CA1215568A - Apparatus and method for making cartons - Google Patents
Apparatus and method for making cartonsInfo
- Publication number
- CA1215568A CA1215568A CA000423984A CA423984A CA1215568A CA 1215568 A CA1215568 A CA 1215568A CA 000423984 A CA000423984 A CA 000423984A CA 423984 A CA423984 A CA 423984A CA 1215568 A CA1215568 A CA 1215568A
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- CA
- Canada
- Prior art keywords
- web
- printed
- length
- accumulator
- corrugated
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Abstract
ABSTRACT OF THE DISCLOSURE
Apparatus making foldable box blanks of pre-printed corrugated material by continuously delivering pre-printed web material to a reciprocating press which is operated intermittently to cut and score the web material and utilizing an accumulator mechanism which receives the pre-printed web material continuously and delivers it intermittently.
Apparatus making foldable box blanks of pre-printed corrugated material by continuously delivering pre-printed web material to a reciprocating press which is operated intermittently to cut and score the web material and utilizing an accumulator mechanism which receives the pre-printed web material continuously and delivers it intermittently.
Description
~o~ 303 1.SS~
This invention relates to the apparatus and method of making double-faced, corrugated boxes with printing thereon and more particularly, for making such boxes in a continuous process.
Heretofore, boxes formed or corrugated material with flat sheets at opposite sides of a corrugated coil were made by severing the three-layered material into individual boards and subsequently, printing, cutting, and scoring in multiple stages of operations. The corrugated material presents problems in attempting to use contlnuous processes because of the rigidity of the material which prevents sufficient flexibility for rotary opera-tions.
It is an object of the invention to provide a method and apparatus for forming a printed, corrugated - box from a continuous web of double-faced corrugated material, one face of which is printed.
It is another object of the invention to provide apparatus for forming printed corrugated boxes in which the web of material is delivered continuously to a reciprocating press at which the web ma-terial is ~ . . .
cut and scored.
Still another object of the invention is to provide an accumulator arrangement in which web material is supported in a manner receiving the material cont~nuously and delivering it intermittently.
It is an object of the invention to provide a method and apparatus of forming printed corrugated boxes continuously in which means are provided to add flexibility to a web of corru~ated material making s~i~
it possible to use equipment for handling flexible webs.
The objects of the invention are accomplished by apparatus in which a web of paper mat;erial is printed with various indicia and messages including a printed reference mark and wherein another web of single back corrugated paper web is formed. The printed web and the single-backed web are joined -toge-ther to form a double-backed continuous web of printed corrugated web material. ~he double-backed printed material is delivered continuously from a firs-t station to an accumulator and from the accumulator the material is delivered at an intermittent rate to a reciprocating press in which the web material is cut and scored to form a box blank. Between the first and second station is an accumulator which suspends the web material with the length of web between the first and second stations varying between a maximum and a minimum. Control means are provided for regulating the speed of delivery from the first station so that the speed varies between a maximum and minimum. Such speed is varied under the influence of control means which respond to the maximum length of material in the accumulator to cause delivery at a minimum rate and respond to a minimum length of material in the accumulator to deliver the web at a maximum rate. ~eans also are provided to make even thick corrugated material which normally is very stiff and substantially inflexible adapted for use in an accumulator which requires longitudinally Flexible materials by making spaced false scoring or lines of Compak A-3n3 ~2~.S~
weakening -to make the otherwise relatively stiff material sufficiently flexible for use with the accumulator.
The objects of the invention are accomplished by the embodin;ent disclosed in t:he following description and illustrated in the drawings in which:
Figure 1 is a diagramrnatic view of the apparatus for continuously forming foldable box blanks of pre-printed corrugated material;
Fi-~ure 2 illustrates an example of the type oE
~o~ blank that can be formed;
Figure 3 is a bottom view of a portion of the double-faced corrugated material after it has been printed, Figure 4 is a diagrammatic view of a portion of the apparatus illustrated in Figure l;
Figure 5 is an enlarged top view of a portion of a clamping element shown in Figure 4;
Figure 6 is a side view of the clamping arrange-ment illustrated in Figure 5;
Figure 7 is a view of a section of the corrugated material as it appears in one stage of the method of forming box blanks; and Figure 8 is a view showing a section of the corrugated material as it appears in a la-ter stage of the blanking operation.
Figure 1 il]ustrates the apparatus by which foldable carton 12, that is, blanks of pre-printed corrugated material, such as shown in Figure 2 can be produced for subsequent assembly. Such cartons 12 can take a variety of shapes but by way of example can have Compak A-303 ~2~55;~
four sides 14 foldable along longitudinally ex-tending score or crease lines 16. The sides 14 are foldable along the score lines 16 and a tab 18 attached -to one of the sides may be glued to the side at the opposite edge of the blank 12. Similarily, bottom tabs 2 and 21 can be folded along transversly extending score line 22 and glued to form the bottom of the carton. Side flaps 23 and box cover 24 can be folded along score line 25 to close the top of the box. The box blank 12 can be pre-printed in one or more colors at locations - shown for example by the markings 27 and 28.
