NZ244433A - Presenting package for filling: machine folding of flaps - Google Patents

Description

244 433 PATENTS ACT. 1953 No.: 244433 Date: 22 September 1992 COMPLETE SPECIFICATION "Improvements in or Relating to a Method of Manufacturing Packaging and an Apparatus Therefor" We, PRINTPAC-UEB LIMITED, a company duly incorporated under the laws of New Zealand of 630 Great South Road, Greenlane South, Auckland, New Zealand hereby declare the invention for which we pray that a patent may be granted to us, and the method by which it is to be performed, to be particularly described in and by the following statement:- 244433 This invention relates to a method of manufacturing packaging as well as an apparatus for manufacturing packaging. In particular, the invention relates to a method of manufacturing a package for holding kiwi fruit and the like produce.

It is an object of the invention to provide a method of manufacturing packaging and an apparatus therefor which will, at the very least, provide the public with a useful choice.

Accordingly in a first aspect the present invention consists in a method of preparing and presenting containers for use, said containers being of a kind having a substantially square or (preferably) rectangular base with upstands from each of one pair (preferably the ends if a container has a rectangular base) of walls (sides) to penetrate an opening/openings of top closing flaps "hinged" from the other pair of walls (sides), (I) (A) where the height of the walls is greater than or of a similar dimension to the distal extent of each closing flap (i) machine folding each of the top closing flaps outwardly against the wall from which each is integral and from which it is to hinge (eg using about a 180° fold at the intended hinging line of fold for closing purposes), and (ii) closing the top closing flaps of container, OR (B) where the wall height is less than the distal extent of each closing flap (i) machine folding each of the top closing flaps substantially centrally of its distal edge and the intended hinging line of fold for closing purposes, such folding preferably being at about 180° outwardly of the container and (ii) machine folding each of the top closing flaps against the wall with which it is integral and from which it is hinged at the intended hinging line of fold for closing 244433 purposes (eg a fold of about 180°) while allowing the distal region outwardly of said first mentioned machine fold to underlie the base of the container, AND (II) machine stacking each said container with like presented containers from below.

Preferably said container has the walls and closing flaps formed of a corrugated paper/board (laminated or not) where the corrugations run parallel to the intended hinging fold.

Preferably prior to step (I) the closing flaps are in the same plane as the wall from which they depend.

In another aspect, the invention consists in a method of forming or presenting a package for use, said package having a base, four side walls and a pair of lid flaps extending from a pair of said side walls, a longitudinal fold line provided between said lid flaps and said side walls, comprising the steps of: initially providing said lid flaps in the same plane as said side walls; machine folding said lid flaps outwardly about said fold line through an angle of about 180°; and machine closing said lid flaps; or positioning the distal longitudinal parts of said lid flaps under said base and forming a stack of said packages.

In yet a further aspect the invention consists in an apparatus for preparing and presenting containers for use, said containers being of a kind having substantially square (or preferably) rectangular base with upstands from each of one pair (preferably the ends if a container has a rectangular base) of walls (sides) to penetrate an opening/openings of top closing flaps "hinged" from the other pair of walls (sides), comprising: r 24 443 (I) (A) where the height of the walls is greater than or of a similar dimension to the distal extent of each closing flap (i) a machine folding apparatus for folding each of the top closing flaps outwardly against the wall from which each is integral and from which it is to hinge (eg able to fold said top closing flaps through 180° at the intended hinging line or fold for closing purposes), and (ii) a lid flap closing means for closing the top closing flaps of container, or (B) where the wall height is less than the distal extent of each closing flap (i) a first machine folding apparatus for folding each of the top closing flaps substantially centrally of its distal edge and the intended hinging line or fold for closing purposes, such folding preferably being at about 180° outwardly of the container and, (ii) a second machine folding apparatus for folding each of the top closing flaps against the wall with which it is integral and from which it is hinged at the intended hinging line of fold for closing purposes (eg a fold of about 180°) while allowing the distal region outwardly of said first mentioned machine fold to underlie the base of the container, AND (II) a stacking apparatus for stacking each said container with the like presented containers from below.

