end
panels, side
panels, and reinforcing panels, wherein the reinforcing panels are attached to
an outer
surface of the side panels so that each interior face of the container is
substantially planar.
[0003] Containers are frequently utilized to store and aid in transporting
products. These containers can be square, hexagonal, or octagonal. The shape
of the
container can provide additional strength to the container. For example,
octagonal-
shaped containers provide greater resistance to bulge over conventional
rectangular,
square or even hexagonal-shaped containers. An octagonal-shaped container may
also
provide increased stacking strength.
[0004] In at least some known blank of sheet material is used to form a
container for transporting a product. More specifically, these known
containers are
formed by a machine that folds a plurality of panels along fold lines and
secures these
panels with an adhesive. Such containers may have certain strength
requirements for
transporting products. These strength requirements may include a stacking
strength
requirement such that the containers can be stacked on one another during
transport
without collapsing. To meet these strength requirements, at least some known
containers
include reinforced corners or side walls for providing additional strength
including
stacking strength. In at least some known embodiments, additional panels may
be placed
in a face-to-face relationship with a corner panel or side panel. However, it
is difficult to
form a container from a single sheet of material that includes multiple
reinforcing panels
along the corner and side panels.
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[0005] Additionally, in at least some known containers, reinforced comer
or side panels are attached to an interior surface of the formed container.
Containers
having reinforced corner or side panels attached to an interior surface of the
container
are less than optimal for certain applications, such as storing and
transporting fresh fruit
or produce, because the interior reinforced panels create non-planar interior
surfaces that
can damage or "bruise" the contents within the container. Accordingly, a need
exists for
a reinforced container formed from a single blank that can be easily formed at
high-
speeds and that has a generally planar interior surface.
BRIEF DESCRIPTION
[0006] In one aspect, a blank of sheet material for forming a polygonal
container is provided. The blank includes a bottom panel; two opposing side
panels, each
side panel extending from a side edge of the bottom panel; two opposing end
panels, each
end panel extending from an end edge of the bottom panel; and a reinforcing
panel
assembly extending from a first side edge of a first end panel of the two end
panels, the
reinforcing panel assembly comprising: a comer panel extending from the first
side edge
of the first end panel; a first reinforcing side panel extending from a side
edge of the
corner panel; a second reinforcing side panel extending from a side edge of
the first
reinforcing side panel; a reinforcing comer panel extending from a side edge
of the
second reinforcing side panel; and an inner end panel extending from a side
edge of the
reinforcing corner panel, wherein the comer panel and the reinforcing corner
panel are
configured, upon articulation of the blank, to be positioned into face-to-face
relationship
to form a corner wall of the container extending at an oblique angle from a
side edge of
an end wall of the container to an end edge of a side wall of the container;
wherein the
corner panel has a first height, and the reinforcing corner panel has a second
height that
is less than the first height; wherein the reinforcing comer panel includes
opposing top
and bottom edges, and wherein the difference between the first height and the
second
height is substantially equal to a thickness of the bottom panel such that the
bottom edge
of the reinforcing corner panel rests on the bottom panel when the container
is formed.
[0007] In another aspect, a polygonal container formed from a blank of
sheet material is provided. The container includes a bottom panel; two
opposing side
panels, each side panel extending from a side edge of the bottom panel; two
opposing
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end panels, each end panel extending from an end edge of the bottom panel; and
a
reinforcing panel assembly extending from a first side edge of a first end
panel of the
two end panels, the reinforcing panel assembly comprising: a corner panel
extending
from the first side edge of the first end panel; a first reinforcing side
panel extending
from a side edge of the corner panel; a second reinforcing side panel
extending from a
side edge of the first reinforcing side panel; a reinforcing corner panel
extending from a
side edge of the second reinforcing side panel; and an inner end panel
extending from a
side edge of the reinforcing corner panel, wherein the comer panel and the
reinforcing
corner panel are configured, upon articulation of the blank, to be positioned
into face-to-
face relationship to form a corner wall of the container extending at an
oblique angle
from a side edge of an end wall of the container to an end edge of a side wall
of the
container; and wherein the comer panel has a first height, and the end panel
has a second
height that is less than the first height such that an outer edge of the
bottom panel rests
against the corner panel when the container is folined.
[0008] In yet another aspect, a method for forming a polygonal container
from a blank of sheet material is provided. The blank includes a bottom panel;
two
opposing side panels, each side panel emanating from a side edge of the bottom
panel;
two opposing end panels, each end panel emanating from an end edge of the
bottom
panel; and a reinforcing panel assembly extending from a first side edge of a
first end
panel of the two end panels, the reinforcing panel assembly comprising a
corner panel
extending from the first side edge of the first end panel, a first outer
reinforcing side
panel extending from a side edge of the corner panel, a first inner
reinforcing side panel
at least partially overlying the first outer reinforcing side panel, and a
reinforcing comer
panel positioned in face-to-face relationship with the corner panel, the comer
panel and
the reinforcing comer panel forming a corner wall extending between the first
end panel
and a first side panel of the two side panels and at an oblique angle to the
first end panel;
wherein at least a portion of the reinforcing panel assembly is attached to an
exterior
surface of the first side panel, wherein the first inner reinforcing side
panel is adhered to
the exterior surface of the first side panel.
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BRIEF DESCRIPTION OF THE DRAWINGS
[0009] Figure 1 is a top plan view of a blank of sheet material for
constructing a container according to a first embodiment of the present
disclosure.
[0010] Figure 2 is a perspective view of a container formed from the blank
shown in Figure 1.
[0011] Figure 3 is a top plan view of a blank of sheet material for
constructing a container according to a first alternative embodiment of the
present
disclosure.
[0012] Figure 4 is a perspective view of a container formed from the blank
shown in Figure 3.
[0013] Figure 5 is a top plan view of a blank of sheet material for
constructing a container according to a second alternative embodiment of the
present
disclosure.
[0014] Figure 6 is a perspective view of a container formed from the blank
shown in Figure 5.
[0015] Figure 7 is a top plan view of a blank of sheet material for
constructing a container according to a third alternative embodiment of the
present
disclosure.
[0016] Figure 8 is a perspective view of a container formed from the blank
shown in Figure 7.
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[0017] Figure 9 is a top plan view of a blank of sheet material for
constructing a container according to a fourth alternative embodiment of the
present
disclosure.
[0018] Figure 10 is a perspective view of a container that is partially formed
from the blank shown in Figure 9.
[0019] Figure 11 is a perspective view of a container formed from the blank
shown in Figure 9.
[0020] Figure 12 is a top plan view of a blank of sheet material for
constructing a container according to a fifth alternative embodiment of the
present
disclosure.
[0021] Figure 13 is a perspective view of a container formed from the blank
shown in Figure 12.
[0022] Figure 14 is a top plan view of a blank of sheet material for
constructing a container according to a sixth alternative embodiment of the
present
disclosure.
[0023] Figure 15 is a perspective view of a container formed from the blank
shown in Figure 14.
[0024] Figure 16 is a top plan view of a blank of sheet material for
constructing a container according to a seventh alternative embodiment of the
present
disclosure.
[0025] Figure 17 is a perspective view of a container formed from the blank
shown in Figure 16.
[0026] Figure 18 is a top plan view of a blank of sheet material for
constructing a container according to an eighth alternative embodiment of the
present
disclosure.
[0027] Figure 19 is a perspective view of a container formed from the blank
shown in Figure 18.
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[0028] Figure 20 is a side view of a machine for forming a container from a
blank.
[0029] Figure 21 is a top view of the machine shown in Figure 20.
[0030] Figure 22 is a perspective view of a hopper station of the machine
shown in Figures 20 and 21.
[0031] Figure 23 is perspective view of the hopper station shown in Figure
22 and a forming station of the machine shown in Figures 20 and 21.
[0032] Figure 24 is another perspective view of the forming station of the
machine shown in Figures 20 and 21.
[0033] Figure 25 is a perspective view of an initial forming station of the
forming station shown in Figures 23 and 24.
[0034] Figure 26 is an enlarged view of the initial forming station shown in
Figure 25.
[0035] Figure 27 is a perspective view of rotatable guide rails suitable for
use in the forming station shown in Figures 23 and 24.
[0036] Figure 28 is a perspective view of a secondary forming station of the
forming station shown in Figures 23 and 24.
[0037] Figure 29 is another perspective view of the secondary forming
station shown in Figure 28.
[0038] Figure 30 is an enlarged view of the secondary forming station
shown in Figures 28 and 29.
[0039] Figure 31 is a schematic cross-sectional view of the secondary
forming station shown in Figures 28-30.
[0040] Figure 32 is a perspective view of transfer mechanisms suitable for
use in an upstream end of the secondary forming station shown in Figures 28-
30.
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[0041] Figure 33 is another perspective view of the secondary forming
station shown in Figure 28.
[0042] Figure 34 is a perspective view of an angling station and a second
adhesive application station of the forming station shown in Figures 23 and
24.
[0043] Figure 35 is another perspective view of the angling station and the
second adhesive application station shown in Figure 34.
[0044] Figure 36 is a perspective view of a compression station of the
forming station shown in Figures 23 and 24, the compression station having a
blank
positioned therein.
[0045] Figure 37 is another perspective view of the compression station
shown in Figure 36.
[0046] Figure 38 is a top perspective view of the compression station shown
in Figure 36 without a blank positioned therein.
[0047] Figure 39 is another perspective view of the compression station
shown in Figure 36.
[0048] Figure 40 is another perspective view of the compression station
shown in Figure 36 without a blank positioned therein.
[0049] Figure 41 is a perspective view of the compression station shown in
Figure 36 from a bottom end of the compression station.
[0050] Figure 42 is a perspective view of an ejection station of the machine
shown in Figures 20 and 21.
DETAILED DESCRIPTION
[0051] The following detailed description illustrates the invention by way of
example and not by way of limitation. The description clearly enables one
skilled in the art
to make and use the invention, describes several embodiments, adaptations,
variations,
alternatives, and uses of the invention, including what is presently believed
to be the best
mode of carrying out the invention.
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[0052] The present disclosure provides a stackable, reinforced container
formed from a single sheet of material, and a method for constructing the
container. The
container is sometimes referred to as a reinforced mitered tray or a
reinforced eight-sided
tray. This reinforced miter tray is configured to have a generally planar
interior surface
because the reinforcing panel assemblies are attached to the exterior surface
of the
container. Thus, the container provides a reinforced-structure without an
uneven interior
surface that may damage the product placed inside the container. The container
may be
constructed from a blank of sheet material using a machine. In one embodiment,
the
container is fabricated from a corrugated cardboard material. The container,
however, may
be fabricated using any suitable material, and therefore is not limited to a
specific type of
material. In alternative embodiments, the container is fabricated using
cardboard, plastic,
fiberboard, paperboard, foamboard, corrugated paper, and/or any suitable
material known
to those skilled in the art and guided by the teachings herein provided.
[0053] In an example embodiment, the container includes at least one
marking thereon including, without limitation, indicia that communicates the
product, a
manufacturer of the product and/or a seller of the product. For example, the
marking may
include printed text that indicates a product's name and briefly describes the
product, logos
and/or trademarks that indicate a manufacturer and/or seller of the product.
and/or designs
and/or ornamentation that attract attention. "Printing," "printed," and/or any
other form of
"print" as used herein may include, but is not limited to including, ink jet
printing, laser
printing, screen printing, giclee, pen and ink, painting, offset lithography,
flexography,
relief print, rotogravure, dye transfer, and/or any suitable printing
technique known to those
skilled in the art and guided by the teachings herein provided. In another
embodiment, the
container is void of markings, such as, without limitation, indicia that
communicates the
product, a manufacturer of the product and/or a seller of the product.
[0054] Referring now to the drawings, and more specifically to Figure 1,
which is a top plan view of an example embodiment of a blank 10 of sheet
material. A
container 150 (shown in Figure 2) is formed from blank 10. Blank 10 has a
first or interior
surface 12 and an opposing second or exterior surface 14. Further, blank 10
defines a
leading edge 16 and an opposing trailing edge 18. In one embodiment, blank 10
includes,
in series from leading edge 16 to trailing edge 18, a first top panel 20, a
front panel 22
(generally, a first side panel), a bottom panel 24, a rear panel 26
(generally, a second side
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panel), and a second top panel 28 coupled together along preformed, generally
parallel,
fold lines 30, 32, 34, and 36. respectively. More specifically, first top
panel 20 extends
between leading edge 16 and fold line 30, first side panel 22 extends from
first top panel 20
along fold line 30 to fold line 32, bottom panel 24 extends from first side
panel 22 along
fold line 32, second side panel 26 extends from bottom panel 24 along fold
line 34 to fold
line 36, and second top panel 28 extends from second side panel 26 along fold
line 36 to
trailing edge 18. When a container 150 (shown in Figure 2) is formed from
blank 10, fold
line 30 defines a front edge of top panel 20 and a top edge of first side
panel 22, and fold
line 36 defines a top edge of second side panel 26 and a rear edge of top
panel 28.
[0055] Fold lines 30, 32, 34, and/or 36, as well as other fold lines and/or
hinge lines described herein, may include any suitable line of weakening
and/or line of
separation known to those skilled in the art and guided by the teachings
herein provided.
As noted above, front and rear panels 22 and 26 may be considered side panels.
When
container 150 is formed from blank 10, fold line 32 defines a bottom edge of
first side
panel 22 and a front edge, or first side edge, of bottom panel 24, and fold
line 34 defines a
rear edge, or second side edge, of bottom panel 24 and a bottom edge of second
side panel
26. As used throughout this description, front edges and rear edges are also
considered to
be side edges and outer edges of bottom panel 24. In the example embodiment,
four oval
shaped cutouts 38 are defined within first and second side panels 22 and 26.
In an
alternative embodiment, cutouts 38 may be of any shape and/or defined within
any suitable
panel, such as first end panel 64 and/or second end panel 70, described in
more detail
below. Alternatively, blank 10 may include more or less than four cutouts 38,
or blank 10
may not include any cutouts 38.
[0056] First side panel 22 and second side panel 26 are substantially
congruent and have a rectangular shape. Bottom panel 24 has an octagonal
shape. More
specifically, first side panel 22 and second side panel 26 have a width Wi.
Bottom panel
24 has a width W2, which is longer that width W1. Alternatively, width W1 is
substantially
equal to or longer than width W2. Further, in the example embodiment, first
and second
side panels 22 and 26 have a first height HI, and bottom panel 24 has a first
depth D1 that is
larger than first height Hi. In an alternative embodiment, height Hi is
substantially equal to
or larger than depth DI. In the example embodiment, first side panel 22,
second side panel
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26, and/or bottom panel 24 are equally dimensioned, however, first side panel
22, second
side panel 26, and/or bottom panel 24 may be other than equally dimensioned.
[0057] In the example embodiment, bottom panel 24 may be considered to
be substantially rectangular in shape with four cut-off corners or angled
edges 40, 42, 44,
and 46 formed by cut lines. As such, the cut-off corner edges of otherwise
rectangular
bottom panel 24 define an octagonal shape of bottom panel 24. As used
throughout this
description, angled edges 40, 42, 44, and 46 are considered outer edges of
bottom panel 24.
