JP2010502478A - Method for producing a container having a multilayer wall and a container produced thereby - Google Patents

Abstract

It is possible to manufacture a container having a multilayer wall from a corrugated cardboard material without substantially generating waste material.
Disclosed is a method for producing a container having a multilayer wall from one blank, preferably using a continuous process, and a container produced thereby. Various embodiments of the present invention, either alone or in combination, expose an intermediate flap made from a flap material folded inward or outward so that the ends are close to each other, and an exposed container formed from the blank. An outer flap covering the edge and a stress relief portion characterizing the corner to reduce stress at the corner. The container manufacturing method according to the present invention includes: folding and adhering the flap material to the inner panel; bending the combined inner panel and intermediate panel upward around the mandrel; Continuing to bend the outer panel upward until is formed.
[Selection] Figure 6

Description

  Large containers, commonly referred to as large boxes, are used to accommodate various materials not only for transportation but also for retail display. Because more than 95% of all US products are shipped in cardboard boxes, and because of the cost advantage associated with this type of packaging, many bins are made from cardboard board. Although about 90% of corrugated paperboard is a single layer, a large box with relatively large dimensions requires the reinforcement provided by the multi-layer structure in relation to the nature of the items placed inside.

  The prior art has various ways to establish the desired level of sidewall burst strength, bottom crush resistance and vertical load resistance for the bin. Some solutions use two or three layers of corrugated paperboard as the initial material, and other solutions rely on layered walls or nested boxes. However, these solutions have not only advantages but also disadvantages. Disadvantages include high manufacturing costs due to material handling conditions during manufacturing, many uses of adhesives or manufacturing equipment, and difficult handling before and after manufacturing (before box processing or shipping, such as when handling blanks with large areas) For example, after processing such as when a manufactured bin is prepared) and generation of waste materials, which are well known to those skilled in the art.

  In view of these shortcomings, the improved bin and related manufacturing processes use single layer corrugated material that is easy to manufacture or supply, and uses a small amount of adhesive during processing, before processing, during processing and processing. It will later require minimal effort, generate a small amount of waste, and require minimal handling. There are such requirements, but they are not satisfied.

  The method according to the invention relates to the production of containers with multilayer walls from corrugated cardboard material which produces the least amount of waste material. The container is made of a single sheet or preferably a cardboard material such as a single layer cardboard or a double layer cardboard (single or double arch). The method according to the present invention winds the sheet or cardboard material around a winding mandrel. The mandrel creates the physical shape of the container during the folding and adhering (eg, gluing) process. The method according to the invention also winds the flap material to produce the container wall. This eliminates the conventional method of bonding the “inner box” to the container.

  The container produced by the method according to the present invention has at least one container wall made of a pair of opposing flap materials attached or non-removably bonded to the conventional side wall of the container. In addition, the container manufactured by the method according to the present invention, alone or in combination, is not subjected to pressure, the vertical bent portion of the corner, the meshing or mating flap material, the corner stress relieving portion, Other features that will be apparent from the specification.

  The method according to the invention is advantageous for continuous processes because it produces a container with multi-layer walls from a single sheet or cardboard material (as opposed to the use of inserts or the arrangement of boxes in a box). It is possible to make the container in one operation. Furthermore, the continuous process usually makes it unnecessary to manipulate, ie handle, the container blank. Containers with multi-layer walls are typically large, for example, about 40 "or about 1 m wide. At this size, conventional multi-layer container blanks are very large and about 15 feet or about 4. Although the length of the blank according to the present invention is about 30 feet or about 9 m, if the container according to the present invention is formed by a conventional method, for example, one apparatus produces the blank. However, storage, transportation and handling of such large blanks can be very difficult (30 feet) when the blank is moved to a warehouse and then to a machine for processing or box making. It is not easy to carry a bundle of blanks.) Based on conventional blanks by using a continuous process in which cardboard material or certain types of materials are fed to a machine for processing or box making. Associated with the box manufacturing process, handling conditions of all, the bundle of material is removed.

  While the benefits of using a continuous process approach to manufacturing containers according to the present invention have been emphasized, the present invention is not limited to such an approach. Even in the continuous process, a blank is formed prior to processing the material into a container. The term “blank” as used herein includes both conventional container blanks not obtained from a continuous process and container blanks obtained from a continuous process. If a distinction is required and the distinction is not clear from the context, a “conventional blank” or similar term refers to a blank that cannot be obtained from a continuous process.

