AU2014233552B2 - Machine for erecting a carton from a blank - Google Patents

Abstract

A machine for erecting a carton from a blank comprises a feeder for feeding a blank, a support member being movable between a support position at which the support member is positioned under a crease formed along the respective fold lines located between a side wall panel and its associated side wall cuff panel and a retracted position, a side wall cuff folding member for folding the side wall cuff panel relative to its associated side wall panel, the side wall cuff folding member operable to fold the side wall cuff panel about the fold line in an initial folding movement whilst the support member is in the support position such that the support member contacts the blank along at least part of the fold line during the initial folding movement, the support member being moved to a retracted position and the side wall cuff folding member further folding the side wall cuff panel about the fold line until the side wall cuff panel is positioned parallel to its associated side wall panel, a base contacting member for contacting the base of the blank, the base contacting member being movable to cause the base to move to thereby cause the side wall panels and end wall panels to fold relative to the base and to cause the gusset panels to fold about an oblique fold line to form respective gussets, a gusset guide member for guiding a gusset panel so that it is positioned adjacent to an end wall panel, and an end wall cuff folder for folding the end wall cuff panel about its respective fold line so that the end wall cuff panel lies parallel to its respective end wall panel, and an end wall cuff retainer for retaining the end wall cuff panel in position following folding of the end wall cuff panel by the end wall cuff folder. 77-77 _7 it 2-Z )488 Zoj

Description

Machine for erecting a carton from a blank

TECHNICAL FIELD [0001] The present invention relates to a machine for erecting a carton from a blank. The present invention also relates to a method for erecting a carton from a blank.

BACKGROUND ART [0002] Packaging, storage and transport of meat and meat products provide a number of challenges to the packaging industry. Meat and meat products can exude moisture when not in a frozen condition. This often requires that a moisture proof liner be included in the cartons in which the meat and meat products are stored. Furthermore, meat products are often stored for extended periods in cold storage.

[0003] A number of cartons are in commercial use for the packaging, storage and transport of meat and meat products. These cartons have a number of different designs, including corner post designs for providing enhanced strength for stacking and leak proof-base designs to cater for moisture that may be exuded from the meat. A number of packaging cartons are fitted with polypropylene liners, in the form of insert sheets, again to cater for any moisture that may be exuded from the meat.

[0004] Cartons, such as cardboard or paperboard boxes, are normally made by erecting the carton from a blank. The blanks are cut to shape and fold lines formed at the appropriate places during manufacture of the blank at the blank manufacturing facility. The blanks are then stacked for storage and transport. It will be appreciated that the blanks are effectively a flat sheet of paperboard. As a result, the blanks take up the minimum space during storage and transport.

[0005] When it is desired to use the blanks for packaging and storage of items or materials, the blanks must be erected into a carton, such as a box. This will typically involve folding of the blank to form the carton. In some cartons, glue is used to hold parts of the carton in place. In other cartons, insert tabs or folded panels hold the carton together. Cartons may be erected by hand or by machine. In large packaging facilities, machine erection is desirable as large numbers of cartons will need to be erected each day.

[0006] It is an object of the present invention to provide a machine for erecting a carton from a blank. It is another object of the present invention to provide a method for erecting a carton from a blank.

2014233552 21 Oct 2019 [0007] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.

SUMMARY OF INVENTION [0008] In a first aspect, the present invention provides a machine for erecting a carton from a blank, the blank comprising a base, side wall panels connected to the base along respective fold lines, end wall panels connected to the base along respective fold lines, the side wall panels each having a side wall cuff panel connected thereto along a fold line, wherein in the erected carton, the side wall cuff panels are folded so that they come into contact with their respective side wall panels and are maintained in place to thereby form side wall cuffs extending from an upper edge of the respective side walls of the container, the machine comprising:

- a support member being movable between a support position at which the support member is positioned under a fold line located between a side wall panel and its associated side wall cuff panel and a retracted position,

- a side wall cuff folding member for folding the side wall cuff panel relative to its associated side wall panel,

- the side wall cuff folding member operable to fold the side wall cuff panel about the fold line in an initial folding movement whilst the support member is in the support position such that the support member contacts the blank along at least part of the fold line during the initial folding movement, the support member being moved to a retracted position and the side wall cuff folding member further folding the side wall cuff panel about the fold line until the side wall cuff panel is positioned parallel to its associated side wall panel.

[0009] In some embodiments, glue is positioned between the side wall cuff panel and the side wall panel and the glue fixes the side wall cuff panel to the side wall panel.

[0010] The support member may comprise a support blade or a support edge. The support member may be rotatably movable between the support position and the retracted position. Alternatively, the support member may be reciprocally movable between the support position and the retracted position.

[0011] The side wall cuff folding member may be movable along an arcuate path. As the side wall cuff folding member moves along the arcuate path, it comes into contact with the side

2014233552 21 Oct 2019 wall cuff and forms the side wall cuff about its fold line. The side wall cuff folding member may comprise a plate or a bar that is movable along an arcuate path. The side wall cuff folding member may be pivotally movable.

[0012] The side wall cuff folding member may be mounted to a pinion. The pinion may be rotatably driven by a rack that is reciprocally moved by a piston and cylinder arrangement or a ram. As the rack extends, it causes the pinion to rotate which, in turn results in the side wall cuff folding member also rotating. The piston and cylinder arrangement or the ram may comprise a pneumatic cylinder or a pneumatic ram. It will be understood that other arrangements may be used to move the side wall cuff folding member to cause folding of the side wall cuff panels.

[0013] In some embodiments, the blank may be securely held in place whilst the side wall cuffs are folded. In one embodiment, the blank is supported on a deck and a clamping means clamps the blank to the deck during folding of the cuffs. The clamping means may comprise a cylinder having a reciprocally movable arm carrying a clamping surface at one end. The cylinder may be extended such that the clamping surface comes into contact with the blank to thereby clamp the blank between the clamping surface and the deck.

[0014] It will be appreciated that, in most commercial embodiments, the machine will be provided with respective side wall cuff folding members that fold the side wall cuffs on each side of the blank. Similarly, it will be understood that the machine will be provided with support members for each side of the blank.

[0015] In some embodiments, the machine includes a glue applicator for applying glue between the side wall cuff panel and its associated side wall panel. In some embodiments, the glue applicator applies glue to a surface of the side wall cuff panel that comes into contact with a surface of the associated side wall panel. The glue applicator may be of conventional construction and need not be described further. The glue applicator may apply a hot melt adhesive.

[0016] In a second aspect, the present invention provides a machine for erecting a carton from a blank, the blank comprising a base, side wall panels connected to the base about respective fold lines, end wall panels connected to the base about respective fold lines, the end wall panels each having an end wall cuff panel connected thereto about a fold line, wherein in the erected carton, the end wall cuff panels are folded so that they extend general parallel to their respective end wall panels and are maintained in place to thereby form end wall cuffs extending from an upper edge of the respective end walls of the container, the machine comprising:

2014233552 21 Oct 2019

- an end wall cuff folder for folding the end wall cuff panel about its respective fold line so that the end wall cuff panel extends generally parallel to its respective end wall panel, and

- an end wall cuff retainer for retaining the end wall cuff panel in position following folding of the end wall cuff panel by the end wall cuff folder.

[0017] In some embodiments, the end wall cuff panel is glued to maintain it in position. Desirably, the end wall cuff retainer retains the end wall cuff panel in position to allow the glue to set to a greater extent.

[0018] In some embodiments, the machine is arranged such that end wall cuff retainer moves relative to the container so that the end wall cuff retainer comes into contact with the end wall cuff panel following folding of the end wall cuff panel. In some embodiments, the end wall cuff retainer is located in a fixed position and the container is moved to bring the end wall cuff into contact with the end wall cuff retainer. Desirably, the end wall cuff folder maintains contact with the end wall cuff panel until the end wall cuff retainer is in contact with the end wall cuff panel. In this manner, the end wall cuff panel is held in place by either the end wall cuff folder or the end wall cuff retainer (or both) until the glue has set to a sufficient extent to hold the end wall cuff panel in position to thereby form the end wall cuff.

