BE1028206B1 - Plano folding process and mechanisms - Google Patents

Abstract

Apparatus and methods for forming boxes from blanks include advancing the blank on a drive train while one or more side panel fingers move different side panels of the blank up and down in an alternating manner. 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 prone to bending along false ridges extending 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

The sale of goods and services via the Internet has increased significantly 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 packaged for shipment. Out of the wide range of products ordered, packaging can present a number of challenges for manufacturers and distributors. For example, while products must be packaged in all shapes and sizes and shipped to customers, manufacturers and/or distributors may have only 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 large uses additional packaging material, which is wasteful and costly. 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 within the carton during shipment, resulting in product damage during transit. In many cases, filling material is placed around the product in the box to prevent the product from being moved too much. however, the extra filling material costs money and time.

[0004] There are packaging machines that are able to adapt packaging boxes to specific product sizes in order to limit or eliminate some of the challenges mentioned above. 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 “blank”). The blank is then folded into a box.

Before being formed into a carton 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 or fold lines extending 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) to form blanks can be problematic. For example, the blank formed from warp material can often extend over multiple segments of the warp material. Thus, blanks formed from warp material typically have score or fold lines extending across one or more panels, tabs or other portions of the blank. These chain crease or fold lines 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 create weaknesses 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 across blanks are exacerbated when the packaging machine is instructed to form a variety of adaptable carton sizes, as discussed above, from generic warp material. In such situations, false creases extending across the blanks can occur at any point along the blank's length, depending on the size and layout of the blank, 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 associated with false creasing during the adaptable carton forming process.

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

BRIEF SUMMARY

The present invention relates to packaging machines. More particularly, the present invention relates to methods and apparatus for forming custom packaging boxes from generic warp material. In one embodiment of the present invention, a method of forming a carton from a blank includes, for example, providing a blank on a drivetrain. The blank may comprise a number of panels, including a front panel, an intermediate panel, a bottom panel, a back panel and a glue tab extending from the back panel. Each panel has one or more side flaps extending from

> Extend BE2020/5235. In such an embodiment, the method further comprises advancing the blank on the driveline and folding the side flaps sideways in an alternate manner.

In one embodiment of the present invention, a method of forming a carton comprises providing a blank on a drivetrain and advancing the blank thereon. As the blank advances on the drivetrain, various side flaps of the blank are alternately moved up and down to stiffen panels from which the side flaps extend. Also, a container holds the side flaps that are folded in position and holds a bottom panel of the blank downward while the adjacent panels of the blank are folded up and over to form rear, front and top surfaces of the carton. In such an embodiment, the leading bottom corner of the container is chamfered so that front panels of the blank can be partially folded before the front panel completely passes a leading edge of the container.

In one embodiment of the present invention, a method of forming a carton comprises providing a blank on a drivetrain and advancing the blank thereon. As the blank advances on the drivetrain, various 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 down while adjacent panels of the blank are folded up and over to form rear, front and top surfaces of the carton. Also, a spatula arm folds the glue lip down and the leading edge of the spatula contacts a border of the two front panels of the blank. In this way, the two front panels are folded on the border to form the top and front surfaces of the box.

In one embodiment of the present invention, a method of forming a carton comprises providing a blank on a drivetrain and advancing the blank thereon. As the blank advances on the drivetrain, various side flaps of the blank are alternately moved up and down to stiffen panels from which the side flaps extend. Also, a container 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 rear, front and top surfaces of the carton.

In one embodiment of the present invention, a method of forming a carton from a blank comprises providing a blank on a drivetrain. The blank may comprise a number of panels, including a front panel, an intermediate panel, a bottom panel, a back panel and a glue tab extending from the back 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 folding the blank up and down in an alternate manner.

* BE2020/5235 side flaps. A holder holds the folded side flaps in position as the blank advances on the drivetrain. As the blank advances, the two front panels and the two back panels are folded up and over to form the top, front, back and glue lip surfaces of the carton, respectively. In addition, in such an embodiment, one or more trailing angled arms and one or more leading angled arms hold the trailing bottom corner and the top leading corner of the carton at a fixed angle.