The carton 12 is made of double-faced corrugated paper formed in the initial stages of the carton forming apparatus 10. As seen in Figure 1 a paper web 30 is delivered to a corrugating machine 32 and results in a corrugated web 34 which is bonded to a web 35 to form a single-faced web 36. The web 36 has corrugations which extend generally transversly making the web 36 relatively stiff in a transverse direction but permitting flexibility in a longitudinal direction. This makes it possible for the web 36 to be temporarily stored at an accumulator station indicated at 40. The accumulator station 40 can be in the form of a platform 41 per-mitting the web 36 to be in a slack condition for removal from the accumulator qO on demand from a roll 42 forming a Eirst conveyor.
Paper stock in the form of a weh 44 can be delivered on demand to a printing machine 46. In the printing machine 46, the web 44 can be printed in one or more colors with various messag~s and designs Comp~k ~-303 iS~
and delivered from the machine in the form of a printed web 48 includes the printed markings 27 and 28 also seen in the carton blank l2 in the Figure 2. In addition, the web 48 is printed with registration marks 50 along the margin of the printed web 48.
The printed web 48 is delivered Erom the printer 46 over rolls 52 to a backing machine 56 sometimes called a double-backer. The sinyle-faced web 36 also is delivered to the backing machine 56 after it has first passed through a gluing station 58 at which adhesive is applied to the corrugated web portion. Subsequently, the printed web 48 is joined with the single-faced web 36 at the roll station 60 and is delivered through the backing machine 56 where the joined webs are heated by electric heaters 61 and the adhesive is cured so that the single-faced web 36 and the printed web 48 are joined together to form a double-backed web 62. The web 62 moves to rolls designated at 64 which form a conveyor means for discharging the web 62 from the backlng machine 56.
The double-backed web 62 having a corrugated core and backing at opposite sides is moved through the backing machine 56 at a speed determined by a motor 66 regulated by a control mechanism 6~.
From the double-backer machine 56 the web 62 is delivered through an accumulator station 70 and through a cut-ting and scoring press or station 72.
The press includes a stationary die 74 and a reciprocating die 76. The reciprocating die 76 is moved up and down vertically at a uniform speed. As Compa~ ~-3()3 ~2~5~
-the web 62 enters the reciprocati.ng press 72, the dies 74 and 76 meet to cut and score the web 62. During such cutting and scoring the web 62 must be momentarily stopped. Nevertheless, the die 76 can be reciprocated at a relatively fast rate, for example, approximately 75 cycles per minute during which time the longitudinally and transversely extending score lines are formed and the perimeter oE the carton 12 is cut.
The web 62 must be supplied to the press 72 in-termittently by supply rolls 78 which must supply the web 62 in a rnotion synchronized to the motion of the press 72. More particularly, the web 62 must be delivered in accordance with the position of the pre-printed material 27 and 28 on the web 62. Such synchron-ization is accomplished by a scanner 80 disposed along one edge of the web 62 to sense the position of the registration marks 60 and signal a control system 82 which regulates a motor mechanism 84 driving the supply xolls 78 in synchronization with the reciprocation of the die 76. In this manner, the press 72 reclprocates at a constant rate and the supply rolls 78 deliver the printed double-backed web material 62 intermittently through the press 72 to insure that the cutting and scoring portions of the dies 74 and 76 are appropriately aligned with the printed markings 27 and 28. If the position of the pre-printed materials 27 and 28 should vary, so also will the position of the registration marks 50 and the intermitten-t rate of the supply . rolls 78 will be similarily varied to insure that the position of the printed material is properly synchronized Com~a~ ~-303 ~,~?,~3~ ~ ~
with the movement of the dies 74 and 76 rela-tive to each otherr The accumula-tor station 70 disposed between the rolls 6~ and -the supply roll 78 of the press 72 must accomodate the problem of receiving the web 62 at a relative continuous rate from the rolls 64 dis-posing or delivering the web 62 intermittently at the supply rolls 78. Alsol both the continuous delivery rate from the accumulator 70 are variable. Both sets of rolls 64 and 78 are operated simultaneously but substantially independently of each other although the rates of operation are selected to be generally similar.
The accumulator station 70 includes a pair Oe similar but oppositly extending flexible support members 86 in the form of bent, flexible rods made of material such as fiberglass reinforced resin, for ex-ample. Each of the support rods 86 is bent into a general U-shape with a bight portion 88 adapted to be disposed at the underside of the web 62 and a pair of legs 90 extending from the bight 88 and having their free ends fixed by brackets 92 at opposite of the path of the web movement and associated with the backing machine 56 and with the press 72.
As seen in Figures 5 and 6 the brackets 92 include stacked washers 93, 94 and 95 which clamp each of the legs 90 to a rod 96 transversly to the path of movement of the web 62 by means of a bolt 97.