In a further aspect the invention consists in an apparatus for forming or presenting a package for use, said package having a base, four side walls and a pair of lid flaps extending from said side walls with a longitudinal fold line between said lid flaps and said side walls, comprising: an advancing mechanism for advancing a partly or completely assembled package or packages having said lid flaps in the same plane as said side walls, at least one pair of side rails provided at a predetermined height, wherein said package • 2 4 4 4 advances substantially between said side rails in use, and a folding apparatus for folding said lid flaps over said side rails through an angle of about 180° and either (i) an apparatus for closing said lid flaps; or (ii) a second folding apparatus for folding the distal ends of said lid flaps under said base.

Preferably said side rails :are height adjustable.

Preferably said apparatus includes a stacker for stacking a plurality of said packages in a stack of predetermined height. 2 4 4 4 3 3 The preferred form of the invention shall now be described with reference to the accompanying drawings wherein; Fig 1 is a plan view of a blank for forming a package; Fig 2 is a perspective view of an assembled package formed from the blank of Fig 1; Fig 3 is a perspective view of an assembled package with the distal edge of one lid flap positioned under the base of the package; 244433 ■ » ~~ * Fig 4 is a plan view of the underside of the package of Fig 3 showing part of the lid flap positioned under the base; Fig 5 is a plan view of the blank used to form the support member for use in the package shown in Fig 2 or Fig 3; Fig 6 is a perspective view of a folded support member formed from the blank as shown in Fig 5; Fig 7 is a plan view of the blank of Fig 1 showing regions where adhesive is applied to the package; Figs 8 A-E are schematic end-on views of the sequence of steps for forming the package as shown in Fig 2 or Fig 3; Fig 9 is a plan view of a blank used to form a package shown in Fig 11; Fig 10 is a plan view of the blank used to form the support panel for the package shown in Fig 11; Fig 11 is a perspective view of a package; Figs 12 A - D are schematic end-on views of the sequence of steps for forming the package as show in Fig 11; Fig 13 is a side elevation of apparatus for assembling the packages from blanks; Fig 14 is a close-up, side elevation of stage 1 of the manufacturing process; Fig IS is a side close-up, elevation of stage 2 of the manufacturing process; Fig 16 is a close-up, side elevation of stage 3 of the manufacturing process; Fig 17 is a perspective view of another form of package which may be assembled; and Fig 18 is another perspective view of another form of package which may be assembled. 2444 The invention relates to a method of manufacturing a package and an apparatus therefor. The method and/or apparatus can be used to form any type of package having an integral lid. In the preferred embodiment of the invention however, the method and/or apparatus are used to form a stackable package designed to hold produce such as kiwifruit Examples of packages that can be formed using the invention are shown in Figs 2, 3 and 11.

With reference to Figs 2, 3 and 11 the stackable package formed by the invention is in the form of a tray, carton or case 1. The tray, carton or case 1 has a square or, preferably, rectangular base 2 and a pair of end walls 3 extending upwardly therefrom. A pair of side walls 4 are also provided which extend upwardly from the base 2.

The package has a pair of panel supports 6 which are provided adjacent the end walls 3 and/or the side walls 4. Desirably, a pair of panel supports 6 are provided adjacent each end wall 3. The panel supports 6 can be formed from the blank shown in Fig 5 (to form the panel support of Fig 6) or from the blank of Fig 10 for example. The panel supports 6 form stacking elements and to achieve efficient stacking a pair of protrusions 8 are provided on the upper edge thereof with a pair of corresponding recesses 14 adjacent the lower edge thereof. The protrusions 8 are positionable in the recesses 14 of an adjacent tray 1. The blanks shown in Figs 1, 5, 9 and 10 are formed from a self-supporting sheet material selected from the group consisting of thick paper board, multiple-ply paper board and paper board with a sandwiched corrugated core (hereinafter referred to a corrugated board with the corrugations constituting the "medium"). In the preferred embodiment of the invention however, the blanks shown in Figs 1, S, 9 and 10 are formed from corrugated board which has a twin or multi-ply medium and includes stiffening agents (commonly referred to as "dual-arch" material). 244433 The corrugated board may be formed by the process described in patent GB2,101,039 for example.

The package has a lid which is in the form of a pair of lid flaps 20 which can be folded over the package. The lid flaps 20 extend from the side walls 4 and are connected thereto by a fold line 21.

The preferred method of forming the package shown in either Fig 2 or Fig 3 shall now be described.

