BE1027638B1 - Packaging machine feeding, separating, and folding mechanisms - Google Patents

Abstract

A machine for packaging one or more articles comprising a supply system that can supply multiple feeds of sheet material into the machine without moving the supply system or forming creases or bends in the sheet material. The machine also includes a separation system with a cutting table and multiple angled blades that cut the sheet material into lengths that can be made into blanks. The machine also includes a creasing system with a creasing roller that creates transverse creases in the sheet material as the sheet material moves through the machine.

Description

Packaging machine feeding, separating and folding mechanisms

BACKGROUND OF THE INVENTION

1. Field of the invention

Exemplary embodiments of the invention pertain to systems, methods and apparatus for packaging articles in boxes. Specifically, exemplary embodiments relate to packaging machine mechanisms that feed sheet material to the packaging machine, separate the sheet material into lengths used to make blanks, and crease the sheet material to make blanks.

2. State of the art

Transportation and packaging industries often use equipment for processing cardboard and other sheet material that converts sheet material into blanks. An advantage of such equipment is that a shipper can make boxes of required dimensions as needed instead of keeping a stock of standard, pre-made boxes of various sizes. Accordingly, the dispatcher can eliminate the need to predict his requirement for particular carton sizes as well as the need to stock pre-made standard size cartons. Instead, the shipper can store one or more bales of chain material, which can be used to generate a variety of carton sizes based on the specific carton sizes required at the time of each shipment. This allows the shipper to reduce the storage space normally required for periodically used shipping supplies, as well as reduce the waste and costs associated with the inherently inaccurate process of predicting the required carton sizes, as the items shipped and their respective sizes over time to time may vary.

In addition to reducing the inefficiencies associated with storing pre-made boxes of various sizes, making custom sized boxes also reduces packaging and shipping costs. In the packaging industry, it is estimated that shipped items are usually packed in boxes that are approximately 65% larger than the shipped items. Boxes that are too large for a particular item are more expensive than a box that is custom made for the item because of the cost of the excess material used to make the larger box. When an item is packed in an oversized box, filling material (e.g. Styrofoam, foam peanuts, paper, air cushion, etc.) is often placed in the box to prevent the item from moving in the box and to prevent the box from collapsing when a pressure is exerted (for example when boxes are applied or stacked). These filler materials further increase the cost associated with packaging an item in an oversized box.

Custom sized boxes also reduce shipping costs associated with shipping items as compared to shipping the items in the oversized boxes. A shipping vehicle filled with boxes that are 65% larger than the packaged items is much less cost-efficient to operate than a shipping vehicle filled with boxes adapted to the packaged items. In other words, a shipping vehicle filled with custom sized packages can carry a significantly greater number of packages, which can reduce the number of shipping vehicles required to ship the same number of items. Accordingly, in addition to or as an alternative to calculating shipping costs based on the weight of a package, shipping prices are often affected by the size of the package shipped. Thus, reducing the size of an item's package can reduce the cost of shipping the item. Even when shipping costs are not calculated based on the dimensions of the packages (for example, only the weight of the packages), using custom sized packages can reduce the shipping costs because the smaller, custom packages will weigh less than the ones to be large packages due to the use of less packaging and filling material.

While sheet material handling machines and related equipment can potentially alleviate the inconveniences associated with stocking standard shipping supplies and reduce the amount of space required to store such shipping supplies, prior art machines and related equipment have various cons. For example, prior art systems are primarily concerned with making boxes and sealing boxes once they are filled. Such systems require the use of several separate machines and considerable manual labor. For example, a typical box forming system includes a converting machine that cuts, notches, and / or creases sheet material to form a blank. After the blank is formed, an operator removes the blank from the forming machine and a fabrication connection is made in the blank. A fabrication joint is located where two opposite ends of the blank are attached together. This can be done manually and / or with additional machines. For example, an operator can apply glue (for example, with a Glue Gun) to one end of the blank and can fold the blank to join the opposite ends together with the glue between them. Alternatively, the operator can at least partially fold the blank and apply the blank in a gluing machine that applies glue to one end of the blank and joins the two opposite ends.

In both cases, significant operator involvement is required. In addition, the use of a separate gluing machine makes the system wrapped and the overall system can be significantly enlarged.

Once the manufacturer joint has been made, the blank can be partially erected and bottom flaps of the blank can be folded and secured to form a bottom surface of a carton. Again, typically an operator has to erect the box. The bottom flaps can be folded and secured manually by the operator or with additional machines. Then an operator places the item (s) to be packaged in the box and the top flaps are folded and secured.

While some efforts have been made to manufacture individual packaging machines that manufacture blanks and erect and seal the blank around the packaging item (s), there remains room for improvement in packaging machines and related methods.

BRIEF SUMMARY

Exemplary embodiments of the invention pertain to systems, methods and apparatus for packaging articles in boxes. Specifically, exemplary embodiments relate to packaging machine mechanisms that feed sheet material to the packaging machine, separate the sheet material into lengths used to make blanks, and crease and cut the sheet material to make blanks.