[0019] The end wall cuff folder may comprise an end wall cuff folding member. The end wall cuff folding member may be may be movable along an arcuate path. As the end wall cuff folding member moves along the arcuate path, it comes into contact with the end wall cuff panel and folds the end wall cuff panel about its fold line. The end wall cuff folding member may comprise a plate or a bar that is movable along an arcuate path.

[0020] The end wall cuff folding member may be mounted to a pinion. The pinion may be rotatably driven by a rack that is reciprocally moved by a piston and cylinder arrangement or a ram. As the rack extends, it causes the pinion to rotate which, in turn results in the end wall cuff folding member also rotating. The piston and cylinder arrangement or the ram may comprise a pneumatic cylinder or a pneumatic ram. It will be understood that other arrangements may be used to move the end wall cuff folding member to cause folding of the end wall cuff panels.

[0021] The end wall cuff folding member may comprise a plate or a bar. The end wall cuff folding member may be provided with a plurality of spaced fingers or spaced projections. The end wall cuff retainer member may comprise a plate or a bar. The end wall cuff retainer may be provided with a plurality of spaced fingers or spaced projections. The spaced fingers or spaced projections of the end wall cuff folding member may be positioned such that at least some of

2014233552 21 Oct 2019 them become positioned between at least some of the spaced fingers or spaced projections of the end wall cuff retainer when the end wall cuff retainer comes into contact with the end cuff panel. In this manner, both the end wall cuff folder and the end wall cuff retainer can come into contact with the end wall cuff panel when the end wall cuff retainer first comes into contact with that panel. The end wall cuff folder can then be retracted from the end wall cuff panel. In this arrangement, at least one of the end wall cuff folder and the end wall cuff retainer is always in contact with the end wall cuff panel for the period from when the end wall cuff panel is first folded into its final position to when the container is removed from the end wall cuff retainer. This provides for an increased period of time during which the end wall cuff panel is held in position, which provides additional time for the glue that holds the end wall cuff in position to set (compared to the situation if the end wall cuff folder was the only part of the machine that acted to hold the end wall cuff panel in place whilst the glue was setting). If the end wall cuff retainer was not provided, the end wall cuff folder would likely be needed to hold the end wall cuff panel in position for a longer period of time to enable the glue to set sufficiently to hold the end wall cuff in place. This would result in the production rate of the carton erecting machine being lower.

[0022] In some embodiments, the apparatus further comprises a forming chamber comprising plurality of spaced side wall contacting members and a plurality of spaced end wall contacting members, the side wall contacting members and the end wall contacting members defining an opening of complementary size and shape to the base of the blank, a base contacting member that is reciprocally movable, the base contacting member movable to contact the base of the blank and to move the base of the blank into the opening defined by the side wall contacting members and the end wall contacting members wherein continued operation of the base contacting member moves the blank through the opening and the side wall contacting members contact the side wall panels of the blank and the end wall contacting members contact the end wall panels of the blank to thereby fold the side wall panels and the end wall panels relative to the base, and to cause the gusset panels to fold.

[0023] The forming chamber may further be the provided with gusset guide members that guide the gusset panels to a position whereby the gusset panels lie adjacent to and in an abutment with a respective end wall. The gusset guide members may comprise rods that are angled downwardly and inwardly.

[0024] The gusset guide members may be movable between an operable position in which the gusset guide members come into contact with the gusset panels to thereby guide the gusset

2014233552 21 Oct 2019 panels to the position whereby the gusset panels lie adjacent to and in an abutment with a respective end wall and a retracted position in which the gusset guide members are moved away from the forming chamber. In one embodiment, the gusset guide members are rotatably moved between the operable position and the retracted position. Moving the gusset guide members to the retracted position provides the necessary clearance required to enable the end wall cuff folding members to operate to fold over the end wall cuffs without coming into contact with the gusset guide members.

[0025] The apparatus of the present invention may further include an apparatus for supplying a blank from a stack of blanks, the apparatus comprising opposed spaced rails, each rail being movable inwardly and outwardly, each rail being movable between an outer position at which the rail is positioned laterally outwards of an outer edge of a blank and an inner position, and a lifting apparatus for lifting a single blank from the stack of blanks, wherein, in use, the opposed rails are moved to the outer position, the lifting apparatus lifts a single blank off the stack of blanks, the opposed rails are moved to end in a position in which they at least partially underlie the blank, and the lifting apparatus is operated to position the blank such that it is supported by the opposed rails.

[0026] The apparatus for supplying the blank from a stack of blanks may further comprise a blank mover for moving the blank along the rails. The blank mover may comprise one or more extendable cylinders carrying pushers that come into contact with a rear edge of the blank and push the blank along the rails as the cylinder is extended. In another embodiment, the blank mover may comprise one or more feed rollers.

[0027] In some embodiments, the lifting apparatus may comprise one or more vacuum lifters or one or more suction lifters. The vacuum lifters or suction lifters may comprise one or more suction cups. The lifting apparatus may be movable upwardly and downwardly. In operation, the lifting apparatus may be moved from an upper position to a lower position at which the apparatus contact the blank, following which the lifting apparatus is moved upwardly to lift the blank upwardly. Once the blank is positioned above the opposed rails, the opposed rails are moved to an inner position. The lifting apparatus may then be operated to drop the blank onto the rails. The blank may then be pushed along the rails. The opposed rails may be moved inwardly and outwardly by the use of one or more stepper motors (servos). This allows for precise control of the positioning of the rails. Each rail may comprise a generally horizontally extending portion and an upwardly extending portion that, in use, contacts an outer edge of the blank to thereby enable the upwardly extending portion to be securely positioned against the

2014233552 21 Oct 2019 blank.

[0028] In a another embodiment, the present invention provides a carton erecting machine for erecting a carton from a blank, the blank comprising a base, side wall panels connected to the base along respective fold lines, end wall panels connected to the base along respective fold lines, the side wall panels each having a side wall cuff panel connected thereto along a fold line, wherein in the erected carton, the side wall cuff panels are folded so that they come into contact with their respective side wall panels and are maintained in place to thereby form side wall cuffs extending from an upper edge of the respective side walls of the container, the blank further comprising end wall cuff panels connected to the end wall panels along respective fold lines and gusset panels extending between each of the side wall panels and an adjacent end wall panel, the carton erecting machine comprising a feeder for feeding a blank, a support member being movable between a support position at which the support member is positioned under a crease formed along the respective fold lines located between a side wall panel and its associated side wall cuff panel and a retracted position, a side wall cuff folding member for folding the side wall cuff panel relative to its associated side wall panel, the side wall cuff folding member operable to fold the side wall cuff panel about the fold line in an initial folding movement whilst the support member is in the support position such that the support member contacts the blank along at least part of the fold line during the initial folding movement, the support member being moved to a retracted position and the side wall cuff folding member further folding the side wall cuff panel about the fold line until the side wall cuff panel is positioned parallel to its associated side wall panel, a base contacting member for contacting the base of the blank, the base contacting member being movable to cause the base to move to thereby cause the side wall panels and end wall panels to fold relative to the base and to cause the gusset panels to fold about an oblique fold line to form respective gussets, a gusset guide member for guiding a gusset panel so that it is positioned adjacent to an end wall panel, and an end wall cuff folder for folding the end wall cuff panel about its respective fold line so that the end wall cuff panel lies parallel to its respective end wall panel, and an end wall cuff retainer for retaining the end wall cuff panel in position following folding of the end wall cuff panel by the end wall cuff folder.