The packages shown in Fig 2 and Fig 3 are very similar, the only difference comprising the arrangement of apertures through the lid 20. Fig 2 shows a first aperture 31 positionable over the protrusion 8 of the support panel 6 when the lid is in the closed condition. A further aperture 32 through the lid is provided adjacent the distal extent 33 of the lid flap 20. The second aperture 32 is provided so that when the distal extent 33 of the lid flap 20 of a first package is positioned under the base 2, a protrusion 8 of a second equivalent package positioned under the first package can extend through the aperture 32 To enable the lid flap 20 to be positioned under the package as shown in Fig 3, a longitudinal fold line 34 is provided substantially centrally of the distal extent 33 and the fold line or hinging line 21.

Fig 3 shows a lid flap 20 having the first lid aperture 31. However, a pair of further cutouts 35 are provided adjacent the distal extent 33 of the lid flap 20.

The functioning of the cutout 35 can be demonstrated more clearly by reference to Fig 4. The depth 36 of the cutout 35 is such that a small region (shown generally by arrow 37) of the lid flap 20 overlies the aperture 18 through the base 2. Accordingly, when the lid flap 20 of a first package is positioned under the base 2 (as shown in Fig 3 and Fig 4) and the protrusion 8 of a second equivalent package positioned thereunder extends through the aperture 18, the region 3' 244433 caught by the protrusion 8 of the second package so that the lid flap 20 will be held securely under the package. This is desirable where a stack of packages with the lid flaps positioned under each package are required such as in the on-line packaging of produce. This presents the package with the internal space readily accessible.

In forming the package of Fig 2 or Fig 3 the package blank shown in Fig 1 and panel support blank shown in Fig 5 are stamped out from dual-arch corrugated board material The apertures 18, 31, 32 and 38 are formed in the package blank of Fig 1 at that stage. Fold lines between the base 2 and the side walls 4 and end walls 3 as well as the fold lines between the side walls 4 and the lid flaps 20 are formed in the blank of Fig 1 by forming a perforated line where the fold is required.

With reference to Fig 7, the corrugations of the board in the regions of the blank showing in shading are precrushed. Precrushing is carried out in the region of the package where horizontal flutes are provided which are prone to flat crush when a stack of packages is formed. This is achieved by applying pressure (eg. using rollers) over the blank in the required areas. This pre-crushing step is desirable as it reduces the tendency of a stack of packages to decrease in height over time.

The panel support of Fig 6 is then formed. Adhesive is applied to the support blank shown in Fig 5 on the portion 7. It will be noted that the portion 7 is longitudinally shorter than the portion 10 of the support panel 6. This results in the format of an asymmetric support panel 6 which provides a pair of recesses 41 in the support panel 6 in which the side flaps 40 (which extend from the side walls 4) can be positioned when the support panel 6 is provided in the package.

The two portions 7 and 10 of the panel support 6 shown in Fig 5 are folded at fold line 30 so as to form the panel support of Fig 6. 244433 » » In the next stage, a plurality of blanks as shown in Fig 7 are loaded into a feeder. A plurality of assembled supports as shown in Fig 6 are also loaded in the feeder which are located adjacent each end wall 3 of the assembled package.

The package blanks as shown in Fig 7 can be dropped vertically so that they bear against a pair of roller adhesive applicators which apply two strips, for example, of adhesive to each of the end walls 3 as well as the foldable tabs 40. Other means for applying the adhesive and greater or lesser strips of adhesive are clearly envisaged within the scope of the invention.

The blank of Fig 7 is then vertically displaced in front of a reciprocating mandrel having a rectangular frame conforming to the shape of the package as shown in Fig 2 and Fig 3. The mandrel carries a pair of panel supports (as shown in Fig 6) and locates these adjacent each of the end walls 3. Frame work is provided to apply pressure to the outside surface of the side walls so that the end walls 3 and side walls 4 form under the pressure of the rectangular frame.

With reference to Fig 8, a reciprocating rotatable arm having a suction cup 42 adjacent the end thereof picks up the partly assembled package (see Fig 8A) and provides the package so that the longitudinal axis of the package is parallel to the longitudinal axis of the folding part of the apparatus. Figs 8 B to D show the folding sequence for the lid flaps 20.