For example, one embodiment of a packaging machine used to convert substantially rigid sheet material into blanks for assembly into boxes or other packages includes a supply system. The supply system directs a first supply of the sheet material and a second supply of the sheet material to the packaging machine. The feeding system includes a low friction first surface and a related first advancement mechanism. The first advancement mechanism is configured to engage the first feed of the sheet material along the first low friction surface and advance it to the packaging machine. A second low friction surface and related second advancement mechanism is also provided. The second advancement mechanism is configured to engage the second feed of the sheet material along the second low friction surface and advance it to the packaging machine. The first low friction surface and the second low friction surface form an acute angle adapted to allow the sheet material to be advanced to the packaging machine without creating any folds or creases in the sheet material. The forming machine also includes one or more forming tools arranged to perform one or more forming functions on the sheet material as the sheet material advances through the packaging machine, the one or more forming functions being selected from the group consisting of creasing, bending, folding, perforating, cutting and notching to make the blanks.

In another embodiment, a packaging machine used to convert substantially rigid sheet material into blanks for assembly in boxes or other packages includes a separation system that separates the sheet material into length for use in making the blanks. The separation system includes a cutting table with a cutting edge, a first knife, and a second knife. The first knife has a mounted end, a freely protruded and a first knife edge extending at least partially therebetween. The first knife edge is angled relative to the cutting edge of the cutting table to create a point of contact between the first knife edge and the cutting edge of the cutting table when the first knife is moved from an elevated position to a lowered position. The second knife has a mounted end, a free end, and a second knife edge extending at least partially therebetween. The second knife edge is angled with respect to the cutting edge of the cutting table to create a contact point between the second knife edge and the cutting edge of the cutting table when the second knife is moved between a raised position and a lowered position. The free ends of the first and second knives are placed side by side near a center of the sheet material. The mounted ends of the first and second knives are disposed adjacent to opposite sides of the sheet material.

In another embodiment, a packaging machine used to convert substantially rigid sheet material into blanks for assembly in boxes or other packages includes a creasing system that forms transverse creases in the sheet material. The transverse ridges are directed across the sheet material and transverse to the length of the sheet material. The creasing system includes a backing plate that supports the sheet material, a first creasing roll, and a second creasing roll. The first creasing roll is directed over the sheet material and transverse to the length of the sheet material. The first creasing roll has a first creasing cam extending radially from the first creasing roll. The first creasing roll is oriented to rotate so that the first creasing cam engages the sheet material to form a crease in the sheet material. The second creasing roll is directed across the sheet material and transverse to the length of the sheet material. The second creasing roll has a second creasing cam extending radially from the second creasing roll. The second creasing roll is arranged to rotate so that the second creasing cam engages the sheet material to form a score in the sheet material. The first and second creasing roll are placed next to each other and are independently controllable.

These and other objects and features of the present disclosure will become fully apparent from the following description and appended claims, or may be learned by the practice of the disclosure set forth below.

BRIEF DESCRIPTION OF THE FIGURES

[00013] In order 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 illustrated in the accompanying figures. it is to be understood that these drawings represent only illustrated embodiments of the invention and are therefore not to be construed as limiting its scope. The invention will be described and illustrated with additional specificity and details using the accompanying figures, wherein:

Figure 1 illustrates an example of a packaging machine used for packaging articles.

Figures 2-4 illustrate different cross-sections of a feeding system of the packaging machine of Figure 1.

Figures 5 and 6 illustrate side and top views of a separating mechanism of the packaging machine of Figure 1.

Figure 7 illustrates a blank formed with the packaging machine of Figure 1.

Figure 8 illustrates a dual roll creasing mechanism of the packaging machine of Figure 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The embodiments described herein generally relate to systems, methods, and devices for packaging article (s) in boxes. More specifically, the described embodiments relate to packaging machine mechanisms that feed sheet material into the packaging machine, separate the sheet material into lengths used to make blanks, and form creases in the sheet material to make blanks therefrom.

While the present description will be described in detail with reference to specific configurations, the descriptions are merely illustrative and should not be construed as limiting the scope of the present description. Various modifications can be made to the illustrated configurations without departing from the spirit and scope of the invention as defined by the claims. For a better understanding, the same components are indicated with the same reference numbers in the various accompanying figures.

Throughout the specification and claims, components are described as being in specific orientations or relative positions. Such descriptions are used for convenience only and are not intended to limit the invention. For example, a component can be described as being above or below another component. However, it will be appreciated that the machines, the system, and the mechanisms in some embodiments may be oriented in other ways. As a result, a component described as being above another component may in some embodiments be placed below or to the side of the other component. In some instances, a component described as being positioned between "above" or "below" another component may be understood as being positioned on one or another side of sheet material being converted into blanks.