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

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

BRIEF DESCRIPTION OF THE FIGURES

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 made 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 should therefore not 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 exemplary box forming machine and system comprising a material supply system, a blank cutting machine, a product supply 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;

> BE2020/5235

Figure 3 illustrates an exemplary blank formed by a blank forming machine comprising a plurality of panels, side flaps and a glue flap;

Figure 4 illustrates a driveline of a box forming machine, the driveline advancing a blank on a conveyor belt, and illustrating a plurality of arms, holders and side flap fingers;

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

Figure 6 further illustrates the blank along the drivetrain with the side flap finger folding up a pair of side panels as the blank advances on the drivetrain;

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

Figure 8 illustrates arms of the carton forming machine lifting panels of the blank to form front and rear faces of the carton;

Figures 9 and 10 illustrate the drivetrain of the box forming machine without the blank to show a pair of subsequent angled arms raising as the following angled arms advance along the driveline;

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

Figure 12 illustrates a spatula arm of the box forming machine folding down a glue flap as the blank advances on the drive train;

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

Figure 14 illustrates the pair of arms illustrated in Figure 13 wherein a front panel of the blank is folded down to form a top surface of the carton 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 drive train;

Figures 16 illustrate an upper side arm of the carton forming machine folding down side flaps of the blank to form a side surface of the carton as the blank advances on the drive train; and

° BE2020/5235

Figure 17 illustrates a lower side arm of the carton forming machine folding up side flaps of the blank to form a side surface of the carton as the blank advances on the drive train.

DETAILED DESCRIPTION

The present invention relates to packaging machines. More specifically, the present invention relates to methods and apparatus for forming custom packaging boxes from generic warp material. For example, in one embodiment of the present invention, a method of forming a carton from a blank includes providing a blank on a drivetrain. The blank may comprise a number of panels, including a front panel, an intermediate panel, a bottom panel, and a back 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 extending thereover. In such an embodiment, the method further comprises advancing the blank on a driveline and folding the side flaps up and down in an alternate manner.

Embodiments of the present invention solve one or more of the above-discussed problems in the art by providing methods and apparatus for forming cartons (or "blanks") that may or may not have false creases extending thereover. . 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 final carton.

Turning now to the figures, Figure 1 illustrates an exemplary box forming machine and system 100, comprising a material supply system 102, a blank cutting machine 104, a product supply machine 106, and a box forming machine 108. As seen in Figure 1, the material supply system 102 includes several stacks of chain material. 110 that can be fed to the empty slicer 104. As noted above, the warp material 110 may include creases 112 where the material is folded to form the stacks 110 of continuous warp segments 114 .

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

The warp material is fed to the blank cutting machine to form a flat box template, or "blank", illustrated in more detail in Figure 3 . First, in Figure 2, a detail 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 carton 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 that feeds one or more goods onto the blank formed by the blank cutting machine 104 before the carton forming machine 108 folds the blank into a carton.

In addition, the product feeding machine 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 that minimize additional space around the one or more goods within the final box product. After the one or more goods are placed on the proper 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 having a plurality of panels, side flaps and/or tabs that can be bent at different angles to form the packaging boxes of various shapes and sizes. Figure 3 shows an example of a blank 300 cut by the blank cutting machine 104 from a piece of chain material 110. For reference, the arrow to the right 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 back panel D, and a glue tab panel E. Each panel includes opposing side panels or flaps A'-E' extending transversely to each side of the blank. 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 advances in the blank 300 through the box forming machine 108 .

Likewise, the back panel D designates a panel that it follows behind other panels as the blank 300 advances through the box forming machine 108. The bottom panel C is positioned mainly 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 as a non-limiting example of a blank configuration. It will be appreciated that the blank cutting machine 104 blanks of a

; BE2020/5235 can form any number of shapes, sizes and panel configurations to produce boxes that can pack any number of product shapes and sizes. For example, a blank in one or more embodiments may have more panels or fewer panels than those illustrated in Fig

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 can be formed that does not include glue tabs or two or more glue tabs positioned at different locations on the blank.

However, for the purpose of illustrating and describing various embodiments of the box forming machine according to 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 may only be illustrative of boundaries between panels and/or tabs where the carton forming machine 108 may bend the blank 300 to form a carton. In one or more embodiments of the present invention, the blank cutting machine 104 may score, press, fold, or otherwise affect the material at the boundary lines of the blank 300 to create weaknesses in the material. In this manner, the blank is more likely to bend at the depicted boundary lines 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 apparent. are from the description and figures that follow.

