BE1026699B1 - PLANO FOLDING PROCESS AND MECHANISMS - Google Patents

Abstract

Devices and methods for forming boxes from blanks include propelling the blanks on a drivetrain while one or more side panel fingers alternately down and down different side panels of the blank. One or more holders hold the side panels in place while the blank moves on the drivetrain. The side panels moved up and down stiffen several panels from which they extend. The stiffened panels may be less sensitive to bend along false creases that extend across the blank during folding and bending steps of the box forming process.

Description

Plano folding process and mechanisms

BACKGROUND

Technical Field The invention relates to packaging machines. More particularly, the invention relates to methods and apparatus for forming custom packaging boxes from sheet material.

The Relevant Technology Sales of goods and services over the Internet have increased sharply in recent years and this trend is expected to continue. The vast majority of online orders are shipped to the customer, requiring most products purchased online to be packed for shipping. From the wide range of products ordered, the packaging can present a number of challenges for manufacturers and distributors. For example, while products must be packaged in all shapes and sizes and sent to customers, manufacturers and / or distributors can only have a limited number of box sizes to package such products.

As a result, products are often placed in boxes that are too large. using boxes that are too big uses extra packaging material, which is wasteful and expensive. Packaging boxes that are too large for the product being shipped also result in wasted space in the box and around the product. This extra space can cause the product to shift, bounce, or otherwise move in the box during shipping, resulting in damage to the product during shipping. In many cases, filler material is placed around the product in the box to prevent the product from being moved too much. the extra filling material costs money and time.

There are packaging machines capable of adapting packaging boxes to specific product sizes to mitigate or eliminate some of the above challenges. In such machines, boxes are formed from sheet material that is fed to the machine, whereby the sheet material is cut into a box template (or "plano"). The blank is then folded into a box.

Before being formed into a box template, the sheet material can be folded back and forth on top of itself in alternating segments in a stack. As such, the sheet material includes score lines or folds that extend across the material between segments. Because of these score or fold lines, the use of warp material (e.g., sheet material folded back and forth on itself) for forming blanks can be problematic. For example, the blank formed from chain material can often extend over several

BE2018 / 5698 segments of the chain material. Thus, blanks formed from warp material typically have crease or fold lines that extend over one or more panels, tabs, or other parts of the blank. These chain creases or folds that extend across the blank are called “false creases” because they are unlikely to fall directly on the blank where the blank is to be folded. That is, packaging machines typically bend the blanks at boundaries between the panels and lips to form boxes, and false creases do not necessarily correspond to those boundaries. As such, false creases form weak points in the blank material that can cause certain panels or flaps of the blank to collapse, bend, tear or otherwise fail during bending or other box folding processes within a packaging machine.

The difficulties caused by false creases extending over blanks are exacerbated when the packaging machine is instructed to form a variety of adjustable box sizes, as discussed above, from generic chain material. In such situations, false creases extending over the blanks may occur at any point along the length of the blanks, depending on the size and arrangement of the blanks, which may change based on the size of the product being packaged. Essentially, the position of false creases on blanks can change from one blank to the next. This variety makes it difficult for manufacturers and / or distributors to adapt the packaging machines to overcome the difficulties false creases present during the adaptive box forming process.

Accordingly, there are a number of problems in the art that need to be addressed. The material claimed herein is not limited to embodiments that solve any drawbacks, or that only work in environments such as those described above. Rather, this background is provided only to illustrate an exemplary technical field where some embodiments described herein can be practiced.

BRIEF SUMMARY The present invention relates to packaging machines. More particularly, the present invention relates to methods and devices for forming custom packaging boxes from generic chain material. In one embodiment of the present invention, a method of forming a box from a blank includes, for example, providing a blank on a drivetrain. The blank can include a number of panels, including a front panel, an intermediate panel, a bottom panel, a rear panel, and a glue lip extending from the rear panel. Each panel has one or more side flaps, which extend from it

BE2018 / 5698. In such an embodiment, the method further comprises advancing the blank on the drivetrain and alternately folding the side flaps sideways. In one embodiment of the present invention, a method of forming a box comprises providing a blank on a drivetrain and advancing the blank thereon. As the blank moves on the drivetrain, several side flaps of the blank are alternately moved up and down to stiffen panels from which the side flaps extend. Also, a holder holds the side flaps that are folded in position and holds a bottom panel of the blank down while the neighboring panels of the blank are folded up and over to form back, front and top surfaces of the box. In such an embodiment, the leading bottom corner of the container is beveled so that front panels of the blank can be partially folded before the front panel completely passes a front edge of the container.

In one embodiment of the present invention, a box forming method comprises providing a blank on a drivetrain and advancing the blank thereon. As the blank moves on the drivetrain, several side flaps of the blank are alternately moved up and down to stiffen panels from which the side flaps extend. In such an embodiment, a container holds the side flaps that are folded in position and holds a bottom panel of the blank downwardly while adjacent panels of the blank are folded up and over to form back, front and top surfaces of the box. Also, a spatula arm folds the adhesive lip down and the leading edge of the spatula contacts a boundary of the two front panels of the blank. In this way, the two front panels are folded on the boundary to form the top and front surfaces of the box.