  The container manufacturing method according to the present invention uses a flap material bent inward or outward in order to create a container wall between the outer wall and the inner wall of the manufactured container. In a preferred embodiment of the present invention, the blank flap materials used to manufacture the container are individually or combined to form the side walls. Opposing flap materials are folded together and attached to the panel from which the flap material extends, for example, with an adhesive. When folded and bonded, the flap materials together form an additional side wall of the container. By using this method of manufacturing the equivalent of a three-layered container in which the flap material constitutes an intermediate flap, a container that does not substantially generate waste material can be manufactured. The intermediate panel may be continuous in the vertical blank direction, may not be continuous, or a combination thereof.

  The method according to the invention involves producing a container with a multi-layer wall with vertical bends that are substantially free of pressure at all corners. Since the container is formed around a mandrel having the desired shape of (at least the side wall of) the container, the resulting rest state of the container is the use shape of the container. For this reason, each of the vertical corners of a container having four sides is less prone to rupture and breakage in use as known in the prior art. The same applies to the 6 and 8 corner types. Since the vertical corners in the structure having four side surfaces are not bent by more than 90 ° from the “use” shape to the “disassembly” shape of the container, the handling and storage properties of the container are improved. When a corner edge is under stress, the edge is usually not subjected to dynamic loading. That is, the edge portion is folded and stored. On the other hand, when the container receives a dynamic load, such as during use and transportation of goods, the edge portion is usually in a shape that is not subjected to stress. This structure facilitates the restoration of the container shape from the “disassembled” shape, which is a major advantage over the prior art for large containers.

  In another method according to the present invention, a corner stress relaxation portion is formed by selective material removal, preferably at the intersection of the flap joint and panel joint in the outermost panel and flap. Since the intersection is subject to bi-directional manipulation (panel folding and flap folding), the selective removal of material from the intersection allows for a high degree of bonding and reduces the stress that occurs at a particular location. Remove. A substantially circular piece of material is removed from the folded intersection and / or its vicinity. Blanks and / or container stock incorporate this feature as a structural element.

  In the method according to the present invention, two flaps or slits separating the flap portions are spaced from the score to facilitate bending of two adjacent panels. Preferably, the spacing with respect to the outer panel and flap is preferably approximately equal to the thickness dimension of the material (cardboard or blank) used to manufacture the container, for example when a three-layer container is made. . When implemented, each flap has a width dimension that is different (long or short) from the width dimension of the panel from which the flap extends. When the container is assembled to its final shape, the wide outer flap extends to the outer edge of the container and the inner flap extends to the middle and inner layers. This provides additional stack strength, effectively utilizes the outer panel of the container, and causes contact to the outer panel. It will be apparent to those skilled in the art that this shape is easily realized with the stress relief portion.

  The container resulting from the implementation of various embodiments of the present invention comprises a container having multiple side walls, a container blank, and one blank forming a container made therefrom. The blank has an inner panel that defines a longitudinal direction from a first end to a second end and forms an inner wall of the container when assembled, the inner panel comprising a plurality of inner panel portions. Each inner panel portion is continuous with an adjacent inner panel portion, and each inner panel portion constitutes one inner wall of the container when assembled.

  The blank has at least one set of flap materials, the flap materials having opposing intermediate flaps extending from the inner panel. The sum of the average lateral lengths of the flap material from the intersection to the edge of the flap material panel is from the intersection of the first flap material to the intersection of the second flap material. Equal to or shorter than the lateral length of the panel. Each flap material or intermediate flap preferably has a plurality of flap portions, each flap portion being continuous with or separated from the adjacent flap portions, The flap portion of the container constitutes one side wall of the container when assembled.

  Further, the blank has an outer panel that, in the three-layer side wall embodiment, extends longitudinally from the inner panel and forms the outer wall of the container when assembled, the outer panel preferably comprising: There are a plurality of outer panel portions, each outer panel portion being continuous with an adjacent outer panel portion, and each outer panel portion constitutes one outer wall of the container when assembled. If additional intermediate sidewalls are desired, the outer panel preferably extends from the last intermediate panel. In the three-layer sidewall embodiment, such an intermediate panel is disposed longitudinally between the inner panel and the outer panel.

  As described above, in the embodiment of the present invention, the total of the average lateral width of the flap material is equal to or smaller than the lateral width of the panel in which the flap material extends. This relationship allows at least one set of opposing flaps to be rolled during container manufacture so that the edges of each flap are brought closer together and the associated panel from which the flaps extend. In the embodiment of the three-layer structure, the flap material may constitute one of an inner panel and an intermediate panel, and the panel from which the flap material extends may constitute the other panel. The wound structure functions as a side wall when the container material is assembled into the container. It will be apparent to those skilled in the art that the lateral length value changes as the shape of the edge of the flap changes. For this reason, although the total length is described using the term “average”, it is within the scope of the present invention to include shapes that do not cause overlapping when the flaps are wound and brought close together. It is.