Figures 4 to 17 illustrate various steps of a method of forming a carton in the carton forming machine 108, and components of the carton forming machine 108 that folds the blanks into the cartons. In these figures, for illustrative purposes, the blank 300 is shown advancing through the box forming machine 108 without any goods or products placed thereon. It is understood, however, as discussed above, that one or more goods may be placed on the blank before the blank moves through the molding machine 108 so that a carton is formed around the goods. In particular, in the embodiment of the blank 300 shown herein, one or more goods can be placed on the bottom panel C, which forms the bottom surface of the carton 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 advances the blank 300 through the forming machine 108 . To this end, the driveline 400 may include one or more drive mechanisms that advance the blank 300 along the driveline 400 . One or more embodiments may include different drive mechanisms, such as conveyor belts, chains, roller surfaces, rails, and the like, or combinations thereof.

’ BE2020/5235

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 can enter the box forming machine 108 in a flat manner as it begins to advance along the drivetrain 400. For example, as shown in Figure 4, the front panel A and associated side panels A' are generally flat, 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 pushed 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 upwards, as shown in Figure 6, the side panel fingers 406 can be positioned above side panels C°.

As described herein, moving the side flaps up and down in an alternate manner means that alternate 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 the side panels A' and side panels B' shown in Figures 5 and 6, respectively, the panels from which the side panels project 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 any location other than the boundary therebetween because the side panels B' extending therefrom are folded and are no longer co-planar with intermediate panel B Similarly, the side panels A' that are folded/bent down can stiffen the front panel À from which they extend. The same is true for the other panels A-E if the side panels A'-E' are alternately bent up and down as the blank 300 advances on the drivetrain 400.

Stiffening the panels AE as the blank 300 advances on the drivetrain 400 can reinforce the panels AE and ensure that the panels AE are bent or folded at the proper boundary lines between adjacent panels during subsequent blank folding methods and steps of the box forming process described herein. is described. Along these lines, stiffening several panels of the blank 300 can reduce the risk of panels bending or folding along false ridges extending across the blank 300 at locations other than the boundaries between the panels.

Figure 6 illustrates an example of a false crease 112 extending across blank 300 . As can be seen in Figure 6, the blank 300, which was cut from warp material 110, extends along chain bead 112, creating a "false bead" in the blank 300. The false creases 112 of blank 300 can create weaknesses in the blank material that cause panels A-E and side panels A'-E' to bend or fold inappropriately during the molding of the carton. However, because the side panels B' are lifted at an angle by the side panel fingers 406, intermediate panel B and the side panels B' can be stiffened. That is, the intermediate panel B may tend to bend at the proper boundary between the adjacent panels A and C, rather than bend along the false bead 112, due to the angle of the side panels B' relative 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 that are folded down into their flat position. For example, the container 404 illustrated in Figure 6 includes a lower edge that sits on top of the side panel A' as the blank 300 advances on the drivetrain 400. In one or more embodiments, the containers 404 may be stationary. In one or more other embodiments, the containers 404 can be temporarily or permanently biased to accommodate the needs of different blanks and panel configurations. As will be apparent from the following figures, the holders 404 can also hold the position of the side panels A'-E' folded upwards as 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 the side panel fingers 406 pushing up the side panels D' to stiffen back panel D. As shown, side panels A' are folded down, side panels B' are folded up, side panels C' are folded down, side panels D' are folded up and side panels E' may be folded down. 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 plano (300) propels on the 400 drivetrain.

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 carton. As shown in Figure 8, once the front panel A extends completely beyond the front ends of the containers 404, one or more arms 402 - over which the front panel 1 and intermediate panel B have advanced - can be raised as the blank 300 advances on the

“U BE2020/5235 drivetrain 400. When the arms 402 lift 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 bead 112 shown. Thus the stiffening of the panels A-E, as a result of the up and down folded A'-E”, ensures that any false creases 112 that may extend transversely to the blank 300 have no negative influence on the folding steps of the box forming machine 108 .