The bracket arrangements 92 make it possible to adjust the inclination of the support rods 86 relative to the Compak A-303 55~;~
transverse rods 96 so that the web 62 passing over the bight portions 88 deflects the suppor-t rods 86 and resiliently supports the web 62.
The web 62 passes from the rolls 64 and over the bight portion 88 of the rod element 86 associated with the backing machine 56 and over the bight 88 of the other rod element associated with the press 72.
As shown in Figure l, the web 62 which is flexible due to the transversly extending corrugations, drapes between the two bight portions 88 to form a loop lO0 which varies in length from a maximum indicated in the full line position in Figure l to a minimum 1ndi-cated in broken line at 102. In the maximum length position of the loop lO0, the web 62 engages a switch mechanism 104 which sends a signal to the control mechanism 68 regulating the speed of the motor 66.
Control mechanism 68 may be of a type which controls the motor 66 to operate at either a maximum speed or a minimum speed, with both of such speeds being select-- 20 able.
As the web 62 1eaves the delivery rolls 64 and is draped in the maximum length position shown at lO0 in Figure l, switch 104 is engaged to cause the motor to drive the rolls 64 at its lowest selected speed. Eventually this will cause the supply rolls 78 to transport the web fi2 at a faster rate than ,it is being delivered by the rolls 64. This results in the web 62 r,~oving toward the minimum length position indicated at 102 and out of engagement with the control switch 104.
Such movement :results in regulating the control 68 so ~.2~5~i~
that the motor 66 increases its speed to the selected maximum rate and the web 62 is subsequently delivered from the rolls 64 at a higher rate. Eventually, if the web 62 again comes into engagement with the switch 104, speed of the delivery from backing machine 56 will be diminished. In this manner the web 62 is draped in a position varying between its maximum length at 100 and its minimum length at 102. During such movement of the web 62, the rod elements 86 act to support the web 62 and permit it to move vertically and horizontally in undulating motions which are absorbed by the rod elements 86.
In actual practice it was found that glass rods having a diameter of about one-half of an inch were adequate to support a length of relatively heavy . ~eight of corrugated paper stock.
After the cut and scored web 62 leaves the cutting and scoring station or press 72 the box blanks 12 can be separated from the scrap portion of the web 62 and the cut and scored blanks 12 can be stacked in unfolded condition for shipment to a point at which they can be assemhled to receive the materials to be packaged.
The successful operation and synchronization of the continuously moving web with the intermittently opera-ting presC, 72 relies on the longitudinal flexibility of the corrugated, double-hacked material so that it can assume a draped position between the rods 86 associated with the backing machine 56 and the press 72.
As flexibility is relatively easily achieved with thinner _g_ .
, ,.
Compak A-3 n 3 ~2~5~3 . .
sizes of corrugated double-backed material. However, when the corrugated web material is of a thicker dimension the longitudinal stiffness of the material is increased so that i-t does not easily form a loop between the positions indicated at 100 and ln2 in Figure 1. with thinner webs of corrugated material the threading of the material between the roll 42 from the accumulator 40 the the glue station indicated at 48 can be over roll 110 and as indicated in dotted lines at 112 over a pair of rolls 114 and 116 to the glue station 58. This path of movement as indicated in part by the lines 112, bypasses scoring apparatus indicated at 120. The scoring apparatus 120 includes a pair or rotating cyliners 122 and 124 the rotation of which is synchronized with the printing machinel46 by drive means 126. The cylinder 124 is provided with a bar 128 which e~tends the full length of the cylinder 124 and transversly to the direction of travel of the web 36. When the web 36 is of a heavier material it is threaded between the rolls 114 and 116 over the cylinder 122 so that the web 36 passes through the nip between the rolls 122 and 124 and thereafter to the glue station 58.
As the cylinders 122 and 124 rotate in unison and ln synchronization with the printing machine 46, the bar 138 engages a single corrugation and crushes it to form a crushed corrugation 132 is in a predetermined fi~ed relationship relative to the ~
registration marks 50 printed on the web 48 coming from the printing machine 46 and in uniformly spaced 5~i~
relationship as illustrated, for example, in Figure 3~
After leaving the scoring apparatus 120, the single backed corrugated web 36 passes under roll 116 to the glue station 58. The glue station 58 includes a glue application roll 134 which applies glue to the corrugations 130 of the web 126.
The adhesive which can be in the nature of a solution of corn starch is applied only to the tips of the corrugations 130 leaving the crushed corrugation 132 without any adhesive.
Subsequently, at the roll station 60 forming the entry to the backing machine 56, the web 36 and the prin-ted web 48 are brought into contact wi-th each other and after passing through the backing machine ~6 results in the finished double-backed web 62 which is delivered from the roll station 64. Since adhesive is not applied to the crushed corrugation 132 a line of weakening is formed which extends transversely of the web 62 as indicated at the crushed corrugation 132 in Figure 8. As a result as the web 62 enters the accumulator station 70 and passes over the flexible rod 86, the web 62 folds due to it own weight along the resultant line of weakening so that it is free to assume the looped position between the positions indicated at 100 and 102. This permits operation of the accumulator 70 to properly synchronize the delivery of the web 62 to the reciprocating press 72.
