AU2004203089A1 - Box erecting machine - Google Patents

Description

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT Applicant(s): RYAN MANUFACTURING LIMITED Invention Title: BOX ERECTING MACHINE The following statement is a full description of this invention, including the best method of performing it known to me/us: -2- Box erecting machine TECHNICAL FIELD This invention relates generally to a machine for erecting boxes from flat blanks of sheet material, typically cardboard or the like.

BACKGROUND ART Folded boxes of various sizes, shapes and types, made from various materials, are important throughout commerce and industry in multitudinous applications. One particular application is the horticultural industry, where such open-topped boxes are routinely used to package fruit for convenient handling and transport. Optionally the box may receive some form of closure. The cardboard boxes commonly used in fruit packaging basically consist of a compartment defined by a flat base with peripheral walls either perpendicular to the bottom or angled slightly outward relative to the vertical. The box material is typically relatively stiff corrugated cardboard and double-thickness walls with reinforced corners providing a box with sufficient strength to allow multiple boxes to be stacked without the walls collapsing.

Given the demand for such boxes it is desirable that they be produced cheaply, quickly and reliably, while minimizing the need for inspection of the finished product. A machine for high-speed automated production of such items should be of simple construction, easy to operate and maintain, operate reliably and have a minimum of moving parts. A difficulty in such machines, particularly for producing relatively large boxes, has been the accuracy of the folds, since any error is compounded when the boxes are stacked. Advantageously, the H:LInda\Keep'spec\P53680 42878 SPEC .doc 8/07/04 -3machine should also be adaptable to manufacture the new designs and accommodate different materials and features.

Other difficulties with the known machines result from inexact synchronization between separately driven cooperating parts, thereby reducing folding accuracy and reliability of operation. Moreover, the actuator and connection expenditures necessary are much increased due to the additional components required; consequently, manufacture of the machine is more costly. Although box fabrication machines have been long in existence, they have suffered from deficiencies and generally not satisfied the aforementioned objectives.

US Patent No. 5 632 713 describes a box forming machine for folding sheet material blanks into open top boxes having double walls. Two opposing blank folding mechanisms each have a pivotably mounted inner plate with an outer plate pivotably connected thereto for cooperating to fold and press the double-walls together. The pivot on the outside edge of the inner plate (to which the outer plate is fixed) however, necessitates a somewhat complicated mechanical linkage to provide the coordination between the two plates during the folding process. Further complication and expense results since separately driven folding mechanisms arranged around the four sides of the blank are required to fold the four walls.

It is an object of the present invention to address the foregoing difficulties and objectives or at least to provide the public with a useful choice.

H:\Lnda\Keep\spec\P53680 42878 SPECl .doc 8/07/04 Further aspects and advantages of the present invention will become apparent from the ensuing description which is given by way of example only.

Any publication cited in this specification is hereby incorporated by reference, however this does not constitute an admission that the document forms part of the common general knowledge in the art, in New Zealand or in any other country. The applicant reserves the right to challenge the pertinency of any publication cited herein, or to challenge the accuracy of any assertion made in a cited publication. As used herein, the word "comprises" means "includes, but is not limited to" and its derivatives have a corresponding meaning.

DISCLOSURE OF THE INVENTION According to one aspect of the present invention there is provided apparatus for forming sheet material blanks into boxes, each blank having a base panel and wall-defining panels joined to the edges of the base panel along wall fold lines, with substantially parallel intermediate fold lines dividing inner and outer parts of a pair of opposing wall-defining panels, the apparatus including: a reciprocating plunger; a forming chamber for receiving the plunger to fold the blank along the wall fold lines; two opposing blank folding mechanisms, each of the blank folding mechanisms having; an inner plate mounted for pivotal movement; the two inner plates being positioned at opposite sides of the forming chamber; an outer plate mounted for pivotal movement alongside the inner plate; actuating means for pivoting respectively the inner plate toward a lower part of the forming chamber, and for pivoting the outer plate toward the inner plate, H:\nda\Keep\spec\P53680 42878 SPECl .doc 8/07/04 whereby upon driving the plunger to press the blank into the forming chamber the walldefining panels are folded together along the wall fold lines and, after the plunger is retracted, the box sides are formed through operation of the actuating means by folding the pair of opposing wall-defining panels along the intermediate fold lines as the outer plates pivot toward the inner plates and the inner plates pivot toward the lower part of the forming chamber.

