GB2385311A

GB2385311A - A forming tool for erecting a flattened sleeve

Info

Publication number: GB2385311A
Application number: GB0314578A
Authority: GB
Inventors: Tony Freemantle
Original assignee: T Freemantle Ltd
Current assignee: T Freemantle Ltd
Priority date: 2002-03-15
Filing date: 2003-03-10
Publication date: 2003-08-20
Anticipated expiration: 2023-03-10
Also published as: GB2385311B; GB0314578D0

Abstract

A forming tool 30 for reception of a packaging sleeve comprises a mounting plate 60, a base 52 and opposing side walls 46,54, wherein the forming tool 30 causes the movement of the sleeve from a flattened state to an erected state. At least one of the side walls 46,56, preferably the side wall which is first contacted by the sleeve 46, may have on its upper edge a lip portion 48, which acts as a locating and limiting means for one of the side walls of the sleeve. The mounting plate 60 of the forming tool 30 preferably includes location means 63,65 which serve to locate the forming tool 30 with complimentary location means 61,67 on a drive mechanism, which itself may include a plurality of forming tools 30 arranged at spaced intervals. In use, placement means (24, fig 3) remove a flattened sleeve to be placed in the forming tool 30, from a store, wherein relative movement of the forming tool 30 and placement means (24, fig 3) causes the sleeve as it is positioned in the forming tool 30 to be erected.

Description

Packaging Apparatus and Tool therefor The invention to which this application relates is apparatus and a method for erecting a packaging sleeve from a blank, folded substantially flat condition to an in-use condition for subsequent insertion of an article, most typically a tray, therein to form a package.

Reference hereonin is made to the insertion of an article in the form of a tray but this reference does not limit the invention for use solely with a tray. In addition reference to a sleeve incorporates many different designs of sleeve, examples of which are provided herein in a non-limiting manner.

Particularly, although not necessarily exclusively, the sleeve is what is known as a 5-fold sleeve formed from card and having a top face, bottom face, and two opposed side walls joining said top and bottom faces and with one of the side walls having an intermediate elongate fold line. The sleeve, when erected, defines a passage with an opening at each end thereof into which a tray can be inserted. Typically, two of the fold lines define the corners between the front face and side walls, two fold lines define the corners between the side walls and the bottom face, with the fifth fold line located intermediate the corner fold lines of one of the side walls. When provided in the folded or blank condition as referred to herein, the free ends of the sleeve are already joined together, typically by gluing, in an overlapping manner, said join typically but not always, positioned at or adjacent one of the side walls.

Typically, the packages are provided as retail packs, provided to hold a foodstuff such as a frozen or chilled foodstuff for purchase in a retail outlet and subsequently, by removal of the

sleeve, and typically an enclosing film, the foodstuff can be eaten or first cooked in the tray at home.

Large numbers of said packages are sold on a daily basis and conventionally the packages are formed manually or automatically using appropriate machinery. In each case there is a significant problem in terms of the relatively slow throughput of the packages due to the package forming process and apparatus, if any. If a manual process is used, the sleeve is moved from a blank to an erected form by hand and the tray inserted into the sleeve passage through one of the openings.

In an automatic process the sleeve is moved from a blank to an erected form by the provision of mechanical fingers which locate on the bottom face of the blank and pull the same downwards and away from the top face and so move the sleeve into a former into which the tray can then be inserted either manually or by automatic pushers. In one embodiment, the fingers include suction means such as vacuum pads to locate and move the sleeve.

Thus, if the process is performed manually, the same is intensive in terms of personnel and, if performed automatically, the process is slow due to the fact that no continuous forming operation occurs. Other automated package forming apparatus is known but tends to relate to the erection of boxes from blanks rather than sleeve blanks and, as such, is not applicable or usable in practical terms as is evidenced by the conventional apparatus and methods currently used for sleeves. One box blank erecting apparatus is disclosed in US2900880 where a box with right angled side faces with respect to the front and bottom faces is formed.

The aim of the present invention is to provide a package forming apparatus and forming tool for use therewith, which

allows the formation of a package comprising an erected sleeve with an article placed therein and to allow the package to be formed efficiently and reliably while also improving the speed and throughput of the same.

In accordance with the invention there is provided a forming tool for the reception of a package sleeve, said sleeve provided to receive an article therein through an opening when erected in the tool, said tool provided to allow the movement of the sleeve from the flattened condition in which the sleeve approaches the blank and, upon contact with the blank, to an erected form therein, characterised in that said forming tool has a mounting plate base and opposing side walls, the shape and relative angular orientation of which define the shape to which the sleeve is erected when positioned in the tool.