As used herein, the term "blank" will refer to a substantially flat material that can be folded into a box-like shape. Blankets can be made from a stock of sheet material (e.g. thick paper, corrugated board, cardboard, etc.). In some cases, the sheet material is a warp material that is folded back and forth to form a bale. A blank can have notches, cuts, separations and / or ridges that allow the blank to be bent and / or folded into a box. In addition, a blank can be made from any suitable material, well known to those of skill in the art. For example, cardboard or corrugated cardboard can be used as the blank material. A suitable material can also be of any thickness or weight that allows bending and / or creasing into a box-like shape.

Figure 1 illustrates an example of a packaging machine 100 used to manufacture and dispose blanks around items to be packaged. In the illustrated embodiment, articles are delivered to the machine 100 for packaging via conveyor 102. The dimensions of the articles can be obtained while the article (s) are being placed on or before the conveyor belt 102.

In any event, the article (s) is / are advanced in the packaging machine 100 on the conveyor belt 102. The packaging machine 100 makes a blank that is tailored for the article or articles from the sheet material 104. The packaging machine 100 folds and secures the blank around the article or articles. The packaged article or articles are then advanced from the packaging machine 100 onto another conveyor belt 106.

FEED MECHANISM

A common challenge in packaging machines is supplying the sheet material to the machine. For example, the feed mechanisms of some packaging machines create creases or folds as the sheet material is fed to the packaging machine. The creases or folds can cause problems as the sheet material passes through the packaging machine. For example, the creases or folds can cause the packaging material to be caught or clamped in the packaging machine. The creases or creases can also cause the packaging machine to form desired folds and / or cuts in the sheet material at undesired locations in the sheet material.

In the illustrated output format, the packaging machine includes a feed mechanism 108 that is configured to supply multiple streams or feeds of sheet material to the forming machine 100 without creating unwanted creases or folds in the sheet material. In addition, the feed mechanism 108 does not require a cassette changer that moves up or down to feed sheet material from different streams of sheet material into the packaging machine 100.

The feed mechanism 108 is illustrated in Figures 2-4. In some embodiments, as shown in Figure 2, the feed mechanism 108 includes a first track 110 that directs a first supply 112 of sheet material 104 to a first end of the packaging machine 100 and a second track 114 that directs a second supply 116 of sheet material 114 to a first end of the packaging machine 100. The first track 110 and the second track 114 may each include a substantially planar surface on which to advance the respective supply of sheet material. In addition, the first track 110 and the second track 114 may include guides 118, 120 that help the first and second feeders 112, 116 to lay the sheet material 104 substantially flat on the planar surface of the track 110, 114, respectively. In some embodiments, the guides 118, 120 may pivot and include one or more wheels that engage the first and second supplies 112, 116 of sheet material 104.

As best seen in Figures 3 and 4, the feed system 108 also includes a low friction first surface 122 and an associated first propulsion mechanism.

124. The first low friction surface 122 is substantially aligned with the planar surface of track 110. The first advancement mechanism 124 is positioned and configured to engage and advance the first feed 112 of sheet material 104 along the first low friction surface 122. to move. More specifically, the first advancement mechanism 124 may include one or more rollers, brake discs, and / or belts that can rotate and engage the first feed 112. The first advancement mechanism 124 may be located at a distance equal to or less than the thickness of the first feed 112 from the first low friction surface 122. The first low friction surface 122 acts as a support site for the first feed 112 and engagement of the first advancement mechanism 124 with the first feed 112 causes the first feed 112 to advance along the first low friction surface 122 and onto the packaging machine 100.

The delivery system 108 also includes a second low friction surface 126 and the related advancement mechanism 128. The second low friction surface 126 is generally aligned with the planar surface of track 114. The second advancement mechanism 128 is disposed and arranged to engage and advance the second supply 116 of sheet material 104 along the second low friction surface 126. More specifically, the second advancement mechanism 128 may include one or more pulleys and related belts that can rotate and engage the second feed 116. The second advancement mechanism 128 may be located at a distance equal to or less than 1s than the thickness of the second feed 116 from the second low friction surface 126. The second low friction surface 126 acts as a backing plate for the second feed 116 and engagement of the second advancement mechanism 128 with the second feed 116 causes the second feed 116 to advance along a second low friction surface 126 and onto the packaging machine 100.

In some embodiments, the first and second advancement mechanisms 124, 128 are activated independently of each other. For example, either the first advancement mechanism 124 may be activated to advance the first feed 112 to the conversion machine 100, or the second advancement mechanism 128 may be activated to advance the second feed 114 to the conversion machine 100. In such an embodiment, sheet material 104 is advanced from only one of the first supplies 112 and the second supplies 114 to the forming machine 100 at a time. This makes it possible to produce a desired type of sheet material 104 (e.g., size, thickness, strength, etc.) as needed and advancing to the packaging machine 100.