The actuating means connects the outer plate and inner plate for coordinated reciprocating movement. Preferably the apparatus further includes adhesive application means and the outer plate and inner plate compress the box sides therebetween to bond them in place after they have received adhesive. Preferably a double thickness wall section is formed from folding over the wall-defining panel, but optionally, the wall sections of the box need not be double-walled. One or more other layers (for example, a separate stiffening panel, a flap or lid for the box) may also be compressed between the inner and outer plates. It should be understood that herein the term fold lines is meant to include score lines, crease lines, perforation lines and the like formed in the blank and subsequently the actual fold made along such lines. Connecting the respective outer plate and inner plate for coordinated reciprocating movement has resulted in more exact synchronization between these cooperating parts, increasing folding accuracy and reliability of operation. Moreover, additional actuator and connection expenditures are avoided, thus reducing manufacturing costs. It will be understood that many different linkages and mechanisms can be used to achieve this connection between two reciprocating components, and preferably the connection should incorporate provision for adjustment of the relative positions of the inner plate and the outer plate e.g. to accommodate different sheet materials.

H:\Linda\Keep\spec\P53680 42878 SPECI.doc 8/07/04 -6- The apparatus is preferably a high speed automated machine for sequentially forming boxes, the general operation and control of which will be known to the skilled person, as will the construction of component parts not herein described in detail.

Guides are prefeably provided between the blank folding mechanisms on opposing sides of the forming chamber, the guides cooperating with the plunger to fold two opposite walldefining panels into a substantially upright position. Preferably an outer plate pivot axis about which each outer plate pivots is fixed relative to an inner plate pivot axis about which each inner plate pivots.

Preferably the outer plate and inner plate compress the box sides therebetween at or near the point defining the extent of inward pivoting travel of the inner plate toward the lower part of the forming chamber. The folding mechanism is preferably adapted to overbend the box sides beyond a position where they extend perpendicular to the base panel, to a degree that the box sides spring back to be generally perpendicular when released from the folding mechanism. The amount of overbending may be expected to vary with box geometry and design, such as flap type and adhesive application points, however approximately overbending has found to be satisfactory for the box construction illustrated with regard to the preferred embodiment of the invention.

Preferably the wall-defining panels include flaps for engagement with each of the adjacent wall sections for securing the wall sections in position. The apparatus preferably further includes adhesive application means and flap forming means for folding the flaps and clamping them to the respective wall portions.

H:\LlndaXKeep\spec\P53680 42878 SPEC1.doc 8/07/04 Preferably the apparatus is adapted for forming rectangular boxes and each outer plate has a pair or opposing flap-abutting faces extending perpendicular to the wall-engaging face.

The flap forming means includes flap-bending plates the movement of which are synchronized with that of the inner plate to press the flaps and adjacent wall-section against the respective flap-abutting faces. The adhesive applied between the flaps and the adjacent wall section thereby also bonds the wall sections in position.

The actuating means preferably includes a drive member and an actuator for reciprocating the drive member, both the inner plate and the outer plate being operatively connected to the drive member.

Preferably the outer plate is elongate and is pivoted about a longitudinal axis thereof, and the actuating means drivingly connects longitudinally spaced apart portions of the inner plate for applying a torque to reciprocate the inner plate about the longitudinal axis. In this manner problems uneven compression, misalignment and inaccuracy) caused by torsional deflection of an elongate outer plate can be mitigated by applying the torque to longitudinally spaced apart portions of the inner plate.

Preferably the drive member is an elongate drive shaft drivingly connected to the actuator and extending substantially parallel to the long axis of the outer plate. The longitudinally spaced apart portions are preferably drivingly connected by a pair of pulleys joined by a belt or chain, connecting the drive shaft and outer plate. Optionally they may be connected by gears etc.

H:\Linda\Keep'spec\P53680 42878 SPEC1 .doc 8/07104 -8- Preferably the actuator is a rotary actuator a motor). The actuator is preferably mounted toward one of the longitudinal ends of the drive shaft and the spaced apart positions are at longitudinally opposed ends of the outer plate.

