ES2507556T3 - Method for creating multi-wall containers - Google Patents

Abstract

A method for creating a multi-wall container precursor (22, 122) from a single blank of material that defines a longitudinal direction from a first end to a second end, the method comprising: defining an inner panel (40) that forms the inner side walls of the container when mounted, the inner panel comprising a plurality of inner portions of the panel (42, 44, 46, 48), each inner panel portion adjoining any adjacent inner panel portion and each inner panel portion comprising an inner side wall of the container when mounted; defining at least one pair of opposing intermediate fins (50) extending from the inner panel (40) to a distal edge (53 a / b, 55 a / b, 57 a / b, 59 a / b) and where each central fin (50) comprises a plurality of fin portions (52 a / b, 54 a / b, 56 a / b, 58 a / b), bordering each fin portion with any adjacent fin portion and each pair comprising opposite portions of fin an intermediate side wall of the container when mounted; defining an outer panel (60) that extends from the inner panel (40) and forms the outer side walls of the container when mounted, the outer panel comprising a plurality of outer portions of the panel (62, 64, 66, 68), bordering each outer panel portion with any adjacent outer panel portion and each outer panel portion comprising an outer side wall of the container when mounted; and retract at least one pair of opposing intermediate fins (50) to approximate their respective distal edges (53 a / b, 55 a / b, 57 a / b, 59 a / b) with each other and attach them to the inner panel (40) , thereby forming intermediate side walls when the die is assembled in the container, characterized in that the sum of the lateral length of the pair of intermediate fins from its intersection (43 a / b, 45 a / b, 47 a / b, 49 a / b) with the inner panel (40) to the distal edge is equal to or less than the side length of the inner panel from the intersection of a first opposite intermediate fin (53a, 55a, 57a, 59a) to the intersection of a second opposite intermediate fin (53b, 55b, 57b, 59b).

Description

Method for creating multi-wall containers

5 Background of the invention

Large format containers, which are generally referred to as "containers", are used to maintain a variety of materials, usually for transport, but also for retail display. Because more than 95% of all products in the US are shipped in corrugated cardboard boxes, and

10 Due to the cost advantages associated with this form of packaging, most of the containers are constructed from corrugated cardboard. But while about 90% of all corrugated cardboard is single-wall, the relatively large dimensions of containers in conjunction with the nature of the products placed in the containers require the additional force provided by the construction of multiple walls.

The prior art is replete with several methods for establishing a desired level of resistance to the side wall bursting, lower crush resistance and vertical load capacity for containers. Some solutions employ the use of double or triple wall corrugated cardboard as the starting material, while others rely on layered walls or nest boxes. Each of these approaches, however, includes advantages as well as disadvantages. Exemplary disadvantages include high manufacturing costs due to the requirements of

20 material handling during manufacturing, significant use of adhesives or manufacturing equipment, handling difficulties before and after manufacturing (prior to the transformation of the box, such as when handling large blank or post-processing parts , as when trying to prepare the containers manufactured for shipping), and generation of waste material, all of which are well known to the person skilled in the art.

25 In view of these disadvantages, an improved container and a related manufacturing process would use single wall corrugated material easy to create from easy resource, would use minimal amounts of adhesive during the transformation process, would require minimal human effort before, during and after the process of transformation, would generate a minimum of waste, and would require a minimum manipulation, among other requirements. Yes

30 There are such needs, so far, those needs have not been met.

Document FR-A-1 289322, on which the preamble of claim 1 is based, discloses a method of creating a multi-wall container.

Summary of the invention

The method according to the invention is defined in independent claim 1, which is directed to the creation of multi-wall containers with minimal intentional waste.

Other embodiments are the subject of the dependent claims.

Although the above description of the embodiments of the method of the invention emphasizes the advantages of using a continuous process approach for manufacturing containers according to the invention, the invention is not limited to such approaches. In addition, even in a continuous process, blanks will be formed before the

45 transformation of the material into a discrete container. Therefore, the term "blank" as used herein includes both blank parts of conventional containers not derived from a continuous process, as well as those derived from it. In the event that a distinction must be made, and it is not clear from the context of use, the term "conventional blanks" or a similar phrase shall refer to the blanks not derived from a continuous process.