As seen in Figures 3 and 4, the first low friction surface 122 and the second low friction surface 126 form an acute angle to each other. In the illustrated embodiment, the vertex of the corner is formed by the second ends of the first and second low friction surfaces 122, 126. The first ends of the first and second low friction surfaces 122, 126 are closer to a first end. of the packaging machine 100 where the sheet material 104 enters the forming machine 100 and the second ends thereof are located closer to an opposite second part of the forming machine 100. The angle is small enough to allow the sheet material 104 to be advanced in the forming machine 100 without creating any folds or creases in the sheet material. For example, in some embodiments, the angle is less than about 15 °, 12.5 °, 10 °, 7.5 °, 5 °, 3 °, or 2 °. The relatively small angle directs the sheet material 104 such that as the sheet material 104 advances towards tracks 130 of the packaging machine 100, the sheet material 104 does not bend enough to create an undesired crease or crease. In addition, the relatively small angle allows either the feed 112, 114 of the sheet material 104 to be advanced to the packaging machine 100 without requiring adjustment, repositioning, or reorientation of the feed mechanism 108.

While the first and second low friction surfaces 122, 126 form the corner, the specific configuration of how the corner formed may differ between embodiments. For example, in the illustrated output shape, the second low friction surface 126 is substantially parallel to the horizontal direction and / or a direction of feed of the sheet material 104 through the packaging machine 100, while the first low friction surface 122 faces upward from the second. low friction surface 126 (and the horizontal direction and / or the feed direction of the sheet material 104 through the packaging machine 100). In other words, the first end of the first low friction surface 122 is further from the second low friction surface 126 than the second end of the first low friction surface 122.

In other embodiments, however, the first low friction surface 122 may be substantially parallel to the horizontal direction and / or the feed direction of the sheet material 104 through the packaging machine 100 and the second low friction surface 126 may face downward. with respect to the first low friction surface 122 (and the horizontal alignment and / or the feed direction of the sheet material 104 through the packaging machine 100). In still other embodiments, both the first and second low friction surfaces 122, 126 may be angled relative to the horizontal direction and / or the feed direction of the sheet material 104 through the packaging machine 100. For example, the low friction first surface may be applied. friction 122 may be upward from the horizontal direction and / or the feed direction of the sheet material 104 by the packaging machine 100 and the second low friction surface may be downward from the horizontal direction and / or the feed direction of the sheet material 104 through the packaging machine 100.

In some instances, the first and second low friction surfaces 122, 126 may be angled away from the horizontal direction and / or the feed direction of the sheet material 104 through the packaging machine 100 of equal and opposite magnitude (+2 , 5 ° and -2.5 °). In other instances, the first and second low friction surfaces 122, 126 may be angled away from the horizontal and / or feeding direction of the sheet material 104 by the packaging machine 100 of different sizes (+ 3.5 ° and -1.5 °). ).

In still other embodiments, the first and second low friction surfaces 122, 126 may be oriented substantially parallel to each other. In such a case, the first and second low friction surfaces 122, 126 may be spaced sufficiently apart to allow the sheet material to be advanced to the packaging machine without any folds or creases in the sheet material and with limited or no repositioning of the supply system. In some instances, the first and second low friction surfaces 122, 126 are spaced about 4 inches or less, about 3 inches or less, about 2.5 inches or less, about 2 inches or less, about 1.5 mch or less, about 1 inch or less, about 0.75 inch or less, about 0.5 inch or less, about 0.25 inch or less, spaced about 0.1 inch or less apart.

It will be appreciated that other aspects of the first or second low friction surface 122, 126 may vary from one embodiment to the next. For example, in the illustrated embodiment, the first and second low friction surfaces 122, 126 are formed of separate components that are joined together. However, in other embodiments, a single component may be formed with the first and second low friction surfaces 122, 126 disposed on opposite sides thereof.

Regardless of the specific orientations of the first and second low friction surfaces 122, 126, the first and second advancement mechanisms 124, 128 may be oriented to engage the first and second feeds 112, 114, respectively, to provide the first and advance second feeds 112, 114 along the first and second low friction surfaces 122, 126. For example, as shown in Figures 3 and 4, the orientation of the advancement mechanism 124 substantially corresponds to the orientation of the first low-friction surface 122, and the orientation of the second advancement mechanism 128 substantially corresponds to the orientation of the second surface at low friction 126.

Furthermore, as can be seen in the figures, the first advancement mechanism 124 is positioned above the first low friction surface 122. In addition, the second low friction surface 126 is positioned below the first low friction surface 122.

As a result, the second low friction surface 126 and the first advancement mechanism 124 are positioned on either side of the first low friction surface 122. Similarly, the second advancement mechanism 128 is positioned below the second low friction surface 126. This has as a result, the second advancement mechanism 128 and the first low friction surface 122 are positioned on opposite sides of the second low friction surface 126.

SEPARATION MECHANISM

Once the sheet material 104 is advanced into the packaging machine 100, the sheet material 104 must be cut or separated into lengths that can be used to form individual blanks. Rolling knives are mostly used for cutting the sheet material. An advantage of rolling knives is their reliability. However, a disadvantage of rolling knives is that the cutting speed is relatively low because the rolling knives have to move across the sheet material to make the cuts. Due to the slow cutting speed of rotary cutters, the throughput of packaging machines containing them is lower than desired.