In effect the scoring apparatus 120 forms a false score that weakens the web 62 so that it can fold in either direction.
The line of weakening is located at the edge of each box or carton blank 12. In other words, the spaced apart a distance equal to the dimension ~ss~;~
of a single box blank 12 and occur at the opposite edges of the portion from which the blank 12 is formed.
To conver-t the apparatus from an arrangement to handle relatively heavy corrugated material to one processing corrugated materials which are move flexible longitudinally, it is possible t:o bypass the scoring apparatus 120 by rethreading the web 36 to travel in the path indicated by broken lines 112 in Figure 1.
The method and apparatus for forming web material and particularly corrugated double-backed material into foldable box blanks has been provided in which single-backed corrugated web material and a pre-printed web of material are joined together to form a double-backed, printed corrugated web from which foldable box blanks are cut and scored by a reciprocating press.
The press receives the web of material intermittently from an accumulator mechanism which receives the double-backed corruga-ted material. The accumulator receives material continuously at a rate varying between a maximum and a minimum and delivers it to the press at an intermittent rate which causes the web material in the accumulator to vary between a maximum and a minimum.
Means are provided responding to the variable length of the web material passinq through the accumulator so that when the web material therein is at a maximum length, the delivery of web material to the accumulator is reduced to a minimum and when the length of material is at a minimum, the rate of delivery is increase~, there-by making it possible to form foldable pre-printed box blanks of corrugated material by employing a reciprocating ~ss~
press. The accumulator relies on the longitudinal flexibility of the web of corrugated material and such flexibility is enhanced in heavier grades of corrugated stock by an apparatus which forms lines of weakening permitting transverse folding of the web at uniformly spaced locations.
This invention relates to the apparatus and method of making double-faced, corrugated boxes with printing thereon and more particularly, for making such boxes in a continuous process.
Heretofore, boxes formed or corrugated material with flat sheets at opposite sides of a corrugated coil were made by severing the three-layered material into individual boards and subsequently, printing, cutting, and scoring in multiple stages of operations. The corrugated material presents problems in attempting to use contlnuous processes because of the rigidity of the material which prevents sufficient flexibility for rotary opera-tions.
It is an object of the invention to provide a method and apparatus for forming a printed, corrugated - box from a continuous web of double-faced corrugated material, one face of which is printed.
It is another object of the invention to provide apparatus for forming printed corrugated boxes in which the web of material is delivered continuously to a reciprocating press at which the web ma-terial is ~ . . .
cut and scored.
Still another object of the invention is to provide an accumulator arrangement in which web material is supported in a manner receiving the material cont~nuously and delivering it intermittently.
It is an object of the invention to provide a method and apparatus of forming printed corrugated boxes continuously in which means are provided to add flexibility to a web of corru~ated material making s~i~
it possible to use equipment for handling flexible webs.
The objects of the invention are accomplished by apparatus in which a web of paper mat;erial is printed with various indicia and messages including a printed reference mark and wherein another web of single back corrugated paper web is formed. The printed web and the single-backed web are joined -toge-ther to form a double-backed continuous web of printed corrugated web material. ~he double-backed printed material is delivered continuously from a firs-t station to an accumulator and from the accumulator the material is delivered at an intermittent rate to a reciprocating press in which the web material is cut and scored to form a box blank. Between the first and second station is an accumulator which suspends the web material with the length of web between the first and second stations varying between a maximum and a minimum. Control means are provided for regulating the speed of delivery from the first station so that the speed varies between a maximum and minimum. Such speed is varied under the influence of control means which respond to the maximum length of material in the accumulator to cause delivery at a minimum rate and respond to a minimum length of material in the accumulator to deliver the web at a maximum rate. ~eans also are provided to make even thick corrugated material which normally is very stiff and substantially inflexible adapted for use in an accumulator which requires longitudinally Flexible materials by making spaced false scoring or lines of Compak A-3n3 ~2~.S~
weakening -to make the otherwise relatively stiff material sufficiently flexible for use with the accumulator.
The objects of the invention are accomplished by the embodin;ent disclosed in t:he following description and illustrated in the drawings in which:
Figure 1 is a diagramrnatic view of the apparatus for continuously forming foldable box blanks of pre-printed corrugated material;
Fi-~ure 2 illustrates an example of the type oE
~o~ blank that can be formed;
Figure 3 is a bottom view of a portion of the double-faced corrugated material after it has been printed, Figure 4 is a diagrammatic view of a portion of the apparatus illustrated in Figure l;
Figure 5 is an enlarged top view of a portion of a clamping element shown in Figure 4;
Figure 6 is a side view of the clamping arrange-ment illustrated in Figure 5;
Figure 7 is a view of a section of the corrugated material as it appears in one stage of the method of forming box blanks; and Figure 8 is a view showing a section of the corrugated material as it appears in a la-ter stage of the blanking operation.