Brief description of the drawings

Figure 1 is a perspective view of a first embodiment of the invention shown in a generally assembled state;

Figure 2 is a detailed perspective view of a portion of the double coated corrugated material used in the construction of the first embodiment;

Figure 3 is a plan view of the first embodiment with the upper alleles shown 60 in broken lines to better illustrate the stratification of the corrugated material;

Figure 3a is a detailed plan view of a corner of the embodiment shown in Figure 3;

Figure 4 is a plan view of a "blank" which is used to form the first form of embodiment of the invention;

Figure 5 is a detailed plan view of a stress relief function and the function of the vertical crush resistance geometry of the first embodiment of the invention;

Figure 6 is a perspective view of a first stage in the formation of a multi-wall container using the ~ blank ~ of Figure 4 where the intermediate fins fold in close proximity to form an intermediate side wall of material corrugated;

Figure 7 is a perspective view of a second stage in the formation of a multi-wall container using the blank in Figure 4;

Figure 8 is a perspective view of a third stage in the formation of a multi-wall container using the "blank" of Figure 4 where the combined inner panel and intermediate fins are involved;

Figure 9 is a perspective view of a fourth stage in the formation of a multi-wall container using the "blank" of Figure 4 where an inner glue tongue is attached to an inner panel, thereby forming a basic container form;

Figure 10 is a perspective view of a fifth stage in the formation of a multi-wall container using the "blank" of Figure 4, where the outer panels are wrapped around the base container of Figure 9;

Figure 11 is a perspective view of a sixth stage in the formation of a multi-wall container using the "blank" of Figure 4 where an outer glue tongue is attached to an outer panel, completing the formation of the first embodiment;

Figure 12 is a detailed perspective view of a strain relief feature shown in Figure 5 when the "blank ~ of Figure 4 becomes the container of Figure 11, and the upper and lower fins are fold inward;

Figure 13 is a plan view of a system for receiving converted blanks and creating assembled containers therefrom;

Figure 14 is an isometric view of a folding and glue station, which is part of the system shown in Figure 13;

Figure 15 is a perspective view of a machine for winding upwards, which is part of the system shown in Figure 13; Y

Figure 16 is a schematic elevational view of the rotator part of the upward winding machine shown in Figure 15 where it shows that the relative movement of the four mandrel bars.

Description of the embodiments of the invention

The following discussion is presented to allow a person skilled in the art to make and use the invention. Various modifications to the embodiments shown herein will be readily apparent to those skilled in the art without departing from the scope of the present invention, as defined by the appended claims.

Turning next to the various figures, where equal numbers indicate similar parts, and more particularly to Figures 1-4, an embodiment of the invention will now be described which employs many of the features and elements of the invention. A container 20 comprises a "blank" 22, which is preferably constructed of a corrugated material coated, double-walled, such as corrugated cardboard 7.9 mm (5/16 ") l shown in Figure 2. In the illustrated embodiment, the container 20 has dimensions of

55 approximately 1041 mm H x 1219 W x 1016 mm D (42 "H x 48" W x 40 "O), while blank 22 has maximum dimensions of about 9017 mm lx 2108 mm W (355" L x 83 ~ W). In the illustrated embodiment, the container 20 has triple side walls and single upper and lower superimposed fins.

To form the container 20, it is necessary to create a container blank 22 either before assembly or in line with the assembly process. As best shown in Figure 4, the container blank 22 is a unitary piece of corrugated material, such as the type shown in Figure 2, with the direction of undulation extending laterally. From a single sheet, selected marks, cuts and perforations are carried out, such as by means of a rotary cutter die (s) or other means appreciated by the expert. Each container blank 22 then comprises an inner panel 40, opposite intermediate fins 50, an outer panel 65, and a plurality of end fins 70. The container-shaped brill piece 22 further preferably comprises an inner tongue 30 and a optional outer glue tab 80. For purposes of

convention, the observed sides of all panels and fins are as indicated, with the reverse being similarly numbered, but within the series of one hundred. Thus, the inside panel back 40, for example, is labeled interior panel 140.

