US3817018A

US3817018A - Method for forming a package

Info

Publication number: US3817018A
Application number: US00285211A
Authority: US
Inventors: J Vickers
Original assignee: Stone Container Corp
Current assignee: Stone Container Corp
Priority date: 1970-07-24
Filing date: 1972-08-31
Publication date: 1974-06-18
Anticipated expiration: 1991-06-18

Abstract

A method for forming a package containing a quantity of lading wherein the container for the lading is formed from two blanks made of rigid foldable material, each including an end wall and alternate side wall forming panels, one being unflanged and one including peripheral flanges along each longitudinal edge. The method includes the steps of: forming one of the blanks into a generally U-shape while concurrently partially surrounding the lading, forming the second blank into a generally U-shape concurrently partially surrounding the first blank and its lading with the end wall forming panels in opposed facing relation, and securing each alternate side wall forming panel of the unflanged blank to the peripheral flanges along one longitudinal edge of the flanged blank to form the package. The blanks are not attached together during the folding operations.

Description

United States Patent 1191 Viekers [73] Assignee: Stone Container Corporation,

Chicago, Ill.

[22] Filed: Aug. 31, 1972 [21] Appl. No.: 285,211

Related US. Application Data [75] Inventor:

[63] Continuation-impart of Ser. No. 57,945, July 24,

I970, abandoned.

[52] US. Cl. 53/32, 53/207 [51] Int. Cl B65b 11/18 [58] Field of Search 53/26, 24, 194, 207, 209,

Great Britain 220/DlG. 25

[4 June 18, 1974 Primary Examiner-Travis McGehee Assistant Examiner-John Sipos Attorney, Agent, or Firm-Silverman & Cass [5 7] ABSTRACT A method for forming a package containing a quantity of lading wherein the container for the lading is formed from two blanks made of rigid foldable material, each including an end wall and alternate side wall forming panels, one being unflanged and one including peripheral flanges along each longitudinal edge. The method includes the steps of: forming one of the blanks into a generally U-shape: while concurrently partially surrounding the lading, forming the second blank into a generally U-shape concurrently partially surrounding the first blank and its lading with the end wall forming panels in opposed facing relation, and securing each alternate side wall forming panel of the unflanged blank to the peripheral flanges along one longitudinal edge of the flanged. blank to form the package. The blanks are not attachedtogether' during the folding operations.

34 Claims, 11 Drawing Figures PATENTEDJun 1 81914 3 817' 01 8 sum 1 0r 6 PRINTED-1 mm ale-117L018 SHEET UF 6 PATENTEDJuN 18 I974 sum 5 or 6 1 METHOD FOR FORMING A PACKAGE RELATED APPLICATION This application is a continuation-in-part of my copending application Ser. No. 57,945 filed on July 24, 1970 now abandoned.

BACKGROUND AND SUMMARY OF THE INVENTION This invention relates to a method for fonning a package. More particularly it relates to a method for packaging a quantity of lading where the container for the lading is fonned from two separate blanks made of rigid foldable material.

Packaging containers currently in use conventionally include relatively large flaps or flanges overlapped to form one or more walls, usually the top and bottom of the container. Use of overlapped flanges in this manner results in a significant waste of raw material, a major factor in container cost.

In addition, containers or cartons formed of cardboard, corrugated board, folding carton box board, fiberboard, and the like are conventionally made using a single blank stamped from a sheet or roll of material. Provision of a blank including the various flaps and flanges necessary to the final container shape requires that the blank be substantially larger than the final container dimensions. This results in further waste of raw material because of the quantities of offal produced.

In many instances these types of containers require secondary operations to provide partial assembly prior to filling. For example, one common type of corrugated container is made of a single blank defining four side walls each provided with outward extending flaps at opposite ends which define the top and bottom walls. Three of the four corners between adjacent side walls are defined by fold lines or creases provided in the blank. The fourth is provided by connection between the opposite transverse edges of the blank. This is done either by gluing a flap formed at one transverse edge to the opposite side wall or by taping.

The blank, when pre-assembled as described, may be delivered to the, user in a knocked down flat condition. When used, the sidewalls are merely positioned such that adjacent walls are mutually perpendicular and the flaps folded and fastened together to form the top and bottom walls. The utilization of a partially preassembled blank simplifies to some extent the actual packaging operation; However, the necessity of performing secondary operations upon the blank contributes to the overall cost of the container.

Other problems, such as hermetic sealing of the container, cannot be readily accomplished unless separate insert panels are incorporated in the container construction. This results in further material cost and increased complexity of assembly procedures.

Containers of the general type having overlapped flanges forming one or more of the walls cannot be conveniently adapted to provide a reclosable lid, nor is it practical, without substantial increase in complexity and material cost, to provide means for carrying the resulting package.

In the package formed by the method of the present invention these deficiencies are overcome by utilization of two separate blanks, interconnected for form the container of the package. Maximum utilization of materials is accomplished and a versatile container readily adaptable to a variety of specific applications is provided. The method of the invention is primarily applicable to the formation of master shipping containers for quantities of pre-packaged canned or boxed goods.

Containers formed of two separate blanks have been devised in the past. However, the method of interconnection used and the complicated assembly procedures required have detracted from their adaptability as a commercially acceptable arrangement for packaging.

Example of such prior art containers and packages. and methods and apparatus for assembling same, are disclosed in the following patents: U.S. Pat. No. 3,272,4l9; U.S. Pat. No. 3,500,609; U.S. Pat. No. 3,622,063; U.S. Pat. No. 3,654,745; Canadian Pat. No. 796,155.

The present invention differs from the inventions disclosed in the above listed patents in that there is provided a method for forming a package containing a quantity of lading wherein the container for the lading is formed from two blanks made of rigid foldable material,each blank including an end wall and alternate side wall forming panels, one being unflanged and one including peripheral flanges along each longitudinal and transverse edge, the method including the steps of forming one of the blanks into a generally U-shape concurrently in partially surrounding relation to the lading, forming the other of the blanks into a generally U- shape concurrently in partially surrounding relation to the first blank and its lading with the end wall forming panels in opposed facing relation, and securing each alternate side wall forming panel of the unflanged blank to the peripheral flanges along one longitudinal edge of the flanged blank to form the package. The blanks are not attached to each other during the folding thereof.