In one embodiment of the present invention, a box forming method comprises providing a blank on a drivetrain and advancing the blank thereon. As the blank moves on the drivetrain, several side flaps of the blank are alternately moved up and down to stiffen panels from which the side flaps extend. Also, a holder holds the side flaps that are folded in position and holds a bottom panel of the blank down while adjacent panels of the blank are folded up and over to form back, front and top surfaces of the box.

In an embodiment of the present invention, a method of forming a box from a blank comprises providing a blank on a drivetrain. The blank can include a number of panels, including a front panel, an intermediate panel, a bottom panel, a rear panel, and an adhesive lip extending from the rear panel. Each panel has one or more side flaps extending therefrom. In such an embodiment, the method comprises advancing the blank on the drivetrain and alternately folding up and down the

BE2018 / 5698 side flaps. A holder holds the folded side flaps in position while the blank moves on the drivetrain. As the blank moves forward, the two front panels and the two rear panels fold up and over to form the top, front, back, and adhesive lip surfaces of the box, respectively. In addition, in such an embodiment, one or more subsequent angled arms and one or more leading angled arms retain the next bottom corner and the leading top corner of the box at a fixed angle.

In an embodiment of the present invention, a box forming machine includes a drivetrain. The drivetrain has a longitudinal direction and a drive mechanism adapted to move a blank on the drivetrain. The box forming machine also includes one or more fingers and one or more holders. The fingers are arranged to alternately lift and push side flaps of the blank as the blank advances on the drivetrain. The one or more holders are adapted to hold the side flaps of the blank in position while the blank advances on the drivetrain.

This summary is provided to introduce a selection of concepts in a simple form which are further described below in the detailed description. This summary is not intended to identify the main characteristics or essential characteristics of the claimed subject, nor is it intended to be used as an aid in determining the scope of the claimed subject. Additional features and advantages of the disclosed embodiments will be set forth in the description that follows, and will be apparent from the description, or learned from the practice of the invention. These and other features will become more apparent from the following description and the appended claims or may be learned from the practice of the present invention.

BRIEF DESCRIPTION OF THE FIGURES To further clarify the above and other advantages and features of the present invention, a more specific description of the invention will be given by reference to specific embodiments thereof which are illustrated in the accompanying figures. It will be understood that these drawings represent only illustrated embodiments of the invention and therefore should not be construed as limiting its scope. The invention will be described and illustrated with additional specificity and details using the attached figures, in which:

Figure 1 illustrates an exemplary box forming machine and system comprising a material feeding system, a blank cutting machine, a product feeding machine and a box forming machine;

Figure 2 illustrates a detail view of the system illustrated in Figure 1, including the product feeding machine and the box forming machine;

BE2018 / 5698 Figure 3 illustrates an exemplary blank formed by a blank forming machine comprising a number of panels, side flaps and an adhesive flap;

Figure 4 shows a drive train of a box-forming machine, the drive train moving a blank on a conveyor belt, illustrating a number of arms, holders and side flap fingers;

Figure 5 further illustrates the blank along the drivetrain with a side flap finger, a first set of side flaps being folded down while advancing the blank on the drivetrain;

Figure 6 illustrates the blank further along the drivetrain, the side flap finger folding a pair of side panels upward while the blank advances on the drivetrain;

Figure 7 illustrates the blank further along the drivetrain, the number of side flaps being folded up and down in an alternating manner and the various panels and side flaps held in place by the holders as the blank advances on the drivetrain;

Figure 8 illustrates arms of the box forming machine which lifts panels from the blank to form front and rear faces of the box;

Figures 9 and 10 illustrate the drivetrain of the box-forming machine without the blank to show a set of subsequent angled arms that rise as the following angled arms advance along the drivetrain;

Figure 11 illustrates a rear perspective view of a set of subsequent angled arms on a drivetrain holding an angled rear corner of a box as the blank advances on the drivetrain;

Figure 12 illustrates a spatula arm of the box-forming machine that folds a glue flap down as the blank advances on the drivetrain;

Figure 13 illustrates a set of box forming machine arms that fold up blank panels of the blank to form a front surface of the carton as the blank advances on the drivetrain;

Figure 14 illustrates the set of arms illustrated in Figure 13 wherein a front panel of the blank is folded down to form an upper surface of the box as the blank advances on the drivetrain;

Figure 15 illustrates a leading angled arm of the box forming machine holding an upper front corner of the box at an angle as the blank advances on the drivetrain;

Figures 16 illustrate a top side arm of the box forming machine which folds down side flaps of the blank to form a side surface of the box as the blank advances on the drivetrain; and

BE2018 / 5698 Figure 17 illustrates a bottom side arm of the box forming machine which folds side flaps of the blank up to form a side surface of the box as the blank advances on the drivetrain.