Figure 1 il]ustrates the apparatus by which foldable carton 12, that is, blanks of pre-printed corrugated material, such as shown in Figure 2 can be produced for subsequent assembly. Such cartons 12 can take a variety of shapes but by way of example can have Compak A-303 ~2~55;~
four sides 14 foldable along longitudinally ex-tending score or crease lines 16. The sides 14 are foldable along the score lines 16 and a tab 18 attached -to one of the sides may be glued to the side at the opposite edge of the blank 12. Similarily, bottom tabs 2 and 21 can be folded along transversly extending score line 22 and glued to form the bottom of the carton. Side flaps 23 and box cover 24 can be folded along score line 25 to close the top of the box. The box blank 12 can be pre-printed in one or more colors at locations - shown for example by the markings 27 and 28.
The carton 12 is made of double-faced corrugated paper formed in the initial stages of the carton forming apparatus 10. As seen in Figure 1 a paper web 30 is delivered to a corrugating machine 32 and results in a corrugated web 34 which is bonded to a web 35 to form a single-faced web 36. The web 36 has corrugations which extend generally transversly making the web 36 relatively stiff in a transverse direction but permitting flexibility in a longitudinal direction. This makes it possible for the web 36 to be temporarily stored at an accumulator station indicated at 40. The accumulator station 40 can be in the form of a platform 41 per-mitting the web 36 to be in a slack condition for removal from the accumulator qO on demand from a roll 42 forming a Eirst conveyor.
Paper stock in the form of a weh 44 can be delivered on demand to a printing machine 46. In the printing machine 46, the web 44 can be printed in one or more colors with various messag~s and designs Comp~k ~-303 iS~
and delivered from the machine in the form of a printed web 48 includes the printed markings 27 and 28 also seen in the carton blank l2 in the Figure 2. In addition, the web 48 is printed with registration marks 50 along the margin of the printed web 48.
The printed web 48 is delivered Erom the printer 46 over rolls 52 to a backing machine 56 sometimes called a double-backer. The sinyle-faced web 36 also is delivered to the backing machine 56 after it has first passed through a gluing station 58 at which adhesive is applied to the corrugated web portion. Subsequently, the printed web 48 is joined with the single-faced web 36 at the roll station 60 and is delivered through the backing machine 56 where the joined webs are heated by electric heaters 61 and the adhesive is cured so that the single-faced web 36 and the printed web 48 are joined together to form a double-backed web 62. The web 62 moves to rolls designated at 64 which form a conveyor means for discharging the web 62 from the backlng machine 56.
The double-backed web 62 having a corrugated core and backing at opposite sides is moved through the backing machine 56 at a speed determined by a motor 66 regulated by a control mechanism 6~.
From the double-backer machine 56 the web 62 is delivered through an accumulator station 70 and through a cut-ting and scoring press or station 72.
The press includes a stationary die 74 and a reciprocating die 76. The reciprocating die 76 is moved up and down vertically at a uniform speed. As Compa~ ~-3()3 ~2~5~
-the web 62 enters the reciprocati.ng press 72, the dies 74 and 76 meet to cut and score the web 62. During such cutting and scoring the web 62 must be momentarily stopped. Nevertheless, the die 76 can be reciprocated at a relatively fast rate, for example, approximately 75 cycles per minute during which time the longitudinally and transversely extending score lines are formed and the perimeter oE the carton 12 is cut.
The web 62 must be supplied to the press 72 in-termittently by supply rolls 78 which must supply the web 62 in a rnotion synchronized to the motion of the press 72. More particularly, the web 62 must be delivered in accordance with the position of the pre-printed material 27 and 28 on the web 62. Such synchron-ization is accomplished by a scanner 80 disposed along one edge of the web 62 to sense the position of the registration marks 60 and signal a control system 82 which regulates a motor mechanism 84 driving the supply xolls 78 in synchronization with the reciprocation of the die 76. In this manner, the press 72 reclprocates at a constant rate and the supply rolls 78 deliver the printed double-backed web material 62 intermittently through the press 72 to insure that the cutting and scoring portions of the dies 74 and 76 are appropriately aligned with the printed markings 27 and 28. If the position of the pre-printed materials 27 and 28 should vary, so also will the position of the registration marks 50 and the intermitten-t rate of the supply . rolls 78 will be similarily varied to insure that the position of the printed material is properly synchronized Com~a~ ~-303 ~,~?,~3~ ~ ~
with the movement of the dies 74 and 76 rela-tive to each otherr The accumula-tor station 70 disposed between the rolls 6~ and -the supply roll 78 of the press 72 must accomodate the problem of receiving the web 62 at a relative continuous rate from the rolls 64 dis-posing or delivering the web 62 intermittently at the supply rolls 78. Alsol both the continuous delivery rate from the accumulator 70 are variable. Both sets of rolls 64 and 78 are operated simultaneously but substantially independently of each other although the rates of operation are selected to be generally similar.