The individual steps of the method can be accomplished in several different ways and in different sequence as will be disclosed hereinafter- BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a package formed by the method of the present invention; I

FIG. 2 is a perspective view of a blank utilized in forming a part of the package shown in FIG. I;

' F IG. 3 is a perspective view of another blank utilized in forming a part of the package shown in FIG. 1;

FIG. 4 is an exploded perspective view of the container of the package shown in FIG. 1;

FIG. 5 is a perspective view of another package formed by the method of the present invention;

FIG. 6 is a perspective view of another package which may be formed with the method of the invention;

FIG. 7 is a flow diagram illustrating various successive steps that can be followed in practicing several specific packaging methods of the invention;

FIG. 8 is a flow diagram illustrating various successive steps that can be followed in practicing further specific packaging methods of the invention;

FIG. 9 is a flow diagram illustrating various successive steps that can be followed in practicing additional specific packaging methods of the invention;

FIG. 10 is a flow diagram illustrating successive steps that can be followed in practicing another specific packaging method of the invention;

FIG. 11 is a flow diagram illustrating successive steps that can be followed in practicing still another specific packaging method of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS Referring now to the drawings, there is shown in FIGS. 1 to 4 a packaging container generally designated which is formed by the method of the invention.

The container 10 is made of any suitable material which is rigid and foldable such as cardboard, fiberboard, corrugated board, folding carton box board and the like. The container size and shape may vary as desired. Also the steps of the method can be utilized in forming master shipping containers usually made of corrugated board and smaller cartons or boxes made of folding carton box board.

The container 10 is formed of two separate blanks, l2 and 13, one flanged and one unflanged, each formed to a generally U-shape and fastened together to form the completed shape. The blanks l2 and 13 are shown in FIGS. 2 and 3 respectively. Each blank includes a center panel which forms an end wall and alternate side panels which form side walls of the container 10. In the Figures the blanks are positioned to show the surfaces of the panels that define the exterior of the container walls in order that the manner of interconnection of the blanks be best understood.

The flanged blank 12 is divided into a center, end wall forming panel 15 and alternate side wall forming panels 17 by score lines or fold lines 19. The end wall forming panel 15 is provided with a pair of peripheral flanges 21 along the longitudinal edge of the blank. The alternate side wall forming panels include peripheral flanges 23 along each longitudinal edge and a peripheral flange 25 along the transverse edge of the blank. The blank is provided with fold lines or creases 27 which separate the flanges from the adjacent wall forming panels.

The

flanges

21 and 23 along each longitudinal edge are separated by a generally V-shaped notch formed at each fold line or crease 19. The notches of course can also be rectangular or square resulting in overlapping or separated corners of the

flanges

21 and 23. The

flanges

23 and 25 are in turn separated by a generally right angle notch formed at each corner of the blank. It is readily apparent therefore that the blank 12 may be formed from a sheet or roll of material with only a minimum of waste, namely, that amount of material removed to form the notches.

The unflanged blank 13 includes an end wall forming portion 29 and alternate side wall forming panels 31 separated by creases or fold lines 33. This blank is void of any notches or slits and can be readily formed from sheet stock with negligible waste of material.

As seen in FIGS. 1 and 4, the assembled container is defined by interconnection of the

blanks

12 and 13. The alternate side wall forming panels of each blank are generally perpendicular to the end wall forming panels along

creases

19 and 33 and are interposed between the side wall forming panels of the other blank. The

flanges

21 and 23 along opposite longitudinal edges of the blank 12 are disposed generally perpendicularly to their adjacent wall forming panels as are the flanges 25 along the transverse edges of the blank 12. They extend inwardly with respect to or generally away from the surface of the blank defining the exterior surface of the container 10. The notches provided in the flanged blank accommodate the positioning of the flanges without overlap of material.

In the embodiment of FIGS. 1 to 4 the unflanged blank is disposed such that each-opposing side wall forming panel 31 is in overlying relation to and connected to the flanges formed on one longitudinal edge of the flanged blank 12. The end wall forming panel 29 of the unflanged blank is in turn positioned in overlying relation and connected to the flanges 25 along the transverse edges of the flanged blank 12. In this way a completely enclosed container is provided free of any open slots which would allow entry of contaminants. Also of significant importance is the fact that the external surface of the container is completely free of exposed flaps or flanges which would be accidentally engaged upon other objects during use. This precludes to a significant degree accidental damage that might be occasioned by the pressure of such flaps or flanges on the exterior surface of the container and presents a neat appearance.

The method for forming the container 10 by connecting the unflanged blank 13 to the flanges of the flanged blank 12 may vary widely depending upon the specific application. Solid thermoplastics material or other adhesive may be applied to the flanges of the flanged blank 12 or to the contacting surface of the unflanged blank 13. The adhesive pattern may be intermittent providing only sufficient bonding to prevent inadvertent opening or, when complete hermetic sealing is required, the adhesive may be applied as in a continuous strip extending around the notches formed in the blank as shown by the pattern 35 in FIG. 2. With this latter arrangement the adhesive completely seals the container without the necessity of inserted panels within the container as is required in conventional containers.

Adhesives such as glues or tapes are suitable for interconnection of the

blanks

12 and 13. Another highly suitable adhesive is a thermoplastic solid material that is liquid at elevated temperature and solid at normal room temperature. Such a product is commonly known as hot melt adhesive. Also, staples, brads, or other mechanical fasteners could be used with effectiveness.

Assembly of the container 10 is accomplished as illustrated in FIG. 4. Typically, the flanged blank 12 is first formed into a generally U-shape along fold lines 19 around lading to be packaged. The

peripheral flanges

21 and 23, along each longitudinal edge, are then folded generally perpendicularly to their respective wall defining positions along fold lines 27 to form agenerally U-shaped planar surface along each longitudinal edge and partially about a quantity of lading.