DETAILED DESCRIPTION The present invention relates to packaging machines. More specifically, the present invention relates to methods and devices for forming custom packaging boxes from generic chain material. For example, in one embodiment of the present invention, a method of forming a box from a blank comprises providing a blank on a drivetrain. The blank can include a number of panels, including a front panel, an intermediate panel, a bottom panel, and a rear panel. Each panel has one or more side flaps extending therefrom. In addition, each blank may or may not include one or more false creases that extend over it. In such an embodiment, the method further comprises advancing the blank on a drivetrain and alternately folding the side flaps up and down.

Embodiments of the present invention solve one or more of the above-discussed problems in the art by providing methods and apparatus for forming boxes from (or "blanks") which may or may not have false ridges extending over them . The methods and apparatus described herein include steps and devices that stiffen various panels and flaps of the blanks formed from warp material, so that the false creases do not adversely affect the folding process or the structural integrity of the last box. Turning now to the Figures, Figure 1 illustrates an exemplary box forming machine and system 100 comprising a material feeding system 102, a blank cutting machine 104, a product feeding machine 106, and a box forming machine 108. As seen in Figure 1, the material supply system 102 includes several stacks of warp material 110 which can be fed to the empty cutting machine 104. As noted above, the warp material 110 may include ribs 112 where the material is folded to form the stacks 110 of contiguous warp segments 114.

The warp material 110 illustrated herein may comprise corrugated board, cardboard or other packaging materials, or a combination thereof. Although the warp material may comprise corrugated board / carton, one or more embodiments of warp material stacks 110 may include materials other than corrugated board / carton that can be used to form packages and cartons. For example, chain materials can include various plastics, rubbers, paper, or other useful materials, or combinations thereof that are well known in the art of packaging and box formation.

BE2018 / 5698 The warp material is fed to the blank cutting machine to form a flat box template, or "blank", which is illustrated in more detail in Figure 3. First, in Figure 2, a detailed view of the blank cutting machine 104, product feeding machine 106, and box forming machine 108 is shown. The blank cutting machine 104 feeds a blank to the box-forming machine 108, which folds the blank into a carton for packaging one or more goods. In the exemplary system illustrated in Figure 2, the product supply machine 108 may include a conveyor belt 116 which supplies one or more goods to the blank formed by the blank cutting machine 104 before the box forming machine 108 folds the blank into a box.

In addition, the product feeder 106 may include one or more scanners 118, including one or more dimensional and / or barcode scanners that determine the dimensions of the one or more goods being packaged. This size data can then be passed to the blank cutting machine 104, which in turn can cut a blank to optimum dimensions, which minimizes extra space around the one or more goods within the final carton product. After the one or more goods have been placed in the correct area of the blank formed in the blank cutting machine 104, the one or more goods and the blank are fed to the box forming machine 108. As such, the box forming machine 108 can form a box around the one or more goods placed on the blank.

As noted above, a blank formed in the blank forming machine 104 may comprise a flat sheet material with a number of panels, side flaps and / or lips that can be bent at different angles to form the packaging boxes of different shapes and sizes. Figure 3 shows an example of a blank 300 cut by the blank cutting machine 104 from a portion of chain material 110. For reference, the arrow on the right side of Figure 3 indicates the forward direction in which the blank 300 advances through the box forming machine 108. In the illustrated example, the blank 300 includes a front panel A, an intermediate panel B, a bottom panel C, a rear panel D, and a glue lip panel E. Each panel includes opposing side panels or flaps A'-E 'transverse to each side of the corresponding panels AE can extend.

The front panel A is referred to as the "front panel" because it is oriented in the forward direction as it travels in the blank 300 through the box forming machine 108. Likewise, the back panel D designates a panel to run behind other panels as the blank 300 advances through the box forming machine 108. The bottom panel C is mainly positioned where the one or more goods can be placed by the product feeding machine 106. The bottom panel C can bottom surface of the final box.

The blank 300 illustrated in Figure 3 is intended to be a non-limiting example of a blank configuration. It will be understood that the blank cutting machine 104 blanks of one

BE2018 / 5698 can form any number of shapes, dimensions and panel configurations to produce boxes capable of packaging any number of product shapes and sizes. For example, in one or more embodiments, a blank may have more panels or fewer panels than those illustrated in Figure 3. Also, in one or more embodiments, a blank may comprise panels having only one side panel extending therefrom, more than two side panels extending therefrom , or no side panels extending therefrom. In one or more embodiments, a blank may be formed that does not include glue lips or two or more glue lips that are positioned at different locations on the blank.

However, for purposes of illustrating and describing various embodiments of the box forming machine of the present invention, the blank 300 shown in Figure 3 will be the blank 300 illustrated in the following Figures. The dotted lines shown on the blank 300 of Figure 3 can only illustrate boundaries between panels and / or lips where the box forming machine 108 can bend the blank 300 to form a box. In one or more embodiments of the present invention, the blank cutting machine 104 may score, press, bend, or otherwise affect the material at the boundary lines of the blank 300 to form weaknesses in the material. In this way, the blank is more likely to bend at the boundary lines shown when the side panels A'-E 'or panels AE are manipulated by the box forming machine 108. The illustrated blank 300 is arranged to form a rectangular shaped box, as will be clear. are from the description and figures that follow.