The reciprocating drive shaft is preferably driven by a continuously rotating crank connected to the drive shaft by a connecting rod. The means for moving the inner plate includes a linkage operatively connected to the drive shaft for reciprocating the inner plate. Preferably conveyor means are provided for positioning the blanks above the forming chamber The apparatus preferably further includes a creasing assembly for creasing the intermediate fold lines, the creasing assembly including: an anvil roller and a pressure wheel for receiving the blank therebetween and an actuator for controlling engagement of the pressure wheel with the anvil roller, whereby the creasing assembly cooperates with the conveyor means to crease the intermediate fold lines.

Preferably the apparatus further includes: a magazine adapted to contain a plurality of the planar blanks in an upright position; first transfer means for sequentially removing blanks from the magazine and transferring them to the conveyor means while raising and rotating them through approximately 900, wherein the plunger reciprocates generally vertically, and H:\LInda\Keepspec\P53680 42878 SPECl .doc 8/07/04 -9formed boxes are delivered through an aperture at the lower part of the forming chamber.

This arrangement has been found to be advantageous on a machine for producing larger boxes particularly with respect to ergonomics, since the blanks may be conveniently delivered near ground level, thus reducing access difficulties and heavy lifting. Conveniently the total height of the machine may be reduced and the resulting formed boxes are also delivered near ground level and may, for example, drop onto a second transfer means (e.g.

a conveyor) for transferring each individual box from the apparatus.

Preferably the first transfer means includes: swing arms; vacuum cups pivotally fixed to the swing arms for grasping each blank; a slider bar fixed to the vacuum cups; a pivoting guide for slidably receiving the slider bar and adapted to rotate the vacuum cups during movement of the swing arms, and an actuator for reciprocating the swing arms.

This invention provides a high-speed automated apparatus which is effective and efficient in operational use, which may be economically constructed and has an overall simple design which minimizes manufacturing costs and maximizes performance.

H: inda\KeepspecP53680 42878 SPECI .doc 8/07/04 BRIEF DESCRIPTION OF THE DRAWINGS Further aspects of the present invention will become apparent from the following description which is given by way of example only and with reference to the accompanying drawings in which: Figure la is a pictorial view of a flat sheet blank that is folded by the apparatus of the present invention; Figure lb is a pictorial view of a box formed from the flat sheet blank of Fig. la; Figure 2 is a partially cut away pictorial view of the apparatus of the present invention; Figure 3 is a pictorial view of a first transfer means of the apparatus of Fig. 2; Figure 4a is a pictorial view of a conveyor assembly of the apparatus of Fig. 2; Figure 4b is a pictorial view of a creasing roller assembly of the assembly of Fig. 4a; Figure 5 is a pictorial view of the blank folding mechanisms of the apparatus of Fig. 2; Figure 6 is a simplified view of the mechanism of of Fig. 5 where some of the components have been removed for clarity, and Figures 7a, 7b and 7c are transverse sectional elevations of the forming means of Fig. 5 in three sequential operating positions respectively.

BEST MODES FOR CARRYING OUT THE INVENTION With reference now to the drawings, in which like numerals refer to like components throughout the description, a flat pre-cut sheet blank 1 which is folded by the apparatus of the present invention to form a box, tray or the like is depicted in Fig la. Preferably, blank 1 is made of a self-supporting corrugated cardboard material and includes a generally H:\Unda\Xeep~spec\P53680 42878 SPECI .doc 8/07/04 -11rectangular shaped base panel 2 joined to two opposite wall-defining panels 3 and 4 along parallel wall fold lines 5 and 6 respectively. The pair of opposing wall-defining panels 7 and 8 are joined to the base panel 2 along parallel wall fold lines 10 and 11 respectively.

Notches 9 extend parallel to the fold lines 10, 11. Each of the pair of wall-defining panels 7 and 8 has an intermediate fold line 12 extending parallel to the respective wall fold lines 11 and dividing the panels into inner and outer parts 72 and 73.

As seen in Figs. 1 a and I b the open-topped box 20 has a rectangular horizontal base and upright walls and is formed by folding the blank 1, the pair of wall-defining panels 7 and 8 io being folded to form a double thickness wall section of the box. Inner and outer flaps and 16 are formed on both ends of the double wall-defining panels 7 and 8, the flaps 15, 16 are fixed by adhesive (not shown) to the inside and outside respectively of the abutting wall portions to further reinforce the box. The outer flap 16 is formed between the notches 9 and 13. Inner flap 15 includes a intermediate portion 17 (between fold lines 70, 71) extending obliquely to the plane of the adjacent wall 3 (or to form an aperture 18 at each corner of the box for facilitating stacking.