Moreover, each angled corner edge 40, 42, 44, and 46 has a length Li, and
angled edges 40
and 44 and angled edges 42 and 46 are substantially parallel. Alternatively,
bottom panel
24 may have any suitable shape that enables container 150 to function as
described herein.
For example, bottom panel 24 may be in the shape of a rectangle having corners
that are
truncated by a segmented edge such that bottom panel 24 has more than eight
sides. In
another example, bottom panel 24 may be in the shape of a rectangle having
corners that
are truncated by an arcuate edge such that bottom panel 24 has four
substantially straight
sides and four arcuate sides.
[0058] In the example embodiment, first side panel 22 includes two free
side edges 48 and 50, and second side panel 26 includes two free side edges 52
and 54.
Side edges 48, 50, 52, and 54 are substantially parallel to each other.
Alternatively, side
edges 48, 50, 52, and/or 54 are other than substantially parallel. In the
example
embodiment, each side edge 48, 50, 52, and 54 is connected to a respective
angled edge 40,
42, 44, or 46. Each side edge 48, 50, 52, and 54 may be directly connected to
a respective
angled edge 40, 42, 44, or 46 or, as shown in Figure 1, may be slightly offset
from a
respective angled edge 40, 42, 44, or 46 to facilitate forming container 150
from blank 10
by allowing clearance for a thickness of a panel that is directly or
indirectly attached to first
side panel 22 or second side panel 26. Side edges 48, 50, 52, and 54 and
angled edges 40,
42, 44, and 46 partially define a respective cutout 56, 58, 60, or 62. More
specifically, side
edge 48 and angled edge 40 partially define cutout 56, side edge 52 and angled
edge 42
partially define cutout 60, side edge 54 and angled edge 44 partially define
cutout 62, and
side edge 50 and angled edge 46 partially define cutout 58.
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[0059] A first end panel 64 extends from bottom panel 24 along a fold line
66 to a free edge 68, and a second end panel 70 extends from bottom panel 24
along a fold
line 72 to a free edge 74. Fold line 66 defines a bottom edge of first end
panel 64 and a
side edge of bottom panel 24, and fold line 72 defines a bottom edge of second
end panel
70 and a side edge of bottom panel 24. First and second end panels 64 and 70
are each
generally rectangularly shaped. End panels 64 and 70 each have a depth D2 that
is shorter
than depth DI such that end panels 64 and 70 are narrower than bottom panel
24. In the
example embodiment, end panels 64 and 70 each have a height H2 such that
height H2 is
substantially equal to height H1. Alternatively, height H2 is other than equal
to height F11.
In the example embodiment, fold line 66 extends between ends of angled corner
edges 40
and 42, and fold line 72 extends between ends of angled corner edges 44 and
46.
[0060] In the example embodiment, a reinforcing panel 76 extends from
side edges of each end panel 64 and 70. Reinforcing panel 76 is also referred
to herein as a
reinforcing panel assembly that includes a plurality of panels as described in
more detail
herein. Each side edge of end panels 64 and 70 is defined by a respective fold
line 78, 80,
82, or 84. Fold lines 78, 80, 82, and 84 are substantially parallel to each
other.
Alternatively, fold lines 78, 80, 82, and/or 84 are other than substantially
parallel. In the
example embodiment, each reinforcing panel assembly 76 includes a free bottom
edge 86.
Each free bottom edge 86 at least partially defines cutouts 56, 58, 60, and
62. Further, each
reinforcing panel assembly 76 is substantially similar and includes an outer
reinforcing
panel assembly 88, an inner reinforcing panel assembly 90, and an inner end
panel 92
connected along substantially parallel fold lines 94 and 96. Fold line 94
defines a side edge
of outer reinforcing panel assembly 88 and a side edge of inner reinforcing
panel assembly
90, and fold line 96 defines a side edge of inner reinforcing panel assembly
90 and a side
edge of inner end panel 92. Moreover, outer reinforcing panel assembly 88
includes a
corner panel 98 and a first reinforcing side panel 100, and inner reinforcing
panel assembly
90 includes a reinforcing corner panel 102 and a second reinforcing side panel
104. Each
reinforcing panel assembly 76 is configured to form a reinforcing corner
assembly 151
(shown in Figure 2) when container 150 is formed from blank 10.
[0061] More specifically, outer reinforcing panel assembly 88 extends along
each of fold lines 78, 80, 82, and 84. Further, inner reinforcing panel
assembly 90 extends
from each outer reinforcing panel assembly 88 along fold line 94, and inner
end panel 92
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extends from each inner reinforcing panel assembly 90 along fold line 96 to a
free edge
106. Inner reinforcing panel assemblies 90 and outer reinforcing panel
assemblies 88 are
substantially rectangular in shape. More specifically, inner reinforcing panel
assemblies 90
have a width W3, and outer reinforcing panel assemblies 88 have a width W4,
which is
substantially equal to width W3. Further, in the example embodiment, corner
panel 98,
first reinforcing side panel 100, and second reinforcing side panel 104 have a
height H3 that
is greater than height H2 of end panels 64 and 70 such that, when container
150 (Figure 2)
is formed, corner panel 98, first reinforcing side panel 100, and/or second
reinforcing side
panel 104 are in face-to-face relationship with an outer edge of bottom panel
24 as shown
in Figure 2. In an alternative embodiment, height H3 is equal to or less than
height H2.
Further, in the example embodiment, inner end panel 92 and reinforcing corner
panel 102
have a height H4 that is less than height H3. Accordingly, bottom edge 86
includes an outer
bottom edge 108 and an inner bottom edge 110 which is offset from outer bottom
edge
108. In the example embodiment, outer bottom edge 108 extends from a
respective fold
line 78, 80, 82, or 84 to fold line 114, and inner bottom edge 110 extends
from fold line
114 to free edge 106. In the example embodiment, the difference between height
H3 and
H4 is substantially equal to a thickness of the bottom panel 24, such that at
least a portion
of inner bottom edge 110 rests on bottom panel 24 when blank 10 is articulated
to form
container 150.
[0062] Each outer reinforcing panel assembly 88 includes a fold line 112
that bisects each outer reinforcing panel assembly 88 into corner panel 98 and
first
reinforcing side panel 100. Fold line 112 defines an edge of comer panel 98
and a side
edge of first reinforcing side panel 100, and fold line 94 defines a side edge
of first
reinforcing side panel 100. In the example embodiment, comer panel 98 and
first
reinforcing side panel 100 are substantially rectangular. Further, in the
example
embodiment, each inner reinforcing panel assembly 90 includes a fold line 114
that bisects
each inner reinforcing panel assembly 90 into reinforcing corner panel 102 and
second
reinforcing side panel 104. Fold line 114 defines an edge of reinforcing
corner panel 102
and a side edge of second reinforcing side panel 104, fold line 96 defines a
side edge of
reinforcing corner panel 102, and fold line 94 defines a side edge of second
reinforcing
side panel 104.
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[0063] In the example embodiment, reinforcing corner panel 102 and
second reinforcing side panel 104 are substantially rectangular. Further,
corner panel 98
and reinforcing corner panel 102 are substantially congruent, and first and
second
reinforcing side panels 100 and 104 are substantially congruent.
[0064] Each corner panel 98 and each reinforcing corner panel 102 have a
width W5 that is substantially equal to length LI. In addition, each first
reinforcing side
panel 100 and second reinforcing side panel 104 have a width W6 that is
greater than width
W5. In an alternative embodiment, width W6 is other than greater than width
W5. Further,
in the example embodiment, each inner end panel 92 has a depth D3 that is
equal to
approximately half of the depth D2 of first and second end panels 64 and 70.
In an
alternative embodiment, depth D3 is other than equal to approximately half the
depth D2.
[0065] In the example embodiment, first end panel 64 includes two tabs 116
extending from free edge 68, and second end panel 70 includes two tabs 116
extending
from free edge 74. Alternatively, first end panel 64 and/or second end panel
70 may
include any suitable number of tabs 116 that enables blank and/or container to
function as
described herein. Alternatively, first end panel 64 and/or second end panel 70
does not
include any tabs 116. Moreover, it will be understood that one or more tabs
116 may be
included in any of the embodiments described herein. For example, one or more
tabs 116
may extend from leading edge 16, trailing edge 18, fold line 30, and/or fold
line 36 of the
embodiments described herein.
[0066] In the example embodiment, each inner end panel 92 includes a
reinforcing tab 118 extending from a top edge 120 of inner end panel 92. Each
reinforcing
tab 118 is positioned along top edge 120 such that reinforcing tab 118 is
substantially
aligned with, and in a face-to-face relationship with a respective tab 116 on
end panel 64 or
70 when inner end panel 92 is rotated about fold line 94 to form container 150
(described
in more detail below). Alternatively, one or more inner end panels 92 does not
include
reinforcing tab 118.
[0067] Further, in the example embodiment, a pair of cutouts 122 is defined
along each fold line 66 and 72. Cutouts 122 may have any suitable
configuration that
enables blank 10 and/or container 150 to function as described herein. In one
embodiment,
each cutout 122 is sized to receive a reinforced tab 172 (Figure 2) for
stacking containers
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150 and/or to provide venting for cavity 170 (Figure 2). Alternatively, fold
line 66 and/or
fold line 72 may include any suitable number of cutouts 122 that enables blank
10 and/or
container 150 to function as described herein. Alternatively, fold line 66
and/or fold line 72
does not include any cutouts 122. Moreover, it will be understood that cutouts
122 may be
included in any of the embodiments described herein. For example, one or more
cutouts
122 may be defined in fold lines 32 andior 34 of the embodiments described
herein.
[0068] Further, in the example embodiment, each inner end panel 92
includes a notch 124 defined in the bottom edge 86 thereof. Notch 124 is
configured to
correspond to one of cutouts 122 such that cutout 122 is not obstructed by
inner end panel
92 when container 150 is formed. In an alternative embodiment, notch 124 may
have any
suitable configuration that enables blank 10 and/or container 150 to function
as described
herein. Alternatively, one or more inner end panels 92 does not include notch
124.
Moreover, it will be understood that notch 124 may be included in any of the
embodiments
described herein on any suitable panel.
[0069] In the example embodiment, first top panel 20 and second top panel
28 are substantially congruent and have a trapezoidal shape. More
specifically, first top
panel 20 includes an angled edge 126 extending between an intersection 128 of
fold line 30
and free edge 48 toward bottom edge 86, and an angled edge 130 extending
between an
intersection 132 of fold line 30 and free edge 50 toward bottom edge 86.
Similarly, second
top panel 28 includes an angled edge 134 extending between an intersection 136
of fold
line 36 and free edge 52 toward bottom edge 86, and an angled edge 138
extending
between an intersection 140 of fold line 36 and free edge 54 toward bottom
edge 86. As
such, angled edge 126, free edge 48, angled edge 40, and bottom edge 86
partially define
cutout 56; angled edge 134, free edge 52, angled edge 42, and bottom edge 86
partially
define cutout 60; angled edge 138, free edge 54, angled edge 44, and bottom
edge 86
partially define cutout 62; and angled edge 130, free edge 50, angled edge 46,
and bottom
edge partially define cutout 58. In the illustrated embodiment, angled edges
126 and 130
are offset from the intersections 128 and 132 between fold line 30 and free
edges 48 and
50, and angled edges 134 and 138 are offset from the intersections 136 and 140
between
fold line 34 and free edges 52 and 54. in alternative embodiments, angled
edges 126, 130,
134. and/or 138 may extend from a respective intersection 128, 132, 136, or
140.
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[0070] In addition, first and second top panels 20 and 28 have a depth D4
that is smaller than half of depth DI. In an alternative embodiment, depth D4
is
substantially equal to or larger than half of depth Di. In the example
embodiment, first
side panel 22 and second side panel 26 and/or bottom panel 24 and top panels
20 and 28
are equally dimensioned, however, first side panel 22 and second side panel 26
and/or
bottom panel 24 and top panels 20 and 28 may be other than equally
dimensioned. In the
illustrated embodiment, first top panel 20 is separated from adjacent
reinforcing panel
assemblies 76 by a first side edge 142 and a second side edge 144. Similarly,
second top
panel 28 is separated from adjacent reinforcing panel assemblies 76 by first
side edge 142
and second side edge 144.
[0071] Further, in the example embodiment, each first side edge 142 and
each second side edge 144 include a notch 146 defined therein. Notch 146 is
configured to
correspond to a reinforced tab 172 (Figure 2) formed by tab 116 and
reinforcing tab 118
such that first and second top panels 20 and 28 lay flush with the top edge
174 (Figure 2) of
container 150 when container 150 is formed. In an alternative embodiment,
notch 146 may
have any suitable configuration that enables blank 10 and/or container 150 to
function as
described herein. Alternatively, one or more first side edge 142 and/or second
side edge
144 does not include notch 146. Moreover, it will be understood that notch 146
may be
included in any of the embodiments described herein on any suitable panel.
[0072] Figure 2 is a perspective view of container 150 that is formed from
blank 10 (shown in Figure 1). Although container 150 is shown as being formed
without a
product to be contained therein, container 150 may also be formed having a
product
therein. Further, container 150 may include any suitable number of products of
any
suitable shape.
[0073] Container 150 is formed using machine 1000, described in more
detail below. In the example embodiment, bottom panel 24 is sized to
correspond to
product(s) contained within container 150. Each inner end panel 92 and
respective inner
reinforcing panel assembly 90 are folded about fold line 94 such that inner
reinforcing
panel assembly 90 and outer reinforcing panel assembly 88 are in an at least
partially
overlying relationship, and such that inner end panel 92 is in an at least
partially overlying
relationship with at least a portion of first or second end panel 64 or 70.
More specifically,
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blank 10 is folded along fold line 94 such that comer panel 98 and reinforcing
corner panel
102 are substantially aligned in an at least partially overlying relationship,
first and second
reinforcing side panels 100 and 104 are substantially aligned in an at least
partially
overlying relationship, and inner end panel 92 and at least a portion of first
or second end
panel 64 or 70 are substantially aligned in an at least partially overlying
relationship. In the
example embodiment, inner end panel 92, a respective end panel 64 or 70,
reinforcing side
panels 100 and 104, and/or corner panel 98 and reinforcing corner panel 102
are secured in
the above-described relationships. For example, inner end panel 92, a
respective end panel
64 or 70, reinforcing side panels 100 and 104, and/or corner panel 98 and
reinforcing
corner panel 102 are held against the product to be contained or by a section
of machine
1000 (described in more detail below) which applies a force on exterior
surface 14 as
container 150 continues to be erected. In another example, inner end panel 92
may be
adhered to a respective end panel 64 or 70, reinforcing side panels 100 and
104 may be
adhered together, and/or corner panels 98 and 102 may be adhered together. A
reinforcing
corner assembly 151 is formed by comer panels 98 and 102, reinforcing side
panels 100
and 104, and inner end panel 92. Exterior surfaces 14 of inner end panel 92,
reinforcing
corner panel 102, and second reinforcing side panel 104 define an interior
surface of
reinforcing corner assemblies 151, and exterior surfaces 14 of corner panel 98
and first
reinforcing side panel 100 define an exterior surface of reinforcing corner
assemblies 151.