5 The inner panel 40 comprises parts of the inner panel 42, 44, 46 and 48, separated by marks 34a, 34b, and 34c. The inner tongue 30 extends longitudinally from the inner panel portion 42, and is separated therefrom by a mark 32. Extending laterally outwardly from inner panel portions 42, 44, 46, and 48, Y defined in part by a marking- slits 43 alb, 45 alb, 47 alb and 49 alb, and by the marks 34a, 34b and 34c (as well as edges 51 alb, and grooves 73a and 73b), are respective intermediate fins 50, identified in this embodiment as fin portions intermediate 52 alb, 54 alb, 56 alb and 58 alb. Although those skilled in the art will appreciate that other forms of marking (eg, point-to-plane), as well as grooves or grooved induso can be used in place of the marking portions 34a, 34b, and 34c that partially define each pair of portion of intermediate fin 52 alb, 54 alb, 56 alb and 58 alb, strength and additional handling advantages can be obtained by retaining robust physical bonding between adjacent intermediate fin portions, as will be described below.

In addition, each "fin" 50 may comprise physically discrete fin portions (such as end fins 70, discussed below), visually discrete fin portions as illustrated herein, or it may be totally contiguous ( no marking). Because it is only necessary to form a wall or lining within the container 20, there is no intrinsic need to form physically discrete fin portions, as long as the parts of the blank 22 that fold to meet the opposite portions of the blank 22 may result in the creation of such a wall or layer.

The distal ends of each intermediate fin portion are characterized by serrated edges 53 alb, 55 alb, 57 alb and 59 alb, again as best shown in Figure 4. The inclusion of these serrated edges, or any non-linear edge, it will be beneficial to delocalize burst and spine compression stresses that can

25 occur after assembly and use of containers 20, as will be described later in detail below. Thus, curvilinear edges or rectilinear edges, such as the repetition of square or sawtooth geometries, are considered desirable. However, it is not necessary for the operation or constitution of the embodiments of the invention to incorporate said nonlinear edges, and a linear edge will provide benefits as described herein.

While the panel 40 and the inner intermediate fins 50 both form the side walls of the container, only the outer panel 60 forms the side walls; End fins 70 constitute a single lower part and the upper sides of the container 20 as shown in Figure 11. The outer panel 60 comprises outer portions of the panel 62, 64, 66 and 68, separated by marks 38a, 38b, and 38c; outer panel part 62 is separated

35 of the inner panel part 48 by a marker 36. An outer glue tab 80 extends longitudinally from the inner panel part 42, and is separated therefrom by a mark 82. Which extend laterally outwardly from panel portions exterior 62, 64, 66 and 68, and defined in part by the point-to-point marks 63 alb, 65 alb, 67 alb and 69 alb, and by indentations 73 alb, 75 alb, 77 aIb and 79 alb (as well as the edges 71 alb), are end fins 72 alb, 74 alb, 76 alb and 78 alb, as shown. Those skilled in the art will appreciate that grooves can be used instead of grooves 73 alb, 75 alb, 77 alb and 79 alb, although, as will be described in detail below, the advantages can be achieved through the use of grooves. with respect to the stress relief characteristic 90.

It should be noted that the lateral width (or mounted, the height) of the outer panel 60 is greater than that of the inner panel 40.

45 This larger dimension refers to the consequence of the increased external dimensions when the container 20 is formed (which is examined and shown below). Similarly, the longitudinal length (or mounted, width and depth) of the outer panel 60 is greater than that of the inner panel 40. Those skilled in the art will appreciate that the increases are related to the number of walls used to form the container, as well as the thickness of the material that comprises the walls.

