CA2110766A1

CA2110766A1 - Method and apparatus for forming packages

Info

Publication number: CA2110766A1
Application number: CA002110766A
Authority: CA
Inventors: Roland Zinzius
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-12-06
Filing date: 1993-12-06
Publication date: 1995-06-07

Abstract

An apparatus for converting a one-piece paperboard blank into a packaging tray comprises an upright magazine for storing a stack of paperboard blanks, a feeding device beneath the magazine for removing the blanks one by one and advancing the blanks to a forming station, and a forming and gluing device for simultaneously folding and gluing the blank to form an upright tray. The forming and gluing device includes a plunger moving in a vertical axis. The plunger includes a press means corresponding to the dimensions of the bottom panel. The forming station further has a frame defining an opening to accommodate the plunger in its movement along the vertical axis and includes upwardly and outwardly sloped walls defining the opening. The sloped walls engage the second and third panels of the blank to form side and rear panels of the tray. A glue applicator is used to add glue to the glue flaps and to fold the glue flaps onto the other of said second and third panels in order to complete the formation of the tray.

Description

l 2110766 The present invention relates to a method and apparatus for forming packages, and more parti-cularly, to forming a tray from a blank.
There are many mechanical devices for handling paperboard blanks and forming various types of packaging. However, such equipment is often complex while using many moving parts.
It is an aim of the present invention to provide a simple apparatus for forming paperboard trays, such as trays for packaging a plurality of individual-serving yogurt containers.
It is a further aim of the present invention to provide an improved method of drawing paperboard blanks from a stack and forming the blank into a tray.
A construction in accordance with the present invention comprises a substantially upright magazine for storing a stack of paperboard blanks, wherein each blank includes a first rectangular panel to define a bottom wall of the tray and second and third panels adjacent the first panel and joined thereto by fold lines. The second and third panels define side and end walls of the tray, and glue flaps are associated with one of the second and third panels.
A feeding means is provided beneath the magazine for advancing the blanks one by one horizontally to a form-ing station. Forming and gluing means are provided for simultaneously folding and gluing the blank to form an upright tray. The forming and gluing means includes a plunger moving in a vertical axis, wherein the plunger includes a flat plate having dimensions corresponding to the dimensions of said first panel. The forming station includes a frame having upwardly and outwardly sloped walls surrounding an opening having dimensions to receive the first panel of the blank and the plate of the plunger and the sloped walls engage the second and third panels of the blank to form the side and rear panels of the tray. Means are associated with the

- 2 _ 2110766 sloped walls to apply glue to the glue flaps and to fold the glue flaps onto the other of the second and third panels in order to complete the formation of the tray. Means are provided for advancing the tray from the forming station.
In a more specific embodiment of the present invention, the magazine is supported on a horizontal frame, and the means for advancing the blanks one by one to the forming station includes a carriage provided below the magazine and movable for a limited distance in a horizontal plane in a track provided on the frame, between a first position directly underneath the maga-zine and a second position adjacent the forming station. The carriage includes a tractive roller which is driven by a motor, and the tractive roller is effec-tive for engaging a blank on the carriage and discharging it from the carriage to the forming station when the carriage has reached its second position.
In another more specific embodiment, the forming station includes a further frame to which the plunger means is mounted. The plunger means includes a piston and cylinder arrangement to which the plate is mounted for reciprocal movement through and away from the opening along a vertical axis.
Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration, a preferred embodiment thereof, and in which:
Fig. 1 is a side elevation of an embodiment of the present invention;
Fig. 2 is a side elevation, partly in cross-section, similar to Fig. 1 and showing the apparatus in a different operative position;
Fig. 3 is a vertical cross-section, taken along line 3-3 of Fig. l;
Fig. 4 is a horizontal cross-section, taken along line 4-4 of Fig. l;