Typically, at least one of the side walls has at its upper edge, a lip portion, said lip portion acting as a locating and limiting means for movement of one of the side walls of the sleeve in a direction away from the forming tool and thereby serving to locate the sleeve blank in position during and after formation.

Typically, the side wall which has the lip portion is the same side wall which is first contacted by the sleeve blank as it is introduced into the forming tool.

In one embodiment, the side walls of the forming tool are angled to match the angles at which the sleeve blank side walls are to lie when erected. The forming tool can either be adjustable to allow parts of the same to be adjusted to suit the particular design of the sleeve to be formed therein or, alternatively, the forming tools are removable from the drive means to allow the appropriately shaped forming tools to be positioned on the drive means to suit the sleeve to be formed at that time. Thus it will be appreciated that any one forming

apparatus can be provided to be used with as many sets of forming tools as required to allow the apparatus to be used to form the sleeve blanks of different design.

Preferably the width of the forming tool is less than the width of the package so as to be narrower and allow end portions of the sleeve or tray to protrude. These ends can, if required, be picked up on removal means such as a set of belts to remove the formed package from the tool.

Typically the forming tools are mounted in a spaced manner along a drive means, said drive means having a forward path during which the blanks are erected, the article inserted and the package removed, and a return path by which the forming tools are returned to a start position for the reception of a new sleeve blank.

In one embodiment the drive means has a linear forward path and a return path.

Preferably, a number of said forming tools are located at spaced intervals on the drive means for linear movement. Typically, upon the removal of the formed package, each forming tool is moved to a start position to repeat the forming operation for the next sleeve blank inserted therein, and so on, thus providing a continuous package forming apparatus.

Typically, the sleeve blanks are held in a store magazine for feeding to the rotational placement apparatus which presents each blank in turn for insertion into a respective forming tool, as it passes the location for the presentation of the blank by the placement tool.

Typically, the drive mechanisms for the rotational placement apparatus and the forming tool drive means are mechanically linked so as to be synchronised, thereby ensuring that each sleeve blank is inserted into a respective forming tool in the required position and path as the forming tools move. It is preferred that the forming tools move continuously or at least move continuously in the vicinity of the placement means as the relative movement between the placement means in a first direction and the forming tool cause the commencement of erection of the sleeve blank.

Typically, the sleeve blank is inserted into the forming tool with the intermediate fold line folded to lie outwardly of the blank such that the side surface with the intermediate fold line first contacts with the forming tool.

In one embodiment, erection fingers and/or a bar are provided to further assist the erection of the sleeve blank, and retain the sleeve in the forming tool. In one embodiment said fingers may make first contact with the blank prior to the forming tool.

In order to aid the removal of the formed package from the forming tool, removal means may be provided to locate with the formed package and to carry the same away from the forming tool at the end of the package forming path. In a preferred embodiment, at least one, but preferably two, driven removal belts are provided and positioned with respect to the forming tool such that as the package in the tool reaches the belts, the belts contact and support the moving package in a first direction as the forming tool turns on the drive means to commence its return path. The formed packages can then be moved to a packing or storage location by the drive belts. Further removal means in the form of mechanical fingers may also be provided.

Typically the forming tool includes a base, and first and second opposing side walls, said side walls lying perpendicular to the direction of travel of the forming tools on the drive means. In one embodiment the rear side wall, as the forming tool is moving along the forward path, is first contacted by the sleeve blank from the placement means and, yet further by the side wall of the blank which includes the intermediate fold line.

Typically the rear side wall can be formed to suit particular sleeve forming requirements and can include any or any combination of an angled portion and/or vertical portion, and/or a lip at the free edge of the said side wall.

Typically the forming tool can be attached to the drive means by releasable location means mounted on a plate, said plate having location means for location with respect to the drive means plate and wherein one of the location means is slotted for location on a peg by movement of the plate in a first direction, and the second location means is slotted so as to allow location on a second peg by movement in a second direction by rotation about the first peg. Typically the second peg is provided to receive locking means so as to retain the forming tool in location.

Typically the forming tools are provided in sets, each set provided to allow the formation of a particular sleeve design.

In one embodiment the article inserted into the erected sleeve is a tray, said tray, with foodstuffs therein, moved into the sleeve while the sleeve is retained in the forming tool. In one embodiment the tray is manually inserted. Alternatively and preferably, automatic feed means are provided to allow the trays to be moved to be inserted into the erected sleeves in a

direction perpendicular to the movement of the forming tools along the drive means. Preferably the insertion occurs as the forming tools continue to move along the forward path of the drive means and yet further the movement means for the tray are synchronised with the movement of the forming tools on the drive means.