  In the embodiments of the present invention, the edges of the opposing flap materials that mesh or mate with each other are formed, for example, by punching. Stress generated in the butt joint after winding and formation of the container is distributed in use over a wide area and long edges of adjacent side walls. This is particularly important when maximizing burst strength and vertical compressive strength.

  Industrial embodiments of the present invention (system) have multiple locations where various treatments can be performed on the blank or cardboard material to produce the container. For the purposes of immediate disclosure, the method of forming a container according to the present invention starts with an appropriately sized “blank”. This term is as already defined. The selection of features incorporated into the container determines the presence and order of the devices and methods used to form the intended container. For illustrative purposes only, the basic structure of a three-layered container with four sides is described below. When the blank is processed, the flap material is bonded to the associated panel and the container material is rolled as described above. When the container blank is rolled, the panels that form adjacent layers are compressed together and bonded together to form the container. The container is later moved and optionally disassembled.

The perspective view of 1st Example of this invention of the assembled state. The detailed perspective view of a part of corrugated board material which has a liner on both sides used for the 1st example. The top view of 1st Example which saw through the upper flap in order to demonstrate the layer of cardboard material. FIG. 4 is a detailed plan view of a corner portion of the embodiment shown in FIG. 3. The top view of the blank used in order to form 1st Example of this invention. The detailed top view which shows the stress relaxation part and vertical compression resistance shape of 1st Example of this invention. FIG. 5 is a perspective view showing a first step in forming a container with multi-layer walls using the blank shown in FIG. 4 where the intermediate flaps are folded closely to form an intermediate sidewall with corrugated material. The perspective view which shows the 2nd step in formation of the container which has a multilayer wall using the blank shown in FIG. FIG. 5 is a perspective view showing a third step in forming a container with multilayer walls using the blank shown in FIG. 4 with the inner panel and intermediate flap wound thereon. FIG. 5 is a perspective view showing a fourth step in forming a container with multi-layer walls using the blank shown in FIG. 4 where an inner adhesive tab is attached to the inner panel to form a basic container shape. FIG. 10 is a perspective view showing a fifth step in forming a container with multi-layer walls using the blank shown in FIG. 4 with an outer panel wrapped around the basic container shown in FIG. 9. FIG. 5 is a perspective view showing a sixth step in forming a container with multi-layer walls using the blank shown in FIG. 4 with an outer adhesive tab attached to the outer panel and completing the shape of the first embodiment. 5 is a detailed perspective view of the stress relaxation portion shown in FIG. 5 when the blank shown in FIG. 4 is processed into the container shown in FIG. 11 and the upper and lower flaps are folded inward. The top view of the apparatus which receives the processed blank and manufactures the container assembled from this blank. FIG. 14 is an isometric view of a position for folding and bonding that is part of the apparatus shown in FIG. 13. FIG. 14 is a perspective view of an upward winder that is a part of the apparatus shown in FIG. 13. FIG. 16 is a front view of a rotating portion of the upward winder shown in FIG. 15 in which four mandrel bars are relatively moved.

  The following description is made to enable those skilled in the art to use the present invention. It will be apparent to those skilled in the art that various modifications can be made to the embodiments described herein, and general modifications herein can be made without departing from the spirit and scope of the invention as defined by the claims. The principles may be applied to other embodiments and applications. Thus, the present invention is not limited to the embodiments shown herein, but is given the widest scope consistent with the principles and features disclosed herein.

  Referring to the drawings, like numerals indicate like parts, and particularly with reference to FIGS. 1-4, embodiments of the invention are described which employ many features and elements of the invention. The container 20 preferably includes a “blank” 22 made from a single layer cardboard material having liners on both sides, such as the 5/16 ”L flute cardboard shown in FIG. In the illustrated embodiment, the container 20 has a dimension on the order of 42 "H x 48" W x 40 "D, and the blank 22 has a maximum dimension on the order of 355" L x 83 "W. In the example, the container 20 has three layers of side walls and overlapping bottom and top flaps.