The accumulator station 70 includes a pair Oe similar but oppositly extending flexible support members 86 in the form of bent, flexible rods made of material such as fiberglass reinforced resin, for ex-ample. Each of the support rods 86 is bent into a general U-shape with a bight portion 88 adapted to be disposed at the underside of the web 62 and a pair of legs 90 extending from the bight 88 and having their free ends fixed by brackets 92 at opposite of the path of the web movement and associated with the backing machine 56 and with the press 72.
As seen in Figures 5 and 6 the brackets 92 include stacked washers 93, 94 and 95 which clamp each of the legs 90 to a rod 96 transversly to the path of movement of the web 62 by means of a bolt 97.
The bracket arrangements 92 make it possible to adjust the inclination of the support rods 86 relative to the Compak A-303 55~;~
transverse rods 96 so that the web 62 passing over the bight portions 88 deflects the suppor-t rods 86 and resiliently supports the web 62.
The web 62 passes from the rolls 64 and over the bight portion 88 of the rod element 86 associated with the backing machine 56 and over the bight 88 of the other rod element associated with the press 72.
As shown in Figure l, the web 62 which is flexible due to the transversly extending corrugations, drapes between the two bight portions 88 to form a loop lO0 which varies in length from a maximum indicated in the full line position in Figure l to a minimum 1ndi-cated in broken line at 102. In the maximum length position of the loop lO0, the web 62 engages a switch mechanism 104 which sends a signal to the control mechanism 68 regulating the speed of the motor 66.
Control mechanism 68 may be of a type which controls the motor 66 to operate at either a maximum speed or a minimum speed, with both of such speeds being select-- 20 able.
As the web 62 1eaves the delivery rolls 64 and is draped in the maximum length position shown at lO0 in Figure l, switch 104 is engaged to cause the motor to drive the rolls 64 at its lowest selected speed. Eventually this will cause the supply rolls 78 to transport the web fi2 at a faster rate than ,it is being delivered by the rolls 64. This results in the web 62 r,~oving toward the minimum length position indicated at 102 and out of engagement with the control switch 104.
Such movement :results in regulating the control 68 so ~.2~5~i~
that the motor 66 increases its speed to the selected maximum rate and the web 62 is subsequently delivered from the rolls 64 at a higher rate. Eventually, if the web 62 again comes into engagement with the switch 104, speed of the delivery from backing machine 56 will be diminished. In this manner the web 62 is draped in a position varying between its maximum length at 100 and its minimum length at 102. During such movement of the web 62, the rod elements 86 act to support the web 62 and permit it to move vertically and horizontally in undulating motions which are absorbed by the rod elements 86.
In actual practice it was found that glass rods having a diameter of about one-half of an inch were adequate to support a length of relatively heavy . ~eight of corrugated paper stock.
After the cut and scored web 62 leaves the cutting and scoring station or press 72 the box blanks 12 can be separated from the scrap portion of the web 62 and the cut and scored blanks 12 can be stacked in unfolded condition for shipment to a point at which they can be assemhled to receive the materials to be packaged.
The successful operation and synchronization of the continuously moving web with the intermittently opera-ting presC, 72 relies on the longitudinal flexibility of the corrugated, double-hacked material so that it can assume a draped position between the rods 86 associated with the backing machine 56 and the press 72.
As flexibility is relatively easily achieved with thinner _g_ .
, ,.
Compak A-3 n 3 ~2~5~3 . .
sizes of corrugated double-backed material. However, when the corrugated web material is of a thicker dimension the longitudinal stiffness of the material is increased so that i-t does not easily form a loop between the positions indicated at 100 and ln2 in Figure 1. with thinner webs of corrugated material the threading of the material between the roll 42 from the accumulator 40 the the glue station indicated at 48 can be over roll 110 and as indicated in dotted lines at 112 over a pair of rolls 114 and 116 to the glue station 58. This path of movement as indicated in part by the lines 112, bypasses scoring apparatus indicated at 120. The scoring apparatus 120 includes a pair or rotating cyliners 122 and 124 the rotation of which is synchronized with the printing machinel46 by drive means 126. The cylinder 124 is provided with a bar 128 which e~tends the full length of the cylinder 124 and transversly to the direction of travel of the web 36. When the web 36 is of a heavier material it is threaded between the rolls 114 and 116 over the cylinder 122 so that the web 36 passes through the nip between the rolls 122 and 124 and thereafter to the glue station 58.
As the cylinders 122 and 124 rotate in unison and ln synchronization with the printing machine 46, the bar 138 engages a single corrugation and crushes it to form a crushed corrugation 132 is in a predetermined fi~ed relationship relative to the ~
registration marks 50 printed on the web 48 coming from the printing machine 46 and in uniformly spaced 5~i~
relationship as illustrated, for example, in Figure 3~
After leaving the scoring apparatus 120, the single backed corrugated web 36 passes under roll 116 to the glue station 58. The glue station 58 includes a glue application roll 134 which applies glue to the corrugations 130 of the web 126.