[0029] In another aspect, the present invention provides a method for erecting a carton from blank, the blank comprising a base, side wall panels connected to the base along respective fold lines, end wall panels connected to the base along respective fold lines, the side wall panels each having a side wall cuff panel connected thereto along a fold line, wherein in the erected carton, the side wall cuff panels are folded so that they come into contact with their respective side wall panels and are maintained in place to thereby form side wall cuffs extending from an upper edge

2014233552 21 Oct 2019 of the respective side walls of the container, the blank further comprising end wall cuff panels connected to the end wall panels along respective fold lines and gusset panels extending between each of the side wall panels and an adjacent end wall panel, the method comprising positioning a blank such that a support member is located below a fold line between the side wall panel and the side wall cuff panel, operating a side wall cuff folding member to cause the side wall cuff panel to fold about the fold line between the side wall panel and the side wall cuff panel, moving the support member to a retracted position and continuing operation of the side wall cuff folding member to cause the side wall cuff panel to continue folding until it comes into contact with a respective end wall panel whereby glue holds the side wall cuff panel in position, retracting the side wall cuff folding member, positioning the blank such that the base of the blank is positioned over an opening defined by side wall contacting members and end wall contacting members, operating a base contacting member to move the base of the blank into the opening whereby the side wall contacting members contact the side wall panels and the end wall contacting members contact the end wall panels to cause the side wall panels and end wall panels to fold relative to the base and to cause the gusset panels to fold outwardly, continuing operation of the base contacting member to move the base further into the opening to cause the gusset panels to contact gusset guide members wherein further movement of the base causes the gusset guide members to guide the gusset panels into a position whereby the gusset panels lie parallel to and in abutment with respective end walls, contacting the gusset panels with a roller to hold the gusset panels in position and moving the gusset guide members away from the end walls, operating end wall cuff folding members to fold the end wall cuff panels over until they lie parallel to and in abutment with respective end walls, operating the base contacting member to further move the blank whereby the end wall cuffs come into contact with respective end wall cuff retainers, retracting the end wall cuff folding members after the end wall cuffs have come into contact with the respective end wall cuff retainers and retracting the base contacting member to leave the carton erecting from the blank being held between space end wall cuff retainers.

[0030] In one embodiment, the base contacting member is reciprocally movable in a vertical direction and the base contacting member moves the blank downwardly through the opening during erection of the carton.

[0031] In one embodiment, a next carton that is erected ejects a previous carton that is being held between the opposed end wall cuff retainers.

[0032] In one embodiment, the roller is retracted before the base contacting member moves the car into a position in which the end wall cuff retainers hold the end wall cuffs.

2014233552 21 Oct 2019 [0033] In another embodiment, the present invention also provides a carton erected from a blank, the blank comprising a base, side wall panels connected to the base along respective fold lines, end wall panels connected to the base along respective fold lines, the side wall panels each having a side wall cuff panel connected thereto along a fold line, wherein in the erected carton, the side wall cuff panels are folded so that they come into contact with their respective side wall panels and are maintained in place to thereby form side wall cuffs extending from an upper edge of the respective side walls of the container, the blank further comprising end wall cuff panels connected to the end wall panels along respective fold lines and gusset panels extending between each of the side wall panels and an adjacent end wall panel, the carton comprising a base, opposed side walls and opposed end walls, the side walls having side wall cuffs formed an upper part thereof, the end walls having gusset panels in abutment with an outer surface of the end wall panels and end wall cuffs folded over an upper part of the end walls and the gusset panels that lie adjacent to respective end walls.

[0034] The side wall cuffs may be glued to their respective side walls. The gusset panels may be glued to their respective end walls. The end wall cuff panels may be glued to their respective gusset panels and/or end wall panels.

[0035] In one aspect, the present invention also provides a carton erected from the machine described herein or erected in accordance with the method described herein.

[0036] The reference to any prior art in this specification is not, and should not be taken as an acknowledgement or any form of suggestion that the prior art forms part of the common general knowledge.

BRIEF DESCRIPTION OF DRAWINGS [0037] Various embodiments of the invention will be described with reference to the following drawings, in which:

[0038] Figure 1 shows a perspective view of a carton erecting machine in accordance with an embodiment of the present invention. Figures 2 to 26 show the various features of the carton erecting machine of figure 1, with the figures being provided in sequential order to illustrate both the components of the carton erecting machine and the operation and functioning of those components during erection of a carton;

[0039] Figure 1A shows a schematic view of the apparatus shown in figure 1 but with protective screens or protective sheeting removed so that further detail can be seen;

2014233552 21 Oct 2019 [0040] Figure 2 shows a perspective view of the trolley-stack lift part of the in-feed section of the carton erecting machine shown in figure 1;

[0041] Figure 3 shows a perspective view of the blank pickup system of the in-feed section of the carton erecting machine shown in figure 1;

[0042] Figure 4 shows the blank pickup system of figure 3 after the blank has been picked up and the in-feed rails moved inwardly towards the side edges of the blank;

[0043] Figure 5 shows the next stage of feeding a blank in which the in-feed rails have been moved to a loose blank width position and the blank has been dropped by the vacuum pickup system;

[0044] Figure 5 A shows a perspective view of the mounting arrangement for the in-feed rails;

[0045] Figure 6 shows an underneath perspective view of the blank passing through the sets of wheels;

[0046] Figure 7 shows the blank being positioned in the side wall cuff forming station of the carton erecting machine;

[0047] Figure 8 shows an underneath view of the blank in the side wall cuff forming station;

[0048] Figure 9 shows an underneath view of the blank in the side wall cuff forming station with the cuff folder being moved into contact with the side wall cuff panels;

[0049] Figure 10 shows an underneath view of the side wall cuff folding member folding the side wall cuff panel in a first stage of the folding step, with the support member supporting the fold line between the side wall cuff panel and the side wall panel of the blank;

[0050] Figure 11 shows an underneath view showing the support member being retracted;

[0051] Figure 12 shows an underneath view of the side wall cuff folding member completing folding of the side wall cuff panel to form the side wall cuff;

[0052] Figure 13 shows the next step in the carton erection process in which the stop member is retracted;

[0053] Figure 14 shows that the side wall cuff folding member being retracted;

2014233552 21 Oct 2019 [0054] Figure 15 shows the blank being moved from the side cuff forming station to the next station;

[0055] Figure 16 shows retraction of the blank kicker and movement of the support member back to the support position, ready for the next blank being fed to the side wall cuff forming station;

[0056] Figure 17 shows an underneath view of the blank being passed into the carton and end wall cuff forming station;

[0057] Figure 18 shows a perspective view of the carton and end wall cuff forming station;

[0058] Figure 19 shows the first stage of the side walls and end walls being folded;

[0059] Figure 20 shows further formation of the carton and shows the gussets being folded from the gusset panels and being guided to a predetermined orientation by the gusset guide bars;

[0060] Figure 21 shows the gussets being folded so that they lie generally parallel to their respective end wall;

[0061] Figure 22 shows the end wall cuff folder folding over the end wall cuff panel;

[0062] Figure 23 shows the roller being retracted to allow the container to be moved downwardly;

[0063] Figure 24 shows the container being moved downwardly so that the end wall cuff retainers retain the end wall cuff panels in position. In figure 24, some detail has been removed for clarity;

[0064] Figure 25 shows a view of the carton being held by the end wall cuff retainers with the end wall cuff folders being retracted. . In figure 25, some detail has been removed for clarity;

[0065] Figure 26 shows the carton forming mandrel at bottom dead centre with the carton retaining latches in position above the side walls of the carton;

[0066] Figure 27 shows a similar view to figure 26 but with the mandrel raised.

[0067] Figure 28 shows a view of the mandrel and associated equipment used to raise and lower the mandrel, with other equipment being removed so that further detail of the mandrel and associated equipment can be seen,

2014233552 21 Oct 2019 [0068] Figure 29 show a similar view to figure 28, but with the end wall cuff folders starting to fold over; and [0069] Figure 30 shows a blank that can be used to erect a carton using the carton erecting machine shown in figures 1 to 29.

DESCRIPTION OF EMBODIMENTS [0070] It will be appreciated that the drawings have been provided for the purposes of illustrating a preferred embodiment of the present invention. Therefore, it will be understood that the present invention should not be considered to be limited solely to the features as shown in the attached drawings.

[0071] Figures 1 to 29 show a number of views of the carton erecting machine in accordance with one embodiment of the present invention. Figure 1 shows a general outline of the machine with all external cladding and safety barriers in place. Figures 2 to 29 show various views of separate parts of the machine, generally broken down into the separate forming stations of the carton erecting machine. Figures 2 to 29 show the various separate forming stations in the sequence that a blank passing through the carton erecting machine would encounter those separate forming stations. Figures 2 to 29 also show the forming steps that take place in each of the forming stations. In figures 2 to 29, the external cladding and safety barriers have been omitted for clarity. Similarly, some part of the support framework that holds the various components shown in figures 2 to 29 have also been omitted for clarity.