Figures 4 to 17 illustrate various steps of a method of forming a box in the box-forming machine 108, and components of the box-forming machine 108 that folds the blanks into the boxes. In these figures, for illustrative purposes, the blank 300 is shown moving through the box-forming machine 108 without any goods or products placed on it. It is clear, however, as discussed above, that one or more goods can be placed on the blank before the blank moves through the forming machine 108, so that a box is formed around the goods. In particular, in the embodiment of the blank 300 shown herein, one or more goods may be placed on the bottom panel C, which forms the bottom surface of the box being formed.

Figure 4 illustrates an interior portion of the box forming machine 108 with the blank 300 entering the box forming machine 108 from the left. For reference, the direction referred to herein as the "forward" direction is illustrated from left to right in Figure 4 and in the following figures. The box forming machine 108 may include a drive train 108 that moves the blank 300 through the forming machine 108. To this end, the drivetrain 400 may include one or more drive mechanisms that move the blank 300 along the drivetrain 400. One or more embodiments may include different drive mechanisms, such as conveyor belts, chains, roller surfaces, rails, etc., or combinations thereof.

BE2018 / 5698 The box forming machine 108 may also include one or more arms 402, holders 404 and side panel fingers 406, each of which will be described in more detail with reference to the following figures. As shown in Figure 4, the blank 300 may enter the box forming machine 108 in a planar manner as it begins to move along the drivetrain 400. For example, as shown in Figure 4, the front panel A and associated side panels A 'are generally planar, when the blank 300 enters the box forming machine 108.

However, the side panel fingers 406 may alternately move the side panels A'-E 'up and down as the blank 300 advances on the drivetrain 400. For example, as shown in Figure 5, the side panel fingers 406 may move up and down while the drivetrain 400 advances the blank 300 such that the side panels A 'are pressed down, and the side panel fingers 406 are positioned below the side panels B'. Then, as shown in Figure 6, the side panel fingers 406 can move upward as the blank 300 advances on the drivetrain 400 to lift side panels B 'at an angle to the intermediate panel B of blank 300. Once the side panel fingers 406 return, moving upward, as shown in Figure 6, the side panel fingers 406 can be placed above side panels C '.

As described herein, alternately moving the side flaps up and down means alternating side flaps are folded up and down. In other words, one side flap is folded down and the adjacent side flap is folded up, etc. As a result, every other side flap is folded up, while the other side flaps are folded down.

When a side panel is pressed down or lifted by the side panel fingers 406, such as side panels A "and side panels B", shown in Figures 5 and 6, respectively, the panels whose side panels protrude may be stiffened. For example, because side panels B "are lifted, the intermediate panel B from which side panels B" extend is stiffened. The intermediate panel B rigidly attached to side panels B 'is less likely to bend or otherwise fail at a location other than the boundary between them because the side panels B' extending therefrom are folded and are no longer co-planar with intermediate panel B Likewise, the side panels A 'folded / bent down can stiffen the front panel A from where they extend. The same applies to the other panels A-E if the side panels A'-E 'are alternately bent up and down, as the blank 300 moves on the drivetrain 400.

The stiffening of the panels AE as the blank 300 advances on the drivetrain 400 can strengthen the panels AE and ensure that the panels AE are bent or folded at the appropriate boundary lines between adjacent panels during subsequent blank folding methods and steps of the box-forming process herein. is described. Along these lines, stiffening several panels of the plano 300 can reduce the risk of that

BE2018 / 5698 panels bend or fold along false ridges that extend over the blank 300 in places other than the boundaries between the panels.

Figure 6 illustrates an example of a false bead 112 extending over blank 300. As can be seen in Figure 6, the blank 300, which was cut from warp material 110, extends over a warp groove 112, creating a "false bead" in the blank 300. The false creases 112 of blank 300 can form weaknesses in the blank material that cause panels A-E and side panels A "-E" to bend or fold incorrectly while forming the box. However, because side panels B "are lifted at an angle by side panel fingers 406, intermediate panel B and side panels B" can be stiffened. That is, the intermediate panel B may tend to bend at the correct boundary between the adjacent panels A and C, rather than bend along the false groove 112, due to the angle of the side panels B 'to the intermediate panel B.

Likewise, as shown in Figures 5 and 6, the front panel A is stiffened in that the side panels A 'extending therefrom are bent downwardly at an angle to the front panel A. As the blank 300 advances on the drivetrain 400, the holders 404 can hold panels folded down into their flat position. For example, the holder 404 illustrated in Figure 6 includes a bottom edge that sits on top of the side panel A 'when the blank 300 advances on the drivetrain 400. In one or more embodiments, the holders 404 may be stationary. In one or more other embodiments, holders 404 may be temporarily or permanently affected to suit the needs of different blanks and panel configurations. As will be apparent from the following figures, the holders 404 may also retain the position of the side panels A'-E 'folded upwards, while the blank 300 advances on the drivetrain 400.