Figures 5 and 6 illustrate side and top views of a separation mechanism 140 that can be used to separate the sheet material 104 into blanks lengths. The separating mechanism 140 includes knives that cut the sheet material 104 by performing an upward and downward cutting motion. As used herein, "upward and downward cutting motion" is not limited to motions within a vertical plane. Instead, "upward and downward cutting motion" generally refers to the knives that move toward and away from the sheet material 104 to make a cut therein. Thus, therein, the movement of the knives through diagonal and / or horizontal planes can be regarded as upward and downward cutting movements, as long as the knives move towards and away from the sheet material 104 being cut. The upward and downward cutting movement of the knives is also referred to here as moving the knives between non-activated and activated positions.

An upward and downward cutting motion is advantageous because it is easily controllable. Another advantage is that an up and down movement can be very short and less time consuming compared to rotary cutters. Furthermore, the upward and downward cutting movement is performed relative to a cutting table. The cutting table is an element that serves to support the sheet material while the knives perform the cutting movement. As a result, the sheet material will not move undesirably during the cutting movement of the knives. The cutting table also serves as a counter knife to the knives. This means that the cutting table can execute a drawing force on the force that the knives execute on the sheet material. As a result, the sheet material will not move with the downward movement of the knives.

With more specific reference to Figure 5, the separation mechanism 140 is illustrated in a view. As can be seen, the separation mechanism 140 includes a cutting table

142. The cutting table 142 has a top surface that supports the sheet material 104 after the sheet material has advanced past the feed mechanism 108. The cutting table 142 also includes a cutting edge 144, which, as discussed in more detail below, aids in cutting the sheet material 104.

The separating mechanism 140 also includes first and second knives 146, 148. The first knife 146 has a mounted end 150, a free end 152, and a first knife edge 154 extending at least partially therebetween. Likewise, the second knife 148 has a mounted end 156, a free end 158, and a second knife edge 160 extending at least partially therebetween. The free ends 152, 158 of the first and second knives 146, 148 are positioned adjacent to each other above the sheet material 104. For example, in some embodiments, the free ends 152, 158 of the first and second knives 146, 148 are spaced apart. less than 1 inch, 0.75 inch, 0.5 inch, 0.25 inch, or 0.1 inch apart. Furthermore, in some embodiments, the free ends 152, 158 are disposed generally above the center of the sheet material 104. The mounted ends 150, 156 of the first and second knives 146, 148 are positioned adjacent opposite sides of the sheet material 104.

The mounted exits 150, 156 of the first and second knives 146, 148 are respectively connected to tracks 162, 164. The connections between mounted ends 150, 156 and tracks 162, 164 are movable so that the first and second knives 146, 148 can be moved up and down or moved towards and away from the sheet material 104. In addition, the first and second blades 146, 148 are related to one or more actuators 166 (e.g., motor, spring, cylinder, etc.) to move the blades 146, 148 between the raised and lowered positions (also considered here as the non-operating activated and activated positions). In certain embodiments, the one or more actuators 166 associated with the knives 146, 148 simultaneously move the first and second knives 146, 148 between the inactivated and the activated positions. In other embodiments, the one or more actuators 166 and the first and second knives 146, 148 can be moved independently of each other between the non-activated and the activated positions.

The cutting edge 144 of the cutting table 142 and the first and second knives 146, 148 may be arranged to cooperate to cut the sheet material 104. For example, the first and second knives 146, 148 may be sized, shaped, positioned and / or oriented with respect to the cutting edge to allow the cutting edge 144 and the first and second knife edges 154, 160 to efficiently cut the sheet material when the first and second knives 146, 148 are moved from the inactivated position to the activated position.

For example, the first and second knife edges 154, 160 may each be at an angle to the cutting edge 144 of the cutting table 142 to create a point of contact between the first knife edge 154 and the cutting edge 144 and between the second knife edge 160 and the cutting edge. cutting edge 144. Specifically, the cutting edge 144 of the cutting table 142 is in a plane and the first and second knife edges 154, 160 may be angled towards and / or across the plane of the cutting edge 144. In some embodiments, the first knife edge 154 at an angle to cutting edge 144 of the cutting table 142, so that the mounted end 150 of the first knife 146 is disposed on a first side of the plane and the free end 152 of the first knife 146 is disposed on a second side of the flat. Likewise, the second knife edge 160 may be at an angle to the cutting edge 144 of the cutting table 142 so that the mounted end 156 of the second knife 148 is placed on the first side of the plane and the free end 158 on the second side of the plane. the plane is placed.