In the embodiment illustrated, the flanges 25 along the transverse edges of the blank 12 are also folded generally perpendicularly to the adjacent wall defining panels. All flanges are folded away from the surface of the blank which defines the exterior of the container.

The unflanged blank 13 is positioned with the center, end wall forming panel 29 in overlying relation to the flanges 25 of the flanged blank 12, and each side wall forming panel 31 is folded along scores 33 to respectively overlie the

flanges

21, 23 along one longitudinal edge of the blank 12.,The end wall 29 and side walls 31 are connected to the flanges as by the adhesive strip 35.

The lading is placed upon the flanged blank 12 prior to folding of any part thereof or can be placed upon the partially formed flanged blank prior to folding of the flanges 25 andconnection of the unflanged blank 13 to the

flanges

21, 23 and 25.

It must be appreciated that the precise sequence of steps in assembling the container may vary somewhat depending upon the specific application. For example, in a high-speed continuous flow packaging operation, the

flanges

21, 23 might first be folded perpendicularly to the

panels

15 and 17 of the blank prior to forming the blank into a generally U-shape. Also, the forming of the unflanged blank 13 into a generally U- shape and disposition of the end wall forming panel 29 and side wall forming panels 31 in overlying relation to the associated flanges of the flanged blank may be accomplished in a variety of ways. The entire procedure could be accomplished simultaneously, or the end wall forming panel could be disposed in overlying relation to the flanges 25, and the side wall panel 31 then folded into position.

It should be noted that disposition of the unflanged blank 13 in overlying relation to the flanges of the flanged blank 12 not only achieves the important advantages of providing a container having a smooth outer surface free of exposed flanges or flaps but in addition contributes to effective sealing of the container when the connection between blanks is made with adhesive. The normal tendency of the flanges is to return to their initial planar position and thus they will urge outwardly against the interior surface of the unflanged blank 13. By resisting outward movement of the unflanged blank during the fastening stage of assembly, the outward spring action of the flanges causes compression of the adhesive between the flanges and the inner surface of the unflanged blank insuring a complete bond.

In FIG. 5, there is illustrated a slightly modified form of container which is made by the method of the invention. This container is formed of blanks essentially identical to the blanks l2 and 13 illustrated in FIGS. 2 and 3. However, the interconnection between blanks is somewhat altered to provide certain specific advantages.

Here each side wall panel 31 of the unflanged blank 13 is disposed in overlying relation to and is connected to the

flanges

21 and 23 along one longitudinal edge of the flanged blank 12 as in the previous embodiment. However, the flanges 25 along the transverse edges of the flanged blank overlie and are affixed to the outer surface of the end wall forming panel 29 of the unflanged blank. It is believed that this arrangement provides increased resistance to longitudinal separation of the blanks by virtue of the overlap of the flange 25 upon the end wall defining portion 29.

FIG. 5 illustrates another modification in the formation of the container. One of the alternate side walls 31 of the unflanged blank 13 is affixed to the

flanges

21, 23 of one longitudinal edge by a pattern of adhesive such as the pattern 35. The adhesive pattern provides sufficient strength to seal the container during shipping but the bond may be broken when desired to open the container without damage to the side wall or flanges. The side wall 31 thus defines a reclosable lid which may be rescaled to the flanges with additional adhesive or tape. As an alternative, to the adhesive pattern 35 a tear strip type tape may be used between the

flanges

21, 23 and side wall 31.

In FIG. 6 is shown a further modified form of container formed by the method of the invention. Here the container 10 is formed of a flanged blank 12 identical to the flanged blank of previous embodiments. An unflanged blank 13a is provided which is somewhat larger than the unflanged blank 13, previously described.

The unflanged blank 13a includes side wall forming panels 310, and two end wall forming

panel portions

29a and 29b separated by handle defining portions 37. These various portions are separated by creases or fold lines 33a. The handle defining portions 37 include apertures 39 to form a handle opening.

At assembly the handle defining portions are folded upon one another as shown in FIG. 6 to form an upstanding handle. The end wall forming

panel portions

29a and 29b are connected to the flanges 25 and the side wall forming panels are connected to the

flanges

21, 23 along each longitudinal edge of the flanged blank 12 to complete the container shape.

In FIG. 7 there is illustrated a flow diagram of a series of successive steps and variations thereof which can be utilized in the packaging method of the invention for forming the package shown in FIG. 1. In this respect, one of the blanks 12 is first positioned at a first station 50 and lading 52 is positioned on the center panel 15 of the blank 12. The lading 52 is shown as comprising a plurality of cans and it is to be understood that the packaging methods of the invention can be utilized for packaging other types of lading. The blanks 12 are preferably fed sequentially from a stack thereof located adjacent the first station 50. After the lading 52 has been positioned on the center panel 15, the lading and first blank 12 are moved downwardly in a first direction indicated by the arrow 54 to a second station 56. During the movement from the first station to the second station, the alternate side wall forming panels 17 of the first blank 12 are folded upwardly into a generally U- shape partially about the lading 52. At the same time the

flanges

21 and 23 along each longitudinal edge of the blank 12 are folded inwardly to the desired position perpendicular to the end and side

wall forming panels

15 and 17. Preferably and as exploded in FIG. 7, the folded first blank 12 and lading 52 are received within a U-shaped pusher member 58 located at the second station 56. The side panels of the pusher member 58 serve to retain the lading withinthe folded first blank 12 after the first blank 12 embodying thereon have been moved to the second station 56.

Next a suitable operating mechanism is actuated to move the pusher member 58 thereby to move the first blank 12 and lading thereon from the second station 56 in a second direction indicated by the arrow 61 to a third station 62. At the third station 62, the folded first blank 12 and lading thereon are received on a slide plate 64. After the U-shaped member has been retracted to a position shown in phantom lines, another pusher member 66 is operated to move the folded first blank and lading thereon from the third station in a third direction indicated by the arrow 68 to a fourth station 70. As shown, the transverse flanges 25 are folded during the movement of the folded first blank and lading from the third station 62 to the fourth station 70. Typically, this is done by moving the transverse flanges 25 past stationary plow or folding members. Of

course, it is also to be understood that the transverse flanges 25 can be folded downwardly while the folded first blank is at the third station.