Figure 7 illustrates the blank 300 advanced further along the drivetrain 400 shown in Figure 6. Figure 7 illustrates side panel fingers 406 that push side panels D 'up to stiffen back panel D. As shown, side panels A "are folded down, side panels B" folded upwards, side panels C "folded downwards, side panels D" folded upwards and side panels E "may be folded downwards. In this way, the side panel fingers 406 can alternately fold the side panels A'-E 'up and down, while the holders 404 hold the positions of the side panels A'-E' either up or down (or flat), while the blank (300) moves on the drivetrain 400.

[0052] Once the side panels A'-E 'are folded to stiffen the respective panels A-E, the blank 300 can undergo several bending / folding steps to form a box. As shown in Figure 8, once the front panel A extends completely beyond the front ends of the holders 404, one or more arms 402 - over which the front panel A and the intermediate panel B have advanced - can be raised as the blank 300 moves on the

BE2018 / 5698 drivetrain 400. When the arms 402 raise the front panel A and the intermediate panel B as shown, the blank 300 can be bent along the boundary between the intermediate panel and the bottom panel C instead of the false crease 112 shown. stiffening of the panels AE, due to the up and down folded A'-E ', that any false ridges 112 which may extend transversely to the blank 300 do not adversely affect the folding steps of the box forming machine 108.

Also, as shown in Figure 8, rear panel D and adhesive lip panel D 'can be lifted / folded by one or more subsequent angled arms that can rise above drivetrain 400 from below panels D and E. Rear panel D and adhesive lip panel E lifted simultaneously with, just before or just after main panel A and intermediate panel B are lifted by arms 402.

The container, which can include top and bottom portions 404a and 404b, can hold various side panels A'-E 'in position during folding during the folding steps illustrated in Figure 8. In addition, the containers can hold the bottom panel C while the others panels A, B, D and E are lifted by arms 402 and the following angled arms. In this manner, the blank 300 is not lifted from the drivetrain 400 during the folding steps described herein.

Also, in one or more embodiments of the present invention, the leading bottom corners of the containers 404 may be shielded, or angled. In such embodiments, the arms 402 may begin to lift the front and intermediate panel A, B before the front panel A and / or intermediate panel B have advanced through the drivetrain 400 completely past the front edge of the holders 404. In such an embodiment, the beveled corner of the holders 404 can increase the speed of forming a box from the blank 300 in the box forming machine 108, since the arms may begin lifting / folding the front and intermediate panels A, B earlier than if the front and intermediate panels A, B had to be moved fully past the holders 404 before the arms 402 could begin lifting / folding the front and intermediate panels A, B.

The following angled arms mentioned above with reference to Figure 8, which lift the rear panel D and the adhesive lip panel E, are not shown because of the blank 300 mounted on the drivetrain 400. However, Figure 9 illustrates the drivetrain 400 without the blank 300 thereon, to show an embodiment of the following angled arms 900. Before the next angled arms 900 lift the back panel D and the adhesive lip panel E from the blank 300, the following angled arms 900 may be flush with or below the drivetrain 400. Figure 9 illustrates the following angled arms 900 as they begin to rise above the drivetrain 400 to lift the rear panel D and the glue lip panel E. In one or more

BE2018 / 5698 embodiments, the following angled arms 900 can extend upwardly until they are upright, as shown in Figure 10.

In one or more embodiments, the box forming machine 108 may include only one subsequent angled arm 900, or more than two subsequent angled arms 900. In addition, in one or more embodiments of the present invention, the following angled arms 900 may extend at any number of angles, depending on the shape of the box being formed and the required angle of the back panel D relative to the bottom panel C. On in this manner, Figure 11 illustrates a perspective view of a set of following angled arms 900 extending upward with a blank 300 on the drivetrain 400. As shown, the following angled arms 900 extend upwardly above the drivetrain 400 around the rear panel B and the bottom panel C bend at an angle to each other along the boundary between the panels C, D. In one or more embodiments of the present invention, the following angled arms shown can move along the drivetrain 400 with the blank 300 to form the next lower corner of the hold the box while the plano 300 is moving.

Referring to Figure 12, the box forming machine 108 may also include a spatula 1200 which extends downward to fold down the glue lip panel E as the blank advances on the drivetrain 400. The spatula can fold down the glue lip panel E at the same time as lifting the back panel D. In one or more other embodiments, the spatula 1200 can fold the adhesive lip panel down after the back panel D is lifted. Also, the spatula 1200 may include a leading edge 1202 extending transversely across the drivetrain 400. As shown in Figure 13, the leading edge 1202 of the spatula 1200, which is hidden by panel A lifted up by the arms 402, may extend and contact the boundary between front panel A and intermediate panel B As the blank 300 advances on the drivetrain 400, as shown in Figure 14, the arms 402 can continue to rise above the boundary between the front panel A and the intermediate panel B. While the arms 402 rise in this manner, the leading edge can of the spatula 1200 contact the boundary of the front panel A and the intermediate panel B, so that the front panel A bends relative to the intermediate panel B along the leading edge 1202 at that boundary.