  In order to form the container 20, it is necessary to manufacture the container blank 22 prior to assembly or in the assembly process. As shown in FIG. 4, the container blank 22 consists of a single cardboard material with the steps extending laterally, such as the type of cardboard material shown in FIG. A single sheet is provided with selected scores, cuts and perforations by means of a rotary die cutter or other means known to those skilled in the art. The container blank 22 has an inner panel 40, opposing intermediate flaps 50, an outer panel 60, and a plurality of end flaps 70. The container blank 22 preferably further includes an inner tab 30 and an optional outer adhesive tab 80. For conventional purposes, the visible surface of all panels and flaps are as shown, with similar symbols in the 100s on the back. For example, the back side of the inner panel 40 is shown as the inner panel 140.

  Inner panel 40 has inner panel portions 42, 44, 46, 48 separated by scores 34a, 34b, 34c. The inner tab 30 extends longitudinally from the inner panel portion 42 and is separated from the inner panel portion 42 by a score 32. Each intermediate flap 50 extends laterally outward from the inner panel portions 42, 44, 46, 48 and has slit scores 43a / b, 45a / b, 47a / b, 49a / b and scores 34a, 34b, 34c (in addition to this, the edge portions 51a / b and the slits 73a and 73b) are partially defined. Each intermediate flap 50 has intermediate flap portions 52a / b, 54a / b, 56a / b, 58a / b in this embodiment. As will be apparent to those skilled in the art, other forms of scoring (instead of scores 34a, 34b, 34c, which partially define each intermediate flap portion 52a / b, 54a / b, 56a / b, 58a / b) For example, slitting or slotting may be used as well as point-to-flat), and reinforcement and handling by maintaining a strong physical connection between adjacent intermediate flap portions, as described below. The advantage of is realized. Each flap 50 may have a physically separated flap portion (like end flap 70 described below), or may have a visually separated flap portion as shown (scoring). May be continuous). Since it is only necessary to form a wall or layer on the container 20, as long as the flap portion of the blank 22 folded against the opposite portion of the blank 22 can form such a wall or layer, There is no essential need to form a separate flap portion.

  The end of each intermediate flap portion is characterized by chevron edges 53a / b, 55a / b, 57a / b, 59a / b, as shown in FIG. Such chevron edges or non-linear edges effectively prevent rupture and compressive stresses that may occur after assembly and use of container 20, as will be described below. For this reason, curved edges or repetitive square or serrated edges are considered desirable. However, it is not essential that the operation or configuration of embodiments of the present invention include such non-linear edges, which provide the benefits described herein.

  Inner panel 40 and intermediate flap 50 form the side walls of the container, outer panel 60 forms the side walls, and end flaps 70 constitute the bottom and top of container 20, as shown in FIG. Outer panel 60 has outer panel portions 62, 64, 66, 68 separated by scores 38 a, 38 b, 38 c, and outer panel portion 62 is separated from inner panel portion 48 by score 36. The outer adhesive tab 80 extends longitudinally from the outer panel portion 68 and is separated from the outer panel portion 68 by a score 82. End flaps 72a / b, 74a / b, 76a / b, 78a / b extend outward in the lateral direction from the outer panel portions 62, 64, 66, 68 and score between two points 63a / b, 65a / b 67a / b, 69a / b and slits 73a / b, 75a / b, 77a / b, 79a / b (and edge 71a / b). As will be apparent to those skilled in the art, slots may be used in place of the slits 73a / b, 75a / b, 77a / b, 79a / b and, as will be described later, by the use of slits for the stress relaxation portion 90. Profit is brought.

  The lateral width dimension (or height dimension when assembled) of the outer panel 60 is larger than the lateral width dimension of the inner panel 40. This increased dimension corresponds to the increased outer dimension when the container 20 is formed (shown below). Similarly, the length dimension (or width dimension and depth dimension when assembled) of the outer panel 60 is larger than the length dimension of the inner panel 40 in the vertical direction. As will be apparent to those skilled in the art, the increase is related to the number of walls used to form the container and the thickness of the material comprising the walls.

  FIG. 5 shows two features of this example: a stress relief portion 90 characterized as a hole having a diameter of about 0.375 "and a flap offset. The flaps of the container are located between the flap and the side wall panel. It is often torn at the exposed edge located at the boundary, which is due to the influence of the corner with three edges on the underside of the flap, ie the corner with the three edges is on the flap. Crushing the edges, thereby jeopardizing the structural integrity of the flap and the structure associated with it, often with the inherent weakness of the material at this location, often with repeated use of the flap or Introducing a mechanical defect during operation, preferably by providing a round or circular hole in the corner having three edges, but not essential, the flap Not directly have an adverse effect on the lower side. In some cases, depending on the number of the particular container wall, additional stress relief portion may be used with respect to the inner or intermediate walls.