[0072] Figure 30 shows a blank 10 that can be erected into a carton using the carton erecting machine shown in figures 1 to 29. The blank 10 is suitably made from a corrugated paperboard product having a waterproof lining applied to one surface thereof. The waterproof lining is suitably applied to the surface that, in use, forms the interior of the erected container. The blank 10 may be useful erecting a container that is suitable for use in the packaging, storage and transport of meat and meat products.

[0073] The blank 10 has a base 12. Side wall panels 14, 16 are connected to the base 12 along respective fold lines 18, 20. End wall panels 22, 24 are connected to the base 12 along respective fold lines 26, 28. Side wall panel 14 has a side wall cuff panel 30 connected thereto along fold line 32. Similarly, side wall panel 16 has a side wall cuff panel 34 connected thereto along fold line 36. End wall panel 22 has an end wall cuff panel 38 connected thereto along fold line 40. End wall panel 24 has an end wall cuff panel 42 connected thereto along fold line 44

2014233552 21 Oct 2019 [0074] The blank 10 further includes gusset panels 46, 48, 50, 52 that are located between the adjacent ends of each side wall panel and end wall panel. For example, gusset panel 46 extends from one end of side wall panel 14 and also extends from one end of end wall panel 22. Respective fold lines 54, 56 are formed between the gusset panel 46 and the side wall panel 14 and end wall panel 22. An oblique fold line 58 is formed diagonally along the gusset panel 46. The other gusset panels 48, 50, 52 are similarly arranged.

[0075] To erect the blank 10 into a carton, the side wall panels 14, 16 and end wall panels 22, 24 are folded upwardly. This causes the gusset panels 46, 48, 50, 52 to fold into triangular gussets. The triangular gussets formed by gusset panels 46 and 52 are folded to lie parallel to an outer surface of the end wall formed by end wall panel 22. End wall cuff panel 38 is then folded down over the gussets. Glue lines act to hold the end wall cuff panel in place. Thus, the end wall cuff panel 38 forms and end wall cuff that holds the gussets formed by gusset panels 46, 52 in position. Similar erection steps take place with respect to the end wall formed by end wall panel 24. In particular, the gussets 48, 50 are folded so that they are parallel to the end wall 24 and the end wall cuff panel 42 is folded down and glued into position to hold the gussets in place. The side wall cuff panels 30, 34 are folded down so that they lie parallel to the respective side was 14, 16. Glue is used to hold the side wall cuffs formed by panels 30, 34 in position. These steps may take place in any desired sequence. Glue lines 148 applied to the side wall cuff panels and glue lines 204 applied to the end wall cuff panels are also shown in figure 30. It will be appreciated that other glue line patterns may be used.

[0076] The carton erected from the blank 10 has fold down cuffs extending along the upper part of the side walls and end walls. This increases the strength of the upper edges of the carton. Furthermore, the waterproof lining material applied to the blank 10 extends over the upper edges of the carton (which are effectively formed from the fold lines 32, 36, 40, 44), thereby minimising ingress of moisture into the fluting that may be caused by moisture dripping onto the carton. The gussets strengthen the end walls. The design of the blank also provides a closed lower surface to minimise or avoid leakage of moisture from the carton.

[0077] Although the blank 10 shown in figure 30 can be erected into a carton using hand erection, advantageously the blank 10 is erected into a carton using machine erection. Not only does this minimise labour costs, it also enables a large number of cartons to be erected each day. It will be appreciated that a large meat packaging company may require a large number of erected cartons for use each day.

[0078] Figure 1 shows a perspective view of a carton erecting machine that can be used to

2014233552 21 Oct 2019 erect a carton from the blank 10 shown in figure 30. The carton erecting machine shown in figure 1 includes external cladding and access doors that, in use, are normally closed. The external cladding and closed access doors prevent ingress of contamination into the carton forming regions or stations of the carton erecting machine 60. They also provide an important safety barrier to minimise the risk of injury to personnel operating the machine.

[0079] The carton erecting machine 60 shown in figure 1 is supplied with a stack of blanks 62. The stack of blanks 62 are positioned on a trolley 64. A second trolley 66 is shown ready to interchange with the trolley 64 when the stack of blanks 62 on trolley 64 becomes exhausted. In this manner, the trolley 64 can be quickly removed when it is empty and replaced by trolley 66. This minimises disruption to production of cartons. The trolleys are provided with a handle 67 and caster wheels (not numbered) to facilitate easy manoeuvring of the trolley.

[0080] Although the carton erecting machine 60 is shown as being supplied with stacks of blanks that are positioned on trolleys, it will be appreciated that blanks may be supplied to the machine by any other suitable means known to the person skilled in the art. For example, the machine may be arranged such that it receives pallets of blanks, or conveyors may be used to feed blanks into the machine.

[0081] The carton erecting machine 60 has a number of stations at which various performing operations take place. These stations may be generally divided into an in-feed station 68, a side wall cuff formation station 70, a carton formation station and end wall cuff formation 72 and a carton out-feed station 74. Cartons that have been formed in the carton erecting machine 60 may be removed from the machine in the direction of arrows 76, 78, or in the opposite direction to arrow 78.

[0082] The first step in erecting a carton from a blank, such as the blank 10 shown in figure 30, involves lifting a blank from the stack of blanks 62 and feeding it to the first of the forming stations. In order to ensure that the blanks are presented in the proper position to the in-feed station, the trolleys 64, 66 are provided with an end wall 80 and respective short side walls 82, 84. The end wall 80 is of complementary shape to the end of the blanks. It can be seen from figure 1 that the blanks are held in place by the walls 80, 82, 84 that extend at least partly along three sides of the blanks. This firmly seats the blanks against the three walls and securely locates the blanks in a fixed position on the trolley. Once the trolley 64 has been pushed into the in-feed station, an interior wall of the carton erecting machine (not shown) also assists in correctly positioning the blanks. The rear wall 80 of the trolley forms part of the machine safeguard system whether the trolley is locked in place.

2014233552 21 Oct 2019 |0083| Figure 2 shows the initial equipment used to lift a blank from the stack of blanks. The carton erecting machine 60 is provided with lift tynes 86 that are connected to a lifting and floating arrangement so that the height of the top blank in the stack 62 is maintained at an essentially constant level. As one blank is removed from the stack, the lifting and floating arrangement raises the lifting tynes by an amount that is equivalent to the thickness of the blank that has just been removed from the stack. As a result, the top blank remaining on the stack is lifted to essentially the same height as the previous blank that has just been removed from the stack. The lifting and floating arrangement may be of conventional construction and the person skilled in the art will readily understand how the lifting and floating arrangement is constructed and operated. Thus, the lifting and floating arrangement need not be described further. The skilled person will understand that they are a number of different conventional blank feeding apparatus that can be used in the present invention.

[0084] The in-feed arrangement will now be described in more detail with reference to figures 2 to 5. The following features of the in-feed arrangement are mounted within the carton erecting machine 60. However, details of the mounting of these components have been omitted from figures 2 to 5 for clari ty.

|0085| The in-feed arrangement includes in-feed rails 88. 90. In-feed rails 88, 90 are mounted via respective mounting blocks 91, 92, 93, 94 to respective transverse rods 96, 98. The mounting blocks 91,92 can slide along transverse rod 96. Similarly, the mounting blocks 93, 94 can slide along transverse rod 98. Servo motors (not shown in figure 5, but described in more detail with reference to figure 5 A) are used to closely control the position of the in-fed rails 88, 90.

|0086| Figure 5A shows how the in-feed rails 88, 90 are mounted and moved. A frame 300 having top members 302, 304, 306, 308 and appropriate legs (not numbered) is provided. The frame also includes intermediate members 310. 312, 314 and another member opposite member 314 that is hidden in figure 5A. Four linear guide shafts 320, 96, 324, 98 are mounted to the respective top members and cross members of the frame 300 as shown in figure 5A. The mounting blocks 91,92, 93, 94 are provided with bearings to enable the respective mounting blocks to slide along the respective linear guide shafts 96, 98. Similar upper mounting blocks, two of which are numbered at 328 and 330, are used to enable the upper mounting blocks to slide along the upper linear guide shafts 320, 324. Rigid arms, two of which are numbered at 332, 334. connect the lower mounting blocks to the respective upper mounting blocks (for example, mounting block 94 is connected to mounting block 320). A servo motor with gearbox 336 drives

2014233552 21 Oct 2019 a driveshaft 338. The servo motor 336 provides for accurate position control. Drive shaft 338 in turn drives drive belts 340, 342. Operation of the servo motor 336 causes the in-fed rails 88, 92. moved inwardly or outwardly in a controlled manner.