It will also be appreciated that the curved side panels B 'extending from the intermediate panel B can also facilitate the correct folding position between the front and intermediate posts A, B. For example, as shown in Figure 14, the side panel B 'folded upwards contacts the bottom panel C and / or the side panels C' to prevent the intermediate panel B from bending even further, while the arms 402 push down on the front panel A. The same applies to the side panel D 'which extends from the rear panel D, when the rear panel D is pressed up and the glue lip panel E is pressed down by the spatula 1200, as described above. Thus, bending the side panels A'-E 'as described herein

BE2018 / 5698 also function to ensure proper bending of the blank 300 when the arms 402, the next angled arms 900 and the spatula 1200 press on the different panels A-E.

As shown in Fig. 15, as the blank advances on the drivetrain 400, the arms 402 can move along with the front panel A of the blank 300, and the front panel A against the glue lip panel E which is folded down by the spatula 1200 to press. When this happens, the spatula 1200 can be retracted between the glue lip panel E and the front panel A. In one embodiment, the spatula 1200 can retract just before the front panel A makes contact with the glue lip panel E. In another embodiment, the spatula 1200 can retract just after the front panel A makes contact with the glue lip panel E. In yet another embodiment, the spatula 1200 can retract simultaneously when the front panel A makes contact with the glue lip panel E.

As shown in Figure 15, once the front panel A has been folded down by the arms 402, the front panel A can form the top surface of a box 1500. In this way, the intermediate panel B can form a front surface of the box 1500, the bottom panel C, the bottom surface of the box 1500, and the back panel D can form the back surface of the box 1500.

As also shown in Figure 15, the box forming machine 108 may include a leading angled arm 1502. Once the front panel A has been pushed down to form the top surface of the box 1500, the leading angled arm 1502 can extend downwardly and contact the top surface and the front surface of the box 1500. Accordingly, in one embodiment, the leading angled arm arm 1502 includes a first component 1502a configured to contact the top surface and a second component 1502b configured to contact the front surface. In the illustrated embodiment, which shows a rectangular box 1500 formed from the blank 300, the first and second components 1502a and 1502b are arranged at an angle of 90 degrees to each other. In such an embodiment, the leading angled arm 1502 can retain the leading top corner of the box 1500 at an angle of 90 degrees as the blank advances on the drivetrain 400.

However, it will be appreciated that the first and second components of the leading angled arm 1502 may be placed at various angles to one another depending on the shape of the box being formed. For example, in one or more embodiments, the box forming machine 108 may form boxes that are not rectangular in shape. In such embodiments, the leading angled arm 1502 may have first and second components 1502a, 1502b angled greater or less than 90 degrees from each other. In addition, while the embodiment illustrated in the figures is one leading angled

BE2018 / 5698 arm 1502, one or more other embodiments of the box forming machine 108 may include more than one leading angled arm 1502.

Similarly, as discussed above, the following angled arms 900 may extend vertically upwardly from the drivetrain 400 to hold the next bottom corner of the box 1500 at a 90 degree angle as the blank 300 advances on the drivetrain 400. However, as with the leading angled arm 1502, the following angled arms 900 may be positioned at angles other than 90 degrees from the drivetrain 400 to form corners of boxes other than the rectangular boxes.

The box forming machine 108 may also include top and bottom side arms arranged to fold the remaining side panels of the blank 300 to form right and left side surfaces of the box 1500. Figures 16 and 17 illustrate top and bottom side arms 1600, 1700, respectively. The top side arm 1600 can move down while in contact with the side panel A 'extending from the front panel A to fold the side panel A' down to form at least a portion of the right surface of the box 1500. Likewise, the bottom side arm 1700 of the box forming machine 108 may extend upwardly while in contact with the side panel C 'extending from the bottom panel C to fold the side panel C' to at least a portion of the right surface of the box 1500. Likewise, opposite top and bottom side arms 1600, 1700 can form the left surface of the box 1500 by correspondingly folding different side panels to form the left surface of the box 1500.

It will be appreciated that during several folding steps described herein, one or more methods can be provided to adhere the different panels together while the box 1500 is being formed. For example, in one or more embodiments, the box forming machine 108 may include the step of applying glue or other adhesive material to the glue lip panel E. Additionally or alternatively, the box forming machine 108 may include means for applying glue or other adhesive material to at least a portion of the front panel A. In such embodiments, the front panel A and the glue lip panel E may adhere together when brought into contact.

Likewise, one or more embodiments of the box forming machine 104 of the present invention may include means for applying glue or other adhesive material to the various side panels that form the left and right surfaces of the box 1500. In this manner, the box can remain intact after the blank panels of the blank are bent / folded in position along the drive train 400 of the box forming machine 108, as described herein.

It will be appreciated that the different components of the box forming machine 108 described herein may include components, shapes and configurations, or be placed at different angles or distances from one another, other than those

BE2018 / 5698 are described herein, while their own functions described herein are retained. For example, the arms 1402 extending transversely of the drivetrain 400 are illustrated as elongated, rectangular bars. However, one or more other embodiments of the arms 402 may include one or more rod-shaped bars, flat plates, or irregularly shaped components.