At the fourth station 70, a second blank 13 is moved to a location over the folded first blank with lading thereon. If an adhesive has not been previously applied to the exterior facing surfaces of the

flanges

21 and 23, each second blank 13, as it is moved from a magazine adjacent the station 70 to a position over a folded first blank with lading thereon, can be moved past adhesive applicators such as the applicators 72.

In F IG. 7 the blank is shown in a partially folded position as it is being folded into a generally U-shape about the lading positioned on the folded first blank 12. Initially the blank is positioned, unfolded, over the folded first blank. In accordance with one packaging method, the folded first blank 12 with lading thereon is moved upwardly in a fourth direction indicated by the arrow 74 to engage the unfolded second blank 13 at the fourth station 70. Typically this is accomplished by a vertically movable pusher member 76. Folding members are positioned above the fourth station 70 adjacent the path of movement of the

blanks

12 and 13 such that after the folded first blank engages the second blank 13 continued upward movement of the blanks l2 and 13 will cause the second blank 13 to engage the folding members which will then fold the alternate side panels 31 downwardly into the general shape of a U about the lading on the folded first blank 12. In this way a complete package 10 is formed after the blanks l3 and 12 have completed their upward movement from the fourth station 70 to a fifth station 78. If desired, the fifth station 78 can include a compression chamber of known type wherein pressure is applied to the side walls of the package for the purpose of maintaining the side wall forming panels 31 of said second blank 13 in engagement with the

flanges

21 and 23 of the first blank while the adhesive therebetween sets. The pressure on the side walls of the package 10 will impede upward movement of each package 10 through the compression chamber such that the bottom wall of a first formed package 10 will bear against the top wall panel 29 of a subsequent package 10. As a result, in the compression chamber, pressure is also applied against the top wall 29 thereby to press the top wall panel 29 against the transverse flanges to assist the setting of the adhesive therebetween.

A variation of the packaging method just described could be to fold the blank 13 partially about the lading as it is resting on the folded first blank 12 at the fourth station 70. This can be accomplished by a vertically re ciprocable U-shaped forming device (not shown) which would move downwardly after the blank 13 has been moved to the station 70, and then retracted upwardly to allow movement of the completed package from the fourth station70. As shown in phantom lines, the package completed in this manner at the fourth station 70 can be moved by a suitable pusher member either downwardly or laterally and in either case to a compression chamber of the type just described.

The method steps and the variations thereto just described above can be accomplished with suitable mechanisms some of which are partially shown in FIG. 7. Other mechanisms for performing the methods, such as for example stationary folding members adjacent the path of movement of the blank 12 from the first station 50 to the second station 56, carriages and pusher members for moving the first folded blank with lading thereon in the various directions illustrated and compression chambers of the type described above can be found in US. Pats. Nos. 3,531,914 and 3,665,675, the disclosures of which are incorporated herein by reference.

The method steps shown in FIG. 8 are substantially the same as those shown in FIG. 7 except that the modification of folding the transverse flaps 25 downwardly at the third station 62 is shown in FIG. 8. Also, and as better shown in FIG. 9, after folding the transverse flaps 25 downwardly at the third station 62 or while the folded first blank 12 is being moved from the second station 56 to the third station 62, a second blank 13 can be moved over the folded first blank 12 at the third station 62 and then the folded first blank can be moved upwardly to engage the second blank 13 and to move the second blank 13 past stationary folding members which fold the alternate side wall panels thereof downwardly into engagement with the

flanges

21 and 23 of the first blank 12 to complete the formation of a package 10 shown in FIG. 8 with flanges 25 underneath center panel 29. This completed package can be moved into a compression chamber from which it can be moved laterally. Of course, the package could be completed at the third station 62 by folding the blank 13 downwardly into a generally U-shape about the lading on the folded first blank situated at the third station 62.

Subsequently, the completed package could be moved laterally or downwardly into a compression chamber.

It is to be appreciated that the transverse flanges 25 can be omitted from the first blank 12, in which case the folding operation of the transverse flanges shown in FIG. 8 could be omitted and a second blank 13 can be moved over the folded first blank at the third station 62 as shown in FIG. 9. In this variation of the packaging method of the invention, the step of moving the folded first blank 12 from the third station 62 to the fourth station can be omitted.

Other than folding the transverse flanges 25 at the third station 62 instead of folding them while moving the folded first blank from the third station 62 to the fourth station 70, the method steps shown in FIG. 8 are identical with the method steps shown in FIG. 7.

In FIG. 9 there is illustrated variations in the steps of the method illustrated in FIGS. 7 and 8. The packaging method illustrated in FIG. 9 is particularly adapted for forming the packaging container shown in FIG. 5 where the transverse flanges 25 are folded over the top wall panel 29 of the second blank 13. The method steps illustrated in FIG. 9 are for the most part identical to the method steps shown in FIGS. 7 and 8. An important difference however is the position of a magazine for the second blank 13 adjacent the third station 62. With this modification, the blank 13 can be positioned over a first blank 12 at the third station 62 and if desired the package can be completed at the third station 62 with the flanges 25 folded beneath or above the top wall panel 29 of the blank 13. The resulting package can then be moved upwardly, laterally or downwardly into a compression chamber as previously described. Another variation, dependent upon the desired infeed direction of the second blank 13 and the desired arrangement of the various mechanisms is to have a rotatable platform at station 62 for rotating the first blank and lading 90 before the second blank 13 is positioned thereover.

Of course, and as shown in FIG. 9, the partially formed package with the transverse flanges 25 unfolded and with the alternate side wall defining panels partially folded downwardly or completely folded downwardly, can be moved in the fourth direction 68 to the fourth station 70. The transverse flanges 25 can be folded downwardly by plow members during this movement or can be folded downwardly at the fourth station 70. Again from the fourth station 70, the completed package can be moved upwardly, downwardly or laterally into a compression chamber. Also it is to be understood that the folding over of the transverse flanges 25 to complete the package can be accomplished while moving the folded blanks l2 and 13 upwardly in the direction indicated by the arrow 74 to a fifth station.