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

The container, which may include top and bottom portions 404a and 404b, may hold several side panels A'-E' in position during folding during the folding steps illustrated in Figure 8. In addition, the containers may 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 off the drivetrain 400 during the folding steps described herein.

Also, in one or more embodiments of the present invention, the bottom leading corners of the containers 404 may be shielded, or angled. In such embodiments, the arms 402 may begin to lift the front and intermediate panels A, B before the front panel A and/or intermediate panel B have been advanced fully past the leading edge of the containers 404 by the drivetrain 400. In such an embodiment, the chamfered corner of the holders 404 can increase the speed of forming a carton from the blank 300 in the carton forming machine 108 because the arms can begin lifting/folding the front and intermediate panels A, B earlier. then when the front and intermediate panels , B had to be fully advanced past the containers 404 before the arms 402 could start lifting/folding the front and intermediate panels A, B.

The following angled arms mentioned above with reference to Figure 8, which lift the back panel D and the glue lip panel E, are not shown because of the blank 300 applied to 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 glue lip panel E from the blank 300, the next angled arms 900 may be flush with or below the drivetrain 400. Figure 9 illustrates the next 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 embodiments, the following angled arms 900 may 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, the following angled arms 900 in one or more embodiments of the present invention may extend through any number of angles, depending on the shape of the carton being formed and the required angle of the back panel D with respect to the bottom panel C. In this manner, Figure 11 illustrates a perspective view of a pair of next angled arms 900 extending upwardly with a blank 300 on the drivetrain 400. As shown, the following angled arms 900 extend upwardly above the drivetrain 400 about rear panel B and bottom panel C bend at an angle relative 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 may advance along the drivetrain 400 with the blank 300 to reach the next lower corner of the box while the blank 300 moves.

Referring to Figure 12, the box forming machine 108 may also include a spatula 1200 that extends downwardly to fold the adhesive lip panel E downward as the blank advances on the drive train 400. The spatula may fold downward the adhesive lip panel E, simultaneously with lifting the back panel D. In one or more other embodiments, the spatula 1200 may fold the glue lip panel down after the back panel D has been lifted. Also, the spatula 1200 may include a leading edge 1202 extending transversely across the driveline 400 .

As shown in Figure 13, the leading edge 1202 of the spatula 1200, which is concealed by panel A lifted up by the arms 402, may extend toward and contact the boundary between the front panel A and the intermediate panel B. As the blank 300 advances on the drivetrain 400, as shown in Figure 14, the arms 402 may continue to rise across the boundary between the front panel and the intermediate panel B. As the arms 402 rise in this manner, the leading edge may of the spatula 1200 contact the boundary of the front panel A and the intermediate panel B such that the front panel A flexes 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 may 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 upward contacts the bottom panel C and/or the side panels C° to prevent the intermediate panel B from bending any further as the arms 402 push down on the front panel A. The same applies to the side panel D' extending from the back panel D when the back panel D is pushed up and the glue lip panel E is pushed down by the spatula 1200 as described above. Thus, the bending of the side panels A'-E' as described herein can also function to ensure proper bending of the blank 300 as the arms 402, the subsequent angled arms 900 and the spatula 1200 press on the various panels A-E.

As shown in Figure 15, as the blank advances on the drivetrain 400, the arms 402 can advance with the front panel A of the blank 300, and the front panel A against the glue lip panel E folded down by the spatula 1200. to press. When this occurs, the spatula 1200 may be retracted between the adhesive lip panel E and the front panel A. In one embodiment, the spatula 1200 may retract just before the front panel A contacts the adhesive lip panel E. In another embodiment, the spatula 1200 may retract Just after the front panel A contacts the glue tab panel E. In yet another embodiment, the spatula 1200 can retract simultaneously when the front panel A contacts the glue tab panel E.

As shown in Figure 15, once the front panel A is folded down by the arms 402, the front panel A can form the top surface of a carton 1500 . In this way, the intermediate panel B may form a front surface of the carton 1500, the bottom panel C may form the bottom surface of the carton 1500, and the rear panel D may form the rear surface of the carton 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 carton 1500, the leading angled arm 1502 can extend downwardly and contact the top and front surfaces of the carton 1500. Accordingly, in one embodiment, the leading angled arm 1502 can arm 1502 include a first component 15024 adapted to contact the top surface and a second component 1502b adapted to contact the front surface. In the illustrated embodiment showing a rectangular shaped box 1500 formed from the blank 300, the first and second components 15024 and 1502b are arranged at an angle of 90 degrees to each other. In such an embodiment, the leading angled arm 1502 can hold the top leading corner of the carton 1500 at a 90 degree angle as the blank advances on the drivetrain 400.