A specific embodiment of the invention is now described with reference to the accompanying drawings, wherein :- Figure 1A-E illustrate packages formed in accordance with the invention in perspective in various embodiments; Figure 2 illustrates apparatus with which the forming tool of the invention can be used in one embodiment ; Figure 3 illustrates a detailed view of one sleeve being formed utilising a forming tool in accordance with the invention; Figure 4 illustrates the forming tool of the invention in one embodiment; and Figures 5a-c illustrate further forms of the forming tool.

Referring firstly to Figure 1A-E, there are illustrated several embodiments of a package 2 formed in accordance with the invention. The package, in each case, comprises a tray 4 retained at least partially within a sleeve in an erected form 6.

The sleeve, when erected, comprises a top face 8, bottom face 10 and two side walls 12,14 which are opposing and which join the top and bottom faces 8, 10. A series of fold lines are provided and located such that fold lines 15, 16 define the corners between the top face and side walls, fold lines 18 and 20

define the corners between the bottom face and side walls and fold line 22 is located intermediate the edges of one of the side walls 12,14 as shown. The fold line 22 is provided to aid the formation of the sleeve from the blank condition which is an almost completely flattened condition, as shown in Figure 3, but with the free edges 19,21 attached together, and the erected condition shown in Figure 1A-E.

The difference between the packages of Figures 1A-E is the different form of the sleeve, with the sleeve design in Figures 1B, D, E of the type referred to as a band. Reference herein to a sleeve should be taken as referring to the designs shown and also any other sleeve designs, each of which can be erected and packed utilising this invention.

The provision of this form of package, typically to allow foodstuffs held in the tray to be purchased and for the foodstuff type to be indicated on the printed material on the sleeve, is well known and the present invention relates to the formation of the packages of this type in an efficient and quick way compared to conventional apparatus and methods.

The apparatus for use in accordance with one embodiment of the invention is illustrated in a schematic manner in Figure 2.

The apparatus comprises a rotatable placement means located with store means 26. The sleeve blanks are moved one at a time from the store means 25 in the direction indicated by arrow 25 by the placement means (not shown). The placement means typically include a suction cup which contacts the surface 8 and then rotates the blank as shown by arrow 25 through typically 240 to be deposited on a forming tool. With the sleeve blanks formed inasmuch that no further gluing is required the same are carried by the placement means in a flat form. A plurality of said forming tools 30 are provided on a drive means 32 which

causes the forming tools 30 to move along a forward path as indicated by arrow 34 and then a return path, as indicated by arrow 36, to reach the start position 38 for the reception of a further sleeve blank. The actual erection of the blank in the forming tool is shown in more detail in Figure 3 and once the sleeve is erected in the forming tool as illustrated in forming tools 30', the tray 4 can be inserted through the opening 40 defined by the side walls 12,14 and top and bottom faces 8 and 10 so as to be inserted into the sleeve in the erected form and hence form the package.

At the end of the forward path 34 each package 2 leaves the forming tool 30 as indicated by arrow 42 for subsequent collection and loading for transit to a retail premises.

If the sleeve is relatively narrow, in the form of a band such as in Figures 1B, D, E then the machine will erect these bands as with all designs of sleeve as described and as the tray is pushed through the aperture defined by the erected band, it is moved to contact a back stop. The band can be held on two locators in the forming tool to ensure it stays central in the tool as the tray is pushed through. The removal belts then pick up on the tray that is protruding out of the ends of the tool to remove it from the tool.

Turning now to Figure 3, there is illustrated in schematic fashion a detailed use of the apparatus and forming tool in accordance with the invention to form the erected sleeve 6.

The rotatable placement means 24 provides the sleeve blank in the flattened form as indicated, by the reference numeral 44 and guides the sleeve blank which is folded such that the intermediate fold line 22 is the protruding edge of the blank as it moves as indicated by arrow 43. The sleeve blank 44 is then moved in contact with the forming tool as indicated in broken

lines 6'onto the side wall 46 of the forming tool 30 so that the intermediate fold line 22 contacts the side wall 46 of the forming tool and, as the forming tool is moving in the direction indicated by arrow 34, the movement of the blank into the forming tool combined with the movement of the forming tool itself causes the fold line 16 of the blank to locate under the lip portion 48 of the forming tool and in turn, the fold line 18 in corner 50 of the forming tool and in turn, the bottom face 10 contacts with the base 52 of the forming tool and the side wall 14 of the blank with the side wall 54 of the forming tool by which stage the blank is effectively moved to the erected form as illustrated by broken line 6". Guide means 56 can also be provided to force the sleeve into the forming tool as indicated by arrow 58 to ensure that the erected sleeve retains the position within the forming tool and hence reaches the position indicated in Figure 2 where the sleeve 6 is erected and held in the forming tool 30 and so defines the opening 40 into which the tray 4 can be inserted as indicated by arrow 60.