[0074] First side panel 22 is rotated about fold line 32 toward interior
surface 12, and second side panel 26 is rotated about fold line 34 toward
interior surface
12. More specifically, first side panel 22 and second side panel 26 are
rotated to be
substantially perpendicular to bottom panel 24, as shown in Figure 2. First
and second end
panels 64 and 70 are rotated about fold lines 66 and 72, respectively, toward
interior
surface 12. Reinforcing panel assemblies 88 and 90 are rotated about fold
lines 78, 80, 82,
and 84 and fold lines 96. Further, reinforcing side panels 100 and 104 are
rotated about
fold lines 112 and 114 toward corner panels 98 and 102 before or after
reinforcing panel
assemblies 88 and 90 are rotated about fold lines 78, 80, 82, and 84 and fold
lines 96. In
the example embodiment, reinforcing panel assemblies 88 and 90 and reinforcing
side
panels 100 and 104 are rotated such that reinforcing side panels 100 and 104
are
substantially perpendicular to end panels 64 and 70.
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[0075] An exterior surface of first side panel 22 is secured to an interior
surface of two adjacent reinforcing corner assemblies 151, and exterior
surface of second
side panel 26 is attached to an interior surface of two adjacent reinforcing
comer
assemblies 151. More specifically, exterior surface 14 of first side panel 22
is secured to
exterior surface 14 of two adjacent second reinforcing side panels 104, and
exterior surface
14 of second side panel 26 is secured to exterior surface 14 of two adjacent
second
reinforcing side panels 104. In the example embodiment, first side panel 22
and second
side panel 26 are adhered to respective second reinforcing side panels 104.
Alternatively,
first side panel 22 and second side panel 26 are otherwise attached to
respective second
reinforcing side panels 104 using, for example, fasteners, a bonding material,
and/or any
suitable method for attached the panels.
[0076] When container 150 is formed, interior surface 12 of first and second
side panels 22 and 26 is adjacent the side walls of the product. Further,
height H1 of first
and second side panels 22 and 26 is sized to correspond to a height of the
products within
container 150 such that height H1 is substantially equal to or greater than
the height of the
products. Bottom panel 24 forms a bottom wall 152 of container 150, first side
panel 22
and a pair of reinforcing side panels 100 and 104 forms a front wall 154 of
container 150,
and second side panel 26 and a pair of reinforcing side panels 100 and 104
forms a rear
wall 156 of container 150. Front wall 154 and rear wall 156 are also referred
to as first and
second side walls of container 150, respectively. End panel 64 and two inner
end panels 92
form a first end wall 158, and end panel 70 and two inner end panels 92 form a
second end
wall 160. Corner panel 98 and reinforcing corner panel 102 of each reinforcing
panel
assembly 76 form a respective corner wall of container 150. As shown in Figure
2, the
corner panels 98 and 102 form a first corner wall 162, a second comer wall
164, a third
corner wall 166, and a fourth corner wall 168. Bottom wall 152, first side
wall 154, second
side wall 156, first end wall 158, second end wall 160, and corner walls 162,
164, 166, and
168 define a cavity 170 of container 150. Each tab 116 and a corresponding
reinforcing tab
118 form a reinforced tab 172 extending from a top edge 174 of container 150.
[0077] To close container 150, first top panel 20 is rotated about fold line
30 toward cavity 170 such that first top panel 20 is substantially
perpendicular to first side
panel 22 and substantially parallel to bottom panel 24. Further, second top
panel 28 is
rotated about fold line 36 toward cavity 170 such that second top panel 28 is
substantially
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perpendicular to second side panel 26 and substantially parallel to bottom
panel 24. First
and second top panels 20 and 28 thereby form a top wall 176 of container 150.
As shown
in Figure 2, each of first top panel 20 and second top panel 28 are in face-to-
face
relationship with an upper edge of reinforcing corner assemblies 151 such that
at least a
portion of the upper edge of reinforcing corner assemblies 151 is covered by
top wall 176.
More specifically, interior surface 12 of first top panel 20 is in face-to-
face relationship
with an upper edge of two reinforcing corner assemblies 151, specifically, an
upper edge of
each of inner end panel 92, corner panel 98, and reinforcing corner panel 102.
Similarly,
interior surface of second top panel 28 is in face-to-face relationship with
an upper edge of
two reinforcing corner assemblies 151, specifically, an upper edge of each of
inner end
panel 92, corner panel 98, and reinforcing corner panel 102. The offset of
angled edges
126. 130, 134, and 138 permits top panels 20 and 28 to fully cover the upper
edges of
corner panel 98 and reinforcing corner panel 102. The offset of angled edges
126, 130,
134. and 138 thereby facilitates protecting corner assemblies 151 from being
damaged
during use, and further facilitates keeping moisture out of container 150.
[0078] In the example embodiment, first comer wall 162 is oriented at an
oblique angle al with respect to first side wall 154 and an oblique angle a2
with respect to
end wall 158 (shown in Figure 6). Similarly, second corner wall 164 is
oriented at an
oblique angle 131 with respect to first side wall 154 and an oblique angle 132
with respect to
end wall 160 (shown in Figure 6). Similarly, third corner wall 166 is oriented
at an oblique
angle yl with respect to second side wall 156 and an oblique angle y2 with
respect to end
wall 160, and fourth corner wall 168 is oriented at an oblique angle 61 with
respect to
second side wall 156 and an oblique angle .32 with respect to end wall 158
(shown in
Figure 6). In the example embodiment, angles al, a2, 131, 132, yl, y2, 61, and
62 are
substantially equal, however, angles al, a2, 131, 132, yl, y2, 61, and/or 62
can be other than
equal depending of the products positioned within container 150. Further, in
the example
embodiment, inner bottom edges 110 of reinforcing panel assemblies 76 arc
substantially
aligned with fold lines 66 and 72, and angled edges 40, 42, 44, and 46, and
outer bottom
edges 108 of reinforcing panel assemblies 76 overlap fold lines 32 and 34, and
angled
edges 40, 42, 44, and 46.
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[0079] As described above, second reinforcing side panels 104 of
reinforcing panel assembly 76 are attached to the exterior surface 14 of side
panels 22 and
26. The reduced height H4 of inner end panel 92 and reinforcing corner panel
102
compared to the height H3 enables reinforcing side panel 104 to be attached to
the exterior
surface 14 of first and second side panels 22 and 26 when blank 10 is
articulated to form
container 150. At the same time, reduced height H4 of inner end panel 92 and
reinforcing
corner panel 102 enables reinforcing corner panels 102 to rest on bottom panel
24 when
blank 10 is articulated to form container 150, thereby providing additional
stacking support
for container 150. Thus, the interior surfaces 12 of walls forming container
150 are
generally planar, having no open or free edges within container 150. As a
result, container
150 is better suited for transporting products that can be easily damaged
during storage or
transport, such as fresh fruit or produce.
[0080] The above-described method to construct container 150 from blank
may be performed using a machine, as described in more detail below. The
machine
performs the above-described method to continuously form container 150 from
blank 10 as
blank 10 is moved through the machine. In one embodiment, the machine includes
at least
one plow or finger to at least partially rotate at least one of panels 22, 26,
64, 70, 92, 98,
100, 102, and 104 and/or further forms container 150 using a mandrel to
complete rotating
these panels.
[0081] In alternative embodiments, blank 10 may include one or more inner
reinforcing corner panels, which partially form one or more comer walls of
container 150,
as shown and described in more detail below with reference to Figures 7 and 8.
[0082] Figure 3 is a top plan view of an example embodiment of a blank
200 of sheet material. Blank 200 is essentially similar to blank 10 (shown in
Figure 1) and,
as such, similar components are labeled with similar references. More
specifically, blank
200 does not include tabs 116, reinforcing tabs 118, cutouts 122, notches 124,
or notches
146.
[0083] Figure 4 is a perspective view of container 250 that is formed from
blank 200 (shown in Figure 3). Container 250 is essentially similar to
container 150
(shown in Figure 2) and, as such, similar components are labeled with similar
references.
More specifically, container 250 does not include reinforced tabs 172, cutouts
122, notches
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124 or notches 146. Although container 250 is shown as being formed without a
product to
be contained therein, container 250 may also be formed having a product
therein. Further,
container 250 may include any suitable number of products of any suitable
shape. To
construct container 250 from blank 200 a method that is substantially similar
to the method
for forming container 150 from blank 10 is used.
[0084] Figure 5 is a top plan view of an example embodiment of blank 300
of sheet material. Blank 300 is essentially similar to blank 10 (shown in
Figure 1) and, as
such, similar components are labeled with similar references. More
specifically, blank 300
does not include top panels 20 and 28. Moreover, blank 300 includes leading
edge 16 and
trailing edge 18 as top edges of first side panel 22 and second side panel 26,
respectively,
rather than fold lines 30 and 36. Moreover, blank 300 includes cutouts 302 on
each inner
end panel 92. Moreover cutouts 38 are defined within first and second end
panels 64 and
70, rather than first and second side panels 22 and 26. Moreover, blank 300
does not
include tabs 116, reinforcing tabs 118, cutouts 122, notches 124, or notches
146.
[0085] In the example embodiment, blank 300 includes, in series from
leading edge 16 to trailing edge 18, a first side panel 22, a bottom panel 24,
and a second
side panel 26, coupled together along preformed, generally parallel, fold
lines 32 and 34,
respectively. More specifically, first side panel 22 extends from leading edge
16 to fold
line 32, bottom panel 24 extends from first side panel 22 along fold line 32,
and second
side panel 26 extends from bottom panel 24 along fold line 34 to trailing edge
18.
[0086] In the example embodiment, a single oval shaped cutout 38 is
defined within first and second end panels 64 and 70. Further, in the example
embodiment,
each inner end panel 92 has a depth D3 that is equal to approximately half of
the depth D2
of first and second top panels 20 and 28, such that a cutout 302 extending
inward from free
edge 106 is substantially aligned with at least a portion of cutout 38. In an
alternative
embodiment, depth D3 is other than equal to approximately half the depth D2.
Alternatively, blank 300 does not include cutout 302.
[0087] Figure 6 is a perspective view of container 350 that is formed from
blank 300 (shown in Figure 5). Container 350 is essentially similar to
container 150
(shown in Figure 2) and, as such, similar components are labeled with similar
references.
More specifically, container 350 does not include top wall 176, reinforced
tabs 172, cutouts
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122, notches 124 or notches 146. Although container 350 is shown as being
formed
without a product to be contained therein, container 350 may also be formed
having a
product therein. Further, container 350 may include any suitable number of
products of
any suitable shape.
[0088] To construct container 350 from blank 300 a method that is
substantially similar to the method for forming container 150 from blank 10 is
used.
However, no top wall 176 is formed during construction of container 350, as
blank does
not include top panels 20 and 28.
[0089] Figure 7 is a top plan view of an example embodiment of a blank
400 of sheet material. Blank 400 is essentially similar to blank 300 (shown in
Figure 5)
and, as such. similar components are labeled with similar references. More
specifically,
blank 400 includes inner reinforcing corner panels 402, 404, 406, and 408.
Further, blank
400 includes fold lines 410, 412, 414, and 416 rather than free side edges 48,
50, 52, and
54.
[0090] In the illustrated embodiment, a first inner reinforcing corner panel
402 extends from first side panel 22 along fold line 410 to a free edge 418.
Fold line 410
and free edge 418 define side edges of first inner reinforcing corner panel
402, and fold
line 410 defines a side edge of first side panel 22. First inner reinforcing
corner panel 402
is substantially rectangular shaped having a top edge 420 and a bottom edge
422. Bottom
edge 422, angled edge 40, and bottom edge 86 define a removable cutout 424.
Further, first
inner reinforcing corner panel 402 has substantially height H4 such that first
inner
reinforcing comer panel 402 and reinforcing comer panel 102 have a
substantially equal
height. Top edge 420 is substantially collinear with leading edge 16, which
defines a top
edge of first side panel 22. As such bottom edge 422 is offset from fold line
32. In the
example embodiment, bottom edge 422 is offset from fold line 32 by a distance
substantially equal to the thickness of bottom panel 24. Further, first inner
reinforcing
corner panel 402 has a width W7. Width W7 is substantially equal to or greater
than length
L1. Alternatively, width W7 is less than length L1. In the illustrated
embodiment, first
inner reinforcing corner panel 402 has substantially constant width W7 from
top edge 420
to bottom edge 422 such that first inner reinforcing corner panel 402 does not
include
cutoff corners and/or tapered top and/or bottom edges.
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[0091] A second inner reinforcing corner panel 404 extends from first side
panel 22 along fold line 412 to a free edge 426, third inner reinforcing
corner panel 406
extends from second side panel 26 along fold line 414 to a free edge 428, and
fourth inner
reinforcing corner panel 408 extends from second side panel 26 along fold line
416 to a
free edge 430. In the illustrated embodiment, second inner reinforcing corner
panel 404,
third inner reinforcing corner panel 406, and fourth inner reinforcing corner
panel 408 are
each substantially rectangular and have substantially height H4 extending
between
respective top edges 432, 436, 440 and bottom edges 434, 438, and 442 such
that inner
reinforcing corner panels 404, 406, and 408 and reinforcing corner panels 102
have a
substantially equal height. Top edge 432 of second inner reinforcing comer
panel 404 is
substantially collinear with leading edge 16. As such, bottom edge 434 of
second inner
reinforcing corner panel 404 is offset from fold line 32. In the example
embodiment,
bottom edge 434 is offset from fold line 32 by a distance substantially equal
to the
thickness of bottom panel 24. Top edge 436 of third inner reinforcing corner
panel 406 is
substantially collinear with trailing edge 18. As such, bottom edge 438 of
third inner
reinforcing corner panel 406 is offset from fold line 34. In the example
embodiment,
bottom edge 438 is offset from fold line 34 by a distance substantially equal
to the
thickness of bottom panel 24. Top edge 440 of fourth inner reinforcing corner
panel 408 is
substantially collinear with trailing edge 18. As such, bottom edge 442 of
fourth inner
reinforcing corner panel 408 is offset from fold line 34. In the example
embodiment,
bottom edge 442 is offset from fold line 34 by a distance substantially equal
to the
thickness of bottom panel 24. Further, bottom edge 434 of second inner
reinforcing corner
panel 404, angled edge 46, and bottom edge 86 define a removable cutout 444,
bottom
edge 438 of third inner reinforcing corner panel 406, angled edge 42, and
bottom edge 86
define a removable cutout 446, and bottom edge 442 of fourth inner reinforcing
corner
panel 408, angled edge 44, and bottom edge 86 define a removable cutout 448.
[0092] Further, second inner reinforcing corner panel 404, third inner
reinforcing corner panel 406, and fourth inner reinforcing corner panel 408
have width W7.