[0087] The in-feed arrangement also includes a vacuum lifting arrangement 100. The vacuum lifting arrangement includes 4 suction cups 101, 102, 103, 104 (see figure 3) that are mounted to a generally cruciform frame 105. A vacuum line 108 is arranged to be able to selectively provide vacuum to the suction cups. Appropriate valving is used to selectively provide vacuum. Passages in the cruciform frame 105 provide fluid communication between the suction cups and the vacuum line. The vacuum system has four bellowed vacuum cups 101. 102, 103, 104 attached to the cruciform frame 105. A common vacuum delivery line is branched to supply the vacuum cups. A single vacuum control valve is positioned within this common line to control vacuum or air discharge to allow quick transition and self-cleaning (refer to vacuum control valve described in the power point information) this valve is connected to a side channel blower (ring compressor) not show n in the diagram.

[0088] The vacuum lifting arrangement 100 includes vertically extending rods 106, 107 that are mounted to the cruciform frame 105. These rods extend upwardly through complementary openings formed in cross member 110. The cross member 110 is mounted to the frame (not shown) of the carton lifting machine 60. A pneumatic cylinder 112 is selectively extendable and retractable to control the vertical position of the vacuum lifting arrangement 100.

[0089] The rear most frame member 1 14 of the in-feed station houses a kicker cylinder 116 that has a blank kicker member 118 mounted thereto. The blank kicker member 118 may comprise an angled section having a generally vertical surface that contacts a rear part of the blank and a downwardly extending surface.

10090] Operation of the in-feed section will now be described. When the control system of the carton erecting machine 60 determines that it is time to feed another blank to the forming stations, the in-feed rails 88. 90 are moved such that they retract outwardly so that their innermost surfaces are located outside the side edges of the blanks. Il can be seen from figure 3 that in-feed rail 90 comprises a generally right angle section having a vertical portion 118 and a generally horizontal portion 1.20. A covering 122 may be applied to the right angle section of the in-feed rail 90. In-feed rail 88 is similarly arranged. When the in-feed rails arc retracted to the position shown in figure 3, their innermost edges lie outside the outer edges of the blank. This allows the blank to be lifted up by the vacuum lifting arrangement 100 to a position that is above the in-feed rails.

2014233552 21 Oct 2019 [0091] The cylinder 112 is operated such that the vacuum lifting arrangement 100 is lowered and the suction caps 101, 102, 103, 104 come into contact with the upper surface of the blank 10. This is shown in figure 3. The vacuum line is activated and the suction cups grab the blank 10. The cylinder 112 is then operated such that the vacuum lifting apparatus 100 is raised until the blank is located above the horizontal surface of the covering 122 of the in-feed rails 88, 90. The servo motors are then operated to move the in-feed rails 88, 90 until the in-feed rails are moved to a loose blank width position. The vacuum system is then isolated, allowing the blank 10 to drop onto the in-feed rails. At this stage, the blank 10 is supported underneath its side edges by the horizontal surface of the covering 122 of the in-feed rails 88, 90. This is shown in figure 4.

[0092] The servo motors can precisely control the position of the in-feed rails. The servo motors then move the in-feed rails 88, 90 to the width of the blank. This is shown in figure 5. The blank kicker cylinder 116 then extends and the blank kicker member at 118 pushes the blank along the in-feed rails 88, 90 until the leading edges of the blank 10 engagement with the nips of feed rollers 122, 124. This is shown in figure 5. The feed rollers 122, 124 form part of the side wall cuff forming station.

[0093] The lower rollers of feed rollers 122, 124 are keyed to shaft 126. The upper rollers are mounted to brackets 128, 130. The shaft 126 is driven to cause rotation which, in turn, rotates the lower rollers of feed rollers 122, 124. Secondary feed roller pairs 132, 134 are also provided. When the leading edge of the blank 10 is received between the nip of the feed rollers 122, 124, the feed rollers pull the blank 10 therethrough.

[0094] Although not forming part of the apparatus shown in figure 5, it may also be possible to provide another set of wheels in the form of a die wheel and an anvil wheel that are in alignment with the fold lines between the side wall panel and the side wall cuff panel of the blank. These sets of wheels may form a crease in the blank along the fold lines 32, 36 as the blank passes between those sets of wheels. This additional creasing along the fold lines 32, 36 may assist in the subsequent folding of the side wall cuff panels about the fold lines. However, the additional wheels will typically not be required to enable folding of the side wall cuff panels and may be omitted, as shown in figure 5.

[0095] Figure 6 shows an underneath view of the blank 10 passing through the feed rollers 128, 130. A glue applicator 146 is provided to apply glue lines 148 to the underside of the side wall cuff panel 30. Another glue applicator 150 is provided to apply glue lines (not shown) to the side wall cuff panel 34. The glue lines may be continuous glue lines or stitched glue lines.

2014233552 21 Oct 2019 [0096] Figure 7 shows the blank 10 after it has passed through the feed rollers 122, 124 and has been fully received in the final part of the side wall cuff forming station. In order to properly locate the blank 10, a pneumatic cylinder 152 that carries a stop member 154 is activated. This causes the stop member 154 to be moved upwardly to an extended position at which it contacts a near edge of the blank. A similar arrangement is provided on the other side of the blank, with cylinder 156 just being visible in figure 7. Blank location pushers 158, 160, each of which may comprise a pneumatic cylinder carrying a pusher member, push the blank 10 until it comes into contact with the stop members carried by cylinders 152, 156. This ensures that the blank 10 is properly located in the side wall cuff forming station.

[0097] The components and the operation of the final part of the side wall cuff forming station are shown in figures 7 to 16. Turning initially to figure 7, which shows a perspective view from above of the final part of the side wall cuff forming station, it can be seen that the station includes pneumatic cylinders 158, 160, 162 and 164. Each of these pneumatic cylinders carries a rack 166, 168, 170, 172. Each rack is able to be moved in a reciprocal fashion by the pneumatic cylinders. Each rack has a toothed or cogged lower surface that engages with respective pinions, two of which are shown at 174 and 176. The pinions have a side wall cuff folding member 177 mounted thereto (see figure 8). The side wall cuff folding member 177 may comprise a plate. A plurality of holes may be formed in the plate to lower the weight of the plate. As the racks 166, 168 are extended and retracted by their respective pneumatic cylinders 158, 160, the racks cause the pinions 174, 176 to rotate. As the side wall cuff folding member 177 is mounted to the pinions, it rotates with the pinions. A similar side wall cuff folding member 177A is provided on the other side.

[0098] Turning now to figure 8, the final part of the side wall cuff forming station includes support members 182, 184. The support member 182 comprises a plate or blade 186 having a top edge 188. The support member 182 is closely mounted to or keyed to a shaft (not shown) that passes through a cylindrical extension 190 that is formed with all mounted to the lower part of plate 186.Support member 184 is similarly arranged.

[0099] The blank 10 rests on a support deck when it is in the final part of the side wall cuff forming station. The support deck has been omitted from the figures 7 and 8 so that other features can be more clearly seen. In order to firmly hold the blank in position during formation of the side wall cuffs, pneumatic cylinders 179, 181 that carry extendable and retractable arms 183, 185 are mounted to a framework (not shown). The extendable and retractable arms 183, 185 carry respective clamping plates 187, 189. Once the blank has been properly positioned by use of

2014233552 21 Oct 2019 the pushers 158, 160 and stop members 154, the cylinders 179, 181 are operated to extend the arms 183, 185 until the clamping plates contact the side wall panels of the blank and clamp the blank between the clamping plates and the support deck.

[00100] Operation of the final part of the side wall cuff forming station and the steps carried out by the final part of the side wall cuff forming station will now be described. Turning initially to figure 8, the stop member 154 is raised by cylinder 152 and the blank is pushed in by blank location pushers 158, 160 until it contacts the stop member 154 and the other stop member that is carried by cylinder 156. This properly locates the blank in the side wall cuff forming station.