Figure 5 illustrates two features of the embodiment, namely the strain relief feature 90, which is characterized as an orifice of approximately (0.375 ") 10 mm in diameter, and fin movements. It is well known in the art. that the fins in the containers often tear at the exposed edge interface between the fin and a side wall panel. This is partly due to the effect of the three-edge corner

55 present in the lower part of the fin: the three corners of the edge causes a crush of the fin at its edge, thus compromising the structural integrity of the fin and the related structure. This consequence, in conjunction with the inherent weakness of the material in this position, often invites mechanical failure during repeated use or operation of the fin. By establishing a hole, and preferably, but not necessarily, a round or circular hole, the three-edge corner does not directly impact the bottom of the fin. Depending on the number of walls for any particular container, additional stress relief features can be used with respect to the inner or intermediate walls, as the case may be.

Also shown in Figure 5 is a displacement with respect to the grooves that separate the adjacent fins 65 70 and the dot-to-pen marks that separate the adjacent outer panel 60. Unlike the continuous marks 34a, 34b, and 34c of the panel inner 40 (which create inner panel parts 42, 44 and 46) and intermediate fins 50 (which partially define each pair of intermediate fin portion 52 alb, 54 alb, 56 alb and 58 alb), and which translate into walls of the same size, fins 70 that have different dimensions compared to their company panels. Because the fins 70 form end walls opposite the side walls, there is no need for such symmetry. On the other hand, and as best shown in Figure 3, because the fins 70 will be positioned orthogonal to the side walls comprising the inner panel 40, the intermediate fins 50 and the outer panel 60, the fins of more dimensions large will extend over all exposed edges of the outer panels 60 when the container 20 is in the assembled configuration. The consequence of this agreement is that all the edges of the exposed vertical side walls can be ~ covered ~ by the end fins, and that the vertical compression loads can be distributed evenly to the fins

10 extremes See also figure 11.

Turning next to Figures 6-12, the container assembly 20 is shown in detail. The completed blank 22, as described in Figure 4, emerges from a transformation machine and enters a section of the folding process and glue. Using rails or folding blades, intermediate fin portions co-joined 15 52a, 54a, 56a and 58a, and 52b, 54b, 56b, and 58b fold down 180 ~, along the groove marks 43a, 45a, 47a and 49a, and 43b, 45b, 47b and 49b to join in a surface-to-surface contact area with respective inner panel portions 42, 44, 46 and 48 as shown in Figure 6. Before initiation or termination of the 180 ° folding process, adhesive is applied to the surfaces of the contact area preferably using a spray coating system. At the end of the 180 ° folding and the glue process, the edges

20 teeth 53 alb, 55 alb, 57 alb and 59 alb are located halfway around portions of inner panels 42, 44, 46 and 48. the spruce-like nature ~ and gear of the jagged edges 53 alb, 55 alb, 57 alb and 59 alb distribute the joined line over an area larger than a pure straight cut and will now appear at the bottom of the box in flat blank.

25 Using a clamping mechanism, the inner tongue 30 is folded up 90 ° at the mark 32, the inner panel portion 42 (with the intermediate fin pair 52 alb) is folded up 90 ° at the mark 34a, the inner panel portion 44 (with intermediate fin pair 54alb) is folded up 90 ° at mark 34b, inner panel portion 46 (with intermediate fin pair 56 alb) is folded up 90 ° at mark 34C, and the inner panel portion 48 (with the intermediate fin pair 58 alb) is folded up 90 ° at the mark 36, as

30 shown in Fig. 8. All 90 ° folds are "upward ~ and therefore far from the articulation of the toothed edge surface 53 alb, 55 alb, 57 a / b and 59 alb. The resisting structure It is best shown in Figure 9.

Adhesive is applied to the intended coupling surfaces of the outer panel portions 62, 64, 66 and 68, and

35 the upward folding process continues with the outer panel portion 62 folding at 90 ° at the mark 38a, the outer panel portion 64 folding at 90 ° at the mark 38b, the outer portion of the panel 66 folding at 90 ° at the mark 38c, and the outer panel portion 68 folding at 90 ° at the mark 82, with the outer glue tongue 80 completing the folding and the glue process. This process is best shown in Figure 10. As those skilled in the art will appreciate, the upward folding process can be achieved.