It will be appreciated, however, that the first and second components of the leading angled arm 1502 may be positioned at various angles to each other, depending upon the shape of the carton being formed. For example, in one or more embodiments, the box forming machine 108 can form boxes that are not rectangular in shape. In such embodiments, the leading angled arm 1502 may have first and second components 15024, 1502b that are angled greater or less than 90 degrees from each other. In addition, while the embodiment illustrated in the figures shows one leading angled arm 1502, one or more other embodiments of the box forming machine 108 may include more than one leading angled arm 1502.

Likewise, as discussed above, the next angled arms 900 may extend vertically upward from the drivetrain 400 to hold the next bottom corner of the carton 1500 at a 90 degree angle as the blank 300 advances on the drivetrain 400. However, as with the leading angled arm 1502, the trailing 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 shaped boxes.

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

It will be appreciated that during the various folding steps described herein, one or more methods may be provided for bonding the various panels together while the carton 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 tab 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 tab panel E may adhere to each other when brought into contact.

Likewise, one or more embodiments of the carton 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 carton 1500 . In this manner, the carton can remain intact after the panels of the blank have been bent/folded into position along the driveline 400 of the carton forming machine 108, as described herein.

It will be appreciated that the various 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 described herein, while having their own functions. described herein are retained. For example, the arms 1402 extending transversely across the drivetrain 400 are illustrated as elongated, rectangular bars. However, one or more other embodiments of the arms 402 may comprise one or more rod-shaped bars, flat plates, or irregularly shaped components.

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

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

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

For example, the spatula 1200 and leading angled arms 1502 are illustrated extending from the top of the drivetrain 400 downward. 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 extend, for example, at an angle to the drivetrain 400, rather than parallel to the longitudinal direction of the drivetrain 400, as shown herein.

It will also be appreciated that the various 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 modified to form boxes of various other shapes and sizes. Accordingly, the steps, folding processes, and the order in which these steps are performed may be rearranged, modified, or eliminated in one or more other embodiments of the present invention.

For example, in one or more embodiments, the blank 300 may not include an adhesive lip panel E. In such an embodiment, the box forming machine 108 may or may not include a spatula as described herein. Also, the box formed by the box forming machine

For example, © BE2020/5235 108 in one or more embodiments of the present invention, be an open box with one or more open surfaces. In such an embodiment, the carton forming machine 108 may or may not include one or more upper and lower side arms to form left or right surfaces of the carton. Thus, in such an embodiment, the box forming machine 108 may or may not pass a front panel over the top of the one or more goods to form an open top of the box 1500 .

It will be appreciated that altering the sequence, 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 various 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 adapted 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 adapted to form such boxes without chain creases (or "false creases") 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 warp material with warp grooves.

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 limiting. The scope of the invention is therefore indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalence of the claims are to be included within the scope thereof.

Claims (13)