  FIG. 5 shows the offset with respect to the slit separating adjacent flaps 70 and the score between two points separating adjacent outer panels 60. Continuous scores 34a, 34b, 34c of inner panel 40 and intermediate flap 50 (defining inner panel portions 42, 44, 46, forming intermediate flap portions 52a / b, 54a / b, forming equally sized walls , 56a / b, 58a / b), the flap 70 has different dimensions compared to the associated panel. Such symmetry is not required because the flap 70 forms an end wall rather than a side wall. As shown in FIG. 3, because the flap 70 is perpendicular to the side wall including the inner panel 40, the intermediate panel 50, and the outer panel 60, the larger dimension flap is the outer panel when the container 20 is assembled. Extends over the entire 60 exposed edges. As a result, as shown in FIG. 11, all exposed vertical side wall edges are covered by the end flaps, and vertical compressive loads are evenly distributed to the end flaps.

  The assembly of the container 20 is shown in detail in FIGS. The completed blank 22 shown in FIG. 4 is obtained from a processing machine and enters the bending and bonding process. The intermediate flap portions 52a, 54a, 56a, 58a, 52b, 54b, 56b, 58b, which are integrated using a folding rail or paddle, are connected to the inner panel portions 42, 44, 46 as shown in FIG. , 48 are bent 180 ° downward along slit scores 43a, 45a, 47a, 49a, 43b, 45b, 47b, 49b. Prior to the start or end of the 180 ° bending process, an adhesive is applied to the contact surface, preferably using a spray. At the end of the 180 ° bending and bonding process, the chevron edges 53a / b, 55a / b, 57a / b, 59a / b contact the middle of the inner panel portions 42, 44, 46, 48. The serrated mating chevron edges 53a / b, 55a / b, 57a / b, 59a / b have a seam in a wider area than a simple straight cut, at this point under the flat box blank. To position.

  Using the grip mechanism, the inner tab 30 is folded 90 ° upward at the score 32, the inner panel portion 42 is folded 90 ° upward at the score 34a (together with the intermediate flap set 52a / b), and the inner panel portion 44 is Folded 90 ° upward at score 34b (with intermediate flap set 54a / b), inner panel portion 46 folded upward 90 ° at score 34c (with intermediate flap set 56a / b) and inner panel portion 48 It is folded 90 ° upward at score 36 (with intermediate flap set 58a / b) (FIG. 8). All 90 ° bends are upwards and are in a different orientation than the surface bonds of the chevron edges 53a / b, 55a / b, 57a / b, 59a / b. The structure thus formed is shown in FIG.

  Adhesive is applied to the mating surfaces of the outer panels 62, 64, 66, 68, and the upward folding process includes 90 ° folding of the outer panel 62 in the score 38a and 90 ° folding of the outer panel 64 in the score 38b. Bending, 90 ° bending of the outer panel 66 at the score 38c, and 90 ° bending of the outer panel 68 at the score 82 are continued, and the bending and bonding process is terminated at the outer adhesive tab 80. This process is shown in FIG. As will be apparent to those skilled in the art, the upward folding process is accomplished using a forming mandrel or other instrument.

  The 90 ° folding and bonding process includes the inner tab 30, the inner panel 40, the intermediate flap 50 forming the intermediate panel, the outer panel 60, and the optional outer tab 80 shown in FIG. A flat, strong corrugated cardboard blank forms the multi-sided, four-sided container (box) shown in FIG. 11 with the top and bottom of a single layer flap and without the manufacturer's joints. Since the stationary state (manufacturer's resting position) is the use state of the container, when the container is crushed, the container naturally tends to return to the resting position. This advantage is not important for single layer containers, but for containers with multiple walls, the force required to form the desired container shape from the disassembled form becomes important. For this reason, there is a great operational advantage in manufacturing containers with multi-layer walls that have the same rest position as the use position. By having a panel score at each edge, the container can be easily disassembled (in addition, the score line prevents destruction, thereby reducing the structural integrity of the container at a position adjacent to the edge. Kept.)

  By including one, some or all of the above features, significant advantages in terms of strength and material costs are realized (manufacturing efficiency is discussed below). The following table shows the advantages associated with a series of containers according to embodiments of the present invention. In this table, a green field container includes all the features of the above example, and a conventional container (HP) is made from two panel layers of double-layer cardboard material or three panel layers of double-layer cardboard material. The panel layers are nested, but are not adhered to each other.