[00101] The clamping plates 187, 189 are then lowered to thereby clamp the blank 10 between the clamping plates and the support deck. The support members 182, 184 are located in their extended position in which their respective top edges are positioned along and in contact with respective fold lines 32, 36 that lie between the side wall panels and the side wall cuff panels of the blank 10. The top edge of the support members 182, 184 is desirably of a thickness that is about the same as or slightly less than the thickness of the fold lines. The top edges desirably contact the respective fold lines 32, 36 to thereby provide support underneath those fold lines. This is shown in figure 9. As can also be seen in figure 9, the side wall cuff folding member 177 is retracted and is not in contact with the side wall cuff panel 30 at this stage.

[00102] With the blank 10 now being clamped between the clamping plates 187, 189 and the support deck and the top edges of the support members 182, 184 contacting and supporting the creases formed along the fold lines 32, 36, the initial folding of the side wall cuffs of the blank can be completed. Pneumatic cylinders 158, 160 are actuated to cause the side wall cuff folding member 177 to rotate about 95°, which, in turn, causes an initial rotation of the side wall cuff panel 30. A similar rotation occurs for the side wall cuff forming member located on the other side. During this initial rotation of the side wall cuff panels, the top edges of the support members 182, 184 support the fold lines or creases between the side wall cuff panels and their respective side wall panels. This facilitates neat folding of the side wall cuff panels in the initial folding stage. In this regard, it will be appreciated that it is much simpler to fold a paperboard product about a supported fold line, particularly if the folding is taking place across the fluting of the paperboard.

[00103] As the underside of the side wall cuff panels has had glue applied thereto, it is desirable that the initial rotation of the side wall cuff panels is such that they do not come into contact with the outer surface of the support members.

2014233552 21 Oct 2019 [00104] Once the initial rotation of the side wall cuff panels has been completed, the cylinders 192, 194, 196 are activated to retract the support members 182, 184 to the position shown in figure 11. In particular, the cylinders retract which causes the upper edges of the support members 182, 184 to rotate inwardly and away from the side wall cuff panels. This is shown in figure 11.

[00105] The side wall cuff forming members are then caused to further rotate, as shown in figure 12. In particular, the pneumatic cylinders 158, 160 are operated to further extend the racks 166, 168 which, in turn, rotates the pinions and rotates the side wall cuff forming member 177. The side wall cuff forming member 177 is rotated until the side wall cuff panel 30 is brought into contact with the underside of the side wall panel 14. The glue line that has been applied to the underside of side wall cuff panel 30 then causes the side wall cuff panel 32 to adhere to the outer surface of the side wall panel. It has been found that maintaining the side wall cuff forming member 177 in the position shown in figure 12 for about 1.5 seconds is sufficient to allow the glue to set to adhere the side wall cuff panel to the side wall panel and thereby form the side wall cuff. A similar forming operation takes place on the other side of the blank.

[00106] The clamping plates 187, 189 are then retracted/raised and the stop member 154 is lowered. This is shown in figure 13. The side wall cuff forming members are still holding the blank at this stage. The side wall cuff forming members are then retracted (see figure 14) and a secondary kicker cylinder 200 extends to cause the blank pushers to push the blank towards the nip rollers 202 that feed the blank to the next forming station. This is shown in figure 15. The secondary kicker cylinder 200 and the blank location pusher 157 retract and the support members 182, 184 are rotated outwardly to their support position, as shown in figure 16. In this orientation, the final part of the side wall cuff forming station is ready to receive the next blank for processing. The support deck 185 is also shown in figure 16. The support deck is arranged such that the support plates 182, 184 do not come into contact with the support deck. The support deck may have a different shape to that as shown in figure 16.

[00107] The nip rollers 202 comprise secondary feed rollers in the carton erecting machine. The nip rollers 202 receive the leading end of the blank 10 that has had the side wall cuffs formed thereon (as described with reference to figures 7 to 16). The nip rollers 202 draw the blank therethrough. As the blank passes through the nip rollers 202, a series of glue lines, some of which are numbered at 204 in figure 17, are applied to the end wall cuff panel 38. Glue applicators, some of which are numbered at 206 in figure 17, are used to apply in the glue lines to the end wall cuff panel 38. Similarly, when end wall cuff panel 42 passes through the nip

2014233552 21 Oct 2019 rollers 202, glue lines are applied to end wall cuff panel 42.

[00108] Once the blank 10 has fully passed through the nip rollers 202, another kicker cylinder moves a pusher into contact with the trailing edge of the blank. The kicker cylinder then moves the pusher to push the blank so that the blank 10 comes into contact with end stops. The skilled person would readily understand how this arrangement operates. This moves the blank into position in the forming station, as shown in figure 18.

[00109] In the position shown in figure 18, the base 12 of the blank 10 is located above an opening. The opening is of essentially the same size and shape as the base 12 of the blank 10. The opening is defined by side wall contacting members 216, some of which are shown in figure 19 at reference numerals 216, and end wall contacting members 218. Each of the side wall contacting members 216 and the end wall contacting members 218 have a generally horizontally extending outer part, a curved intermediate part and a generally vertically extending inner part. The generally vertically extending inner parts of the side wall contacting members 216 and the end wall contacting members 218 define an opening that is of complementary size and shape to the base 12 of the blank 10. As the mandrel 226 is lowered, the base 12 of the blank 10 is pushed downwardly. This causes the side walls to contact the respective side wall contacting members 216 and the end walls to contact the respective end wall contacting members 218. Each side wall contacting member 216 includes a secondary member 217 that is located towards a corner and has an upper portion and an intermediate portion that is somewhat lower than the equivalent parts of the side wall contacting member 216. The secondary member 217 assists in guiding the gusset panels that are formed as the side walls and end walls of the blank fold upwardly into the correct orientation such that the gusset panel moves to a position that is essentially parallel to the corresponding side wall. This is shown in figure 19.

[00110] Returning to figure 18, a mandrel 226 is positioned above the base 12 of the blank 10. The mandrel 226 includes side plates 228, 230 and end walls 232, 234. The mandrel has a base 235. The mandrel is arranged such that it has a similar size and shape at its lower edge to the base 12 of the blank 10.

[00111] The mandrel 226 is driven by a servo motor and gearbox 236. The servo motor and gearbox 236 is mounted in fixed position to a frame or frame member 237. This servo motor has an inline helical gearbox connection. Accurate positioning of the mandrel 226 is possible by use of the servo motor and gearbox. Attached to the output shaft of the servo motor 236 is a pinion wheel 237 (see figure 28) that engages with a rack 238 to cause vertical reciprocating movement of the mandrel 226. The mandrel 226 is mounted for reciprocating movement along two vertical

2014233552 21 Oct 2019 guide shafts 240, 241 (see figure 28). The servo motor and gearbox 236 is operable to move the mandrel 226 between a top dead centre position and a bottom dead centre position.

[00112] Once the blank 10 is positioned in the location shown in figure 18, the motor 236 is operated to cause the mandrel 226 to be moved downwardly and into contact with the base 12 of the blank 10. The lower edges of the mandrel 226 come into contact with the base 12 of the blank 10. Continued lowering of the mandrel 226 then pushes the base 12 downwardly. This causes the side wall panels and end wall panels to come into contact with the side wall contacting members 216 and the end wall contacting members 218 , respectively, which causes the side walls and the end walls to fold upwardly relative to the base, as shown in figure 19. As the side wall panels and end wall panels fold upwardly, the gusset panels also fold. For example, as shown in figure 19, gusset panel 52 starts to fold about the diagonal fold line therein. As the gusset panels start to fold, their natural tendency is to fold outwardly at an angle of about 45° to their respective side walls. The secondary side wall contacting members 217 act to grant the gusset panels to a position where the gusset panels come into alignment with their respective side walls.