In some embodiments, the separator mechanism 140 includes a pressure element associated with each of the first and second knives 146, 148 to press or hold the first and second knives 146, 148 against the cutting edge 144. For example, Figure 6 illustrates a top view of the first blade 146. As can be seen, the mounted end 150 of the first blade 146 can be mounted (pivotally or at an angle) so that the first blade 146 is inclined in the direction of the blade. cutting edge 144. In addition, a pressure element 168 applies a force to the first knife 144 to ensure that the first knife 146 hits the cutting edge 144 with sufficient force so that the first knife 146 and the cutting edge 144 can cut the sheet material 104. Furthermore, the pressure element 168 ensures that the single moving point of contact between the first knife 154 and the cutting edge 144 is consistent even when the edges are not all perfectly straight. As a result, the pressure element 168 reduces the need for expensive tolerances in the components. The second knife 148 may include a similar pressure element. The pressure elements can include springs, cylinders, motors, etc.

In addition to having the first and second knives 146, 148 angled toward the cutting edge 144 (e.g., the free ends 152, 158 are placed closer to the cutting edge 144 than the mounted ends 150, 156), the first and second knives also taper from the mounted ends 150, 156 toward the free ends 152, 158 so that the first and second knife edges 154, 160 are angled in two directions with respect to the cutting edge 144 of the cutting table 142. For example, the first knife edge 154 has a first end adjacent the mounted end 150 and a second end adjacent the free end 152, and the second protruded end is vertically positioned higher than the first end. In other words, the first knife 146 has a non-cutting edge opposite the first knife edge 154 and the second end of the first knife edge is positioned closer to the non-cutting edge than the first end of the first knife edge 154. Similarly, the second knife edge 160 has a first end adjacent the mounted end 156 and a second end adjacent the free end 158, and the second extruded edge is positioned vertically higher (or closer to a non-cutting edge) than the first end.

As a result of the angled configurations of the first and second knives 146, 148, the points of contact between the first knife edge 154 and the cutting edge 144 and between the second knife edge 160 and the cutting edge 144 move across the cutting edge 144 when the first and second knives are moved between the non-activated and the activated positions. Because the first and second knife edges 154, 160 are arranged substantially as mirror images of each other, when the point of contact between the first knife edge 154 and the cutting edge 144 moves along the cutting edge 144 in a first direction, the point of contact between the second knife edge 160 and the cutting edge 144 in a second direction opposite to a first direction along the cutting edge 144. Nevertheless, it will be clear that the first and second knives also cannot be mirror images of each other. In such cases, the contact points can move in the same direction as when the first and second knives are moved between the non-activated and the activated positions.

CRICKET MECHANISM

As the sheet material 104 advances through the packaging machine 100, various cuts and creases are formed in the sheet material 104 to convert the sheet material into blanks, such as blanks 170 shown in Figure 7. The blank 170 includes cuts (shown in solid lines). ) and shivering (shown in dashed lines). As used herein, a crease can be an impression in the sheet material that simplifies folding of the blank 170 at the impression. Alternatively, a crease can also be a partial cut or nil, in which the sheet material is only partially cut through its full thickness, such that a weakening of the sheet material occurs at the partial cut or score.

The blank 170 includes four central surfaces A, B, C and D. Each of the four central surfaces is provided to form the wall of the box. In the configuration of Figure 7, face B forms the bottom wall of the box, faces A and C form upstanding walls of the box, and face D forms the top wall of the box. Figure 7 also indicates how the length l, width b, and height h of the box results from the dimensions of the blank 170. Each of the faces A, B, C and D has two side flaps, which are respectively designated A ', B', C 'and D'. These side flaps are provided to form the two side walls of the box. In the present embodiment, a closure flap A ”extends from plane A. The closure flap A” serves to join plane A to plane D in forming the box.

One challenge in making blanks, such as blank 170, is to form the transverse creases between faces A, B, C and D. Typically, a creasing tool is moved across the sheet material to form the creases. Analogous to the rolling knives discussed above, the movement of a creasing tool across the sheet material can be relatively slow, reducing the throughput of the packaging machine. In addition, the transverse movement of creasing tools requires that the sheet material be stationary when the creases are formed, otherwise the creases would be formed at angles or the creasing tools should be capable of moving both transversely and longitudinally to crease transversely.

Figure 8 illustrates a creasing system 180 that can be used to form transverse creases in the sheet material 104 in a consistent and rapid manner. The creasing system 180 includes a backing plate 182 that supports the sheet material as the sheet material moves through the packaging machine 100. The creasing system 180 also includes a first creasing roll 184 that faces across the sheet material 104 and is transverse to the length of the sheet material 104. The first creasing roll 184 has a cylindrical body 186 of a predetermined diameter. A first crimping cam 188 extends radially from the cylindrical body 186. The first creasing cam 188 may be formed by the cylindrical body 186 or may include an insert received in a slot in the cylindrical body 186 and extending therefrom.

The first creasing roll 184 is arranged to rotate about its axis to engage the creasing cam 188 with the sheet material 104 to form a crease in the sheet material 104. The backing plate 182 provides a back pressure on the first creasing roll 184 to enable creasing cam 188 to form a crease in the sheet material 104.