The adhesive which can be in the nature of a solution of corn starch is applied only to the tips of the corrugations 130 leaving the crushed corrugation 132 without any adhesive.
Subsequently, at the roll station 60 forming the entry to the backing machine 56, the web 36 and the prin-ted web 48 are brought into contact wi-th each other and after passing through the backing machine ~6 results in the finished double-backed web 62 which is delivered from the roll station 64. Since adhesive is not applied to the crushed corrugation 132 a line of weakening is formed which extends transversely of the web 62 as indicated at the crushed corrugation 132 in Figure 8. As a result as the web 62 enters the accumulator station 70 and passes over the flexible rod 86, the web 62 folds due to it own weight along the resultant line of weakening so that it is free to assume the looped position between the positions indicated at 100 and 102. This permits operation of the accumulator 70 to properly synchronize the delivery of the web 62 to the reciprocating press 72.
In effect the scoring apparatus 120 forms a false score that weakens the web 62 so that it can fold in either direction.
The line of weakening is located at the edge of each box or carton blank 12. In other words, the spaced apart a distance equal to the dimension ~ss~;~
of a single box blank 12 and occur at the opposite edges of the portion from which the blank 12 is formed.
To conver-t the apparatus from an arrangement to handle relatively heavy corrugated material to one processing corrugated materials which are move flexible longitudinally, it is possible t:o bypass the scoring apparatus 120 by rethreading the web 36 to travel in the path indicated by broken lines 112 in Figure 1.
The method and apparatus for forming web material and particularly corrugated double-backed material into foldable box blanks has been provided in which single-backed corrugated web material and a pre-printed web of material are joined together to form a double-backed, printed corrugated web from which foldable box blanks are cut and scored by a reciprocating press.
The press receives the web of material intermittently from an accumulator mechanism which receives the double-backed corruga-ted material. The accumulator receives material continuously at a rate varying between a maximum and a minimum and delivers it to the press at an intermittent rate which causes the web material in the accumulator to vary between a maximum and a minimum.
Means are provided responding to the variable length of the web material passinq through the accumulator so that when the web material therein is at a maximum length, the delivery of web material to the accumulator is reduced to a minimum and when the length of material is at a minimum, the rate of delivery is increase~, there-by making it possible to form foldable pre-printed box blanks of corrugated material by employing a reciprocating ~ss~
press. The accumulator relies on the longitudinal flexibility of the web of corrugated material and such flexibility is enhanced in heavier grades of corrugated stock by an apparatus which forms lines of weakening permitting transverse folding of the web at uniformly spaced locations.
Claims (12)
1. The method of making pre-printed cartons comprising the steps of: forming a continuous single-backed corrugated paper web, including forming uniformly spaced corrugations extending transversely of the direction of web travel and crushing single corrugations at uniformly spaced intervals along said web to form lines of weakening, printing a continuous web of paper material with printed reference marks, joining said corrugated paper web and said continuous web of material to form a continuous double-back printed paper web, conveying said printed paper web from a first station to a second station, supporting said web in a slack condition between said first and second station while said web varies between a maximum and a minimum length passing said web from said second station relative to a sensing means sensing the position of said reference marks, delivering said web to a press reciprocating at a uniform rate in timed relationship to the spacing of said reference marks, and varying the speed of said web delivered to said first station in accordance with the length of said web between said first and second stations, adding adhesive to all corrugations of said single-backed corrugated paper web except said single corrugations prior to joining said continuous web and said single-backed corrugated web.
2. The method of making pre-printed cartons set forth in claim 1 wherein said single corrugations are disposed in predetermined relationship to said reference marks.
3. Apparatus for forming web material into foldable box blanks comprising: supply means forming a preprinted web, a reciprocating press including dies engagable with said web to cut and score blanks for forming boxes, said press reciprocating continuously at a substantially uniform rate, feed means continuously delivering said web intermittently to said press in timed relationship to the reciprocation of said press, an accumulator mechanism interposed between said supply means and said feed means to hold a length of web and intermittently deliver it to said feed means, power means for said supply means to vary the rate of deliver to said web from said supply means between a minimum and a maximum rate and a minimum rate to vary the length of web material in said accumulator mechanism between maximum length and a minimum length, and control means reponsive to a minimum length of said web in said accumulator mechanism to increase the speed of said power means and responsive to a maximum length of said web in said accumulator mechanism to decrease the speed of said power means, said control means being engageable with said web when the length of web in said accumulator mechanism is at a maximum and movable out of engagement with said web when said accumulator mechanism is at a minimum, said accumulator mechanism including resilient means supporting said web.
4. The apparatus of claim 3 wherein said resilient means includes flexible members engaging the underside of said web and suspending it in elevated position above said control means.
5. The apparatus of claim 4 wherein said resilient means are elongated flexible members having a generally U-shaped configuration with the free ends supported at opposite sides of said web and the bight portion engaging the underside of said web.