Fig. 2 illustrates the automated apparatus of the present invention for forming sheet material blanks 1 into boxes 20. The apparatus includes a frame 38 (shown partially cut away for clarity). The apparatus includes a magazine 21 containing a plurality of the blanks 1 in an upright position. A first transfer means 22 (described more fully with respect to Fig. 3) sequentially removes the blanks 1 from the magazine 21 and transfers them to the conveyor 23 while raising and rotating them through approximately 90 degrees. The conveyor 23 (described more fully with respect to Figs. 4 and 5) moves the blanks 1 in the longitudinal direction L to position them for engagement with the forming means 24 which folds the H: nda\Keep~spec\P53680 42878 SPEC1 .doc 8/07/04 -12blanks 1 to form boxes 20 which drop individually onto a second transfer means or output conveyor The transfer means 22 is of a type known per se, but which has not previously been arranged in the manner provided in the invention. Transfer means 22 includes swing arms 26 with their ends being fixed to pivot about horizontal axis A and the opposing ends having vacuum cups 27 pivotally fixed thereto for engaging each blank. A linear actuator or ram 28 drives the reciprocating movement of the swing arms 26. A slider bar 29 fixed to the vacuum cups 27 cooperates with a pivoting guide 30 that receives the slider bar 29 to io control rotation of the vacuum cups 27 during movement of the swing arms 26. The vacuum cups 27 are mounted on rails 31 that are fixed to a pivotally mounted beam 32 joining the ends of the swing arms 26. A trunnion beam 43 spans between the swing arms 26 and is received in trunnion housings 43 at opposing ends.

Referring to Figs. 2 and 4a, the conveyor 23 includes a pair of parallel endless belts (not shown) for engagement with opposing edges of the blank 1 and extending generally inside the channels 77. The transfer means 22 presents each blank 1 toward the conveyor 23 with the intermediate fold lines 12 parallel to the longitudinal axis L. Opposing edges of the blank 1 are clamped between the lower face of the belt (not shown) and clamp arms 33 actuated by a pneumatic cylinder 34. A motor 35 coordinates the rotation of the pair of belts to index the blanks 1 forward to position them for engagement with the forming means 24.

Adhesive applicator 44 applies adhesive to the blank 1.

Creasing roller assemblies 70 (only one of which is shown) are fixed on opposing sides of the conveyor 23 for creasing the intermediate fold lines 12 on the blank 1. As best seen in H:\Linda\Keep\spec\P53680 42878 SPEC1 .doc 8/07/04 -13- Fig. 4b, each creasing roller assembly 70 includes a non-driven pressure wheel 72 having a pair of spaced apart circumferential ridges 73 which in operation are pressed against the cylindrical surface of the driven anvil roller 74 with the blank therebetween. The anvil roller 74 is drivingly connected by a chain 75 and sprocket 76 to a chain drive (not shown) driven by the motor 35 which also drives the endless belts (not shown), thereby driving the anvil roller 74 at conveyor speed. The pressure wheel is mounted to a bracket 77 fixed to a pivoted beam 78 by fasteners (not shown) received in slot 80 to provide for lateral adjustment of its position. Corresponding lateral adjustment of the position of the anvil wheel 74 is provided by a keyway 83 in the shaft 84. The beam 78 is pivoted about pivot 79 by a pneumatic ram 81 and toggle linkage 71, allowing the pressure roller 72 to be moved from the engaged position illustrated, to a raised, disengaged position (not shown).

Forming means 24 (Figs 2) includes a forming chamber 36 below a forming plunger 37 driven by a crank assembly 38 to reciprocate vertically. The forming means 24 includes two opposing blank folding mechanisms 75 (Figs 5 and 6) which cooperate with the forming chamber 36 and the forming plunger 37.