[00113] The apparatus also includes gusset guide members, 270, 272. Similar gusset guide members are located at the opposite end of the forming chamber. Each gusset guide member 270, 272 comprises an angled rod. The gusset guide members 270, 272 may be moved to the position shown in figure 19, in which position in the gusset guide members act to guide the gusset panels and move the gusset panels until they lie adjacent to the corresponding end walls of the carton during forming of the carton. The gusset guide members, in the position shown in figure 19, extend downwardly and inwardly towards the carton. As the gusset panels are formed during erection of the carton, the lower edge of the gusset panels (which is formed by the fold line about the diagonal crease in each gusset panel) comes into contact with the respective gusset guide member. As the mandrel continues to be lowered, the angle and orientation of the gusset guide members forces the gusset panel to turn towards the respective end wall panel and to eventually come into contact with the outer surface of the respective end wall panel. This is shown more clearly in the sequence that occurs as the mandrel is moved downwardly from the position shown in figure 19 to the position shown in figure 21. As can be seen from figure 19, the gusset panels are just starting to form. In figure 20, the lower edges of the gusset panels are starting to come into contact with the gusset guide members 270, 272. This causes the gusset panels 48, 50 to start to fold inwardly towards the end wall panel 24. Continued downward movement of the mandrel moves the blank to the position shown in figure 21 where the gusset panels 48, 50 have been folded so they come into contact with the end wall panel 24. In this

2014233552 21 Oct 2019 orientation, the gussets are parallel to and in abutment with the respective end walls of the carton.

[00114] As the mandrel moves the carton down from the position shown in figure 19 to the position shown in figure 21, a press roller 350 comes into contact with the outer surface of the end walls of the container. The press roller 350 acts to force the gusset panels 48, 50 into close contact with the end wall panel 24. The press roller 350 can move towards and away from the end wall of the carton. In this regard, pneumatic cylinders 352, 354 are provided and the respective ends of the press roller 350 are mounted to extendable and retractable arms of the cylinders 352, 354. Extending the arms of the cylinders 352, 354 moves the press roller 350 towards the end wall of the carton. Retracting the arms of the cylinders 352, 354 moves the press roller 350 away from the end walls of the carton. The press roller 350 also assists in holding the gusset panels 48, 50 in contact with the end wall panel 24 once the upper edge of the carton that is being erected in the machine has passed below the lower edges of the gusset guide members 270, 272.

[00115] In order to maintain the gussets in position, the end wall cuff panel 38 with the glue lines formed thereon is folded down over the gussets. The glue lines causes the end wall cuff panel 38 to adhere to the gussets and to the end wall 24 which, in turn, forms the end wall cuff and holds the gussets place. To achieve the downward folding of the end wall cuff panel, the mandrel 226 has an end wall cuff folder 292. A similar end wall cuff folder 294 is provided at the opposite end of the mandrel. The end wall cuff folder 292 comprises a plate 296 that has a series of spaced projections 298. This is best shown in figure 19. The end wall cuff formers 292, 294 are arranged for rotation in a similar manner to the side wall cuff folding members. Once the gusset guide members 270, 272 have folded the gussets to the position shown in figure 21 and the press roller 350 is holding the gusset panels in position, the gusset guide members 270, 272 are rotated out of the way. In this regard, gusset guide member 270 is pivotally mounted to frame member 400. The vertically extending portion 402 of gusset guide member 270 is mounted to a lever arm 404. Lever arm 404 is, in turn, mounted to an extendable and retractable arm 406 of pneumatic cylinder 408. Extending the arm 406 from the position shown in figure 22 causes the gusset guide member 270 to rotate inwardly towards the mandrel whilst retracting the arm 406 causes the gusset guide member 270 to rotate outwardly away from the mandrel. The other gusset guide members are similarly arranged.

[00116] Once the gusset guide members have been rotated out of the way, the end wall cuff folders 292, 294 are rotated to fold the respective end wall cuff panels 38, 42 over until the end

2014233552 21 Oct 2019 wall cuff panels come into contact with their respective gussets and end walls. This is best shown in figure 22. Press roller 350 holds the gusset panels in contact with their respective end wall.

The glue lines that have been applied to the underneath surface of the end wall cuff panels 38, 42 start to set. Once the glue has set to a sufficient strength, the end wall cuff panels 38, 42 form end wall cuffs that both strengthen the upper part of the end walls of the carton and also hold the gussets in position.

[00117] It will be appreciated that the gussets that are positioned under the folded end wall cuff panels will have a tendency to want to spring outwardly. Thus, it is desirable to hold the end wall cuff panels in position for a longer period of time to provide additional time for the glue to set and therefore adhere the end wall cuffs in position. It will be appreciated that the end wall cuff folder 292 will retain the end wall cuff in position when it is in the orientation shown in figure 22. It would be possible to simply hold the carton in the position shown in figure 22 for a longer period of time in order to allow sufficient time for the glue to properly adhere. However, this would have the effect of slowing the rate of production of the carton erecting machine as one of the forming steps, namely forming the end wall cuffs, would occupy a longer time. To address this issue, the carton erecting machine is also provided with end wall cuff retainer 300 and an identical end wall cuff retainer located at the other end of the forming chamber (not shown). The end wall cuff retainer 300 comprises a plate 304 that has a series of spaced projections or fingers 306 extending outwardly therefrom. This is best shown in figure 25. The spaced projections or fingers 306 are arranged such that they fit into the spaces between the spaced fingers or projections 298 on the end wall cuff folder 292.

[00118] Once the end wall cuff folder has folded over the end wall cuff (as shown in figure 22), the press roller 350 may be retracted to provide clearance to allow the mandrel and the folded-over end wall cuff folder to move further downwardly. In this regard, the press roller 350 is retracted to the position shown in figure 23 by retraction of the arms of cylinders 352, 354. It will be appreciated that the end wall cuff folder 292 is holding the end wall cuff panel and the gusset panels in position relative to the end wall panel of the carton. The mandrel is then moved further downwards and this moves of the carton from the position shown in figure 23 to the position shown in figure 24. At this stage, the spaced projections 306 of the end wall cuff retainer 304 become positioned between the downwardly extending spaced projections or fingers 298 of the end wall cuff folder 292. Therefore, the end wall cuff is now held by both the end wall cuff retainer 304 and the end wall former 292. Spring loaded latches 308, 310 engage the upper side edges of the carton, as best shown in figures 26 and 27. Similar latches are located to contact the upper edge of the other side wall of the carton. These latches may be of conventional

2014233552 21 Oct 2019 construction. The end wall cuff folder 292 is then rotated away from the end wall cuff (see figure 25). Once the carton is supported by the end wall cuff retainers, the mandrel finishes its downward cycle and returns to top dead centre. Figure 26 shows the mandrel 226 commencing its upward movement back towards top dead centre. The latches 308, 310 ensure that the carton is retained in the position shown in figure 26 as the mandrel 226 is raised away from the carton.

[00119] Figure 27 shows a carton 400 that has been erected by the machine being held in position between the cuff retainers 300 located at either end of the forming chamber 410. In figure 27, some details have been omitted for clarity. The carton is retained in the position shown in figure 27 until the next carton has been formed in the forming section. When the mandrel pushes the next carton in a downwards direction towards the position shown in figure 24, the next carton comes into contact with the carton being held between the end wall cuff retainers. The next carton thus pushes the preceding carton down and out from between the end wall cuff retainers. The completed carton can then be removed from the machine by hand or by appropriate extraction mechanisms, such as conveyors, pushers or the like.

[00120] Figures 28 and 29 show a perspective view of the mandrel 226 with surrounding detail removed for greater clarity. The mandrel 226 is connected via guide rods 240, 241 to an upper platform 420. Upper platform 420 is mounted to frame the members 421, 422 and 423. Upper platform 420 also mounts the servo motor and gearbox 236. Pinion wheel 237 is rotatably mounted to the output of the gearbox. Pinion wheel 237 meshes with toothed rack 238. As the pinion wheel rotates, it causes the toothed rack to either raise or lower, depending upon the direction of rotation of the pinion wheel 237. This, in turn, causes the mandrel 226 to be raised or lowered.

[00121] The mandrel 226 carries the end wall cuff folders 292. In order to cause the end wall cuff folders 292 to rotate, toothed racks 430, 432 are mounted to pneumatic cylinders mounted to the mandrel (not shown) so that the racks 430, 432 can be selectively raised and lowered. Each rack 430, 432 meshes with a pinion wheel 434, 436, respectively. As the racks 430, 432 are raised or lowered, pinion wheels 434, 436 are caused to rotate. The end wall cuff folder 292 is mounted via arms 438, 440 to an axle extending between the pinion wheels 434, 436. This is more clearly shown in figure 29. As a result, as the pinion wheels rotate, the end wall cuff folder 292 is also caused to rotate. The end wall cuff folder 292 can rotate between the closed position shown in figure 28 and the open position shown in figure 29.