Any suitable means can be utilized for moving

blanks

12 and 13 from their respective magazines into the desired position at the heretofore indicated stations. Such a feeder or pusher mechanism is generally shown in FIGS. 7-9 and identified with the reference numeral 84.

In FIG. 10 there is illustrated another sequence of steps that can be followed in practicing the method of the invention. In this specific packaging method, a first station 90 similar to the first station 50 shown'in FIG. 7, receives an unfolded first blank 12 and then a quantity of lading or product 92, which product or lading 92 is positioned on the center panel 15 of the first blank 12. Then the lading and first blank 12 are moved downwardly in a first direction 94 past stationary folding members which fold the panels 17 upwardly and inwardly to form the blank 12 into the general shape of a U." Also during this downward movement the

flanges

21 and 23 are folded inwardly to a position perpendicular to the

respective panels

15 and 17 to which they are attached. At the end of the downward movement in the first direction 94, the folded first blank 12 with the lading 92 thereon is located at a second station 96 from which it is pushed in a second direction indicated by arrow 98 to a third station 100. At the third station 100 a second blank 13 is positioned over the folded first blank 12 and then the folded first blank 12 with lading thereon and with the second blank 13 positioned thereover is moved upwardly in a third direction 101 to a fourth station 102. During this movement in the third direction 101, the blanks l2 and 13 are moved past stationary folding members which fold the panels 31 downwardly to fold the second blank 13 into the general shape of a U about the folded first blank 12 and lading 92 thereon.

At the fourth station 102, further pressure can be applied to the

panels

31 and 29 to assist in the adhering of the second blank 13 to the first blank 12. Also or in addition the completed package 10 can be moved laterally in a fourth direction 103 into a compression chamber of the type previously described.

In the method steps illustrated in FIG. 10, the second blanks 13 are not fed directly from a magazine to a position over the folded first blank 12 at the third station 100. Instead, the magazine or stack of blanks 104 is positioned adjacent the second station 96 with the longitudinal axis of the blanks 13 extending generally parallel to the second direction indicated by the arrow 98. Then the lowermost blank 13 in the stack of blanks 104 is moved from the stack 104 in a direction generally parallel to the second direction indicated by the arrow 98. This movement of the lowermost blank 13 is indicated by the arrow 106. At the completion of the movement of the lowermost blank 13 from the stack 104, it is located at an adhesive applying station 107 where adhesive is applied to the underside of the blank 13 along the marginal areas thereof. Alternatively, the adhesive could be applied at selective locations along the margin of the blank 13, such as at the comers of the blank 13 and at positions adjacent the fold lines 33. After adhesive has been applied to the underside of the blank 13 at the adhesive applying station 107, the blank 13 is L moved in the direction indicated by the arrow 108 to a position over the folded first blank 12 at the third station 100. Then the blanks are moved as previously described to form the package 10.

In FIG. 11 there is illustrated another series of steps which can be followed in carrying out the packaging method of the invention. In the method steps shown in FIG. 11, a first blank 12 is moved to a first station from a stack or magazine of first blanks 121, subsequently a quantity of lading 122 is moved onto the center panel 15 of the first blank 12 at the first station 120. It will be noted that in the arrangement shown in FIG. 11, the positions of the lading and stack of the first blanks is reversed from the position of the lading and stack of first blanks shown in FIGS. 7-9. As shown the first blanks 12 are moved from the magazine 121 in a direction indicated by the arrow 123 and the quantity of lading 122 is moved in another direction indicated by the arrow 124 onto the first blank 12 at the first station 120, which direction is 90 to the direction indicated by the arrow 123. As in the other specific methods previously described, the first blank 12 with a quantity of the lading 122 thereon is moved downwardly in a first direction 125 to a second station 126. During this downward movement the side panels 17 are folded upwardly to form the first blank into the general shape of a U about the lading 122. Also at the same time the

flanges

21 and 23 are folded inwardly to a position generally perpendicular to the

panels

15 and 17 to which they are attached.

The apparatus utilized in forming the package 10 with the method steps shown in FIG. 11 differs from the apparatus shown in the previous figures, in that, at the second station 126, there is located a generally upright U-shaped blank and lading receiving framework 127. This framework includes two

upright plates

128 and 129 interconnected at their lower corners by frame members and 131. In this way the framework 127 has an open bottom indicated by the arrow 132. When the folded first blank 12 and lading 122 thereon are received between the

plates

128 and 129, the

plates

128 and 129 face the open sides of the U-shaped folded first blank 12 and thereby serve to retain the lading within the folded first blank 12. The bottom corners of the folded first blank 12 are then supported on the

frame members

130 and 131.

After the folded first blank 12 and lading 122 are received within the framework 127, the framework 127 is moved in the direction indicated by the arrow 133 to a third station 134. As shown, during this movement between the second station 126 and the third station 134, the transverse flanges 25 are folded over such as by moving them past stationary plow members.

Located catty-corner to the third station 134 is a stack or magazine of second blanks 136. In this respect the stack 136 is located downstream of the direction indicated by the arrow 133 and laterally of this direction of movement. A suitable pusher mechanism is located beneath the stack 136 for moving the lowermost second blank 13 thereof in a direction indicated by the arrow 138 (which is parallel but opposite to the direction indicated by the arrow 133) to an intermediate station 140. During this movement adhesive is applied to the longitudinal marginal areas on the underside of the blank 13 by moving the blank 13 past two spaced apart adhesive applicators 141. After the blank 13 has been received at the station 140, it is moved in a transverse direction indicated by the arrow 143 (which is 90 to the direction indicated by the arrow 138) to the third station 134 and to a position over the folded first blank 12 and lading 122 thereon located at the third station 134. During this movement adhesive is applied to the transverse marginal areas of the second blank 13 by moving the blank 13 past two spaced apart adhesive applicators 142.