Alternatively, inner reinforcing corner panels 402, 404, 406, and/or 408 may
have any
suitable dimensions that enable blank 400 and/or container 450 to function as
described
herein. In the example embodiment, inner reinforcing corner panels 404, 406,
and 408
have substantially constant width W7 from respective top edges 420, 432, 436,
440 to
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respective bottom edges 422, 434, 438, 442 such that corner panels 404, 406,
and 408 do
not include cutoff corners and/or tapered top and/or bottom edges. Further,
second, third,
and fourth inner reinforcing comer panels 404, 406, and 408 are substantially
congruent to
first comer panel 402. Alternatively, comer panels 402, 404, 406, and/or 408
are other
than congruent to each other.
[0093] In the example embodiment, fold line 410 is offset from an
intersection between angled corner edge 40 of bottom panel 24 and fold line
32, fold line
412 is offset from an intersection between angled comer edge 46 of bottom
panel 24 and
fold line 32, fold line 414 is offset from an intersection between angled
comer edge 42 of
bottom panel 24 and fold line 34, and fold line 416 is offset from an
intersection between
angled edge 44 of bottom panel 24 and fold line 34. Further, fold lines 410,
412, 414, and
416 are substantially parallel. Moreover, free edges 418, 426, 428, and 430
are
substantially parallel with fold lines 410, 412, 414, and 416. Alternatively,
free edges 418,
426, 428, and/or 430 and/or fold lines 410, 412, 414, and/or 416 are other
than parallel. In
the example embodiment, each free edge 418, 426, 428, and 430 is adjacent to
and
substantially parallel with a bottom edge 86.
[0094] Figure 8 is a perspective view of container 450 that is formed from
blank 400 (shown in Figure 7). Container 450 is essentially similar to
container 350
(shown in Figure 6) and, as such, similar components are labeled with similar
references.
Although container 450 is shown as being formed without a product to be
contained
therein, container 450 may also be formed having a product therein. Further,
container 450
may include any suitable number of products of any suitable shape.
[0095] To construct container 450 from blank 400 a method that is
substantially similar to the method for forming container 350 from blank 300
is used.
However, to construct container 450, first inner reinforcing corner panel 402
is rotated
about fold line 410 toward interior surface 12, and exterior surface 14 of
first inner
reinforcing corner panel 402 is secured to exterior surface 14 of reinforcing
corner panel
102 located on reinforcing panel assembly 76 extending from fold line 78 of
first end panel
64. More specifically, first inner reinforcing comer panel 402 is rotated such
that first
inner reinforcing corner panel 402 is oriented at oblique angle al to first
side wall 154.
Similarly, second inner reinforcing comer panel 404 is rotated about fold line
412 toward
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interior surface 12. Exterior surface 14 of second reinforcing corner panel
404 is secured to
exterior surface 14 of reinforcing corner panel 102 located on reinforcing
panel assembly
76 extending from fold line 82 of second end panel 70. More specifically,
second inner
reinforcing corner panel 404 is rotated such that second inner reinforcing
corner panel 404
is oriented at oblique angle 131 to first side wall 154.
[0096] In the example embodiment, free edges 418 and 426 of inner
reinforcing corner panels 402 and 404 are substantially aligned with fold
lines 96 of a
respective reinforcing panel assembly 76. Alternatively, first inner
reinforcing corner
panel 402 and/or second inner reinforcing corner panel 404 only partially
overlap corner
panels 102 such that free edges 418 and/or 426 are offset from fold lines 96.
Further, in the
example embodiment, bottom edge 422 of first inner reinforcing corner panel
402 is
substantially aligned with angled edge 40 of bottom panel 24, and bottom edge
434 of
second inner reinforcing corner panel 404 is substantially aligned with angled
edge 46 of
bottom panel 24. First inner reinforcing corner panel 402 forms a first corner
wall 452
with a pair of corner panels 98 and 102, and second inner reinforcing corner
panel 404
forms a second corner wall 454 with a pair of corner panels 98 and 102.
[0097] Third inner reinforcing corner panel 406 is rotated about fold line
414 toward interior surface 12. Exterior surface 14 of third inner reinforcing
corner panel
406 is secured to exterior surface 14 of reinforcing corner panel 102 located
on reinforcing
panel assembly 76 extending from fold line 80 of first end panel 64. More
specifically,
third inner reinforcing corner panel 406 is rotated such that third inner
reinforcing corner
panel 406 is oriented at oblique angle yl to second side wall 156. Similarly,
fourth inner
reinforcing corner panel 408 is rotated about fold line 416 toward interior
surface 12.
Exterior surface 14 of fourth inner reinforcing corner panel 408 is secured to
exterior
surface 14 of reinforcing corner panel 102 located on reinforcing panel
assembly 76
extending from fold line 84 of second end panel 70. More specifically, fourth
inner
reinforcing corner panel 408 is rotated such that fourth inner reinforcing
corner panel 408
is oriented at oblique angle 61 to second side wall 156.
[0098] In the example embodiment, free edges 428 and 430 of inner
reinforcing corner panels 406 and 408 arc substantially aligned with fold
lines 96 of a
respective reinforcing panel assembly 76. Alternatively, third inner
reinforcing corner
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panel 406 and/or fourth inner reinforcing corner panel 408 only partially
overlap corner
panels 102 such that free edges 428 and/or 430 are offset from fold lines 96.
Further, in the
example embodiment, bottom edge 438 of third inner reinforcing corner panel
406 is
substantially aligned with angled edge 42 of bottom panel 24, and bottom edge
442 of
fourth inner reinforcing corner panel 408 is substantially aligned with angled
edge 44 of
bottom panel 24. Third inner reinforcing corner panel 406 forms a third corner
wall 456
with a pair of comer panels 98 and 102, and fourth inner reinforcing comer
panel 408
forms a fourth corner wall 458 with a pair of comer panels 98 and 102. Comer
walls 452,
454. 456, and 458 each include three layers of panels, and corner walls 162,
164, 166, and
168 (shown in Figure 2) each include two layers of panels.
[0099] Figure 9 is a top plan view of an example embodiment of a blank
500 of sheet material. Blank 500 is essentially similar to blank 10 (shown in
Figure 1) and
blank 400 (shown in Figure 7) and, as such, similar components are labeled
with similar
references. More specifically, blank 500 is similar to blank 400 and includes
inner
reinforcing comer panels 402, 404, 406, and 408, as shown and described with
respect to
Figure 7. Further, blank 500 includes fold lines 410, 412, 414, and 416 rather
than free
side edges 48, 50, 52, and 54 (shown in Figure 1), as shown and described with
respect to
Figure 7. Additionally, blank 500 includes closure flaps 510 extending from
first and
second top panels 20 and 28.
[0100] In the example embodiment, in addition to cutouts 424, 444, 446,
and 448, blank 500 includes cutouts 502, 504. 506, and 508. More specifically,
angled
edge 126, top edge 420, and bottom edge 86 at least partially define a first
cutout 502;
angled edge 130, top edge 432, and bottom edge 86 at least partially define a
second cutout
504; angled edge 134, top edge 436, and bottom edge 86 at least partially
define a third
cutout 506; and angled edge 138, top edge 440, and bottom edge 86 at least
partially define
a fourth cutout 508. In addition, first and second top panels 20 and 28 each
include
opposing closure flaps 510 extending from opposing fold lines 512 and 514.
[0101] Figure 10 is a perspective view of a container 550 that is partially
formed from blank 500 (shown in Figure 9). Figure 11 is a perspective view of
container
550 formed from blank 500. Container 550 is essentially similar to container
150 (shown
in Figure 2) and container 450 (shown in Figure 8) and, as such, similar
components are
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labeled with similar references. Although container 550 is shown as being
formed without
a product to be contained therein, container 550 may also be formed having a
product
therein. Further, container 550 may include any suitable number of products of
any
suitable shape.
[0102] To construct container 550 from blank 500 a method that is
substantially similar to the method for forming container 450 from blank 400
is used. To
close container 550, top wall 176 is formed using the method used to construct
container
150 from blank 10. In addition, in the example embodiment, closure flaps 510
are rotated
toward exterior surface 14 of first and second end panels 64 and 70 and are
secured thereto.
In the example embodiment, interior surface 12 of each closure flap 510 is
adhered to
exterior surface 14 of end panels 64 or 70.
[0103] Figure 12 is a top plan view of an example embodiment of a blank
600 of sheet material. Blank 600 is essentially similar to blank 300 (shown in
Figure 5)
and, as such, similar components are labeled with similar references. More
specifically,
blank 600 includes top panels 602 and 604. Further, blank 600 includes fold
lines 606 and
608 at top edges of end panels 64 and 70, respectively, rather than free edge
68 and free
edge 74 (shown in Figure 5) defining top edges of end panels 64 and 70,
respectively.
Moreover, blank 600 does not include cutouts 38 and 302 (shown in Figure 5),
however, it
will be understood that blank 600 may include cutouts 38 and/or 302.
[0104] In the example embodiment, blank 600 includes, in series from free
edge 68 to free edge 74, a first top panel 602, end panel 64, bottom panel 24,
end panel 70,
and a second top panel 604 coupled together along preformed, generally
parallel, fold lines
606, 66, 72, and 608, respectively. More specifically, first top panel 602
extends between
free edge 68 and fold line 606, and second top panel 604 extends from end
panel 70 along
fold line 608 to free edge 74. When a container 650 (shown in Figure 13) is
formed from
blank 600, fold line 606 defines a side edge of top panel 602 and a top edge
of end panel
64, and fold line 608 defines a side edge of top panel 604 and a top edge of
end panel 70.
[0105] In the example embodiment, first top panel 602 and second top panel
604 are substantially congruent and have a trapezoidal shape with a cutout
portion 610
defined along free edges 68 and 74, respectively. Cutout portion 610 has any
suitable
configuration that enables blank 600 and/or container 650 to function as
described herein.
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In one embodiment, cutout portion 610 is configured to enable access to cavity
170 (shown
in Figure 13) of container 650. Alternatively, top panel 602 and/or 604 does
not include
cutout portion 610. In the example embodiment, first top panel 602 includes an
angled
edge 612 extending outwardly from an intersection 614 of fold line 606 and
fold line 78
and an angled edge 616 extending outwardly from an intersection 618 of fold
line 606 and
fold line 80. Similarly, second top panel 604 includes an angled edge 620
extending
outwardly from an intersection 622 of fold line 608 and fold line 82 and an
angled edge
624 extending outwardly from an intersection 626 of fold line 608 and fold
line 84.
Angled edges 612, 616, 620, and 624 are configured similarly to angled edges
40, 42, 44,
and 46, respectively.
[0106] In addition, first and second top panels 602 and 604 have a width Ws
that is smaller than half of width W2. More specifically, top panels 602 and
604 each have
width Wg such that each top panel 602 and 604 forms a top shoulder 652 and 654
(shown
in Figure 13), respectively, when container 650 is formed from blank 600. In
an alternative
embodiment, width Wg is substantially equal to or larger than half of width
W2.
Alternatively, width W8 is sized to form a partial top wall. In the example
embodiment,
top panels 602 and 604 are equally dimensioned, however, top panels 602 and
604 may be
other than equally dimensioned. Further, first and second top panels 602 and
604 each
have a pair of opposing closure flaps 628 that extend from a first fold line
630 and a second
fold line 632 of each of first and second top panels 602 and 604.
[0107] In the example embodiment, fold line 606 and fold line 608 each
include a tab 634 defined therein. More specifically, a cut line 636 divides
each fold line
606 and 608 to form tab 634. Further, a slot 638 defined in each top panel 602
and 604
defines a top 640 of each tab 634. Alternatively, fold line 606 and/or fold
line 608 does not
include tab 634 and/or top panel 602 and/or top panel 604 does not include
slot 638.
Moreover, it will be understood that tab 634 and/or slot 638 may be included
in any of the
embodiments described herein. For example, tab 634 may extend from free edge
68 and/or
free edge 74 in any embodiment including such free edges. Further, tab 634 may
extend
from leading edge 16, trailing edge 18, fold line 30, and/or fold line 36 of
the embodiments
described herein.
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[0108] In the example embodiment, fold line 66 and fold line 72 each
include a cutout 642 defined therein. More specifically, a cut line 644
divides each fold
line 66 and 72 and defines cutout 642. Cutout 642 may have any suitable
configuration
that enables blank 600 and/or container 650 to function as described herein.
In one
embodiment, cutout 642 is sized to receive tab 634 for stacking containers 650
and/or to
provide venting for cavity 170. Alternatively, fold line 66 and/or fold line
72 does not
include cutout 642. Moreover, it will be understood that cutout 642 may be
included in
any of the embodiments described herein. For example, cutout 642 may be
defined in fold
lines 32, 34, 66 and/or 72 of the embodiments described herein.
[0109] Further, in the example embodiment, each inner end panel 92
includes a notch 646 defined in a lower free corner 648 thereof. More
specifically, notch
646 is defined at corner 648 defined by free edge 106 and inner bottom edge
110 on each
inner end panel 92. Notch 646 is configured to correspond to a portion of
cutout 642 such
that cutout 642 is not obstructed by inner end panels 92 when container 650 is
formed. In
an alternative embodiment, notch 646 may have any suitable configuration that
enables
blank 600 and/or container 650 to function as described herein. Alternatively,
at least one
inner end panel 92 does not include notch 646. Moreover, it will be understood
that notch
646 may be included in any of the embodiments described herein on any suitable
panel.
[0110] Figure 13 is a perspective view of container 650 that is formed from
blank 600 (shown in Figure 12). Container 650 is essentially similar to
container 350
(shown in Figure 6) and, as such, similar components are labeled with similar
references.
Although container 650 is shown as being formed without a product to be
contained
therein, container 650 may also be formed having a product therein. Further,
container 650
may include any suitable number of products of any suitable shape. To
construct container
650 from blank 600 a method that is substantially similar to the method for
forming
container 350 from blank 300 is used. By forming top shoulders 652 and 654 of
container
650. container 650 is considered to be in the closed configuration rather than
the open
configuration of containers 350.
[0111] To close container 650 and form top shoulders 652 and 654, first top
panel 602 is rotated about fold line 606 toward cavity 170 such that first top
panel 602 is
substantially perpendicular to first end wall 158 and substantially parallel
to bottom wall
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152. Further, second top panel 604 is rotated about fold line 608 toward
cavity 170 such
that second top panel 604 is substantially perpendicular to second end wall
160 and
substantially parallel to bottom wall 152. Closure flaps 628 are then rotated
toward
exterior surface 14 of a respective first reinforcing side panel 100 and are
secured thereto to
form portions of first side wall 154 and second side wall 156, respectively.
In the example
embodiment, interior surface 12 of each closure flap 628 is adhered to
exterior surface 14
of a respective first reinforcing side panel 100. First and second top panels
602 and 604
form top shoulders 652 and 654 of container 650.
[0112] Figure 14 is a top plan view of an example embodiment of a blank
700 of sheet material. Blank 700 is essentially similar to blank 400 (shown in
Figure 7)
and blank 600 (shown in Figure 12) and, as such, similar components are
labeled with
similar references. More specifically, blank 700 is similar to blank 600 and
includes inner
reinforcing comer panels 402, 404, 406, and 408, as shown and described with
respect to
Figure 7. Further, blank 700 includes fold lines 410, 412, 414, and 416 rather
than free
side edges 48, 50, 52, and 54 (shown in Figure 12), as shown and described
with respect to
Figure 7.