  As can be seen from the above table, the container according to the present invention has a compression resistance (an important factor in the evaluation of the container) superior to conventional structures of comparable weight or material usage for comparable compression resistance. There are very few. As shown below, the container manufacturing method according to the present invention increases the cost saving effect by simplifying the manufacturing and handling operations.

  Containers with multi-layer walls, according to embodiments of the present invention, focus on the general handling of container blanks and the blanks forming the containers shown in FIGS. The following disclosure is directed to a system for mass producing containers according to the present invention and implementing the associated methods. Similar to the above disclosure relating to containers having three layers of side walls, the following disclosure describes the process of mass production of such containers and variations thereof. It will be apparent to those skilled in the art that the disclosed aspects and approaches are not limited to the manufacture of containers according to the present invention, but illustrate general and specific implementations that identify preferred means of achieving the objectives. is there.

  Considering the high degree of automation associated with the container manufacturing process, eg, computerized, servo-driven manufacturing equipment, many of the following tasks are performed automatically by machines that have received programming commands. It will be apparent to those skilled in the art that prior to operating such a programmable machine, program parameters must be defined and entered into the machine programming interface. The following disclosure provides examples of manufacturing a desired container based on pre-input instructions for various machines.

  The basic material used to manufacture the container 20 is obtained from a corrugator (not shown) that manufactures double-sided cardboard. The double-sided cardboard may be used immediately or stored as a cut blank until needed. A blank 22 having a total length of about 30 feet (9 meters) is made from the double-sided cardboard, for example, by cutting. Once the cut blank 22 is obtained, the blank is subjected to various slotting, slitting, scoring and cutting steps necessary to form the desired container 20.

  In the preferred system, the various slotting, slitting, scoring and cutting steps are performed by a pair of opposing machines provided to the blank using conventional conveyor means. These machines, preferably the RapidBox unit from Rapidex, Angers, France (Bobst Group, Switzerland), have a programming determined based on the size and shape of a given container. After that, a desired blank is manufactured. Rapid box machines can provide blanks up to 110 "x400" or 2.8mx10m and are particularly suitable for the manufacture of large containers. These steps may be performed by dedicated machines such as various slotting, scoring, slitting and rotary punching machines provided continuously in the production line. Regardless of how the blank is processed, the resulting blank is brought to a position for folding and bonding.

  When removed from the processing machine, the blank 22 is placed on the cradle 210 and then transported to the vacuum conveyor 220 toward a position 230 for folding and bonding as shown in FIG. This transport method is preferable to the conventional type for two reasons. First, complete exposure of the lower surface (the inner panel surface 140, the intermediate flap surface 150) of the inner panel 40 and the intermediate flap 50, which is important during the upward winding process described later, is maintained. Secondly, the specific position of the blank 22 relative to other equipment, which is important when precise application of adhesive is required, is kept accurate. The inner panel surface 140 and the intermediate flap surface 150 are exposed on the upper side, and the blank 22 inverted so that the blank 22 is supported by a conventional conveyor is suitable for transport and folding above the intermediate flap 50 and ( It will be apparent to those skilled in the art to allow the use of downward folding (described below).

  Depending on design considerations including cost and performance criteria, the adhesive applied to the blank 22 from the adhesive application means may be selectively applied or the inner panel surface exposed to the first adhesive means. 140 and / or the entire intermediate flap surface 150 may be applied. Selective adhesion of the adhesive involves a reasonable placement of bond lines or areas at the border of the panel and / or flap. In the illustrated example, the adhesive is applied through spray nozzles 262, 264 that eject PVA or hot melt adhesive, but any amount and type of adhesive that can be applied to the blank 22 is shown. Any adhesive application means is sufficient. The application means and adhesive described above are selected to optimize the speed of the process described above. At about 200 feet per minute, the applied adhesive has sufficient time to cure before folding and contacting the intermediate flap 50.

  When the adhesive is applied to the inner panel surface 140 and / or the intermediate flap surface 150, the actuated bending arm winds the intermediate flap 50 and the intermediate flap surface 150 is attached to the inner panel surface as shown in FIG. 140. A pinch roller combination compresses the intermediate flap 50 and the inner panel 40 together with the conveyor 160, or a lapping process, described below, compresses the two surfaces.

  At this time, the processed blank 22 is transformed into the material 122. Adhesive to the exposed surface of the outer panel 60 (and / or the exposed surface of the intermediate flap 50 located at the bottom of the material 122 at this point) to produce the material 122 for forming the container 20. Must be applied. In the illustrated example, the second adhesive application unit 262 is prepared, and the adhesive is selectively applied to the exposed surface of the outer panel 60.