It should be appreciated that each of these functions are performed as the apparatus continues to move in terms of the rotatable placement means 24 continues to rotate between the store magazine and the forming tool, the drive means 32 continues to move, and the tray feed means as illustrated in Figure 2, move in sequence in accordance with the movement of the forming tools 30 along the drive means. This ability for continuous movement greatly increases the throughput rate of forming the packages.

Figure 4 illustrates one embodiment of forming tool 30 in more detail wherein the forming tool comprises base portion 52, side walls 46 and 54, with the side wall 46 being provided with a lip portion 48 used as described previously. The forming tool also includes a mounting plate 60 by which the forming tool can be

attached to the drive means plate 61 by location means comprising a first slot 63 for location on a first peg 61 and slot 65 for location on peg 67. Typically the forming tool 30 can be positioned by first engaging slot 63 on peg 61 and then rotating the tool as illustrated by arrow 69 about peg 61 to engage slot 65 on peg 67. Typically the peg 67 is threaded to allow the reception of nut 71 to retain the forming tool in position. This therefore means that sets of forming tools can be provided for each design of sleeve to be formed in accordance with the invention with the said sets of forming tools interchangeable with respect to the apparatus and the drive means 32 so that, for example, for a particular production run, the appropriate set of forming tools, with the appropriately formed and angled base 52 and side walls 46,54, can be fitted to the forming apparatus.

Figures 5a, b and c illustrate further embodiments and dimensions of forming tools with alterations to the base 52, side walls 46 and 54 as appropriate to suit particular sleeve designs.

Thus, the invention as herein described allows efficient sleeve erection and package forming in an automated and fast manner.

As such the apparatus and method allows commercially beneficial package forming utilising an article in the form of a tray and a sleeve at least partially surrounding the same to be achieved for the first time.

Claims

Claims 1. A forming tool for the reception of a package sleeve, said sleeve provided to receive an article therein through an opening when erected in the tool, said tool provided to allow the movement of the sleeve from the flattened condition in which the sleeve approaches the blank and, upon contact with the blank, to an erected form therein, characterised in that said forming tool has a mounting plate base and opposing side walls, the shape and relative angular orientation of which define the shape to which the sleeve is erected when positioned in the tool.
2. A forming tool according to claim 1 characterised in that at least one of the side walls has at its upper edge a lip portion, said lip portion acting as a locating and limiting means for movement of one of the side walls of the sleeve in a direction away from the forming tool.
3. A forming tool according to claim 1 characterised in that the side wall which includes a lip portion is the same side wall which is first contacted by the sleeve blank as it is introduced into the forming tool.
4. A forming tool according to claim 1 characterised in that the mounting plate of the forming tool has location means thereon which serve to locate the forming tool with matching location means on the drive mechanism.
5. A forming tool according to claim 1 characterised in that the side walls of the same are angled to match the angles in which the sleeve blank side walls are to lie when erected.

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6. A forming tool according to claim 1 characterised in that parts of the forming tool are adjustable to allow the forming tool to be adjusted to suit particular sleeve designs.
7. A forming tool according to claim 1 characterised in that the width of the forming tool is less than the width of the sleeve.
8. A forming tool according to claim 1 characterised in that a number of forming tools are located at spaced intervals on the drive means for movement along forward and return paths.
9. A forming tool according to claim 1 characterised in that the relative movement of the forming tool and placement means causes the sleeve as it is positioned in the forming tool to be erected.
10 A forming tool according to claim 1 characterised in that the forming tool retains the sleeve in position in the erected condition for the location of a tray therein to form a package held in the forming tool.
11 A forming tool according to claim 1 characterised in that the tool is used in combination with at least one erection finger to move the sleeve to an erected position in the forming tool.
12 A forming tool according to claim 11 characterised in that said fingers make contact with the sleeve prior to the forming tool.
13.. A forming tool according to claim 1 characterised in that the forming tool is removable from drive means for the same so as to allow replacement.

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14 A forming tool according to claim 13 characterised in that the forming tool includes two location points with the drive means, a first location point which limits movement in a first direction and a second location point which limits movement in a second direction.
15. A forming tool as hereinbefore described with reference to the accompanying drawings.