[0113] Figure 15 is a perspective view of a container 750 formed from
blank 700 (shown in Figure 14). Container 750 is essentially similar to
container 450
(shown in Figure 8) and container 650 (shown in Figure 13) and, as such,
similar
components are labeled with similar references. Although container 750 is
shown as being
formed without a product to be contained therein, container 750 may also be
formed having
a product therein. Further, container 750 may include any suitable number of
products of
any suitable shape. To construct container 750 from blank 700 a method that is
substantially similar to the method for forming container 450 from blank 400
is used. To
close container 750, top shoulders 652 and 654 are formed using the method
used to
construct container 650 from blank 600.
[0114] Figure 16 is a top plan view of an example embodiment of a blank
800 of sheet material for forming a container 850 (shown in Figure 17). Blank
800 is
essentially similar to blank 300 (shown in Figure 5) and, as such, similar
components are
labeled with similar references. More specifically, blank 800 includes
reinforcing panels
802 that each include a support panel 804. Moreover, blank 800 does not
include cutouts
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38 and 302, however, it will be understood that blank 800 may include cutouts
38 and/or
302 on end panels 64 and/or 70, first side panel 22, and/or second side panel
26. Further,
in an alternative embodiment, blank 800 includes top panels 20 and 28, as
shown as
described with respect to Figure 1, and/or top panels 602 and 604, as shown
and described
with respect to Figure 12.
[0115] In the example embodiment, blank SOO includes a reinforcing panel
802 that extends from each side edge of end panels 64 and 70. Reinforcing
panel 802 is
also referred to herein as a reinforcing panel assembly that includes a
plurality of panels as
described in more detail herein. More specifically, a reinforcing panel
assembly 802
extends from each of fold lines 78, 80, 82, and 84. Further, each reinforcing
panel
assembly 802 includes free bottom edge 86. Bottom edge 86 includes an outer
bottom edge
108 and an inner bottom edge 110 which is offset from outer bottom edge 108.
Each free
bottom edge 86 at least partially defines cutouts 56, 58, 60, and 62.
Moreover, each
reinforcing panel assembly 802 is substantially similar and includes, in
series from a fold
line 78, 80, 82, or 84 to free edge 106, outer reinforcing panel assembly 88,
inner
reinforcing panel assembly 90, inner end panel 92, and support panel 804,
connected along
substantially parallel fold lines 94, 96, and 806. Fold line 806 defines a
side edge of inner
end panel 92 and a side edge of support panel 804, and free edge 106 defines a
side edge of
support panel 804.
[0116] Outer reinforcing panel assembly 88 includes comer panel 98 and
first reinforcing side panel 100, and inner reinforcing panel assembly 90
includes
reinforcing comer panel 102 and second reinforcing side panel 104. More
specifically,
support panel 804 extends between free edge 106 and fold line 806, inner end
panel 92
extends from support panel 804 along fold line 806, reinforcing corner panel
102 extends
from inner end panel 92 along fold line 96, second reinforcing side panel 104
extends from
reinforcing comer panel 102 along fold line 114, first reinforcing side panel
100 extends
from second reinforcing side panel 104 along fold line 94, and corner panel 98
extends
from first reinforcing side panel 100 along fold line 112 to a respective fold
line 78, SO, 82,
or 84.
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[0117] In the example embodiment, each support panel 804 is substantially
rectangularly shaped, although it will be understood that support panel 804
may have any
suitable shape and/or configuration that enables blank 800 and/or container
850 to function
as described in herein. Further, in the example embodiment, support panel 804
has a width
W, that is substantially constant from a top edge 808 of reinforcing panel
assembly 802 to
bottom edge 86. Alternatively, width W9 may be other than constant between top
edge 808
and bottom edge 86. In the example embodiment, width W9 is less than half of
width W2
of bottom panel 24. Alternatively, width W9 is equal to or greater than half
of width W2
such that support walls 852 and 854 (shown in Figure 17) formed from support
panels 804
divide container 850 and provide support to container 850. In the example
embodiment,
each support panel 804 includes the same width W9. In an alternative
embodiment, at least
one support panel 804 includes a width that is different than width W, of
other support
panels 804.
[0118] Figure 17 is a perspective view of container 850 that is formed from
blank 800 (shown in Figure 16). Container 850 is essentially similar to
container 350
(shown in Figure 6) and, as such, similar components are labeled with similar
references.
Although container 850 is shown as being formed without a product to be
contained
therein, container 850 may also be formed having a product therein. Further,
container 850
may include any suitable number of products of any suitable shape. To
construct container
850 from blank 800 a method that is substantially similar to the method for
forming
container 350 from blank 300 is used except support walls 852 and 854 are
formed. In the
example embodiment, container 850 has an open configuration, however, it will
be
understood that container 850 may include a top wall and be in a closed
configuration.
[0119] To construct container 850 from blank 800, each inner end panel 92
and respective inner reinforcing panel assembly 90 are folded about fold line
94 such that
inner reinforcing panel assembly 90 and outer reinforcing panel assembly 88
arc in an at
least partially overlying relationship, and such that inner end panel 92 is in
an at least
partially overlying relationship with at least a portion of first or second
end panel 64 or 70.
More specifically, blank 800 is folded along fold line 94 such that corner
panel 98 and
reinforcing comer panel 102 are substantially aligned in an at least partially
overlying
relationship, first and second reinforcing side panels 100 and 104 are
substantially aligned
in an at least partially overlying relationship, and inner end panel 92 and at
least a portion
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of first or second end panel 64 or 70 are substantially aligned in an at least
partially
overlying relationship. As blank 800 is being folded about fold line 94,
support panels 804
are folded about fold lines 806 such that exterior surface 14 of support panel
804 is rotated
towards exterior surface 14 of inner end panel 92. Alternatively, support
panels 804 are
rotated about fold lines 806 before or after blank 800 is folded about fold
line 94. In the
example embodiment, after blank 800 is folded about fold lines 94 and 806, one
support
panel 804 is aligned in at least partially overlying relationship with another
support panel
804 such that interior surfaces 12 of support panels 804 are adjacent to each
other.
[0120] In the example embodiment, inner end panel 92, a respective end
panel 64 or 70, reinforcing side panels 100 and 104, corner panels 98 and 102
and/or
support panels 804 arc secured in the above-described relationships. For
example, inner
end panel 92, a respective end panel 64 or 70, reinforcing side panels 100 and
104, corner
panels 98 and 102 and/or support panels 804 are held against the product to be
contained
by a force on exterior surface 14 as container 850 continues to be erected. In
another
example, inner end panel 92 may be adhered to a respective end panel 64 or 70,
reinforcing
side panels 100 and 104 may be adhered together, corner panels 98 and 102 may
be
adhered together, and/or support panels 804 may be adhered together.
Reinforcing panel
assemblies 88 and 90 and reinforcing side panels 100 and 104 are rotated about
fold lines
78, 80, 82, 84, 96, 112 and/or 114 as described with respect to container 350.
Further, the
remainder of container 850 is constructed similarly to container 350.
[0121] When container 850 is formed, support panels 804 form a first
support wall 852 and a second support wall 854 extending into cavity 170. More
specifically, first support wall 852 extends from first end wall 158, and
second support wall
854 extends from second end wall 160. In the example embodiment, support
panels 804
forming each support wall 852 and 854 are in contact with each other along a
height H5 of
each support wall 852 and 854. Alternatively, a gap may be defined between
support
panels 804 forming support wall 852 and/or 854 along at least a portion of
height H5.
Further, in the example embodiment, support wall 852 is separated from support
wall 854
by a distance d1. Alternatively, support walls 852 and 854 are in contact
along at least a
portion of an inner edge 856 of each support wall 852 and 854. In an
alternative
embodiment, at least a portion of support wall 852 overlaps support wall 854.
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[0122] Figure 18 is a top plan view of an example embodiment of a blank
900 of sheet material. Blank 900 is essentially similar to blank 400 (shown in
Figure 7)
and blank 800 (shown in Figure 16) and, as such, similar components are
labeled with
similar references. More specifically, blank 900 is similar to blank 400 and
includes inner
reinforcing corner panels 402, 404, 406, and 408, as shown and described with
respect to
Figure 7. Further, blank 900 includes fold lines 410, 412, 414, and 416 rather
than free
side edges 48, 50, 52, and 54 (shown in Figure 16), as shown and described
with respect to
Figure 7. Further, blank 900 includes reinforcing panel assemblies 802. as
shown and
described with reference to Figure 16.
[0123] In the example embodiment, blank 900 does not include cutouts 38
and 302 (shown in Figure 7), however, it will be understood that blank 900 may
include
cutouts 38 and/or 302 on end panels 64 and/or 70, first side panel 22, and/or
second side
panel 26. Further, in an alternative embodiment, blank 900 includes top panels
20 and 28,
as shown as described with respect to Figure 1, and/or top panels 602 and 604,
as shown
and described with respect to Figure 12.
[0124] Figure 19 is a perspective view of a container 950 formed from
blank 900 (shown in Figure 18). Container 950 is essentially similar to
container 450
(shown in Figure 8) and container 850 (shown in Figure 17) and, as such,
similar
components are labeled with similar references. Although container 950 is
shown as being
formed without a product to be contained therein, container 950 may also be
formed having
a product therein. Further, container 950 may include any suitable number of
products of
any suitable shape. To construct container 950 from blank 900, a method that
is
substantially similar to the methods for forming container 450 and container
850 are used.
[0125] Figure 20 is a side view of a machine 1000 for forming a container
from a blank. Figure 21 is a top view of machine 1000. Various blanks arc
illustrated as
being formed into containers using machine 1000. It will be understood that
any of the
above-described blanks can be formed into a respective container using machine
1000.
However, for clarity, the blanks illustrated as being formed into containers
by machine
1000 are labeled with reference number 10 throughout Figures 20-42, although
the blanks
illustrated in at least some of Figures 20-42 may not be identical to blank 10
(shown in
Figure 1). Similarly, the containers illustrated as being formed by machine
1000 in Figures
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20-42 are labeled with reference number 150, although the containers
illustrated in at least
some of Figures 20-42 may not be identical to container 150 (shown in Figure
2). As used
herein, the terms "downward," "down," and variations thereof refer to a
direction from a
top 1002 of machine 1000 toward a surface or floor 1004 on which machine 1000
is
supported, and the terms "upward," "up," and variations thereof refer to a
direction from
floor 1004 on which machine 1000 is supported toward top 1002 of machine 1000.
Further, as used herein, "operational control communication" refers to a link,
such as a
conductor, a wire, and/or a data link, between two or more components of
machine 1000
that enables signals, electric currents, and/or commands to be communicated
between the
two or more components. The link is configured to enable one component to
control an
operation of another component of machine 1000 using the communicated signals,
electric
currents, and/or commands.
[0126] In the example embodiment, machine 1000 includes a hopper station
1100, a forming station 1200, and an ejection station 1300. More specifically,
hopper
station 1100, forming station 1200, and ejection station 1300 are connected by
a transport
system 1050, such as any suitable conveyor(s) and/or motorized device(s)
configured to
move blank 10 and/or container 150 through machine 1000. In the example
embodiment,
hopper station 1100 is configured to store a stack 1006 of blanks 10 in a
substantially
vertical orientation. More specifically, blanks 10 are stored with interior
surface 12 facing
in a downstream direction A of the machine 1000 and exterior surface 14 facing
away from
the downstream direction A, or in an upstream direction. In alternative
embodiments,
hopper station 1100 may be configured to store stack 1006 of blanks 10 in a
horizontal
orientation.
[0127] Forming station 1200 is generally aligned with and downstream of
hopper station 1100, and includes any suitable number and/or configuration of
components,
such as plows, arms, actuators, plungers, and/or other devices for forming
container 150
from blank 10. In the example embodiment, components of forming station 1200
are in
communication with a control system 1008. Control system 1008 is configured to
control
and/or monitor components of forming station 1200 to form container 150 from
blank 10.
In the example embodiment, control system 1008 includes computer-readable
instructions
for performing the methods described herein, and a processor configured to
execute the
computer-readable instructions. In one embodiment, an operator can select
which blank
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10, 200, 300, 400, 500, 600, 700, 800, and/or 900 is being manipulated by
machine 1000
using control system 1008, and control system 1008 performs the corresponding
method
using the components of forming station 1200. Control system 1008 is also
configured to
automatically adjust the positioning of arms, plows, and/or other devices
described herein
that are used for forming container 150. Thus, when a user selects a container
for forming,
machine 1000 will automatically adjust its forming elements for the various
containers.
[0128] In the example embodiment, control system 1008 is shown as being
centralized within machine 1000, however control system 1008 may be a
distributed
system throughout machine 1000, within a building housing machine 1000, and/or
at a
remote control center. Control system 1008 includes a processor configured to
perform
the methods and/or steps described herein. Further, many of the other
components
described herein include a processor. As used herein, the term "processor" is
not limited to
integrated circuits referred to in the art as a processor, but broadly refers
to a controller, a
microcontroller, a microcomputer, a programmable logic controller (PLC), an
application
specific integrated circuit, and other programmable circuits, and these terms
are used
interchangeably herein. It should be understood that a processor and/or
control system can
also include memory, input channels, and/or output channels.
[0129] In the embodiments described herein, memory may include, without
limitation, a computer-readable medium, such as a random access memory (RAM).
and a
computer-readable non-volatile medium, such as flash memory. Alternatively, a
floppy
disk, a compact disc-read only memory (CD-ROM), a magneto-optical disk (MOD),
and/or
a digital versatile disc (DVD) may also be used. Also, in the embodiments
described
herein, input channels may include, without limitation, sensors and/or
computer peripherals
associated with an operator interface, such as a mouse and a keyboard.
Further, in the
example embodiment, output channels may include, without limitation, a control
device, an
operator interface monitor, and/or a display.
[0130] Processors described herein process information transmitted from a
plurality of electrical and electronic devices that may include, without
limitation, sensors,
actuators, compressors, control systems, and/or monitoring devices. Such
processors may
be physically located in, for example, a control system, a sensor, a
monitoring device, a
desktop computer, a laptop computer, a PLC cabinet, and/or a distributed
control system
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(DCS) cabinet. RAM and storage devices store and transfer information and
instructions to
be executed by the processor(s). RAM and storage devices can also be used to
store and
provide temporary variables, static (i.e., non-changing) information and
instructions, or
other intermediate information to the processors during execution of
instructions by the
processor(s). Instructions that are executed may include, without limitation,
machine
control commands. The execution of sequences of instructions is not limited to
any
specific combination of hardware circuitry and software instructions.
[0131] In the example embodiment, ejection station 1300 is configured to
eject container 150 from forming station 1200. More specifically, in the
example
embodiment, ejection station 1300 includes an exit conveyor 1302 for conveying
formed
containers from an exit 1299 of forming station 1200 to an end 1399 of exit
conveyor 1302.
In the example embodiment, exit conveyor 1302 is part of transport system
1050.