Also, for example, while the arms 402 are illustrated as extending transversely perpendicularly over the drivetrain 400, one or more embodiments may include arms 402 extending over the drivetrain 400 in a non-perpendicular manner.

Also, for example, while the present invention illustrates the side panel fingers 406 as comprising substantially circular bars that are tapered toward its rear end, one or more other embodiments may include side panel fingers 406 of other shapes and / or sizes. For example, the side panel fingers in one or more other embodiments may include rectangular bars, plates, or other irregularly shaped components capable of performing the same functions described herein.

Also, for example, the drivetrain, spatula, subsequent angled arms, leading angled arms and holders of the present invention may include shapes and components other than those described herein, or positioned at angles other than shown. These components of other embodiments can perform the same functions as those described herein.

For example, the spatula 1200 and leading angled arms 1502 are illustrated as extending downward from the top of the drivetrain 400. In one or more embodiments, the spatula 1200 and / or the leading angled arms 1502 may extend from below or to the side of the drivetrain 400 to perform their described functions. Also, the spatula 1200 and / or the leading angled arms 1502 may, for example, extend at an angle to the drivetrain 400 instead of parallel in the longitudinal direction of the drivetrain 400, as shown herein.

It will also be appreciated that the different steps and folding processes performed by the box forming machine 108 described herein may vary in other embodiments. Again, the blank 300 shown here for illustrative purposes can be changed to form boxes of various other shapes and sizes. Accordingly, the steps, folding processes, and the order in which these steps are performed can be rearranged, modified, or abolished in one or more other embodiments of the present invention.

For example, in one or more embodiments, the blank 300 may not include a glue lip panel E. In such an embodiment, the box forming machine 108 may or may not include a spatula as described herein. The box formed by the box-forming machine can also be used

BE2018 / 5698

108, for example, in one or more embodiments of the present invention, are an open box with one or more open surfaces. In such an embodiment, the box forming machine 108 may or may not include one or more top and bottom side arms to form left or right surfaces of the box. For example, in such an embodiment, the box forming machine 108 may or may not bring a front panel over the top of the one or more goods to form an open top of the box 1500.

It will be understood that changing the order, number and types of folding steps and methods described herein may enable a manufacturer and / or distributor to form any number of box shapes and sizes. These different box shapes and sizes can be modified, designed and adapted to package any number of product shapes and sizes to be packed in the box. Accordingly, the box forming machines of the present invention are arranged to form custom boxes that fit around products without wasted box material or added packaging materials. In addition, box forming machines of the present invention are arranged to form such boxes without chain beads (or "false beads") that adversely affect the box forming steps and / or methods described herein. As such, the methods, processes and apparatus described herein can successfully form custom boxes from generic chain material with chain beads.

The present invention can be embodied in other specific forms without departing from its spirit or essential features. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is therefore indicated by the appended claims rather than by the foregoing description. Any changes that fall within the meaning and range of equivalence of the claims should be included within its scope.

Claims (30)