The forming chamber 36 of the illustrated embodiment is a chamber or space bounded on two opposing sides by the two pairs of guides 41 and on the other opposing sides by the inner plates 39 and outer plates 40 of the folding mechanisms 75. The description of the plates 39, 40 as "inner" and "outer" serves only to differentiate the plates, but it will be seen that when the blank 1 is pressed into the forming chamber 36 the inner plate 39 is closer to lower part of the chamber 39 (toward which the base panel 2 is pressed) than the outer plate H:Linda\Keep\spec\P53680 42878 SPEC1 .doc 8/07/04 -14- The plunger 37 has a planar, substantially rectangular face of a size corresponding to that of the base panel 2. The plunger 37 cooperates with guides 41 and plates 39, 40 such that by pressing the positioned blank 1 into the chamber 36 the wall-defining panels 3, 4, 8 and 9 are folded together along the wall fold lines 5, 6, 10, 11 to extend generally upwards.

Both the outer plates 39 and inner plates 40 are pivotally mounted, elongated in the longitudinal direction L and have flat faces for engagement with the blank/box. The guides 41 are provided at longitudinally opposed ends of the chamber 36 and serve for bending the wall sections about the transverse fold lines 5, 6.

Figs 5, 6 and 7a illustrate each inner plate 40 and outer plate 39 at an initial position in its respective reciprocating pivoting movement. Each outer plate 40 has a face 44 for engagement with the outer part of the wall-defining panels 7 and 8 and the faces 44 are initially at an acute angle to the vertical. The outer plates 39 are mounted to pivot about axis 45, extending in the longitudinal direction L. The outer plates 39 include end sections having faces 51 for engagement with the inner flap 15, which extend substantially perpendicular to the respective face 44 and are jointed thereto by a chamfer 52.

Each inner plate 40 is mounted alongside a respective inner plate 39 and for pivotal movement about the axis 76.

Actuating each folding mechanism is an assembly including motor 54, gearbox 80, crank connecting rod 56, and a drive member in the form of drive shaft 53 which is connected by rod 58 and belts 47 to the inner plate 40 and outer plate 39 respectively. The drive shaft H:Linda\Keep~specXP53680 42878 SPECl .doc 8/07/04 53 extends in the longitudinal direction L. Pulleys 48 are fixed to opposing ends of each drive shaft 53 and the belt 47 connects the pulleys 48 with pulleys 49 on the opposing ends of each outer plate 39 for reciprocating the outer plate 39. By applying a torque to reciprocate the outer plate 39 at two longitudinally spaced apart portions the opposing ends) the problems caused by torsional deflection of the tool can be mitigated.

As best seen in Fig. 5, each drive shaft 53 is driven by motor 54 and gearbox 80 which in operation continuously rotates a crank 55. The crank 55 is connected eccentrically to the drive shaft 53 by a connecting rod 56, which thereby reciprocates the drive shaft 53.

Inner plate 40 is fixed to shaft 57 for pivoting about longitudinally extending axis 76 and its reciprocating movement is also driven from the drive shaft 53. The rod 58 eccentrically connected to the drive shaft 53 is joined by a pivot 59 to a lever 60. The lever 60 is pivotally fixed about the axis of a frame bar 61 of the apparatus and includes a further pivot 61. A pin 63 is fixed to the inner plate 40 and a pivotally fixed link 62 connects the pivot 61 and the pin 63 to reciprocate the inner plate 40. Lengthwise adjustment of the rod 58 provides for the clearance between the block 40 and outer plate 39 at the extent of inward travel (see Fig. 7c) to be accurately set. This clearance can be varied to suit different sheet material and is important to ensure the walls are sufficiently compressed for satisfactory bonding.

In this manner the inner plate 40 and the outer plate 39 are connected together for coordinated reciprocating movement, each inner plate 40 and outer plate 39 reciprocates through one cycle to form each box.

H:\Linda\Keepspec\P53680 42878 SPECI .doc 8/07/04 -16- At opposing longitudinal ends of the inner plates 40 are flap-bending plates 65 pivoted generally vertically for travel through approximately 90 degrees for folding the flaps 15, 16 which are clamped between the plates 65 and the faces 51 of the outer plate 39. Rams 66 are connected to each of the flap-bending plates 65 for actuation thereof.

Fig. 7a illustrates the position of the outer plates 39 and inner plates 40 when the blank is pressed into the chamber 36. The planar faces 44 and 69 of the outer plate 39 and block are angled outward at approximately 3 degrees and 15 degrees respectively and the crank is a bottom dead centre. After the plunger 37 is retracted the outer plates 39 are rotated 1o at high speed (due the gear ratio between pulleys 48 and 48) to folds the wall-defining panels 8 and 9 to form a double thickness wall section of the box.