[0132] During operation of machine 1000 to form container 150 from blank
10, stack 1006 of blanks 10 is placed within hopper station 1100. Transport
system 1050
removes one blank 10 from stack 1006 and transfers blank 10 to forming station
1200.
Transport system 1050 transfers blank 10 through the components of forming
station 1200.
The components of forming station 1200 perform the method for forming
container 150
from blank 10. Within forming station 1200, blank 10 is folded into a
partially formed
container 1010. Partially formed container 1010 is formed into container 150
within
forming station 1200, and a subsequent blank 10 is transferred from hopper
station 1100
into forming station 1200. As such, containers 150 are formed continuously by
machine
1000. After container 150 is formed in forming station 1200, transport system
1050
transfers container 150 to ejection station 1300 for ejection from machine
1000.
[0133] Figures 22-42 show perspective views of machine 1000. Arrow A
shows a direction of movement of blank 10 and/or container 150 through machine
1000.
Further, the head of arrow A indicates a "downstream" or "forward" direction
and the tail
of arrow A indicates an "upstream" or "backward" direction. The term "front"
as used
herein with respect to movement through machine 1000 refers to the downstream
end of
blank 10, and the term "rear" as used herein with respect to movement through
machine
1000 refers to the upstream end of blank 10.
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[0134] Figure 22 shows a perspective view of hopper station 1100 having a
generally vertically oriented blank 10 therein. Figure 23 shows a perspective
view of
hopper station 1100 and forming station 1200 wherein blank 10 is being
transported from
hopper station 1100 to forming station 1200 using transport system 1050.
Figure 24 shows
a perspective view of forming station 1200 with blank 10 being placed into a
substantially
horizontal position by transport system 1050.
[0135] Figure 25 shows a perspective view of forming station 1200 with
blank 10 being placed onto transport system 1050 with inner reinforcing panel
assemblies
90 and inner end panels 92 rotated substantially perpendicular to the
remainder of blank 10.
Figure 26 shows an enlarged view of forming station 1200 with blank 10 placed
onto
transport system 1050 with inner reinforcing panel assemblies 90 and inner end
panels 92
rotated substantially perpendicular to the remainder of blank 10. Figure 27
shows an
enlarged view of another suitable embodiment of forming station 1200 which
includes
guide rails configured to maintain inner reinforcing panel assemblies 90 and
inner end
panels 92 in an upright position as blank 10 is transported from an initial
forming station of
forming station 1200 through a first adhesive application station to a
secondary forming
station of forming station 1200.
[0136] Figure 28 is a perspective view of the secondary forming station of
forming station 1200. Figure 29 shows a perspective view of blank 10 being
further
formed within the secondary forming station of forming station 1200. Figure 30
shows a
perspective view of blank 10 having reinforcing corner assemblies 151 formed
within the
secondary forming station of forming station 1200. Figure 31 shows a schematic
cross-
sectional view of blank 10 being formed into partially formed container 1010
within the
secondary forming station of forming station 1200. Figure 32 shows a
perspective view of
transfer mechanisms suitable for use in an upstream end of the secondary
forming station
for positioning blank 10 within the secondary forming station and transporting
blank 10
through the secondary forming station. Figure 33 shows a perspective view of
blank 10
being positioned within the secondary forming station prior to reinforcing
corner
assemblies 151 being formed. Figure 34 shows a perspective view of an angling
station
and a second adhesive application station within forming station 1200. Figure
35 is a
perspective view of a downstream end of the angling station and the second
adhesive
application station.
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[0137] Figure 36 shows a perspective view of partially formed container
1010 positioned within a compression station of forming station 1200. Figure
37 shows a
perspective view of partially formed container 1010 being formed into
container 150
within the compression station. Figure 38 shows a top perspective view of the
compression
station without partially formed container 1010 positioned therein. Figure 39
shows
another perspective view the compression station without a plunger (described
below) and
with a formed container 150 positioned therein. Figure 40 shows another
perspective view
of the compression station without the plunger and without partially formed
container 1010
or container 150 positioned therein. Figure 41 shows a perspective view of the
compression station from a bottom of the compression station. Figure 42 shows
a
perspective view of ejection station 1300, and a formed container 150 being
held within the
compression station of forming station 1200 above exit conveyor 1302.
[0138] Referring to Figures 20-42, machine 1000 is substantially
symmetrical about a longitudinal axis 1012 that extends from a rear end 1014
of machine
1000 to a front end 1016 of machine 1000. As a container 150 is formed using
machine
1000, blank 10 moves along longitudinal axis 1012 from rear end 1014 to front
end 1016.
[0139] Referring to Figures 22-24, hopper station 1100 includes a hopper
1102, a feed mechanism 1104, a transfer arm 1106, and an upper suction device
1108.
Hopper 1102 is configured to support stack 1006 of blanks 10 in a
substantially vertical
position on feed mechanism 1104. Feed mechanism 1104 is part of transport
system 1050,
and includes, in the example embodiment, a conveyor belt mechanism for
transporting
blanks 10 downstream toward transfer arm 1106. Blanks 10 within hopper 1102
are in an
unformed, substantially planar state. Hopper 1102 is further configured to
facilitate
maintaining alignment of blanks 10 within machine 1000 such that an individual
blank 10
may be transported from hopper station 1100 and precisely placed within
forming station
1200.
[0140] Referring to Figures 23-41, forming station 1200 includes an initial
forming station 1202, a first adhesive application station 1204, a secondary
forming station
1206, a second adhesive application station 1208, and a compression station
1210. In the
illustrated embodiment, forming station 1200 also includes a drive system 1212
which
drives and/or actuates various components of machine 1000 as described below.
Although
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drive system 1212 is illustrated as being located in forming station 1200 in
the example
embodiment, drive system 1212 may be located at any suitable location that
enables
machine 1000 to function as described herein.
[0141] Referring to Figures 23-27, initial forming station 1202 includes a
lower suction device 1214, a pusher plate 1216, stationary folding plows 1218,
moveable
folding plows 1220, side plates 1222, support rails 1224, and outer side rails
1226. Outer
side rails 1226 extend the length of machine 1000 and are used to help guide
the outer side
edges of blank 10 as blank 10 moves through machine 1000.
[0142] Referring to Figure 27, in some embodiments, initial forming station
1202 may include rotatable guide rails 1227 configured to maintain inner
reinforcing panel
assemblies 90 and inner end panels 92 in an upright position, as described in
more detail
below. In the illustrated embodiment, a rotatable guide rail 1227 is rotatably
coupled to
each folding plow 1218 and 1220. Rotatable guide rails 1227 are configured to
rotate
about a vertical axis from a first position, in which rotatable guide rails
1227 are oriented
substantially perpendicular to downstream direction A, to a second position in
which
rotatable guide rails 1227 are oriented substantially parallel to the
downstream direction A
of machine 1000. Further, in embodiments including rotatable guide rails 1227,
moveable
folding plows 1220 may be replaced with stationary folding plows 1218. In the
embodiment illustrated in Figure 27, one rotatable guide rail 1227 is shown in
the first
position, two rotatable guide rails 1227 are shown in the second position, and
one rotatable
guide rail 1227 is shown in an intermediate position between the first
position and the
second position.
[0143] Referring to Figure 25-26, first adhesive application station 1204
includes drive rollers 1228 and a first adhesive applicator 1230. As explained
below in
detail, drive rollers 1228 are part of transport system 1050 and are used to
help transport
blank 10 from initial forming station 1202 past first adhesive applicator
1230. First
adhesive applicator 1230 includes a plurality of adhesive sprayers that apply
hot glue or
any other type of adhesive to certain panels of blank 10. Specifically, first
adhesive
applicator 1230 applies adhesive to portions of each corner panel 98, each
first reinforcing
side panel 100, and first and second end panels 64 and 70. In an alternative
embodiment,
first adhesive applicator 1230 applies adhesive to a portion of at least some
of these panels.
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First adhesive application station 1204 also includes photo-eyes, sensors,
proximity
switches and other location detectors for detecting a location of blank 10
within first
adhesive application station 1204. Location data is provided to control system
1008, and
control system 1008 controls when adhesive sprayers are turned on and off to
properly
apply adhesive to blank 10. In the exemplary embodiment, first adhesive
applicator 1230
includes a plurality of glue modules that are each separately controllable by
control system
1008. As such, any suitable number of glue modules are activated depending on
a size
and/or placement of blank 10.
[0144] Referring to Figures 28-31, secondary forming station 1206 is
downstream from initial forming station 1202 and first adhesive application
station 1204.
Secondary forming station 1206 helps form reinforcing corner assemblies 151 on
each
blank 10 that passes through machine 1000. Secondary forming station 1206
includes a
push lug 1232, a stop lug 1234, a servo-mechanical system 1236 (also known as
a servo
drive), a servo chain 1238, rotating folder arms 1240, male forming members
1242, female
forming members 1244, and inner side rails 1246. In the example embodiment,
servo drive
1236 is controlled by control system 1008. Servo drive 1236 drives servo chain
1238
which includes at least one push lug 1232 coupled to servo chain 1238.
Accordingly, servo
drive 1236 drives servo chain 1238 around a first and second sprocket such
that each push
lug 1232 attached to servo chain 1238 rotates from an upstream location within
secondary
forming station 1206 to a downstream location within secondary forming station
1206.
Push lug 1232 is configured to engage blank 10 at trailing top edge 68 or 74
of blank 10.
Push lug 1232 pushes blank 10 into a forming position by pushing blank 10
until the
opposing leading top edge 74 or 68 of blank 10 contacts stop lug 1234.
[0145] Stop lug 1234 is positioned downstream of push lug 1232. Stop lug
1234 is configured to precisely stop blank 10 so that blank 10 can be further
formed within
secondary forming station 1206, and move downwardly out of the path of blank
10 so that,
after secondary forming, blank 10 is able to move further downstream within
machine
1000. More specifically, in the exemplary embodiment, a stop lug 1234 is
positioned on
each side of servo chain 1238, and stop lugs 1234 move upward from below servo
chain
1238 to above servo chain 1238 to stop blank 10 at an appropriate position.
Stop lugs 1234
can be movably coupled to inner side rails 1246 and width-wise adjustable
through
adjustment of a width of inner side rails 1246. Stop lugs 1234 are moveable
upstream and
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downstream with respect to inner side rails 1246 for length-wise adjustment.
As such,
positions of stop lugs 1234 are adjustable depending on a size of blank 10.
[0146] Rotating folder arms 1240 are mounted on each side of secondary
forming station 1206 proximate to inner side rails 1246. Folder arm 1240 is
configured to
rotate inwardly toward blank 10 from a starting position to a folding
position, and then
outwardly to return to the starting position. In rotating between the starting
position and
the folding position, folder arm 1240 contacts a portion of inner reinforcing
panel
assemblies 90 and/or inner end panels 92 to fold inner reinforcing panel
assemblies 90 and
inner end panels 92 from the substantially perpendicular position to a nearly
flat position
(shown in Figure 33) wherein inner reinforcing panel assemblies 90 overlie
respective
outcr reinforcing panel assemblies 88, and inner end panels 92 overlie a
respective end
panel 64 or 70. As folder arm 1240 folds inner reinforcing panel assemblies 90
and inner
end panels 92, a portion of inner reinforcing panel assemblies 90 and/or inner
end panels
92 contacts a respective male forming member 1242 causing inner reinforcing
panel
assemblies 90 to bend along fold line 114 and inner end panel 92 to bed along
fold line 96.
The pre-bending of fold lines 96 and 114, sometimes referred to as "pre-
breaking,"
facilitates forming reinforcing corner assemblies 151, as explained below in
greater detail.
[0147] After folder arm 1240 folds inner reinforcing panel assemblies 90
and inner end panels 92, folder arm 1240 rotates back to the starting position
so that male
forming members 1242 and female forming members 1244 are able to move together
and
form reinforcing corner assemblies 151, as shown in Figure 31. More
specifically, each
male forming member 1242 has an outer surface shaped complementary to an
interior
surface of one of reinforcing corner assemblies 151, and each female forming
member
1244 has an outer surface shaped complementary to an exterior surface of one
of the
reinforcing corner assemblies 151. Thus, when male forming members 1242 and
female
forming members 1244 move toward each other, each female forming member 1244
interfaces with the outside of blank 10 and each male forming member 1242
interfaces
with the inside of blank 10 such that outer reinforcing panel assemblies 88
are glued to
respective inner reinforcing panel assemblies 90, and end panels 64 and 70 are
glued to a
respective inner end panels 92. In addition, the outer profiles of male
forming members
1242 and female forming members 1244 form corner walls 162, 164, 166, and/or
168 of
each reinforcing corner assembly 151. As described above, initial forming
station 1202
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and secondary forming station 1206 cooperate with one another to form
reinforcing corner
assemblies 151. As such, initial forming station 1202 and secondary forming
station 1206
are collectively referred to herein as a reinforcing comer assembly forming
station.
[0148] After forming reinforcing corner assemblies 151, male forming
members 1242 and female forming members 1244 move away from each other. Inner
side
rails 1246 arc positioned to contact first reinforcing side panel 100 on each
reinforcing
corner assembly 151 to maintain an overall angle of reinforcing corner
assembly 151 at
substantially 90 degrees. In other words, inner side rails 1246 help prevent
the formed
reinforcing corner assemblies 151 from springing back out of a perpendicular
position.
Further, stop lug 1234 moves out of the travel path of partially formed
container 1010 such
that partially formed container 1010 can be further moved downstream within
machine
1000.
[0149] Referring to Figures 32-33, secondary forming station 1206 may
also include, in addition to or as an alternative to push lug 1232, stop lug
1234, and/or
servo chain 1238, a pusher arm 1247 and a slide mechanism 1249. Pusher arm
1247
includes a vertically oriented bar 1251 coupled to a vertically-oriented
rotatable plate 1253
that is rotatable in the downstream direction A, but is restricted from
rotating in the
upstream direction. In the illustrated embodiment, for example, rotatable
plate 1253 is
restricted from rotating beyond a substantially vertical orientation (shown in
Figure 32) in
the upstream direction. In other words, rotatable plate 1253 allows blank 10
to move
downstream, but acts as a pusher arm after blank 10 passes downstream of
rotatable plate
1253 to position blank 10 within secondary forming station 1206. Pusher arm
1247 is
moveable from a first position (shown in Figure 32) to a second position
(shown in Figure
33) to engage a trailing edge of blank 10 with rotatable plate 1253 to
position blank 10
within secondary forming station 1206. Slide mechanism 1249 is configured to
move in
the downstream direction A and engage a trailing edge of partially formed
container 1010
to transfer partially formed container 1010 from secondary forming station
1206, through
second adhesive application station 1208, and to compression station 1210.
Pusher arm
1247 and slide mechanism 1249 may be communicatively coupled to control system
1008
to control movements of pusher arm 1247 and slide mechanism 1249.
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[0150] Referring to Figures 34 and 35, machine 1000 also includes an
angling station 1207 positioned between forming members 1242 and 1244 and
compression station 1210. Angling station 1207 is configured to orient
reinforcing side
panels 100 and 104, after reinforcing side panels 100 and 104 are joined
together by
forming members 1242 and 1244, to be at an obtuse angle (an angle of greater
than
approximately 90 degrees) with respect to interior surface 12 of end panels 64
and/or 70.