Conclusions A method of forming a carton from a blank (300), the method comprising: providing a blank (300) on a drivetrain (400), the blank comprising: a plurality of panels (A, B, C, D), including a front panel (A), an intermediate panel (B), a bottom panel (C) and a rear panel (D); and a number of side panels (A ', B', C ', D') extending transversely to the drivetrain, each panel (A, B, C, D) connected to two opposite side panels (A ', B ', C', D '); an adhesive lip (E) with or without connected side panels (E '); positioning one or more goods on the bottom panel (C); advancing the blank (300) on the drivetrain (400); alternately folding the side panels (A ', C') downward and the side panels (B ', D') upward as the blank (300) moves on the drivetrain (400) so that the panels (A, B , C, D) from which each folded side panel (A ', B', C ', D') extends are stiffened; and holding the side panels (B ', D') that are folded upward as the blank advances on the drivetrain (400). The method of claim 1, further comprising lifting the back panel (D) upward to form a back surface of the box. The method of claim 2, further comprising: holding the back panel (D) at a first angle to the bottom panel (C) to hold another bottom corner of the box while the blank (300) advances on the drivetrain (400). The method of claim 3, further comprising: lifting the front panel (A) and the intermediate panel (B) up and over the one or more goods to form an upper surface and a front surface of the box, respectively, so that the front panel (A) comes into contact with a glue lip (E ) extending from the rear panel (D) while the blank (300) moves on the drivetrain (400); and wherein the front panel (A) is held at a second angle to the intermediate panel (B) to hold a next top corner of the box while the blank (300) advances on the drivetrain (400). BE2018 / 5698 The method of claim 4, further comprising holding the bottom panel (C) down while the front panel (A) and the intermediate panel (B) are folded up over the one or more goods. The method of claim 4, further comprising retaining the bottom panel (C) while lifting the back panel (D) to form the back surface of the box. The method of claim 4, wherein a horizontally extending spatula (1200) folds the adhesive strip (E) down and a leading edge of the spatula (1200) engages a boundary between the front panel (A) and the intermediate panel (B) so that the front panel (A) relative to the intermediate panel (B) at the boundary bends during the raising and raising of the front panel (A) and the intermediate panel (B) over the one or more goods. The method of claim 4, further comprising folding the side panels (A ', B', C ', D') to form left and right surfaces of the box as the blank (300) advances on the drivetrain (400 ). The method of claim 4, wherein the side panels (B ', D') that are folded are held in position with a holder (404). The method of claim 9, wherein a leading bottom corner of the container (404) is chamfered. The method of claim 10, wherein the front panel (A) and the intermediate panel (B) begin to be lifted and over the one or more goods before the intermediate panel (B) has completely passed a leading edge of the container (404) when the blank (300) moves on the drivetrain (400). The method of claim 9, wherein the container (404) is stationary while the blank (300) advances on the drivetrain (400). The method of claim 1, wherein the side panels (A ', B', C ', D') are alternately folded up and down by one or more fingers (406) moving up and down while the blank ( 300) advances on the drivetrain (400). BE2018 / 5698 The method of claim 1, wherein one or more fingers (406) extend between the side panels (A ', B', C ', D') as the blank (300) advances on the drivetrain (400). A method of forming a box from chain material, the method comprising: forming a blank (300) from warp material, the warp material comprising warp grooves, the blank (300) having at least one false groove (112) extending transversely across the blank (300); longitudinally advancing the blank (300) along a drivetrain (400), the blank (300) comprising: a plurality of panels (A, B, C, D) comprising a front panel (A), an intermediate panel (B), a bottom panel (C) and a rear panel (D); and a plurality of side panels (A ', B', C ', D') extending transversely to the drivetrain (400), each panel (A, B, C, D) connected to opposite side panels (A ' , B ', C', D '); an adhesive lip (E) with or without connected side panels (E '); alternately folding the side panels (A ', C') downward and the side panels (B ', D') upward as the blank (300) moves on the drivetrain (400) so that the panels (A, B, C, D) from which each folded side panel (A ', B', C ', D') extends are stiffened; and holding the side panels (B ', D') that are folded upward while the blank (300) moves on the drivetrain (400). The method of claim 15, further comprising folding the front panel (A) and the intermediate panel (B) up and over the bottom panel (C) to form a top and front surface of the box, respectively. The method of claim 15, further comprising folding the back panel (D) upward and holding the back panel (D) at an angle to the bottom panel (C) to form a further bottom corner of a box. The method of claim 17, further comprising pushing a glue lip (E) with a spatula (1200) extending from the rear panel (D), the spatula (1200) comprising a front edge contacting a boundary between the front panel (A) and intermediate panel (B) when the intermediate panel (B) and front panel (A) are folded up and over the bottom panel (C) to form a front and top surface of a box, respectively. BE2018 / 5698 The method of claim 15, further comprising holding the side panels (A, B, C, D) as the blank (300) advances on the drivetrain (400) after the side panels (A ', B', C ', D are folded up and down in an alternating manner. The method of claim 19, further comprising holding the bottom panel (C) down when the front panel (A), the intermediate panel (B) and the rear panel (D) are folded around the top, front and back surfaces of form the box. A box forming machine (100) comprising: a longitudinal drive train (400) and a drive mechanism that moves a blank (300) longitudinally on the drive train (400); one or more fingers (406) disposed adjacent to the drivetrain (400), the one or more fingers (406) adapted to move up and down about side panels (A ', C') of the blank (300) and side panels (B ', D') alternately bend upward as the blank (300) advances on the drivetrain (400); one or more holders (404) positioned forward of the one or more fingers (406), the one or more holders (404) positioned so that the side panels (B ', D') of the blank (300) held in place by the one or more holders (404) as the blank (300) advances on the drivetrain (400). The box forming machine according to claim 21, further comprising one or more subsequent angled arms (900) placed on the drivetrain (400). The box forming machine according to claim 22, wherein the one or more succeeding angled arms (900) have a downward position and an elevated position, the one or more succeeding angled arms (900) in an elevated position an angle of a further bottom corner of hold a box made of the blank (300) while the blank (300) moves on the drivetrain (400). The box forming machine of claim 21, further comprising one or more leading angled arms (1502) located at least partially above the drivetrain (400). The box forming machine according to claim 24, wherein the one or more leading angled arms (1502) are arranged to retain an angle of a leading top corner of a box formed from the blank (300) as the blank (300) advances on the drivetrain (400). BE2018 / 5698 The box forming machine according to claim 21, further comprising a spatula (1200) with a leading edge that is directed forward in the longitudinal direction of the drivetrain (400). The box-forming machine according to claim 26, wherein at least a portion of the spatula 5 (1200) includes a surface parallel to the drivetrain (400). The box forming machine according to claim 26, wherein at least a portion of the spatula (1200) is positioned above the drive train (400). 10 The box forming machine according to claim 21, wherein the one or more fingers (406) each include an elongated part that is tapered to a rear end thereof. The box forming machine of claim 29, wherein the elongated member of each of the one or more fingers (406) is positioned parallel to the drivetrain in the longitudinal direction of the drivetrain.