The distance between the backing plate 182 and the outer surface of the cylindrical body 186 is about the same as or greater than the thickness of the sheet material 104. As a result, when the first creasing roll 184 is rotated such that the first creasing cam 188 does not face the sheet material. 104 is oriented (as shown in Figure 8), the sheet material 104 can advance between the first creasing roll 184 and the backing plate 182 without creating any creases therebetween.

In contrast, when the outer radial surface of the first creasing cam 188 faces the support plate 182, the distance therebetween is less than the thickness of the sheet material 104. As a result, the sheet material 104 can be positioned between the first creasing roll 184 and the support plate 182 without Noteworthy until the first creasing roll 184 is rotated such that the first creasing roll 188 faces the backing plate 182. When the first creasing roll 184 is rotated so that the first creasing cam 188 faces the support plate 182, the first creasing cam 188 will engage the sheet material 104 and the sheet material 104 will be compressed between the first creasing cam 188 and the support plate 182.

In some embodiments, the creasing system 180 also includes a second creasing roll 190 that is substantially similar to the first creasing roll 184. For example, the second creasing roll may include a cylindrical body 192 and a second creasing cam 194. The second crimping cam 194 may be formed by the cylindrical body 192 or may include an insert received in a slot in the cylindrical body 192 and extending therefrom. The second creasing roll 190 may be arranged to rotate to engage the second creasing cam 194 with the sheet material 104 to form a Lift in the sheet material 104, as shown in Figure 8. In still other embodiments, the creasing system 180 may have three or more include creasing rolls.

In embodiments comprising two or more creasing rolls 184, 190, at least the first and second creasing rolls 184, 190 can be positioned side by side. For example, the first and second creasing rolls 184, 190 can be spaced (in the feed direction of the sheet material) that is less than 24 inches, less than 18 inches, less than 12 inches, less than 6 inches, or the like. The relatively short distance between the first and second creasing rolls 184, 190 can limit the size of the creasing system 180 as well as allow creasing to be formed in the sheet material 104 close together.

The first and second creasing rolls 184, 190 (or additional creasing rolls) can be controlled independently of each other. For example, the first creasing roll 184 can be rotated to form a crease in the sheet material 104, while the second creasing roll 190 remains separate from the sheet material 104, or vice versa. Alternatively, the first and second creasing rolls 184, 190 may be arranged to simultaneously engage the sheet material 104 to simultaneously form multiple creases therein. In still other embodiments, the first and second creasing rolls 184, 190 may be directed to alternately engage the sheet material 104 to form creases therein. By alternating between the first and second creasing rolls 184, 190, the speed at which the transverse creases can be formed in the sheet material 104 can be substantially increased.

In some embodiments, creasing system 180 or packaging machine 100 includes a feeding mechanism 196 configured to feed sheet material 104 through packaging machine 100. Creasing system 180 may be configured to form creases in sheet material 104 as sheet material 104 passes through. the packaging machine 100 is moving. In other words, the sheet material 104 does not have to stop moving through the packaging machine 100 for the transverse ridges to be formed. Previously, the creasing roll (s) may rotate to engage the sheet material 104 to form creases therein while the sheet material 104 continues to advance through the packaging machine 100 (via the feed mechanism 196).

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 as illustrative only and not limiting. The scope of the invention is therefore indicated by the appended claims rather than by the foregoing description. All changes that fall within the meaning and range of equivalence of the claims are to be included within its scope.

Claims (33)