[00122] In order to provide pneumatic power to drive the end wall cuff folders, the mandrel has a cable way 450 (which is shown in full in figure 18 and shown partially cut away in figures

2014233552 21 Oct 2019 and 29). Cable way 450 carries both pneumatic lines and electrical lines to provide pneumatic and electrical power and transfer of control signals to and from the mandrel.

[00123] The machine may also be provided with an automatic control system to ensure that correct sequencing of the various forming operations takes place. The skilled person would readily understand that such control systems are well within the skill and knowledge of the skilled person and that it is not necessary to provide any further details of such control systems.

[00124] It will be appreciated that the end wall cuff retainers act to hold or retain the end wall cuffs in position whilst the next carton is being formed by the mandrel in the carton folding station. Thus, the end wall cuffs are held in position for the time required to complete the next folding step. This allows additional time for the glue to properly adhere and hold the end wall cuffs in position whilst also minimising the time that the end wall cuff folders are used to hold the end wall cuffs in their final position. This results in an increased production rate for the carton erecting machine.

[00125] The carton erecting machine of the present invention allows for high rates of production of machine erected cartons. The cartons include gussets, side wall cuffs and end wall cuffs.

[00126] In the present specification and claims (if any), the word ‘comprising’ and its derivatives including ‘comprises’ and ‘comprise’ include each of the stated integers but does not exclude the inclusion of one or more further integers.

[00127] In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims (if any) appropriately interpreted by those skilled in the art.

Claims (11)

1. A carton erecting machine for erecting a carton from a blank, the blank comprising a base, side wall panels connected to the base along respective fold lines, end wall panels connected to the base along respective fold lines, the side wall panels each having a side wall cuff panel connected thereto along a fold line, wherein in the erected carton, the side wall cuff panels are folded so that they come into contact with their respective side wall panels and are maintained in place to thereby form side wall cuffs extending from an upper edge of the respective side walls of the container, the blank further comprising end wall cuff panels connected to the end wall panels along respective fold lines and gusset panels extending between each of the side wall panels and an adjacent end wall panel, the carton erecting machine comprising a feeder for feeding a blank, a support member being movable between a support position at which the support member is positioned under a crease formed along the respective fold lines located between a side wall panel and its associated side wall cuff panel and a retracted position, a side wall cuff folding member for folding the side wall cuff panel relative to its associated side wall panel, the side wall cuff folding member operable to fold the side wall cuff panel about the fold line in an initial folding movement whilst the support member is in the support position such that the support member contacts the blank along at least part of the fold line during the initial folding movement, the support member being moved to a retracted position and the side wall cuff folding member further folding the side wall cuff panel about the fold line until the side wall cuff panel is positioned parallel to and in abutment with its associated side wall panel, a base contacting member for contacting the base of the blank, side wall contacting members and end wall contacting members, the base contacting member being movable to cause the base to move to thereby cause the side wall panels and end wall panels to contact respective side wall contacting members and end wall contacting members to cause the side wall panels and end wall panels to fold relative to the base and to cause the gusset panels to fold about an oblique fold line to form respective gussets, a gusset guide member for guiding a gusset panel so that it is positioned adjacent to an end wall panel, and an end wall cuff folder for folding the end wall cuff panel about its respective fold line so that the end wall cuff panel lies parallel to and in abutment with its respective end wall panel, and an end wall cuff retainer for retaining the end wall cuff panel in position following folding of the end wall cuff panel by the end wall cuff folder.

2. A carton erecting machine as claimed in claim 1 wherein the base contacting member is reciprocally movable in a vertical direction and the base contacting member moves the blank downwardly through the opening during erection of the carton.

2014233552 21 Oct 2019

3. A method for erecting a carton from blank, the blank comprising a base, side wall panels connected to the base along respective fold lines, end wall panels connected to the base along respective fold lines, the side wall panels each having a side wall cuff panel connected thereto along a fold line, wherein in the erected carton, the side wall cuff panels are folded so that they come into contact with their respective side wall panels and are maintained in place to thereby form side wall cuffs extending from an upper edge of the respective side walls of the container, the blank further comprising end wall cuff panels connected to the end wall panels along respective fold lines and gusset panels extending between each of the side wall panels and an adjacent end wall panel, the method comprising positioning a blank such that a support member is located below a fold line between the side wall panel and the side wall cuff panel, operating a side wall cuff folding member to cause the side wall cuff panel to fold about the fold line between the side wall panel and the side wall cuff panel, moving the support member to a retracted position and continuing operation of the side wall cuff folding member to cause the side wall cuff panel to continue folding until it comes into contact with a respective end wall panel whereby glue holds the side wall cuff panel in position, retracting the side wall cuff folding member, positioning the blank such that the base of the blank is positioned over an opening defined by side wall contacting members and end wall contacting members, operating a base contacting member to move the base of the blank into the opening whereby the side wall contacting members contact the side wall panels and the end wall contacting members contact the end wall panels to cause the side wall panels and end wall panels to fold relative to the base and to cause the gusset panels to fold outwardly, continuing operation of the base contacting member to move the base further into the opening to cause the gusset panels to contact gusset guide members wherein further movement of the base causes the gusset guide members to guide the gusset panels into a position whereby the gusset panels lie parallel to and in abutment with respective end walls, contacting the gusset panels with a roller to hold the gusset panels in position and moving the gusset guide members away from the end walls, operating end wall cuff folding members to fold the end wall cuff panels over until they lie parallel to and in abutment with respective end walls, operating the base contacting member to further move the blank whereby the end wall cuffs come into contact with respective end wall cuff retainers, retracting the end wall cuff folding members after the end wall cuffs have come into contact with the respective end wall cuff retainers and retracting the base contacting member to leave the carton erecting from the blank being held between space end wall cuff retainers.

4. A method as claimed in claim 3 wherein a next carton that is erected ejects a previous carton

2014233552 21 Oct 2019 that is being held between the opposed end wall cuff retainers.

5. A method as claimed in claim 3 or claim 4 wherein the roller is retracted before the base contacting member moves the car into a position in which the end wall cuff retainers hold the end wall cuffs.

6. A machine for erecting a carton from a blank, the blank comprising a base, side wall panels connected to the base along respective fold lines, end wall panels connected to the base along respective fold lines, the side wall panels each having a side wall cuff panel connected thereto along a fold line, wherein in the erected carton, the side wall cuff panels are folded so that they come into contact with their respective side wall panels and are maintained in place to thereby form side wall cuffs extending from an upper edge of the respective side walls of the container, the machine including a side wall cuff forming section comprising:

a support member being movable between a support position at which the support member is positioned under a fold line located between a side wall panel and its associated side wall cuff panel and a retracted position, a side wall cuff folding member for folding the side wall cuff panel relative to its associated side wall panel, the side wall cuff folding member operable to fold the side wall cuff panel about the fold line in an initial folding movement whilst the support member is in the support position such that the support member contacts the blank along at least part of the fold line during the initial folding movement, the support member being moved to a retracted position and the side wall cuff folding member further folding the side wall cuff panel about the fold line until the side wall cuff panel is positioned parallel to and in abutment with its associated side wall panel.

7. A machine as claimed in claim 6 wherein the support member comprises a support blade or a support edge.

8. A machine as claimed in claim 6 or claim 7 wherein the support member is rotatably movable between the support position and the retracted position or the support member is reciprocally movable between the support position and the retracted position.

9. A machine as claimed in any one of claims 6 to 8 wherein the side wall cuff folding member is movable along an arcuate path

10. A machine as claimed in any one of claims 6 to 9 wherein the blank is supported on a deck

21 Oct 2019 and a clamping means clamps the blank to the deck during folding of the side wall cuffs and the machine includes clamping means comprise a cylinder having a reciprocally movable arm carrying a clamping surface at one end, whereby extension of the cylinder causes the clamping surface comes into contact with the blank to thereby clamp the blank between the clamping surface and the deck.

11. A machine as claimed in any one of claims 6 to 10 wherein the machine includes a glue applicator for applying glue between the side wall cuff panel and its associated side wall panel.