Angling station 1207 includes a guide bar 1248 and a miter plate 1250. In the
example
embodiment, miter plate 1250 is substantially parallel to longitudinal axis
1012 and
oriented at an angle corresponding to an angle between comer panels 98 and 102
and end
panels 64 and/or 70. Miter plate 1250 is configured to force reinforcing side
panels 100
and 104 to rotate outward with respect to end panels 64 and/or 70 to orient
reinforcing side
panels 100 and 104 at an obtuse angle with respect to end panels 64 and/or 70.
In the
example embodiment, the upstream end of miter plate 1250 includes an angled
portion that
causes reinforcing side panels 100 and 104 to rotate outward with respect to
end panels 64
and/or 70 as partially formed container 1010 is transported downstream from
secondary
forming station 1206 to compression station 1210. Guide bar 1248 is oriented
substantially
parallel to miter plate 1250, and is configured to maintain the orientation of
and/or prevent
over rotation of reinforcing corner assemblies 151 as reinforcing side panels
100 and 104
are rotated outward by miter plate 1250. In the example embodiment,
reinforcing corner
assembly 151 is positioned between miter plate 1250 and guide bar 1248 as
partially
formed container 1010 is transported downstream from secondary forming station
1206
past second adhesive application station 1208. As such, angling station 1207
facilitates
positioning reinforcing comer assemblies 151 on an exterior surface of side
panels 22
and/or 26 when container 150 is formed, as described in more detail below.
[0151] Still referring to Figures 34 and 35, second adhesive application
station 1208 includes a second adhesive applicator 1252 positioned adjacent
each miter
plate 1250. Push lug 1232 or slide mechanism 1249 (shown in Figure 32) pushes
partially
formed container 1010 through second adhesive application station 1208 to
compression
station 1210. Second adhesive applicator 1252 includes a plurality of adhesive
sprayers
that apply hot glue or any other type of adhesive to certain panels of blank
10.
Specifically, second adhesive applicator 1252 applies adhesive to portions of
exterior
surface 14 of second reinforcing side panels 104. Additionally or
alternatively, second
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adhesive applicator 1252 may include a glue module configured to apply
adhesive to
portions of exterior surface of first and second side panels 22 and 26. Second
adhesive
application station 1208 also includes photo-eyes, sensors, proximity switches
and other
location detectors for detecting a location of partially formed container 1010
within second
adhesive application station 1208. Location data is provided to control system
1008, and
control system 1008 controls when adhesive sprayers are turned on and off to
properly
apply adhesive to partially formed container 1010. In the example embodiment,
second
adhesive applicator 1252 includes a plurality of glue modules that are each
separately
controllable by control system 1008. As such, any suitable number of glue
modules are
activated depending on a size and/or placement of blank 10. In the example
embodiment,
guide bars 1248 and miter plates 1250 are positioned to maintain an
appropriate distance
between second adhesive applicators 1252 and exterior surface 14 of the
respective second
reinforcing side panel 104 as partially formed container 1010 passes through
machine 1000
to ensure a proper amount and placement of adhesive on the panel.
[0152] As shown in Figures 34-35, machine 1000 also includes a pusher
arm 1254 positioned just downstream of second adhesive application station
1208. In the
example embodiment, pusher arm 1254 includes a pair of vertically-oriented
bars 1256
coupled to a pair of vertically-oriented rotatable bars 1258 that are
rotatable in the
downstream direction, but are restricted from rotating in the upstream
direction. In the
illustrated embodiment, for example, rotatable bars 1258 are restricted from
rotating
beyond a substantially vertical orientation (shown in Figure 34) in the
upstream direction.
In other words, rotatable bars 1258 allow partially formed container 1010 to
move
downstream, but act as pusher arms after partially formed container 1010
passes
downstream of rotatable bars 1258. Rotatable bars 1258 are configured to
engage a rear
edge of partially formed container 1010 as partially formed container 1010 is
ejected from
second adhesive application station 1208. When rotatable bars 1258 engage the
rear edge,
pusher arm 1254 transfers partially formed container 1010 from second adhesive
application station 1208 into compression station 1210. In the example
embodiment,
pusher arm 1254 is a component of transport system 1050.
[0153] Referring to Figures 36-41, compression station 1210 includes a
plunger 1260, two pairs of side panel plows 1262, a pair of end panel plow
assemblies
1264 each including a frame and a pair of end panel plows 1266 coupled to the
frame, a
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plurality of side wall presser assemblies 1268, and an adjustable stop plate
1270.
Adjustable stop plate 1270 is positioned at a downstream end of compression
station 1210
for stopping movement of partially formed container 1010 through compression
station
1210.
[0154] End panel plows 1266 and side panel plows 1262 define a plunger
opening 1272 that extends from top ends of side panel plows 1262 and end panel
plows
1266 to exit conveyor 1302 (Figure 42). Plunger 1260 is configured to contact
interior
surface 12 of bottom panel 24, and push blank 10 into and through plunger
opening 1272.
In the example embodiment, plunger 1260 has a shape that corresponds to a
cross sectional
shape of container 150. More specifically, plunger 1260 corresponds to end
walls 158 and
160 and side walls 154 and 156 of container 150. Plunger 1260 is open at comer
walls
162. 164, 166, and 168. Alternatively, plunger 1260 may also include walls at
corner walls
162. 164, 166, and/or 168.
[0155] In the example embodiment, plunger 1260 includes at least four
upright plates 1274 and 1276 coupled to a vertical actuator 1278 (Figure 37).
More
specifically, side wall upright plates 1274 extend substantially parallel to
longitudinal axis
1012 (Figure 21) and are oriented substantially vertically, and end wall
upright plates 1276
are substantially perpendicular to side wall upright plates 1274 and
longitudinal axis 1012
and are oriented substantially vertically. Upright plates 1274 and 1276 are
configured to
prevent over-rotation of side panels 22 and 26 and end panels 64 and 70 into
cavity 170
(shown in Figure 2) of container 150. Vertical actuator 1278, which is driven
by drive
system 1212, is configured to move plunger 1260 between a first position
(shown in Figure
36), also referred to as a raised position, and a second position (shown in
Figure 38), also
referred to as a lowered position. Control system 1008 is in operational
control
communication with vertical actuator 1278 for controlling movement of plunger
1260
between the first position and the second position.
[0156] Referring to Figures 39 and 40, in the illustrated embodiment,
compression station 1210 includes a first pair 1280 of side panel plows 1262
and a second
pair 1282 of side panel plows 1262. First and second pairs 1280 and 1282 of
side panel
plows 1262 arc positioned on opposite sides of plunger opening 1272. In the
example
embodiment, each side panel plow 1262 includes a substantially horizontal
upper surface, a
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rounded inner surface, and a substantially vertical inner wall. The top
surfaces and
rounded inner surfaces are configured to rotate side panels 22 and/or 26
inwardly toward
plunger opening 1272 and/or plunger 1260 when plunger 1260 pushes blank 10
through
plunger opening 1272. The vertical inner walls extend into plunger opening
1272 to at
least partially define plunger opening 1272, and the top surfaces are oriented
generally
perpendicular to the vertical inner walls. The rounded inner surfaces extend
between and
interconnect the vertical inner walls and the top surfaces.
[0157] Compression station 1210 also includes side wall presser assemblies
1268 configured to press at least a portion of reinforcing corner assemblies
151 against a
respective side panel 22 or 26 to form side walls 154 and 156 of container
150. Each
presser assembly 1268 is positioned alongside one of side panel plows 1262,
and includes a
presser plate 1284 and an actuator 1286. Presser plate 1284 is operatively
coupled to
actuator 1286, and actuator 1286 is configured to move presser plate 1284
towards and
away from plunger opening 1272. Actuator 1286 moves presser plate 1284 from a
first,
outer position, to a second, inner position where presser plate 1284 contacts
and/or presses
one or more panels of reinforcing corner assembly 151 against a respective
side panel 22 or
26. In the example embodiment, each presser plate 1284 is oriented
substantially parallel a
respective side panel 22 and 26 of blank 10 when the side panels 22 and 26 are
rotated to
be substantially perpendicular to bottom panel 24 of the blank 10. Also, in
the example
embodiment, actuator 1286 is configured to move presser plate 1284 in a
direction
substantially perpendicular to longitudinal axis 1012. Presser assemblies 1268
are
configured to couple reinforcing corner assemblies 151 to respective side
panels 22 or 26
by compressing a reinforcing corner assembly 151 and a respective side panel
22 or 26
against one of upright plates 1274 of plunger 1260. More specifically, each
presser plate
1284 is configured to contact an exterior surface of one reinforcing corner
assembly 151,
and press an interior surface of the reinforcing corner assembly 151 against
an exterior
surface 14 of a respective side panel 22 or 26. In the example embodiment,
presser plates
1284 are configured to contact exterior surface 14 of first reinforcing side
panels 100, and
press exterior surface 14 of second reinforcing side panels 104 against
exterior surface 14
of a respective side panel 22 or 26.
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[0158] As noted above, compression station 1210 includes a pair of end
panel plow assemblies 1264 that each include a frame and a pair of end panel
plows 1266
coupled thereto. In the illustrated embodiment, the end panel plow assemblies
1264
include a rear pair 1288 of end panel plows 1266 and a front pair 1290 of end
panel plows
1266. Rear pair 1288 and front pair 1290 of end panel plows 1266 are
positioned on
opposite sides of plunger opening 1272. Each end panel plow 1266 is moveable
with
respect to machine 1000 and is configured to upwardly rotate an end panel 64
or 70 to be
substantially perpendicular to bottom panel 24. More specifically, front pair
1290 is
configured to fold a front end panel 64 or 70, and rear pair 1288 is
configured to fold a rear
end panel 70 or 64. Each end panel plow 1266 includes an angled inner surface
and a
vertical inner wall. As used with respect to end panel plows 1266 and side
panel plows
1262, the term "inner" refers to a direction facing toward plunger opening
1272. The
angled inner surfaces of end panel plows 1266 are configured to rotate end
panels 64 and
70 inwardly toward plunger opening 1272. In the example embodiment, the
vertical inner
wall extends into plunger opening 1272 to at least partially define plunger
opening 1272,
and the inner angled surface extends from the vertical inner wall at an
oblique angle and
away from plunger opening 1272.
[0159] Side panel plows 1262 and end panel plows 1266 are configured to
rotate reinforcing comer assemblies 151 into face-to-face relationship with an
exterior
surface 14 of a respective side panel 22 or 26. More specifically, side panel
plows 1262
and end panel plows 1266 are positioned such that side panels 22 and 26 of
blank 10 are
rotated before end panels 64 and 70 such that reinforcing comer assemblies 151
extending
from end panels 64 and 70 are positioned in face-to-face relationship with
exterior surface
14 of side panels 22 and 26 when the end panels 64 and 70 are oriented
substantially
perpendicular to bottom panel 24. In the illustrated embodiment, for example,
each side
panel plow 1262 is positioned vertically closer to plunger 1260 (e.g., when
plunger 1260 is
in the first position) than end panel plows 1266 such that side panels 22 and
26 are
contacted and rotated by side panel plows 1262 before end panels 64 and 70 are
contacted
and rotated by end panel plows 1266 when plunger 1260 pushes blank 10 through
plunger
opening 1272.
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[0160] In the example embodiment, each end panel plow 1266 and each
side panel plow 1262 is configured to rotate and/or move inwardly toward
plunger opening
1272 and outwardly away from plunger opening 1272. As such, each end panel
plow 1266
and each side panel plow 1262 moves between a first position, also referred to
as an outer
position, and a second position, also referred to as a forming position. In
other suitable
embodiments, one or more of end panel plows 1266 and side panel plows 1262 may
be
stationary plows (i.e., not movable). Control system 1008 is in operational
control
communication with each end panel plow 1266 and each side panel plow 1262 for
controlling rotation and/or movement between the outer position and the
forming position.
In the example embodiment, a sensor determines when partially formed container
1010 is
positioned over plunger opening 1272. End panel plows 1266 and side panel
plows 1262
are moved to the forming position when the sensor determines partially formed
container
1010 is positioned over and/or within plunger opening 1272. End panel plows
1266 and
side panel plows 1262 are moved to the outer position after plunger 1260 is at
least
partially retracted from plunger opening 1272. As such, container 150 is
secured within
plunger opening 1272 by end panel plows 1266 and side panel plows 1262 in the
forming
position, and container 150 is released from plunger opening 1272 onto exit
conveyor 1302
when end panel plows 1266 and side panel plows 1262 are in the outer position.
[0161] Although the example embodiment is described as having four side
panel plows 1262 and four end panel plows 1266, it should be understood that
machine
1000 may include any suitable number of side panel plows 1262 and any suitable
number
of end panel plows 1266 that enables machine 1000 to function as described
herein.
[0162] Referring to Figure 42, exit conveyor 1302 extends past a bottom
1273 of compression station 1210 to receive containers 150 from forming
station 1200.
More specifically, exit conveyor 1302 continuously runs while machine 1000 is
being
operated to form containers 150. Alternatively, exit conveyor 1302 is operated
intermittently when a container 150 is positioned within bottom 1273 of
compression
station 1210. In the example embodiment, container 150 is secured within
plunger opening
1272 by side panel plows 1262, end panel plows 1266, and/or side wall presser
assemblies
1268 over exit conveyor 1302. As such, when side panel plows 1262, end panel
plows
1266, and/or side wall presser assemblies 1268 are moved to outer positions,
container 150
is released from plunger opening 1272 onto exit conveyor 1302. Control system
1008 is in
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operational control communication with exit conveyor 1302 for control thereof.
Top
panels 20 and 28 remain unfolded with respect to a respective side panel 22 or
26, and
container 150 is ejected from machine 1000 in the open configuration.
[0163] During operation of machine 1000, a method for forming a container
150 from blank 10 is performed. It should be understood that the method may be
used to
form any suitable container, such as containers 250, 350, 450, 550, 650, 750,
850 and/or
950 (shown in Figures 4, 6, 8, 10, 13, 15, 17 and 19), using machine 1000. In
the example
embodiment, the method is performed by control system 1008 sending commands
and/or
instructions to components of machine 1000. The processor within control
system 1008 is
programmed with code segments configured to perform the method. Alternatively,
the
method is encoded on a computer-readable medium that is readable by control
system
1008. In such an embodiment. control system 1008 and/or the processor are
configured to
read computer-readable medium for performing the method.
[0164] Referring to Figures 20-42, drive system 1212 includes a motor,
gears, a chain and sprockets that cause much of transport system 1050 to move.
For
example, drive system 1212 causes transfer arm 1106 to rotate to a position
where upper
suction device 1108 comes into contact with a first blank 10 stored within
hopper 1102.
First blank 10 being the most downstream blank housed within hopper 1102. More
specifically, upper suction device 1108 comes into contact with interior
surface 12 of first
blank 10 such that upper suction device 1108 becomes releasably coupled to
first blank 10.