40 by using a shaping mandrel or other help.

The collective effect of multiple folding at 90 degrees and the glue process, take the flat blank. rigid, original corrugated cardboard. comprising inner tongue 30, inner panel 40, intermediate fins 50, which form an intermediate panel, and outer panel 60, as well as optionally outer tongue 80, all as shown in Figure 4, and forms a box container Multiple wall finish, four sides, with single wall fins top and bottom, which does not have 'articulation of the manufacturer', as best shown in Figure 11. Because of the relaxed state (rest position of the manufacturer) It is the state of use of the container, there is a natural tendency of the container to return to its resting position if it collapses. In individual wall construction containers, this advantage is of little importance; however, in multiple 50-wall containers the force necessary to form the desired shape of the container from a folded configuration can be significant if the teachings of the invention were not followed. Therefore, there is a significant work advantage for the construction of a multi-wall container to have a resting position that is the same as its use position. In addition, by incorporating the marks on each edge of the panel, the demolition of the container becomes easier (the marking lines also locate any resulting crushing,

55 thus preserving the structural integrity of the container in places adjacent to the edges).

By incorporating one, some or all of the features described above, significant benefits associated with strength and material costs can be realized (manufacturing efficiencies will be addressed later). The following table exemplifies the relative advantages of a number of embodiments.

60 of containers according to the invention. Here, the Greenfield containers comprise all the features of the embodiment described above, while the prior art (HP) containers were constructed from 2 layers of the double wall corrugated material panel or 3 layers of the corrugated material panel of double wall where the layers of the panel are nested, but not adhered to each other.

Box (Y. cube size)

Crushed in kg (lbs.) Weight in kg (lbs.)

HP 1 -2 layers of panel

4202 (9265) 4.94 (10, 90)

HP 2-2 panel layers

3998 (8815) 4.94 (10, 90)

Greenfield 1 (heavy tail)

6028 (13290) 4.88 (10.75)

Greenfield 2

5633 (12420) 4.63 (10.20)

Greenfield 3

5427 (11965) 4.63 (10.20)

HPT 1-3 layers of the panel

6192 (13650) 6.33 (13.95)

HPT 2-3 layers of panel

5987 (13200) 6.35 (14.00)

As can be seen from the inspection of the anterior lip, containers constructed in accordance with the invention have superior crush resistance (an important factor in container evaluation)

5 on prior art constructions for comparable weights, or the use of significantly less material for comparable crush resistance values. As will be seen below, the methods for manufacturing containers according to the invention further increase cost savings by streamlining manufacturing and handling actions.

10 Until now, the construction of multi-wall containers according to various embodiments of the invention has focused on the general handling of the blank to form precursors of containers and containers, as exemplified in Figures 4, and 6- eleven. The following description refers to a systems approach to mass production of containers and to practice related methods. As with the previous description regarding triple sidewall containers, by the following disclosure describes a process and its

15 variants for mass manufacturing of such containers. The person skilled in the art will appreciate that the methods and approaches described are not exclusive to the creation of containers according to the invention, but represent both general and specific implementations intended to identify the currently preferred means to achieve these objectives.

20 Given the high level of automation associated with container manufacturing processes, for example, a computerized device and servo driven production, many of the following actions are carried out autonomously by machines that have received programming commands supplementary The person skilled in the art will appreciate that before operating this type of programmable machines, it is necessary to define the program parameters and present them to the programming interface of the machine. Consequently, the following description

25 intends to establish a series of samples of the events that give rise to the production of a desired container based on instructions previously introduced in the different machines.

The basic material used for the construction of container 20 is derived from a corrugator (not shown) that produces a continuous band of double-sided corrugated material, from a wall. the band can be consumed

30 immediately, or it can be stored as cut blanks until needed. In the illustrated example, blanks 22 having a total length of about 9 meters (30 feet) are formed from the band by cutting, for example. Once the blanks 22 properly cut are obtained, the blanks are subjected to numerous grooving, cutting, marking, and the cutting processes that are necessary to form a desired container 20 as described above.