After the second blank 13 has been positioned over the foled first blank and lading at the third station 134, a pusher member 146, which is sized to fit through the opening 132, is moved upwardly in a third direction 148 to move .the blanks and lading to a fourth station (not shown). During this movement from the third station 134 to the fourth station the second blank 13 is moved past stationary folding members which fold the side panels 31 downwardly into engagement with the

flanges

21 and 23 on the first blank 12. After the blanks and lading have been moved to the fourth station and folded to complete the formation of a package 10, the completed packages are moved in a fourth direction indicated by the arrow 149 into a compression chamher.

The method steps illustrated in FIG. 11 are preferred for many applications in that there is an inline movement of the quantity of lading 122 through an apparatus which is utilized in carrying out the method steps. Thus, as is readily apparent from FIG. 11, the completed packages 10 exiting from a packaging machine utilized in carrying out the method steps shown in FIG. 11 will be moving in the same direction and in line with the direction of incoming lading 122. In other words, the direction of the completed packages 10 indicated by the arrow 149 is the same as and inline with the direction of movement of the lading 122 as indicated by the arrow 124. Another advantage to the method steps shown in FIG. 11 is the U-shaped framework which serves to maintain the quantity of lading in the folded first blank 12. Also the opening 132 in the bottom of the framework permits the use of the pusher member 146 to move the folded first blank 12 with lading thereon upwardly out of the framework 127 at the third station 134.

With reference to the directions indicated by the

arrows

138 and 143 respectively, it is to be understood that the applicators 141 can be positioned forwardly of the position indicated and that the adhesive applicators 142 can be positioned rearwardly of the position shown. Thus the

applicators

141 and 142 adjacent one corner of the blank 13 can be replaced by a single applicator positioned beneath that comer of the blank 13. Also it is to be understood that the adhesive applied at the adhesive applying station 107 in FIG. 10 can be applied with applicators of the type shown in FIG. 11 and arranged as shown in FIG. 11. In this respect there can be four or three applicators as described above with four being shown in FIG. 10.

As can be appreciated the method of the present invention and the container formed thereby are suitable to a variety of packaging applications and provide for efficient utilization of raw materials and eliminate the need for secondary operations. Various features of the present invention have been particularly shown and described. However, it should be obvious that various modifications may be made without departing from the spirit or scope of the invention as defined by the appended claims.

I claim:

1. A method for forming a package containing a quantity of lading wherein the container for the lading is formed from two blanks made of rigid foldable paperboard material, each blank including an end wall and alternate side wall forming panels, one blank being unflanged and one blank including peripheral flanges along the sides of the end wall forming panel thereof and peripheral flanges along the sides and ends of the side wall forming panels thereof, said method including the steps of placing said lading on the end wall of said flanged blank, forming the flanged blank into a generally U-shape and concurrently partially surrounding said lading, infolding said flanges located on the sides of said panels of the flanged blank, subsequently infolding the flanges on the ends of the side wall forming panels of the flanged blank, forming the second said blank into a generally U-shape and concurrently partially surrounding said lading with said end wall forming panels in opposed facing relation, and with the side wall forming panels of one blank being disposed at to the side wall forming panels of the other blank, and securing each said alternate side wall forming panel of said unflanged blank to said peripheral flanges along one longitudinal edge of said flanged blank to form the package, the flanged blank being formed into said U-shape while physically separated from the other blank.

2. The method according to claim 1 wherein said flanged blank is first formed into a generally U-shape in partially surrounding relation to said lading, and wherein said flanges along the sides of said alternate side wall forming panels are thereafter formed generally perpendicular to said side wall forming panels and said unflanged blank is next formed into a generally U- shape in partially surrounding relation to said lading with said end wall forming panels in opposed facing relation, and each said alternate side wall forming panel thereof is connected to said peripheral flanges of said flanged blank to form the package.

3. A method for forming a package using first and second generally rectangular blanks of paperboard material, each including a center panel and alternate side panels, and said first blank including flanges along the longitudinal edges of the center and side panels and flanges along the ends of the side panels, said method comprising the steps of: positioning said first blank unfolded in a desired position; arranging lading to be packaged on the center panel of said first blank; folding said first blank into a generally U-shape partially about the lading with said center panel forming a bottom wall and said side panels forming two side walls; folding said flanges along each longitudinal edge and along the ends of each side panel to a position generally perpendicular 13 to saidassociated side walls and bottom wall; positioning said second blank over said lading and'said folded first blanktfolding said second blank intoa generally U-shape partially about said lading with said center panel forming a top'wall and with each alternate side panel positioned in overlying relation to the flanges along onelongitudinal edge of said first blank with the side panels of one blank being disposed at 90 to the side panels of the other blank; and securing said flanges of said first blank to said top and side wall forming panels of said second blank.

4.The method according toclaim 3 wherein said first blank is folded into a generally U-shape partially about the lading prior to the folding of said flanges of said first blank.

5. The method according to claim 3 wherein flanges of said first blank are folded prior to the folding of said first blank into a generally U-shape partially about the lading.

6. The method according to claim 3 wherein said flanges of said first blank are folded simultaneously with the folding of said first blank into a generally U- shape partially about the lading.

7. The method according to claim 3 wherein said method includes the steps of folding the flanges located along the ends of said side panels to a position generally perpendicular to said associated side wall forming panelsprior to positioning said second blank over said lading and said folded first blank, positioning said center panel of said second blank in overlying relation to said end flanges, and securing said top wall forming center panel of said second blank to said end flanges of said first blank, said flanges having a tendency to spring back to their original position and in so doing bear against said second blank and thereby assist in the securing of said first blank to said second blank.

8. The method according to claim 3 wherein saidlading is arranged on said center panel of said first blank at a first station after which said lading and said first blank are moved downwardly in a first direction to a second station and said folding of said first blank into a generally U-shape and the folding of flanges is accomplished by moving saidfirst blank downwardly in said first direction past a stationary folding means.

9. The method according to claim 8 including the step of moving the folded first blank in a second direction, laterally of said first direction, to a third station.