6. The apparatus of claim 5 wherein said flexible rod is made of fiberglass reinforced resin.
7. Apparatus for making printed corrugated boxes comprising: means for making a corrugated web of single-backed paper, means for printing a continuous web of material with uniformly spaced areas of printing, means bonding said single-backed web and printed web together to form a corrugated continuous printed web, a conveyor for transporting said corrugated continuous web continuously and at a speed varying between minimum and a maximum, a reciprocating press including dies engageable with said web to cut and score a blank for forming a box, said press being reciprocated continuously at a substantially uniform rate, supply means operable to deliver said web to said press, means for sensing said areas of printed material on said web for regulating the speed of said supply means in timed sequence with said press, accumulator means between said conveyor and said supply means for receiving and storing a variable length of said continuous printed web in a draped condition between said conveyor and said supply means, and means sensing the length of web in said accumulator means and operative to control the rate of delivery of said web from said conveyor to said accumulator means.
8. The apparatus of claim 7 wherein the web received in said accumulator means varies between a maximum and a minimum length, control means responsive to the maximum length of said web to decrease the speed of said conveyor and responsive to a minimum length of said web to increase the speed of said conveyor.
9. The apparatus of claim 8 wherein said control means is engageable with said web when the length of web in said accumulator means is at a maximum and is movable out of engagement with said web when the length within said accumulator means is at a minimum.
10. The apparatus of claim 7 and further comprising scoring means operative on said single-backed web to form a transverse line of weakening for permitting folding of said double-backed web at said accumulator means.
11. The apparatus of claim 10 wherein said scoring means includes a means for crushing a single corrugation of said single-backed web at a predetermined spacing relative to each of said areas of printing.
12. The apparatus of claim 11 wherein said means bonding is operative to apply adhesive to all corrugations of said single-backed web except said single corrugations to form said lines of weakening.
17.
17.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US37734582A | 1982-05-12 | 1982-05-12 | |
| US377,345 | 1982-05-12 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1215568A true CA1215568A (en) | 1986-12-23 |
Family
ID=23488744
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000423984A Expired CA1215568A (en) | 1982-05-12 | 1983-03-18 | Apparatus and method for making cartons |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1215568A (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN107253350A (en) * | 2017-07-26 | 2017-10-17 | 安庆奥迪斯丹包装有限公司 | A kind of corrugated case flanging assembling device |
| US10642551B2 (en) | 2017-07-14 | 2020-05-05 | Georgia-Pacific Corrugated Llc | Engine for generating control plans for digital pre-print paper, sheet, and box manufacturing systems |
| US11449290B2 (en) | 2017-07-14 | 2022-09-20 | Georgia-Pacific Corrugated Llc | Control plan for paper, sheet, and box manufacturing systems |
| US11485101B2 (en) | 2017-07-14 | 2022-11-01 | Georgia-Pacific Corrugated Llc | Controls for paper, sheet, and box manufacturing systems |
| US11520544B2 (en) | 2017-07-14 | 2022-12-06 | Georgia-Pacific Corrugated Llc | Waste determination for generating control plans for digital pre-print paper, sheet, and box manufacturing systems |
| US11807480B2 (en) | 2017-07-14 | 2023-11-07 | Georgia-Pacific Corrugated Llc | Reel editor for pre-print paper, sheet, and box manufacturing systems |
-
1983
- 1983-03-18 CA CA000423984A patent/CA1215568A/en not_active Expired
Cited By (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10642551B2 (en) | 2017-07-14 | 2020-05-05 | Georgia-Pacific Corrugated Llc | Engine for generating control plans for digital pre-print paper, sheet, and box manufacturing systems |
| US11093186B2 (en) | 2017-07-14 | 2021-08-17 | Georgia-Pacific Corrugated Llc | Engine for generating control plans for digital pre-print paper, sheet, and box manufacturing systems |
| US11449290B2 (en) | 2017-07-14 | 2022-09-20 | Georgia-Pacific Corrugated Llc | Control plan for paper, sheet, and box manufacturing systems |
| US11485101B2 (en) | 2017-07-14 | 2022-11-01 | Georgia-Pacific Corrugated Llc | Controls for paper, sheet, and box manufacturing systems |
| US11520544B2 (en) | 2017-07-14 | 2022-12-06 | Georgia-Pacific Corrugated Llc | Waste determination for generating control plans for digital pre-print paper, sheet, and box manufacturing systems |
| US11807480B2 (en) | 2017-07-14 | 2023-11-07 | Georgia-Pacific Corrugated Llc | Reel editor for pre-print paper, sheet, and box manufacturing systems |
| US11907595B2 (en) | 2017-07-14 | 2024-02-20 | Georgia-Pacific Corrugated Llc | Control plan for paper, sheet, and box manufacturing systems |
| US11911992B2 (en) | 2017-07-14 | 2024-02-27 | Georgia-Pacific Corrugated Llc | Controls for paper, sheet, and box manufacturing systems |
| CN107253350A (en) * | 2017-07-26 | 2017-10-17 | 安庆奥迪斯丹包装有限公司 | A kind of corrugated case flanging assembling device |
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