~ 3 ~ ~110766 ..
Fig. 5 is a fragmentary perspective view of a detail of the embodiment shown in Figs. 1 to 4;
Fig. 6 is a fragmentary perspective view, similar to Fig. 5, but showing the detail in a different operative position; and Fig. 7 is a fragmentary perspective view showing the detail of Fig. 5 in a still different operative position.
Referring now to Figs. 1 to 4, there is shown an apparatus for handling blanks B of relatively stiff paperboard material and advancing these blanks from a magazine 10, in which the blanks B are stacked, to a forming station 12.
A carriage 14 is associated with the maga-zine 10 to advance the paperboard blanks B one by one to the forming station 12 where the blank B is engaged by a plunger 18 to pass the blank B through forming walls 20, associated with glue applicators 22 to erect and form the tray T which is then advanced from the forming station 12 on conveyor 24.
The magazine 10 is mounted on a frame 26 and includes, in the present embodiment, four corner mem-bers 28, each of which includes two strips at right angles to form a corner and which includes a vertical component and a component 28a extending at an angle.
The corner members 28 align and maintain the blanks B.
By providing the magazine 10 with an angle, the weight of the stack of blanks B is somewhat alleviated. In addition, an adjustable stack separator 29 is provided in order to interrupt the stack of blanks B in order to further alleviate the pressure on the blanks to be fed from the weight of the stack.
Each blank B, as shown in Fig. 4, includes a bottom panel 2. Fold lines separate end panels 6 on opposite edges of the panel 2, and likewise side panels 4 are separated from the panel 2 by means of fold ~ 4 ~ 2110766 lines. Glue flaps 8 are also hinged to the side panels 4.
Below the magazine 10, and mounted to the frame 26, is a carriage 14 which is adapted to move in a horizontal plane on the frame 26 in a reciprocating movement towards and from the forming station 12.
The track 32 includes elongated slots on each side of the frame 26 relative to the magazine 10.
A carriage tray 34 is adapted to slide in the track 32.
The carriage tray 34 mounts idler rollers 36 and a driven roller 38. A piston and cylinder arrangement 40 is mounted to the frame 26 at one end and to the tray 34 by means of bracket 42 at the other end. The driven roller 38, as shown in Fig. 2, is driven by a small pneumatic motor 38a mounted on the end of the shaft driving the roller 38. The motor 38a is shown in Fig.
1.
An adjustable lip 30 is mounted on the magazine 10 at the discharge end and can be adjusted to accommodate different thicknesses of blanks B so that only one blank is sent forward at a time.
In operation, the carriage 14 on which the stack of blanks B is supported, is moved forward by operating the cylinder 40 while the roller 38 rotates counterclockwise by motor 38a, to advance a single blank B underneath lip 30, and catapults the blank B
towards its position in the forming station 12 as will be described further. When the carriage 14 has reached its limit of travel towards the forming station 12, as shown in Fig. 2, the idler rollers 36 continue to sup-port the bottom of the stack of blanks B and allow a smooth return of the carriage 14, with a minimum of friction, towards its initial position, as shown in Fig. 1. The driven roller 38 will be idle when the carriage 14 is retracted by means of the cylinder and piston arrangement 40.

- 5 - ~110766 The forming station 12 is best shown in Figs. 1 to 3. The forming station 12 includes a frame 16. The frame 16 includes uprights 52 and a transverse member 54 to which the plunger 18 is mounted, as shown in the drawings. The plunger 18 includes a cylinder and piston arrangement 44 which is fixed to the trans-- verse member 54 of the frame 16. In fact, there are two cylinders 44a and 44b in series for operating piston 45. The piston 45 mounts a plate 46 having dimensions which correspond with the panel 2 of the blank B. Plate 46 also mounts adjustable angle members 46a which can be adjusted to the dimension of the blank B.
The frame 16 also includes a bottom support member 56 to which are mounted guideways 50 in the form of tubes for accommodating sliding rods 48 which are fixed to the plate 46. Thus, on operation of the pis-ton and cylinder arrangement 44 to move the plate 46 in a vertical axis, the tubes 50 and rods 48 ensure smooth sliding of the piston 45 and the stability of the plate 46 during this movement.
The forming walls 20 are located below the support plate 56 and include sloped side walls 60.
Although the side walls 60 are illustrated in Figs. 2,

3, and 4, they are best shown in Figs. 5 through 7. As can be seen, the side walls 60 are mounted to frame elements 26a, 26b of horizontal frame 26 and include a sloped portion as well as a vertical skirt portion 60a.
The top of the sloped side wall 60 may be integral with a side channel 58 which is tapered, as shown in Figs. 2 and 5 to 7. End walls 62 are similar to the side walls 60, and the end walls including skirts 62a and side walls with skirts 60a define an opening 65. The open-ing 65 is only slightly larger in dimension than the plate 46 of the plunger 18.
Gates 59 are located beyond the forming wall section 20. Horizontal projecting plates 64 are - 6 ~ 21 107 6 6 provided at each corner. Guide plates 59a are also provided upstream of end walls 62a in order to allow the blank to enter forming station 12 but to prevent rebounding of the blank B and thus, with gates 59, maintain the blank in place.
Glue applicators 22 are mounted to the frame 16 and are located, as shown in Figs. 1, 2, and 5, in such a position as to be able to inject a dab of adhe-sive on the end walls 6 of the blank B at glue spot 9.
Each glue applicator includes a gluing head 66, a feed tube 68 which conducts the glue to the head, and a noz-zle 70 which enables a jet of adhesive to be produced onto the glue spot 9 of the end wall 6 of the blank B.
In operation, when a blank is catapulted from the magazine 10 by means of roller 38 on carriage 14, the blank B will be guided by the channel 58 and will stop when the leading edge of the blank B hits the gates 59. Channels 58, gates 59, and plates 59a locate the blank B in the forming station 12 aligned over the opening 65. The plunger 18 is then operated by activating the cylinder 44a which in turn moves the piston 45 and plate 46 to engage the bottom panel 2 of blank B. This movement downwardly entrains the blank B
in such a manner that the side walls 4 and end walls 6 of the blank B will engage the sloped side walls 60 and end walls 62 respectively, thereby forcing the side panels 4 and end panels 6 to fold upwardly. Projecting plate 64 causes flap 8 to fold more quickly and thereby extend inwardly of the end flap 6 in the succeeding forming steps, as shown in Figs. 6 and 7.
Simultaneously, a dab of glue is shot through the nozzle 70 onto glue spot 9 on the end walls 6 so that when the flap 8 comes in contact with the glue spot 9, it will affix itself to end wall 6. The piston 45 and plate 46 will stop for 0.5 seconds in order to allow the glue to set. This is also at the end of travel of cylinder 44a.