In a preferred system different processes of grooving, creasing, marking, and cutting are carried out by a pair of opposing machines, which are supplied with blanks using conventional means of transport. These machines, preferably RAPIOBOX units from Rapidex (a division of the Bobst Grup of Switzerland) from Angers, France, create the desired blanks through proper programming, which is determined based on

40 in the size and geometry of the intended container. The RAPIOBQX machine can accommodate raw parts up to 2.8 x 10 m (110 "x 400"), which makes it especially suitable for the manufacture of large format containers, as described in this document. In other scenarios, these processes can be carried out by the most dedicated machinery, such as a plurality of several slotting, marking, creasing and rotating die cutting machines, set in series on the production line. Regardless of how the

45 blanks, the resulting blanks are delivered to the folding and glue stations as will now be described.

Upon exiting the transformation machines, the blanks 22 are deposited on the receiving platform 210 as best shown in Figure 13 where they are then transported to air carriers assisted with vacuum 50 220 to the folding and gluing station 230. This mode of transport is desirable in more conventional ways for two reasons. First, it retains full exposure of the lower surface of the inner panel 40 (designated inner panel surface 140) and intermediate fins 50 (designated intermediate fin surface 150), which becomes important during the "winding" process described below. Second, it precisely maintains the specific position of blanks 22 with respect to the other apparatus, which is important when the precision application of adhesive is necessary. However, the professional expert will appreciate that the

inversion of the blank 22 in such a way that the surface of the inner panel 140 and the average surface fins 150 are exposed on an upper side and the blank 22 is supported by a conventional conveyor that will allow transport and proper use of the intermediate flap 50 folded upwards as "unwound" (see below).

Depending on the design considerations, which include cost and performance criteria, adhesive deposited on any blank 22 from adhesive application means can be selectively deposited

or it can be applied to the entire surface of the inner panel 140 and / or the surface of the intermediate fins 150 exposed to a first adhesive means. The selective deposition of adhesive consists of the intelligent location of the adhesive lines or zones within the limits of these panels and / or fins. While in the illustrated embodiment the adhesive is applied through spray nozzles 262 and 264 that expel a PVA or hot melt adhesive, any adhesive application means capable of depositing an amount and type of adhesive intended for any piece in gross 22 is enough. The means of application and adhesive composition illustrated have been chosen in an effort to optimize the production speed of the process illustrated. In more

15 or less 200 feet per minute, the applied adhesive has sufficient time to "set" before folding and pairing the intermediate fins 50 as will now be described.

Once adhesive has been applied to the inner surface of the panel 14Q and / or the surface of the intermediate fins 150, the actuated folding arms cause the intermediate fins 50 to recede, and the surface of the intermediate fins 150 contact the surface of the panel inner 140 as best shown in Fig. 14. A pressure roller combination can be used to compress intermediate fins 50 and inner panel 40 together in conjunction with air conveyor 160, otherwise the winding process described below. It will generate compression contact between these two surfaces.

25 At this point, the converted blank 22 has been transformed into a precursor 122. To prepare the precursor 122 for the construction of the container 20, the adhesive must also be applied to the exposed surface of the outer panel 60 (and / or the exposed surface of intermediate fins 50, which are now in the "bottom" of the precursor 122). In the illustrated embodiments, second means of applying adhesive 262 are provided, and adhesive is selectively applied to the exposed surface of the outer panel 60.

Turning next to Figure 16, when the tongue 30 approaches the reel 270, a fastener 271 opens (if it is not already open) to receive the tongue 30. Depending on the mode of application, a rotator 276 may already be rotating or rotation can begin after the attachment of clamping element 271 with the tongue 30. While showing a mechanical coupling means, alternative means, such as the

35 vacuum coupling are contemplated and will be appreciated by the skilled technician. In addition to the clamping element 271 or its equivalent, the rotator 276 preferably includes a plurality of folding bars equal in number to the number of vertical corners of the container, which in this case is four (4). The folding bars generally locate bending forces during container formation and provide a convenient, low cost and low mass solution for container formation. Although schematically shown herein, the folding bars 272a-d can be hydraulically or mechanically movable in a rotator 276, with the only requirement that the assembly can accept the precursor 122, assist in the formation of the container 20 and release the container 20 in such a way that another precursor 122 can be coupled therewith.