  As shown in FIG. 16, when the tab 30 approaches the winder 270, the clamping element 271 opens to accept the tab 30 (if not already open). Depending on the embodiment, the rotator 276 may already be rotating or may start rotating after engagement of the plump element 271 with the tab 30. While mechanical engagement means are shown, other means such as vacuum engagement are contemplated. In addition to the clamping element 271 or its equivalent, the rotating body 276 preferably has a number of folding bars equal to the number of vertical corners of the container. In this embodiment, the number of corners is four. The folding bar generally concentrates the bending stress when forming the container locally, resulting in convenience, low cost and low weight for forming the container. The folding bars 272a-d are liquid so that the assembly accepts the material 122, assists in forming the container 20, and allows the container 20 to be released to allow other materials 122 to be engaged. It can be moved in the rotating body 276 by pressure drive or by mechanical drive.

  When the blank 122 is wrapped around the rotating body 276, the outer panel 60 is coupled to the intermediate flap 50 (or other predetermined location of the blank 122) and the outer tab 80 is vertical (if the outer tab 80 is present). Sufficient tension is applied to ensure that the corners 82 (FIG. 1) fit. Reducing the discharge speed of the material 122 in front of the rotator 276 while maintaining a constant rotational speed, increasing the rotational speed while maintaining a constant discharge speed, and / or folding. By increasing the relative movement of the bending bars 172a-d, a suitable tension can be applied. The means for maintaining the preferred parameters is to adjust the rotating body 276 up and down so that the blank 122 always engages the rotating body 276 in a planar manner. As shown in FIGS. 15 and 16, the winder 270 is movable in the vertical direction (FIG. 15 shows a hydraulic cylinder 277 connected to the pulley device 278). Alternatively, an external compression element may be used when winding the material onto a mandrel to cause compression between the sidewall layers of the container. It will be apparent to those skilled in the art that the means for ensuring proper winding of the material is not limiting and that there are other means of achieving the same or similar results.

  In order to ensure that the cardboard material wound on the winder 270 does not unintentionally unravel, the outer panels 62-68 are typically adhesives that do not occur when the container 20 is attached to the rotating body 276. In the course of curing, it must be held close to the intermediate panels 52-58. In the present embodiment, the winder 270 has a bottom support table 275 having an upper surface approximately at the height of the blank 22. Since the panel (tab) wound last is kept in compression contact with the support table 275, the container 20 does not leave the winder 270 early. In this position, sufficient tension is applied to the blank 122 to create a bond between the panel surfaces 140, 150 and between the panels 50, 60. The curing time of such an adhesive is usually longer than the time required to wind up the material 122. For this reason, a curing position is required. In this embodiment, as shown in FIG. 13, a rotating structure is used, and the conveyance of the formed container 20 is sufficiently delayed to allow sufficient time for the adhesion to cure, This ensures that the container 20 cannot be unwound.

  Although not necessary for removing the container 20 to remove the formed container 20 from the winder 270, one, some or all of the folding bars 172a-d may cause friction between them and the container 20. Extracted to reduce. In certain embodiments, an external engaging sliding element or other means for removing the container 20 from the mandrel 170 may be used. Preferably, an arm having a plurality of stretching elements (mechanical and / or pneumatic and / or electrical and / or hydraulic) is inserted into the container 20, the stretching element being Stretched into compression contact with the inner wall (or engaged via a vacuum device), the arm is then moved to pull the container 20 from the folding bars 172a-d. Support table 285 is used for reasons similar to support table 275 reasons.

  As the assembly 280 rotates, the formed container 20 is removed from the winder 270. When the formed container reaches a predetermined position on the opposite side of the winder 270 (FIG. 13), the engagement steps are performed in the reverse order and the formed container is removed from the extension arm. Once removed, the moved container may be disassembled for storage and / or transportation.

  Due to the difference in thickness between the side wall panel and the flap, in the embodiment of the present invention, as shown in FIG. 15, the outer flap 70 is bent backward toward the side wall panel. If such a final configuration is desired, embodiments of the present invention fold the end flaps toward the side wall panels at the same time as the intermediate flaps are folded. For this reason, when the raw material 122 is wound up, the outer side flap 70 is not in the extended state but in compression contact with the panel 60. In addition to eliminating the work step of individually folding the end panels when the container 20 is formed, shorter mandrels and container movements when the overall height of the container is reduced by the depth of the end flaps An apparatus may be used. Further, in such an embodiment, it may be considered to omit the tab 80 so that the contact surface is sufficiently planar to avoid bonding and / or crushing.