Fig. 7b illustrates the positions of the outer plates 39 and inner plates 40 when the crank has rotated approximately 90 degrees. Fig. 7c shows the positions when the crank has rotated to approximately top dead centre, and it will be understood that the inner and outer parts 72, 73 of the wall sections 7, 8 are there clamped between the faces 44 and 68.

Likewise the flaps are also clamped between the plates 65 and faces 51 for sufficient time for the adhesive to bond them. Following this step the movement of the outer plate 40 and inner plate 39 are reversed, returning to the position shown in Fig. 7a and thereby allowing the box 20 to drop through the lower part of the forming chamber 36 or be displaced by the next blank 1.

The blank tends to return to its original shape after a forming operation has been performed thereon. For every bend made in the blank, its elastic properties forces each bent portion to attempt to return it to its original shape when the stress is released. Thus, to obtain a H:\ULinda"Keepspec~P53680 42878 SPECl .doc 8/07/04 -17desired degree of bend, the blank must be bent beyond the desired degree of bend to compensate for the elastic properties present in the material. As shown, rotation of the inner plates 40 provides for overbending of the wall sections beyond the vertical, such that they spring back to be generally upright.

The wall sections compressed between the outer plates 39 and the inner plates 40, are preferably being double thickness wall sections formed from folding over the pair of walldefining panels 7, 8. However, two or more other layers, such as a wall panel and a separate stiffening panel, flap or lid (not shown) may be compressed together e.g. to bond them in position after having received adhesive. The outer plate 39 and the block 40 need not cooperate with a plunger which acts to fold the wall-defining panels inward. Other means, for example a blade die etc (not shown) may be provided for folding in the walldefining panels inwardly.

Aspects of the present invention have been described by way of example only and it should be appreciated that modifications and additions may be made thereto without departing from the scope thereof.

In the claims which follow and in the preceding description of the invention, except where the context requires otherwise due to express language or necessary implication, the word "comprise" or variations such as "comprises" or "comprising" is used in an inclusive sense, i.e. to specify the presence of the stated features but not to preclude the presence or addition of further features in various embodiments of the invention.

H:ALinda\Keep\pec\P53680 42878 SPECl .doc 8/07/04 -18- It is to be understood that, if any prior art publication is referred to herein, such reference does not constitute an admission that the publication forms a part of the common general knowledge in the art, in Australia or any other country.

H:\Linda\Keep\spec\P53680 42878 SPECl.doc 8/07/04

Claims (19)

1. Apparatus for forming sheet material blanks into boxes, each blank having a base panel and wall-defining panels joined to the edges of the base panel along wall fold lines, with substantially parallel intermediate fold lines dividing inner and outer parts of a pair of opposing wall-defining panels, the apparatus including: a reciprocating plunger; a forming chamber for receiving the plunger to fold the blank along the wall fold lines; two opposing blank folding mechanisms, each of the blank folding mechanisms having; an inner plate mounted for pivotal movement; the two inner plates being positioned at opposite sides of the forming chamber; an outer plate mounted for pivotal movement alongside the inner plate; actuating means for pivoting respectively the inner plate toward a lower part of the forming chamber, and for pivoting the outer plate toward the inner plate, whereby upon driving the plunger to press the blank into the forming chamber the pair of wall-defining panels are folded together along respective wall fold lines and, after the plunger is retracted, opposing box sides are formed through operation of the actuating means by folding the pair of opposing wall-defining panels along the intermediate fold lines as the outer plates pivot toward the inner plates and the inner plates pivot toward the lower part of the forming chamber. H:LInda\Keepspec\P53680 42878 SPECl .doc 8107104

2. The apparatus of claim 1 wherein the apparatus further includes adhesive application means and the outer plate and inner plate compress the box sides therebetween to bond them in place after they have received adhesive.

3. The apparatus of claim 1 or claim 2 wherein guides are provided between the blank folding mechanisms on opposing sides of the forming chamber, the guides cooperating with the plunger to fold two opposite wall-defining panels into a substantially upright position.