10. The method according to claim 9 wherein said second blank is positioned over said folded first blank and lading thereon at said third station and is then folded into a generally U-shape partially about said ladmg. a

ll. The method according to claim 9 wherein said second blank is positioned over said folded first blank and lading thereonat said third station after which said first and second blanks are moved upwardly in a third direction past a stationary folding means which engages said second blank and folds said second blank into said generally U-shape about said lading.

12. The method according to claim 9 wherein said folded first blank and lading thereon are moved laterally in a third direction to a fourth station, said second blank is positioned oversaid folded first blank and lading thereon at said fourth station and is then folded into said generally U-shape about said lading.

13. The method according to claim 10 wherein said panels of said second blank are secured to said flanges of said first blank by an adhesive applied to either the marginal area of said second blank or to the outer facing sides of said flanges and, after said alternate side panels of said second blank are folded against said flanges, said completed package is moved into a compression chamber where pressure is applied to said side walls of said package to maintain the side wall forming panels in place while the adhesive sets.

14. The method according to claim 11 wherein said panels of said second blank are secured to said flanges of said first blank by an adhesive applied to either the marginal area of said second blank or to the outer facing sides of said flanges and, after said alternate side panels of said second blank arefolded against said side flanges, said completed package is moved into a compression chamber where pressure is applied to said side walls of said package to maintain the side wall forming panels in place while the adhesive sets.

15. The method according to claim 12 wherein said panels of said second blank are secured to said flanges of said first blank by an adhesive applied to either the marginal area of said second blank or to the outer facing sides of said flanges and, after said alternate side panels of said second blank are folded against said flanges, said completed package is moved into a compression chamber where pressure is applied to said side walls of said package to maintain the side wall forming panels in place while the adhesive sets.

16. The method according to claim 3 wherein said panels of said second blank are secured to said flanges of said first blank by an adhesive applied to either the marginal area of said second blank or to the outer facing sides of said flanges and, after said alternate side panels of said second blank are folded against said flanges, said completed package is moved into a compression chamber where pressure is applied to said side walls of said package to maintain the side wall forming panels in place while the adhesive sets.

17. The method according to claim 9 wherein said method includes the step of folding said flanges along the ends of the side panels over to a position perpendicular to said alternate side panels attached thereto at said third station.

18. The method according to claim 17 including the step of positioning said second blank over said folded first blank and lading thereon after said flanges have been folded.

19. The method according to claim 18 wherein said alternate side panels of said second'blank are folded downwardly to fold said second blank into a generally U-shape about the lading at the third station after said second blank has been positioned over said folded first blank and lading thereon.

20. The method according to claim 19 wherein said panels of said second blank are secured to said flanges of said first blank with an adhesive and wherein said method includes the step of moving said completed package laterally in a third direction into a compression chamber where pressure is applied to the walls of said package to maintain the wall forming panels in place while the adhesive sets.

21. The method according to claim 18 including the step of moving said folded first blank with said lading thereon upwardly into engagementwith said second blank and past a folding means which engages and folds over said alternate side panels of said second blank and into engagement with the folded longitudinal flanges on each side of said first blank.

22. The method according to claim 21 wherein said first and second blanks are moved upwardly in said third direction past said folding means and into a compression chamber where pressure is applied to the walls of said package to maintain the wall forming panels in place while adhesive which has been previously applied to either the flanges of the first blank or longitudinal marginal areas of said second blank is allowed to set for the purpose of securing the second blank to said flanges of said first blank.

23. The method according to claim 9 wherein said method includes the step of moving said folded first blank with lading therein in a third direction laterally of said second direction to a fourth station and said flanges on the ends of the side panels being folded over to a position perpendicular to the side wall panels attached thereto during the movement of said folded first blank with lading thereon from said third station to said fourth station.

24. The method according to claim 23 wherein said second blank is positioned over said folded first blank with lading thereon at said fourth station.

25. The method according to claim 24 wherein said folded first blank with lading thereon and with said second blank thereover is moved upwardly in a fourth direction past a stationary folding means which engages and folds said alternate side panels of said second blank downwardly into engagement with the respective flanges of said first blank, the flanges on the ends of the side panels being brought into contact with the underside of the center panel of said second blank during said upward movement.

26. The method according to claim 25 wherein said first and second blanks are moved upwardly past the stationary folding means into a compression chamber where pressure is applied to the walls of the package to maintain the wall forming panels of the second blank in engagement with the flanges of the first blank while adhesive which has been previously applied to either the flanges or to the longitudinal and transverse marginal areas of the second blank sets.

27. The method according to claim 24 wherein said alternate side panels of said second blank are folded downwardly to fold said second blank into the general shape of a U about the lading positioned on said first blank thereby to bring the panels of said second blank into engagement with the flanges of said first blank.

28. The method according to claim 27 wherein said panels of said second blank are secured to the flanges of said first blank with an adhesive which has been previously applied to either the longitudinal and transverse marginal areas of the second blank or to the flanges and wherein said method includes the step of moving said folded first and second blanks with lading therebetween laterally in a fourth direction into a compression chamber where pressure is applied to the walls of the package to maintain the wall forming panels of the second blank in engagement with the flanges of said first blank while the adhesive sets.

29. The method according to claim 9 wherein said second blank is positioned over said folded first blank with lading thereon at said third station and said folded first blank and lading are moved upwardly into engagement with said second blank and past a stationary folding means which engages and then folds said alternate side panels of said second blank downwardly into engagement with said flanges of said first blank.

30. The method according to claim 29 wherein said first and second blanks are moved upwardly in said third direction past said stationary folding means and into a compression chamber where pressure is applied to the walls of the package to maintain the side wall forming panels of said second blank in engagement with the flanges of the first blank while an adhesive therebetween, which has been previously applied to either the flanges of the first blank or to the longitudinal and transverse marginal areas of said second blank, sets.

31. The method according to claim 9 wherein said second blank is positioned over said folded first blank and lading thereon at said third station and is then folded about the lading into the general shape of a U.