  It is desirable to keep the flaps 72-78 connected by a piece of material to prevent premature unfolding (this can be caused by incomplete slitting between the panels at the ends of the flaps). . For this reason, when the dismantled container is delivered to the consumer, the flaps 72-78 are separated and folded into place.

20 Container 22 Blank 30 Inner tab 34a, 34b, 34c Score 40 Inner panel 42, 44, 46, 48 Inner panel part 50 Intermediate flap 52a, 54a, 56a, 58a, 52b, 54b, 56b, 58b Intermediate flap part 60 Outer panel 62, 64, 66, 68 Outer panel portion 70 End flap 80 Outer adhesive tab 90 Stress relief portion

Claims (20)

A method of manufacturing a container having a multilayer wall from one blank that defines a longitudinal direction from a first end to a second end,
Partitioning an inner panel that forms the inner wall of the container when assembled;
Defining at least one pair of opposing intermediate flaps extending from the inner panel;
Defining an outer panel extending from the inner panel and forming an outer wall of the container when assembled;
Wrapping the intermediate flap so that the edges of the intermediate flap are in close proximity to each other and attaching the intermediate flap to the inner panel, thereby forming an intermediate sidewall when the blank is assembled into the container Including
The inner panel has a plurality of inner panel portions, each inner panel portion is continuous with an adjacent inner panel portion, and each inner panel portion constitutes one inner wall of the container when assembled. And
The total lateral length of the intermediate flap from the intersection of the intermediate flap with the inner panel to the edge is from the intersection of the first intermediate flap to the intersection of the second intermediate flap. Equal to or shorter than the lateral length of the inner panel,
Each intermediate flap has a plurality of flap portions, each flap portion being continuous with an adjacent flap portion, the opposing flap portions constituting one intermediate side wall of the container when assembled;
The outer panel has a plurality of outer panel portions, each outer panel portion is continuous with an adjacent outer panel portion, and each outer panel portion constitutes the outer wall of the container when assembled. Container manufacturing method. Forming a first adhesive tab at the first end of the blank and a second adhesive tab at the second end of the blank,
The container of claim 1, wherein the first adhesive tab is attached to the inner panel when the container is assembled and the second adhesive tab is attached to the outer panel when the container is assembled. Production method.   The container manufacturing method according to claim 1, comprising forming a non-linear edge of the intermediate flap.   The container manufacturing method according to claim 3, wherein an edge of the intermediate flap has a shape of a repeated straight line, a curved line, or a combination of a straight line and a curved line.   The container manufacturing method according to claim 1, wherein the edge of the intermediate flap is complementary such that the edge of one intermediate flap is substantially adjacent to the edge of the other intermediate flap when rolled.   The container manufacturing method according to claim 1, comprising forming a score between the intermediate flap portions.   The container manufacturing method of Claim 1 including forming a slit, a slot, or a cut | interruption between the said intermediate | middle flap parts.   The container manufacturing method according to claim 1, comprising forming a score between the inner panel portions.   The container manufacturing method according to claim 1, wherein the blank is made of a corrugated cardboard material having a double-sided liner.   The container manufacturing method according to claim 1, wherein a lateral dimension of the inner panel portion is smaller than a lateral dimension of the outer panel portion. Forming at least one set of opposing end flaps extending from at least some outer panel portions;
The container manufacturing method according to claim 1, wherein each end flap is separated from an adjacent end flap by a slot, slit, or cut.   The container manufacturing method of claim 11, wherein the end flaps extend laterally from each outer panel portion.   The container manufacturing method according to claim 11, comprising forming a stress relaxation portion between the end flap and the outer panel portion.   The container manufacturing method according to claim 12, comprising forming a stress relaxation portion between each end flap and each outer panel portion.   12. A container manufacturing method according to claim 11, wherein the longitudinal length of each end flap is longer or shorter than the longitudinal length of the corresponding outer panel portion from which the end flap extends.   The container manufacturing method according to claim 1, wherein a rest position of the container formed from the blank is the same as a use position of the container formed from the blank.   The container manufacturing method according to claim 1, wherein the blank is made of a cardboard material having a double-sided liner.   The container manufacturing method according to claim 1, wherein the blank is made by a continuous process started by a corrugator.   The said stress relaxation part is a container manufacturing method of Claim 13 which consists of a hole prescribed | regulated by two adjacent end flaps and the said outer side panel.   The container manufacturing method according to claim 1, wherein one inner panel portion has a longitudinal length longer than a longitudinal length of the other inner panel portion.

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