4. The apparatus of any one of the preceding claims wherein an outer plate pivot axis about which each outer plate pivots is fixed relative to an inner plate pivot axis about which each inner plate pivots.

5. The apparatus of any one of the preceding claims wherein the outer plate and inner plate compress the box sides therebetween at or near the point defining the extent of inward pivoting travel of the inner plate toward the lower part of the forming chamber.

6. The apparatus of any one of the preceding claims wherein the folding mechanism is adapted to overbend the box sides beyond a position where they extend perpendicular to the base panel, to a degree that the box sides spring back to be generally perpendicular when released from the folding mechanism. H:LInda\Keep\spec\P53680 42878 SPECi.doc WI704 -21

7. The apparatus of any one of the preceding claims wherein the wall-defining panels include flaps for engagement with each of the adjacent wall sections for securing the wall sections in position and flap forming means for folding the flaps and clamping them to the respective wall portions.

8. The apparatus of any one of the preceding claims wherein each outer plate has a pair or opposing flap-abutting faces extending perpendicular to a wall-engaging face.

9. The apparatus of claim 7 or claim 8 wherein the flap forming means includes flap- bending plates the movement of which are synchronized with that of the inner plate to press the flaps and adjacent wall-section against the respective flap-abutting faces.

The apparatus of any one of the preceding claims wherein the actuating means includes a drive member and an actuator for reciprocating the drive member, both the inner plate and the outer plate being operatively connected to the drive member.

11. The apparatus of any one of the preceding claims wherein the outer plate is elongate and is pivoted about a longitudinal axis thereof, and the actuating means drivingly connects longitudinally spaced apart portions of the inner plate for applying a torque to reciprocate the inner plate about the longitudinal axis. H:\Linda\Keep\spec\P53680 42878 SPEC .doc 8/07/04 -22-

12. The apparatus of claim 10 or claim 11 wherein the drive member is an elongate drive shaft drivingly connected to the actuator and extending substantially parallel to the long axis of the outer plate.

13. The apparatus of claim 12 wherein the drive shaft is driven by a continuously rotating crank connected to the drive shaft by a connecting rod.

14. The apparatus of any one of the preceding claims including conveyor means for positioning the blanks above the forming chamber.

The apparatus of any one of the preceding claims further including a creasing assembly for creasing the intermediate fold lines, the creasing assembly including: an anvil roller and a pressure wheel for receiving the blank therebetween and an actuator for controlling engagement of the pressure wheel with the anvil roller, whereby the creasing assembly cooperates with the positioning means to crease the intermediate fold lines.

16. The apparatus of any one of the preceding claims wherein the apparatus further includes: a magazine adapted to contain a plurality of the planar blanks in an upright position; first transfer means for sequentially removing blanks from the magazine and transferring them to the conveyor means while raising and rotating them through approximately 90 0 wherein the plunger reciprocates generally vertically, and H:\Linda\Keepspec\P53680 42878 SPECi .doc 8/07/04 -23- formed boxes are delivered through an aperture at the lower part of the forming chamber.

17. The apparatus of claim 16 wherein the first transfer means includes: swing arms; vacuum cups pivotally fixed to the swing arms for grasping each blank; a slider bar fixed to the vacuum cups; a pivoting guide for slidably receiving the slider bar and adapted to rotate the vacuum cups during movement of the swing arms, and an actuator for reciprocating the swing arms.

18. Apparatus for forming sheet material blanks into boxes substantially as hereinbefore described and as illustrated in the accompanying drawings.

19. A method for forming sheet material blanks into boxes using apparatus as claimed in any one of claims 1 to 20, including the steps: driving the reciprocating plunger to press the blank into a forming chamber such that the pair of wall-defining panels are folded together along respective wall fold lines; retracting the plunger form the forming chamber; operating the actuating means to form the opposing box sides by folding the pair of opposing wall-defining panels along the intermediate fold lines as the outer plates H:\ULinda\Keep'specP53680 42878 SPECl .doc 8/07/04 -24- pivot toward the inner plates and the inner plates pivot toward the lower part of the forming chamber. Dated this 8th day of July 2004 RYAN MANUFACTURING LIMITED By their Patent Attorneys GRIFFITH HACK Fellows Institute of Patent and Trade Mark Attorneys of Australia H:\Lnda\Keep\spec\P53680 42878 SPECI.doc 8/07/04