32. The method according to claim 31 wherein said flanges are secured to the alternate side panels of said second blank with an adhesive which has been previously applied to either the flanges or to longitudinal and transverse marginal areas of the second blank, and wherein said method includes the step of moving the completed package from the third station laterally in a third direction into a compression chamber where pressure is applied to the side walls of the package to maintain the side wall forming panels of the package in engagement with the flanges while the adhesive therebetween sets.

33. The method according to claim 2 wherein said peripheral flanges along the ends of said side wall forming panels are infolded after said second blank is formed into U-shape partially surrounding said lading, and said infolded flanges being secured to the outer surface of the end wall panel of said second blank.

34. The method according to claim 9 including the step of folding the flanges located along the ends of said side panels to a position generally perpendicular to said associated side wall forming panels while moving said folded first blank in said second direction between said second and third stations.

Claims

1. A method for forming a package containing a quantity of lading wherein the coNtainer for the lading is formed from two blanks made of rigid foldable paperboard material, each blank including an end wall and alternate side wall forming panels, one blank being unflanged and one blank including peripheral flanges along the sides of the end wall forming panel thereof and peripheral flanges along the sides and ends of the side wall forming panels thereof, said method including the steps of placing said lading on the end wall of said flanged blank, forming the flanged blank into a generally U-shape and concurrently partially surrounding said lading, infolding said flanges located on the sides of said panels of the flanged blank, subsequently infolding the flanges on the ends of the side wall forming panels of the flanged blank, forming the second said blank into a generally U-shape and concurrently partially surrounding said lading with said end wall forming panels in opposed facing relation, and with the side wall forming panels of one blank being disposed at 90* to the side wall forming panels of the other blank, and securing each said alternate side wall forming panel of said unflanged blank to said peripheral flanges along one longitudinal edge of said flanged blank to form the package, the flanged blank being formed into said U-shape while physically separated from the other blank.

2. The method according to claim 1 wherein said flanged blank is first formed into a generally U-shape in partially surrounding relation to said lading, and wherein said flanges along the sides of said alternate side wall forming panels are thereafter formed generally perpendicular to said side wall forming panels and said unflanged blank is next formed into a generally U-shape in partially surrounding relation to said lading with said end wall forming panels in opposed facing relation, and each said alternate side wall forming panel thereof is connected to said peripheral flanges of said flanged blank to form the package.

3. A method for forming a package using first and second generally rectangular blanks of paperboard material, each including a center panel and alternate side panels, and said first blank including flanges along the longitudinal edges of the center and side panels and flanges along the ends of the side panels, said method comprising the steps of: positioning said first blank unfolded in a desired position; arranging lading to be packaged on the center panel of said first blank; folding said first blank into a generally U-shape partially about the lading with said center panel forming a bottom wall and said side panels forming two side walls; folding said flanges along each longitudinal edge and along the ends of each side panel to a position generally perpendicular to said associated side walls and bottom wall; positioning said second blank over said lading and said folded first blank; folding said second blank into a generally U-shape partially about said lading with said center panel forming a top wall and with each alternate side panel positioned in overlying relation to the flanges along one longitudinal edge of said first blank with the side panels of one blank being disposed at 90* to the side panels of the other blank; and securing said flanges of said first blank to said top and side wall forming panels of said second blank.

4. The method according to claim 3 wherein said first blank is folded into a generally U-shape partially about the lading prior to the folding of said flanges of said first blank.

6. The method according to claim 3 wherein said flanges of said first blank are folded simultaneously with the folding of said first blank into a generally U-shape partially about the lading.

7. The method according to claim 3 wherein said method includes the steps of folding the flanges located along the ends oF said side panels to a position generally perpendicular to said associated side wall forming panels prior to positioning said second blank over said lading and said folded first blank, positioning said center panel of said second blank in overlying relation to said end flanges, and securing said top wall forming center panel of said second blank to said end flanges of said first blank, said flanges having a tendency to spring back to their original position and in so doing bear against said second blank and thereby assist in the securing of said first blank to said second blank.

8. The method according to claim 3 wherein said lading is arranged on said center panel of said first blank at a first station after which said lading and said first blank are moved downwardly in a first direction to a second station and said folding of said first blank into a generally U-shape and the folding of flanges is accomplished by moving said first blank downwardly in said first direction past a stationary folding means.

10. The method according to claim 9 wherein said second blank is positioned over said folded first blank and lading thereon at said third station and is then folded into a generally U-shape partially about said lading.

11. The method according to claim 9 wherein said second blank is positioned over said folded first blank and lading thereon at said third station after which said first and second blanks are moved upwardly in a third direction past a stationary folding means which engages said second blank and folds said second blank into said generally U-shape about said lading.

12. The method according to claim 9 wherein said folded first blank and lading thereon are moved laterally in a third direction to a fourth station, said second blank is positioned over said folded first blank and lading thereon at said fourth station and is then folded into said generally U-shape about said lading.

14. The method according to claim 11 wherein said panels of said second blank are secured to said flanges of said first blank by an adhesive applied to either the marginal area of said second blank or to the outer facing sides of said flanges and, after said alternate side panels of said second blank are folded against said side flanges, said completed package is moved into a compression chamber where pressure is applied to said side walls of said package to maintain the side wall forming panels in place while the adhesive sets.

19. The method according to claim 18 wherein said alternate side panels of said second blank are folded downwardly to fold said second blank into a generally U-shape about the lading at the third station after said second blank has been positioned over said folded first blank and lading thereon.

21. The method according to claim 18 including the step of moving said folded first blank with said lading thereon upwardly into engagement with said second blank and past a folding means which engages and folds over said alternate side panels of said second blank and into engagement with the folded longitudinal flanges on each side of said first blank.

27. The method according to claim 24 wherein said alternate side panels of said second blank are folded downwardly to fold said second blank into the general shape of a ''''U'''' about the lading positioned on said first blank thereby to bring the panels of said second blank into engagement with the flanges of said first blank.

31. The method according to claim 9 wherein said second blank is positioned over said folded first blank and lading thereon at said third station and is then folded about the lading into the general shape of a ''''U.''''