_ 7 _ 2110766 The cylinder 44b is then activated to extrude the tray T so formed onto the conveyor 24 and will be brought to a yogurt container filling station.
The plunger 18 is then retracted, and the cycle can be repeated.

Claims

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. An apparatus for converting a one-piece paperboard blank into a packaging tray comprising a substantially upright magazine for storing a stack of paperboard blanks, wherein each blank includes a first rectangular panel to define a bottom wall of the tray, and second and third panels adjacent the first panel and joined thereto by fold lines and adapted to define side and end walls of the tray, and glue flaps associated with one of the second and third panels, feeding means beneath the magazine for removing the blanks one by one and advancing the blanks to a forming station, forming and gluing means for simultaneously folding and gluing the blank to form an upright tray, the forming and gluing means including a plunger moving in a vertical axis, the plunger including a press means corresponding to the dimensions of the first panel, the forming station further having a frame defining an opening to accommodate the plunger in its movement along the vertical axis, the frame including upwardly and outwardly sloped walls defining the opening, the sloped walls engaging the second and third panels of the blank to form side and rear panels of the tray, means associated with the sloped walls to apply glue to the glue flaps and to fold the glue flaps onto the other of said second and third panels in order to complete the formation of the tray, and means for advancing the tray from the forming station.

2. An apparatus as defined in claim 1, wherein the means for feeding the blanks from the magazine and advancing them one by one to the forming station includes a frame on which the magazine is supported, a track on said frame, a carriage located below the maga-zine and movable for a limited distance in a horizontal plane on the track between a first position directly underneath the magazine and a second position adjacent the forming station, the carriage including a tractive roller which is driven by a motor and which is effec-tive for engaging a blank on the carriage and discharging it from the carriage to the forming station when the carriage has reached its second position.

3. An apparatus as defined in claim 2, wherein the carriage includes idler rollers supporting the stack of blanks.

4. An apparatus as defined in claim 1, wherein the forming station includes a further frame to which the plunger means is mounted, the plunger means includ-ing a piston and cylinder arrangement including a pair of cylinders in series to which the press means is mounted for reciprocal movement through and away from the opening along said vertical axis, whereby the downward movement of the plunger is momentarily stopped to allow the glue to set before continuing to extrude the tray being formed.

5. An apparatus as defined in claim 1, wherein the magazine includes a first lower portion which is vertical and a second upper portion which extends at an angle in order to alleviate the weight of the stack of blanks on the carriage tray.

6. An apparatus as defined in claim 4, wherein tapered channel-shaped guide members are provided on either side of the frame parallel to the path of travel of the carriage and the blanks, said guide members guiding the blank so as to arrive over the opening defined by the forming walls and whereby the first panel can be engaged by the press means of the plunger for movement through the opening whereby the second and third panels are engaged by the sloped walls to fold the second and third panels of the blank in order to erect said tray from the blank, and glue means for adhering the glue flaps on one of the second and third panels to the other of the second and third panels.

7. An apparatus as defined in claim 6, wherein the piston and the pair of cylinders extend vertically of said frame with said press means mounted to the end of the piston rod, and guide members are arranged in the frame for guiding the movement and orientation of the press means.

8. An apparatus as defined in claim 7, wherein the press means is in the form of a plate having adjustable edge members to conform to the dimensions of the first panel.

9. A method of forming a packaging tray from a blank, wherein the blank includes a first rectangular panel to define a bottom wall of the tray, and second and third panels adjacent the first panel and joined thereto by fold lines and adapted to form side and end walls of the tray, including the steps of feeding the blanks one by one from a substantially vertical stack to a forming station, extruding the blanks through the forming station by first pressing the first panel a first distance through an opening defined to the dimensions of the first opening so that the second and third panels fold to form the walls of the tray, simultaneously applying glue to select ones of the glue flaps and the third panels allowing the glue to set, and pressing the first panel through a second distance to complete the extrusion of the tray.