Conclusions A method of folding a carton from a blank (300), the method being performed on a drive train (400) having a forward direction of travel, the method comprising: providing the blank (300), the blank including: multiple panels (A, B, C, D) comprising an anterior panel (A), an intermediate panel (B), a bottom panel (C) and a posterior panel (D); and multiple side panels (A, B', C', D') extending transversely from the panels (A, B, C, D), each panel (A, B, C, D) being connected to two opposite located side panels (A', B', C, D'); positioning the blank (300) on the drivetrain (400) such that the plurality of side panels (A', B', C', D') of the blank (300) extend transversely of the drivetrain (400); positioning one or more goods on the bottom panel (C) of the blank (300); advancing the blank (300) with the one or more goods along the driveline (400): upward folding of side panels (B', D') that are diagonal to the bottom panel (C); folding the rear panel (D) upwards and holding the rear panel (D) as a rear wall of the carton; and folding the front panel (A) and the intermediate panel (B) upwardly by moving an arm (402) upwardly, during the forward movement of the blank (300), from a first position below the drivetrain (400) to a second position above the drivetrain (400) such that the intermediate panel (B) forms the front wall of the carton; and advancing the blank (300) under the raised arm (402) to fold the front panel (A) above the one or more goods so as to form an upper wall of the carton. The method of claim 1, wherein the upward folding of the side panels (A', B', C°, D') is performed while advancing the blank (300) on the drivetrain (400), by positioning fingers (406) under the side panels (A', B', C', D'). The method of claim 1 or 2, wherein a plurality of panels (A, B, C, D) extend sequentially in the direction of movement of the drivetrain (400), the lower panel (C) being formed by a third of the plurality of panels . A method according to any one of claims 1 to 3, wherein the method further comprises: applying glue to a glue zone in at least two regions of the blank (300) that overlap when the carton is formed, and pressing the blank (300) at the position of the glue zone after the carton is at least partially formed. The method of claim 4, wherein, prior to pressing, a positioning finger (1200) is placed between the regions adjacent to the adhesive zone to prevent early contact between the regions, and then the regions are positioned relative to each other to at least partially forming the carton, after which the positioning finger (1200) is removed from between the regions. The method of claim 5, wherein the positioning finger (1200) extends above the carton in the direction of movement such that the front panel (A) of the carton comes to rest on the positioning finger (1200) when the arm (402) moves anterior and intermediate panel (A, B) folds. A method according to any one of claims 1-6, further comprising folding side panels (A') connected to the top wall (A) downwards and folding side panels (C') connected to the bottom wall (A) upwards. C), such that the aforementioned side panels form the side walls of the box. Apparatus (108) for folding a carton from a blank (300), wherein the blank comprises a plurality of panels (A, B, C, D) and a plurality of side panels (A', B', C', D') forming extending transversely from the panels (A, B, C, D) includes the device (108) comprising: drive train (400) having a forward direction of travel, delivery section for delivering the blank (300) to the drive train (400), such that the plurality of side panels (A', B', C', D') of the blank (300) extend transversely across the drivetrain (400); a positioning section for positioning one or more goods on the bottom panel (C) of the blank (300); a feed section for advancing the blank (300) with the one or more goods along the driveline (400); a first folding section for folding up side panels (B', D') which are diagonal to the bottom panel (C); a second folding section for folding the back panel (D) upwards and holding the back panel (D) as a back wall of the carton; and a third folding section for folding the panel (B) upwardly by moving an arm (402) upwardly from a first position below the drivetrain (400) to a second position above the drivetrain (400) and advancing the said drivetrain. blank (300) under the arm (402) to fold the panel (A) above the one or more goods such that the carton is positioned under the upwardly moved arm (402) about a front wall and an upper wall of the box with the panels (A, B). The apparatus (108) of claim 8, wherein the first folding section includes fingers (406) movable in the transverse direction relative to the driveline such that the distance between opposite fingers (406) can be adjusted to a width of the blank (300) and wherein the fingers (406) extend in a direction opposite to the direction of movement with a distal end movable up and down to engage under the side panels (B', D') which are diagonal from the bottom panel (C). The apparatus (108) of claim 8 or 9, wherein the apparatus (108) further comprises: a glue gun for applying glue to a glue zone in at least two regions of the blank (300) that overlap when the carton is formed ; and pressing element for pressing the blank (300) to the position of the glue zone after the carton has been at least partially formed. The device (108) of claim 10, wherein the device (108) further includes a positioning finger (1200) disposed above the drivetrain (400), the positioning finger (1200) movable in the direction of movement to extend between the regions to prevent early contact between the regions, and after which the regions are positioned relative to each other to at least partially form the carton, after which the positioning finger (1200) is removable from between the regions. The device (108) according to claim 10 or 11, wherein the pressing element is formed by the arm (402), which is further movable in the direction of movement during pressing of the blank (300) at the position of the glue zone. The device (108) according to any one of claims 8-12, wherein the device (108) further comprises a fourth folding section for folding down side panels (A') connected to a top wall (A) and for folding upwards the side panels (C') connected to the lower wall (C), such that the latter side panels form the side walls of the box.