Conclusions A packaging machine for converting substantially rigid sheet material into blanks for assembly into boxes or other packages, the packaging machine comprising: a separating system separating the sheet material m length for use in making the blanks, the separating system comprising: a cutting table having a cutting edge; a first knife having a mounted end, a free end and a first knife edge extending at least partially therebetween, the first knife edge being angled relative to the cutting edge of the cutting table about a single and moving point of contact between the first knife edge and form the cutting edge of the cutting table when the first knife is moved between a non-activated position and an activated position; and a second knife having a mounted end, a free end and a second knife edge extending at least partially therebetween, the second knife edge being at an angle to the cutting edge of the cutting table about a single and moving point of contact between the second knife edge and form the cutting edge of the cutting table when the second blade is moved between a non-activated position and an activated position, the free ends of the first and second blades being disposed adjacent to each other so that both free ends can pass through the sheet material when the first and second knives are moved to the activated positions, and wherein the mounted ends of the first and second knives are positioned on opposite sides of the sheet material. The packaging machine of claim 1, wherein the cutting edge of the cutting table is in a plane. The packaging machine of claim 2, wherein the first knife edge is at an angle to the cutting edge of the cutting table, such that the mounted end of the first knife is placed on a first side of the plane, and the free ejection is placed. on a second side of the plane. The packaging machine according to claim 2 or 3, wherein the second knife edge is at an angle to the cutting edge of the cutting table, such that the mounted end of the second knife is placed on a first side of the plane, and the free end placed on a second side of the plane. The packaging machine according to any of the preceding claims 1-4, further comprising a pressure element adapted to press the first knife against the cutting edge of the cutting table. The packaging machine of claim 5, wherein the pressure element comprises a spring. The packaging machine according to any of the preceding claims 1-6, further comprising a pressure element that is directed to press the second knife against the cutting edge of the cutting table. The packaging machine of claim 7, wherein the pressure element comprises a spring. The packaging machine of any of the preceding claims 1-8, wherein the first knife narrows from the mounted end to the free end such that the first knife edge is at an angle to the cutting edge of the cutting table. The packaging machine of claim 9, wherein the first knife has a non-cutting surface opposite the first knife edge, and the first knife edge has a first end adjacent the mounted end of the first knife and a second end adjacent the free ejected blade. of the first blade, the second end being positioned closer to the non-cutting surface than the first end. The packaging machine of any of the preceding claims 1-10, wherein the second knife narrows from the mounted end to the free end such that the second knife edge is at an angle to the cutting edge of the cutting table. The packaging machine according to any of the preceding claims 1-11, wherein the second knife has a non-cutting surface opposite the second knife edge, and the second knife edge has a first cutout adjacent the mounted end of the second knife and a second end adjacent the free end of the second blade, the second ejected being placed closer to the non-cutting surface than the first end. The packaging machine according to any of the preceding claims 1-12, wherein the contact point between the first knife edge and the cutting edge of the cutting table moves across the cutting edge when the first knife is moved between the non-activated and the activated positions. The packaging machine of claim 13, wherein the contact point between the second knife edge and the cutting edge of the cutting table moves across the cutting edge when the second knife is moved between the non-activated and the activated positions. The packaging machine of claim 14, wherein when the contact point between the first knife edge and the cutting edge moves across the cutting edge in a first direction, the point of contact between the second knife edge and the cutting edge moves in a second direction opposite the first direction. the cutting edge moves. The packaging machine of any of the preceding claims 1-15, wherein the first knife is associated with a first actuator arranged to move the first knife between the non-activated and activated positions. The packaging machine of claim 16, wherein the second knife is associated with a second actuator that is directed to move the second knife between the non-activated and activated positions. The packaging machine of claim 17, wherein the first and second actuators are synchronized to move the first and second knives simultaneously between the inactivated and activated positions. The packaging machine of claim 17, wherein the first and second actuators are independently operable to allow the first and second knives to be moved independently between the non-activated and activated positions. The packaging machine of any of the preceding claims 1-19, wherein the free ends of the first and second knives are spaced less than 1.0 inch, 0.75 inch, 0.25 inch, or 0.1 apart. inches apart. The packaging machine of any one of the preceding claims 1-20, further comprising: a creasing system that forms transverse creases in the sheet material, the transverse ribs being oriented across the sheet material and transverse to the length of the sheet material, the creasing system comprising: a backing plate which the sheet material supports; and a first creasing roll oriented across the sheet material and transverse to the length of the sheet material, the first creasing roll having a first creasing cam extending radially therefrom, the first creasing roll being directed to rotate to engage the first creasing cam. the sheet material to form a crease in the sheet material. The packaging machine of claim 21, further comprising a second creasing roll oriented across the sheet material and transverse to the length of the sheet material, the second creasing roll having a second creasing cam extending therefrom, the second creasing roll being adapted to rotate for engaging the second crease cam with the sheet material to form a crease in the sheet material. The packaging machine of claim 22, wherein the first and second creasing rolls are disposed adjacent to each other and are independently operable. The packaging machine of claim 23, wherein the first and second creasing rolls are spaced apart less than 24 inches, less than 18 inches, less than 12 inches, less than or equal to 6 inches. The packaging machine of any of the preceding claims 21-24, wherein the first creasing cam comprises an insert received in a slot in a first creasing roll and extending therefrom. The packaging machine of any of the preceding claims 21-25, wherein the second creasing cam includes an insert received in a slot in a second creasing roll and extending therefrom. The packaging machine of any of the preceding claims 21-26, wherein the first and second creasing rolls are arranged to alternately engage the sheet material to form creases therein. The packaging machine of any of the preceding claims 21-27, wherein the first and second creasing rolls are arranged to simultaneously engage the sheet material to form a plurality of creases therein. The packaging machine according to any of the preceding claims 21-28, further comprising a feeding mechanism adapted to supply the sheet material to the packaging machine, the creasing system being arranged to form creases in the sheet material as the sheet material advances through the packaging machine . The packaging machine according to any of the preceding claims 21-29, wherein the first creasing roll and the backing plate are arranged on opposite sides of the sheet material. The packaging machine of any of the preceding claims 21-30, wherein the first creasing roll compresses the sheet material toward the backing plate when the first creasing roll is rotated to engage the first creasing cam on the sheet material to form a crease in the sheet material. The packaging machine according to any of the preceding claims 21-31, wherein the second creasing roll and the backing plate are arranged on opposite sides of the sheet material. The packaging machine of any of the preceding claims 21-32, wherein the second creasing roll compresses the sheet material towards the backing plate when the second creasing roll is rotated to engage the second creasing cam on the sheet material to form a crease in the sheet material.