As precursor 122 is wound around rotators 276, sufficient tension must be applied to ensure that the

45 external panel 60 securely joins the intermediate fins 50 (or any other intended part of the precursor 122, as the case may be) and that external tab 80 (if present) fits properly in a vertical corner at 82 (see figure 1 ). The proper tension can be imparted by reducing the ejection speed of the precursor 122 before the rotator 276 while maintaining the rotation speed constant; increasing the rotation speed while maintaining the constant ejection speed; and / or increasing the relative effective displacement of the folding bars 172a-d. However, a preferred means for maintaining the appropriate parameters is to adjust the rotator 276 vertically so that the precursors 122 are always coupled to the rotator 276 in a flat manner. As indicated in Figures 15 and 16, a winder 270 is constructed to move in the vertical direction (see hydraulic ram 277 linked to the pulley of system 278 in Figure 15). Alternatively, an external compression element can be applied during winding of the

55 precursor in the mandrel, the result being compression between the sidewall layers of the container. The above methods for guaranteeing the correct winding of the precursor are not extrusive, and those skilled in the art will appreciate other means to achieve the same or similar results.

To ensure that the corrugated material that is wound on the winder 270 does not inadvertently "unwind", outer panels 62-68 must be retained near intermediate panels 52-58 during the adhesive setting process, which normally does not occur when the container 20 is in rotator 276. In a presently preferred embodiment, the winder 270 includes a lower support table 275, which has an upper surface approximately at the level of blank 22. By keeping the last panellngueta wound in compression contact with the support table 275, the container 20 will not "leave" the winder 270 early. In this position, there is sufficient tension of the precursor 122 so that the connection between the surfaces of the panels 140 and 150 can occur, as well as the surfaces of panels 50 and 60. However, the setting time of said

Adhesive is generally longer than the time it takes to wind precursor 122. Therefore, a ~ curing station ~ is needed. In the presently described embodiment, a carousel arrangement is used, as best shown in Figure 13 where in addition to transporting the container 20 is sufficiently delayed to allow sufficient time for the adhesive to cure, which ensures that container 20 It is not going to

5 ~ unwind. "

To remove the container 20 formed from the winder 270, one, some or all of the folding bars 172a-d can be retracted in such a way as to reduce friction between them and the container 20, although such action is not necessary. for removal of the container 20. In certain embodiments, a sliding element of outer coupling or other means for removing the container 20 from the mandrel 170 can then be employed. Preferably, however, an arm having a plurality of extensible elements (mechanical and / or pneumatic and / or electrical and / or hydraulic) is inserted into the container 20, the extended elements for compressively contacting the inner walls of the container 20 (or coupled with it through vacuum assistance), and then the arm will be removed to "pull" the container 20 of the folding bars 172a-d. The

15 support table 285 is used for reasons similar to those of support table 275.

When the assembly 280 rotates, additional formed containers 20 are removed from the winder 270. Once a formed container reaches a predetermined place (shown in Figure 13 as opposed to the winder 270, the coupling process is reversed, and the container formed removed from the extended arm. Once extra gone,

20 the displaced container can then be "disassembled ~ for storage and / or transport.

Due to the relative difference in thickness between the side panels and the fins, certain embodiments of the method of the invention provide subsequent folding of the outer fins 70 onto the side panels as shown in Figure 15. If a desired Final configuration of this type, these embodiments of the invention fold the end fins onto the side panels, at the same time as the intermediate fins fold. Thus, when precursor 122 is wound, the outer fins 70 are not in the extended position, but are placed in compression contact with the panels 60. In addition to the elimination of the work stage of folding these end panels separately once the container 20 has been formed, shorter mandrels and the container extraction apparatus can be used since the total height of the container is shorter by the depth of the extreme fins. In addition, in such embodiments, it may be considered desirable to remove the tongue 80 so that the contact surface is flat enough to prevent bonding and crushing.