Transfer arm 1106, still being driven by drive system 1212, rotates with blank
10 coupled
thereto such that blank 10 is placed in a substantially horizontal position
with exterior
surface 14 of blank 10 facing downwardly toward support rails 1224. Thus,
transfer arm
1106 moves blank 10 from hopper 1102 to initial forming station 1202.
[0165] While transfer arm 1106 moves blank 10 into a substantially
horizontal position within initial forming station 1202, lower suction device
1214 moves
upwardly from below support rails 1224 to engage exterior surface 14 of blank
10. Thus,
blank 10 is essentially transferred with a "handshake" from upper suction
device 1108 to
lower suction device 1214. Lower suction device 1214 then pulls blank 10
downwardly
onto support rails 1224. As blank 10 is placed on support rails 1224,
stationary folding
plows 1218 and moveable folding plows 1220 engage inner reinforcing panel
assemblies
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90 and/or inner end panels 92 at each corner of blank 10, causing each inner
reinforcing
panel assembly 90 and each inner end panel 92 to rotate about 90 degrees with
respect to
outer reinforcing panel assembly 88 such that each inner reinforcing panel
assembly 90 and
each inner end panel 92 is substantially perpendicular to bottom panel 24 of
blank 10.
Feed mechanism 1104 pushes stack 1006 forward to position the next blank 10 to
be
removed from hopper 1102 by transfer arm 1106.
[0166] Blank 10 is moved from initial forming station 1202 to secondary
forming station 1206 through first adhesive application station 1204. More
specifically,
blank 10 is transported forward into secondary forming station 1206 using
pusher plate
1216 and/or drive rollers 1228. For example, pusher plate 1216 is moved in a
substantially
horizontal direction from a rear position to a forward position and blank 10
is slid forward
into secondary forming station 1206 along support rails 1224. Moveable folding
plows
1220 follow the motion of blank 10 to retain the position of rear inner
reinforcing panel
assemblies 90 and rear inner end panels 92. As blank 10 is transported
forward, rear inner
reinforcing panel assemblies 90 and rear inner end panels 92 are transferred
from moveable
folding plows 1220 to stationary folding plows 1218 to retain the position of
inner
reinforcing panel assemblies 90 and inner end panels 92.
[0167] In embodiments including rotatable guide rails 1227 (shown in
Figure 27), rotatable guide rails 1227 are initially positioned in the first
position such that
side panels 22 and 26 and/or top panels 20 and 28 may be received between
folding plows
1218 and 1220 as blank 10 is pulled downwardly onto support rails 1224 by
lower suction
device 1214. Prior to or concurrently with blank 10 being moved from initial
forming
station 1202 to secondary forming station 1206, rotatable guide rails 1227 are
rotated
approximately 90 degrees to the second position to retain the position of rear
inner
reinforcing panel assemblies 90 and rear inner end panels 92 as blank 10 is
transported
forward. Rear inner reinforcing panel assemblies 90 and rear inner end panels
92 are
transferred from rotatable guide rails 1227 to the downstream stationary
folding plows
1218 as blank 10 is transported forward to retain the position of inner
reinforcing panel
assemblies 90 and inner end panels 92.
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[0168] Drive rollers 1228 contact a leading end panel 64 or 70 and/or
bottom panel 24 as blank 10 is transferred from initial forming station 1202
to first
adhesive application station 1204. Once drive rollers 1228 engage blank 10,
pusher plate
1216 retracts to the rear position.
[0169] As blank 10 is transported through first adhesive application station
1204, adhesive is applied to interior surface 12 of corner panels 98, first
reinforcing side
panels 100, and/or end panels 64 and/or 70 using first adhesive applicator
1230. More
specifically, sensors within first adhesive application station 1204 detect a
position of blank
with respect to first adhesive applicator 1230 to control first adhesive
applicator 1230 to
properly apply the adhesive. As the trailing top edge 68 or 74 of blank 10
exits first
adhesive application station 1204, push lug 1232 engages trailing top edge 68
or 74 to
move blank 10 through secondary forming station 1206. More specifically, using
sensors
and/or other devices, control system 1008 controls servo drive 1236 to
position push lug
1232 adjacent trailing top etWe 68 or 74. Servo drive 1236 then controls
movement of
blank 10 through secondary forming station 1206 using push lug 1232. In the
example
embodiment, push lug 1232 moves blank 10 through secondary forming station
1206 until
leading top edge 74 or 68 is adjacent to, or in contact with, stop lug 1234.
Push lug 1232
and stop lug 1234 are configured to properly position blank 10 within
secondary forming
station 1206.
[0170] In embodiments including pusher arm 1247 (shown in Figures 32
and 33), the leading top edge 74 or 68 of blank 10 engages rotatable plate
1253 as blank 10
exits first adhesive application station 1204, and rotates rotatable plate
1253 in the
downstream direction. Rotatable plate 1253 returns to its original vertical
position once
blank 10 has passed downstream of rotatable plate 1253. Pusher arm 1247 moves
from the
first position (shown in Figure 32) to the second position (shown in Figure
33) to engage
the trailing top edge 68 or 74 of blank 10 with rotatable plate 1253, and to
position blank
10 within secondary forming station 1206.
[0171] Within secondary forming station 1206, reinforcing corner
assemblies 151 are formed using male forming member 1242 and female forming
member
1244. More specifically, in the example embodiment, folder arm 1240 rotates
from the
starting position to the folding position to fold interior surface 12 of inner
reinforcing panel
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assemblies 90 into face-to-face relationship with interior surface 12 of a
respective outer
reinforcing panel assembly 88. When folder arms 1240 are at the folding
position, inner
reinforcing panel assemblies 90 are not in contact with outer reinforcing
panel assemblies
88; however, in some embodiments, inner reinforcing panel assemblies 90 can be
rotated
into contact with outer reinforcing panel assemblies 88 by folder arms 1240.
In the
example embodiment, as inner reinforcing panel assemblies 90 are rotated by
folder arms
1240, inner end panels 92 and reinforcing corner panels 102 are slightly
rotated about fold
lines 96 and/or 114 by coming into contact with male forming member 1242. As
such,
folder arms 1240 and male forming members 1242 pre-break inner reinforcing
panel
assemblies 90 and inner end panels 92 along fold lines 114 and 96,
respectively. Once
inner reinforcing panel assemblies 90 are positioned with respect to outer
reinforcing panel
assemblies 88 and inner end panels 92 are positioned with respect to end
panels 64 and/or
70, folder arms 1240 retract to the starting position.
[0172] When folder arms 1240 have retracted, male forming members 1242
move downward toward blank 10 and female forming members 1244 move upward
toward
blank 10. Male forming members 1242 contact the inner, or upper, surface of
blank 10 and
female forming members 1244 contact the outer, or lower, surface of blank 10.
When male
and female forming members 1242 and 1244 compress toward each other with blank
10
therebetween, corner panels 98 and 102 are rotated about fold lines 96 and 78,
80, 82, or 84
and reinforcing side panels 100 and 104 are rotated about fold lines 112 and
114. Further,
when male and female forming members 1242 and 1244 move together, at least
inner end
panel 92 is adhered to a respective end panel 64 and 70. Alternatively or
additionally,
reinforcing side panels 100 and 104 are adhered together and/or comer panels
98 and 102
are adhered together by male and female forming members 1242 and 1244. When
reinforcing corner assemblies 151 are formed by male and female forming
members 1242
and 1244, partially formed container 1010 is formed from blank 10. Male
forming
members 1242 move upward and female forming members 1244 move downward to
release partially formed container 1010. As partially formed container 1010 is
released,
inner side rails 1246 contact first reinforcing side panel 100 to maintain a
position of
reinforcing corner assembly 151 with respect to the remainder of blank 10.
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[0173] Stop lug 1234 moves out of the path of partially formed container
1010, and push lug 1232 or slide mechanism 1249 (shown in Figure 32) moves
partially
formed container 1010 into compression station 1210 through angling station
1207 and
second adhesive application station 1208. As partially formed container 1010
is moved
through angling station 1207, reinforcing side panels 100 and 104 are rotated
to be at an
obtuse angle to end panel 64 and/or 70 by guide bars 1248 and miter plates
1250. While
partially formed container 1010 is transported through angling station 1207
and second
adhesive application station 1208, second adhesive applicator 1252 applies
adhesive to
second reinforcing side panels 104, as described above. Pusher arm 1254
engages trailing
top edge 68 or 74 of blank 10 to move partially formed container 1010 into
compression
station 1210 and over plunger opening 1272.
[0174] Pusher arm 1254 positions partially formed container 1010 between
plunger 1260 and plunger opening 1272, and plunger 1260 moves downward from
the
upper position toward the lower position to contact interior surface 12 of
bottom panel 24
using vertical actuator 1278. Plunger 1260 pushes bottom panel 24 into and
through
plunger opening 1272. Side panel plows 1262 and end panel plows 1266 are in
the
forming position as partially folined container 1010 is pushed through plunger
opening
1272. As partially formed container 1010 is pushed through plunger opening
1272, side
panel plows 1262 contact side panels 22 and 26, and rotate side panels 22 and
26 toward
interior surface 12 of bottom panel 24 to be substantially perpendicular to
bottom panel 24.
After or as side panels 22 and 26 are rotated, end panel plows 1266 contact
end panels 64
and 70, and rotate end panels 64 and 70 toward interior surface 12 of bottom
panel 24 to be
substantially perpendicular to bottom panel 24. In the example embodiment, the
relative
position of side panel plows 1262 and end panel plows 1266 causes side panels
22 and 26
to be rotated before end panels 64 and 70 are rotated. As end panels 64 and 70
are rotated,
reinforcing corner assemblies 151 are also rotated into face-to-face
relationship with a
respective side panel 22 or 26. More specifically, an interior surface of each
reinforcing
corner assembly 151 is rotated into face-to-face relationship with an exterior
surface 14 of
a respective side panel 22 or 26.
[0175] After end panels 64 and 70 are rotated to be substantially
perpendicular to bottom panel 24, and reinforcing corner assemblies 151 are
positioned in
face-to-face relationship with a respective side panel 22 or 26, side wall
presser assemblies
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1268 are actuated to press reinforcing corner assemblies 151 against a
respective side panel
22 or 26. More specifically, actuator 1286 moves presser plate 1284 towards
plunger
opening 1272 and into contact with exterior surface 14 of first reinforcing
side panel 100.
Presser plate 1284 presses exterior surface 14 of second reinforcing side
panel 104 against
exterior surface 14 of a respective side panel 22 or 26, either or both of
which have
adhesive applied thereto, to couple reinforcing corner assembly 151 to a
respective side
panel 22 or 26. Presser assemblies 1268 are thus configured to press an
interior surface of
reinforcing comer assemblies 151 against an exterior surface 14 of a
respective side panel
22 or 26 to secure reinforcing comer assemblies 151 to a respective side panel
22 or 26,
and thereby form side walls 154 and 156. In the example embodiment, adhesive
is applied
by second adhesive applicator 1252 to an interior surface of reinforcing
corner assemblies
151. More specifically, adhesive is applied to exterior surface 14 of second
reinforcing
side panels 104. Additionally or alternatively, adhesive is applied to
exterior surface 14 of
side panels 22 and 26.
[0176] Container 150 is then formed from blank 10. At any suitable time
during formation of container 150 from blank 10, a second blank 10 may be
removed from
hopper 1102 to form a second container 150. As such, the method may be
performed to
continuously form containers 150 using machine 1000. After container 150 is
formed, side
panel plows 1262, end panel plows 1266, and/or sidewall presser assemblies
1268 secure
container 150 within plunger opening 1272. Plunger 1260 retracts upwardly out
of cavity
170 of container 150 to the upper position, and side panel plows 1262, end
panel plows
1266, and/or sidewall presser assemblies 1268 move to outer positions to
release container
150 from plunger opening 1272. In the example embodiment, container 150 then
falls
downward to exit conveyor 1302. Exit conveyor 1302 transports container 150
from
plunger opening 1272 and/or forming station 1200. More specifically, exit
conveyor 1302
extends from ejection station 1300 past the bottom of compression station 1210
for
receiving container 150 from plunger 1260 and transferring container 150 from
forming
station 1200 to ejection station 1300. When machine 1000 forms a container
having top
panels, the container is ejected from machine 1000 without the top panels
rotated into
position such that the container is configured to have a product placed
therein. Container
150 can then be filled with a product and transported to a machine that folds
top panels 20
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and 28 and secures container 150 in the closed position. The machine can also
tape
container 150 in the closed position.
[0177] The above-described blanks and containers provide a reinforcing
polygonal container. More specifically, the embodiments described herein
provide an
octagonal container having reinforced corner walls, side walls, and end walls
for storing
and/or transporting a product therein. Further, the embodiments described
herein provide a
polygonal container having a top wall. More specifically, the top wall may be
formed from
top panels emanating from the side walls of the container or the end walls of
the container.
The top wall may be a full top wall covering substantially the entire cavity
of the container
or may be a partial top wall, such as top shoulders, that allows access to the
cavity of the
container when the top wall is formed. Additionally, the blanks and containers
described
herein may include a support wall for additional support of the container
when, for
example, the containers are stacked. The support wall may also act as a
partition or divider
for the cavity of the container.
[0178] Moreover, the blanks and containers described herein include
reinforcing panel assemblies and reinforcing corner assemblies that are
secured to an
exterior surface of the containers such that the interior surface of the
containers are
substantially planar. As a result, the blanks and containers described herein
are better
suited for transporting products that can be easily damaged during storage or
transport,
such as fresh fruit or produce.
[0179] The machine described herein facilitates forming containers from the
above-described blanks. More specifically, the machine more quickly and easily
forms the
containers, as compared to a person manually forming the containers from the
blanks. As
such, the machine facilitates producing many containers in a shorter time
period, as
compared to manual construction of the containers. Further, the above-
described machine
facilitates automating the method for forming a container from a blank such
that cost and
time for producing a container is reduced as compared to manually forming the
containers.
Further, the above-described machine facilitates securing the reinforcing
corner assemblies
of the blanks to an exterior surface of the container such that the interior
surface of the
containers are substantially planar.
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[0180] Example embodiments of blanks, containers formed therefrom, and
a machine for forming the containers from the blanks are described above in
detail. The
blanks, container, and machine are not limited to the specific embodiments
described
herein, but rather, components of the blanks, containers, and/or machine may
be utilized
independently and separately from other components described herein.
[0181] Although specific features of various embodiments of the disclosure
may be shown in some drawings and not in others, this is for convenience only.
In
accordance with the principles of the disclosure, any feature of a drawing may
be
referenced and/or claimed in combination with any feature of any other
drawing.
[0182] This written description uses examples to disclose the invention,
including the best mode, and also to enable any person skilled in the art to
practice the
invention, including making and using any devices or systems and performing
any
incorporated methods. The patentable scope of the invention is defined by the
claims, and
may include other examples that occur to those skilled in the art. Such other
examples are
intended to be within the scope of the claims if they have structural elements
that do not
differ from the literal language of the claims, or if they include equivalent
structural
elements with insubstantial differences from the literal language of the
claims.