In processes such as in the previous paragraph, it is desirable to retain a small section of material binding fins 72-78 to prevent premature deployment (this may occur through incomplete cutting between the

35 panels at the distal end of the fins). Therefore, when the disassembled containers are delivered to the customer, the fins 72-78 are separated and folded in place.

Claims (11)

1. A method for creating a multi-wall container precursor (22, 122) from a single piece in raw material defining a longitudinal direction from a first end to a second end, the method comprising: defining an inner panel (40) that forms the inner side walls of the container when it is mounted, the inner panel comprising a plurality of inner portions of the panel (42, 44, 46, 48), bordering each inner panel portion with any portion of adjacent inner panel and each inner panel portion comprising an inner side wall of the container when mounted; defining at least one pair of opposite intermediate fins (50) extending from the inner panel (40) to a distal edge (53 alb, 55 alb, 57 alb, 59 alb) and where each central fin (50) comprises a plurality of fin portions (52 aib, 54 aib, 56 alb, 58 alb), each fin portion adjoining any adjacent fin portion and each opposite pair of fin portions comprising an intermediate side wall of the container 15 when mounted; defining an outer panel (60) that extends from the inner panel (40) and forms the outer side walls of the container when mounted, the outer panel comprising a plurality of outer portions of the panel (62, 64, 66, 68), bordering each outer panel portion with any adjacent outer panel portion and each outer panel portion comprising an outer side wall of the container when mounted; and retreating at least one pair of opposing intermediate fins (50) to approximate their respective distal edges (53 alb, 55 alb, 57 alb, 59 alb) with each other and attach them to the inner panel (40), thereby forming intermediate side walls when the die is assembled in the container, characterized in that the sum of the lateral length of the pair of intermediate fins from its intersection (43 alb, 45 alb, 47 alb, 49 alb) with the panel 25 inside (40) to the distal edge is equal to or less than the side length of the inner panel from the intersection of a first opposite intermediate fin (53a, 55a, 57a, 59a) to the intersection of a second opposite intermediate fin (53b, 55b , 57b, 59b). 2. The method of claim 1, further comprising establishing a glue tongue (80) at the first end of the blank and a glue tongue (80) at the second end of the blank where the First glue tongue (BO) adheres to the inner panel (40) when the container is mounted and the second glue tongue (80) adheres to the outer panel (60) when the container is mounted.

3.

The method of claim 1, further comprising the formation of nonlinear distal edges of the intermediate fins (50).

Four.

The method of claim 3, wherein the distal edges of the intermediate fins (SO) are one of a rectilinear, curvilinea, or a rectilinear combination and curvilinear design.

5.

The method of claim 1, wherein the distal edges of the intermediate fins (SO) are complementary so that upon recoil, the distal edge of an intermediate fin (50) will substantially abut the distal edge of the opposite intermediate fin ( SW).

6.

The method of claim 1, further comprising establishing a mark (34a, 34b, 34c) between the intermediate fin portions (50).

7.

The method of claim 1, further comprising establishing a mark (34a, 34b, 34c) between the portions of the inner panel (40).

8.

The method of claim 1, wherein the material comprises a double coated corrugated material. * "

9.

The method of claim 1, comprising forming the portion of the lateral dimension of any inner panel (40) that is smaller than the lateral dimension of any portion of the outer panel (60).

The method of claim 1, which further comprises forming at least one pair of opposite end fins (70) extending from at least some portions of the outer panel (60) where each end fin (70) is separated from any adjacent end fin (70) by a groove (73, 75, 77, 79), a slit or a hole.

eleven.

The method of claim 10, wherein pairs of opposite end fins (70) extend laterally from each portion of the outer panel (60).

12.

The method of claim 10, wherein the longitudinal length of each end fin (70) is greater or less than the longitudinal length of a portion of the corresponding outer panel (60) from which it extends.

The method of claim 1, wherein a portion of the inner panel (40) has a longer length than any other inner panel portion (40).