Horizontally reciprocating flight bars 44 are provided which advance the partly assembled package with the lid flaps 20 in the same plane as the side walls 4 past a pair of side rails 43. The side rails 43 are preferably height adjustable. In the embodiment of Fig 8C, the side walls 43 are provided slightly under the perforated line 34 shown in Fig 1. A pair of pneumatically operated folding arms fold the distal ends of the lid flaps 20 downwardly in the direction of the arrow numbered 45. 244433 » 4 The package is then advanced to the station shown in Fig 8D. The side rails (not shown) provided are slightly shorter than the side walls 4. The lid flaps 20 are then folded in the direction of the arrows 46 against the side walls 4.

At both stations C and D the fold is through an angle of around 180°.

The overall result of prefolding through fold line 34 as well as the fold line between the side wall 4 and the lid flap 20 serves to "deaden the memory" in the corrugated board. This reduces the tendency of the lid flaps 20 to revert to the position in the same plane as the side walls 4 (as shown in Fig 8B) when a person is packing the package with produce for example. The folding stage shown at station 8C is desirable as it helps to hold the lid flaps 20 under the base of the package as shown in Fig 8E.

With reference to Fig 8E, the next stage in the process is the stacking of a plurality of packages with the lid flaps 20 positioned under the base 2 of each of the packages.

We now turn to Figs 9 through to Fig 12 showing a package according to an alternative preferred form of the invention. In this embodiment, the height of the side walls 4 is greater than, or of a similar dimension to, the width of the lid flap 20.

With reference to Fig 9, the corrugations of the board forming the base and the lid flaps are precrushed as shown in the shaded areas.

Adhesive is then applied to the end walls 3 and the tabs 40. The panel support is formed in a similar manner to that described for the package shown in the embodiments of Figs 2 and 3.

The steps form formation of the package shown in Fig 11 are substantially the same as those described for the earlier embodiment. However, only one folding step for the lid flaps 20 is required in this embodiment With reference to Fig 12, the 24 4 4 partly assembled package shown in Fig 12B is advanced past a pair of side rails having a height slightly less than the height of the side walls 4 of the package. The lid flaps are folded through an angle of around 180° outwardly from the box so as to be forced against the side rails 43 by pneumatically actuated folding arms.

The lid flaps 20 are then closed via pneumatically operated folding arms and the package is formed into a stack of packages.

Preferred apparatus for folding the lids of and stacking the assembled packages will now be described with reference to Figs 13 to 16.

The partially assembled boxes enter the apparatus at Stage 1 at which stage their lid flaps are unfolded and upright The packages exit the apparatus fully assembled and stacked out of Stage 3. Stages 1 and 2 of the apparatus share a height adjustable wall labelled SO. This wall abuts the partially assembled box and at Stage 1 the top of the wall is approximate^ the same height as fold 34 of the partially assembled box. At Stage 2 the top of the wall is approximately at the height of foldline 21 of the partially assembled box. Stage 1 contains lid flap folding mechanism 51 and Stage 2 contains lid flap folding mecharism 56. Lid flap folding mechanism 51 consists of a folding bar 52 and an actuator 53. These are connected to a guide rod 55 and a height adjusting actuator 54. The lid flap folding mechanism of Stage 2, 56, consists of a folding bar 57, an actuator 58, a guide rod 80 and a height adjusting actuator 60. Stage 3 of the apparatus consists of an ejector mechanism labelled 74 and a finishing and stacking mechanism. The ejector mechanism consists of an abutment device 75 and an actuator 76. The finishing and stacking mechanism consists of a grabbing and lifting device 62 and a holding and stacking device 61. The grabbing and lifting device 62 consists of a substantially L-shaped grab bar 64, a support frame 63 and a cam action 65. The holding and stacking mechanism consists 244433 • » of non-return gates 66 and 67 and a holding device consisting of holding bars 70 and 71 which are operated by the action of actuators 72 and 73 which are attached to cross-members 68 and 69.

When the partialfy assembled box enters the apparatus at Stage 1, the height adjusting actuator 54 is set for the height of the box. Actuator 53 is in the extended position which causes the folding bar 52 to be in the uppermost portion of its range of motion. Actuator 53 is then contracted which causes folding bar 52 to rotate downwards towards the lower portion of its range of motion. It abuts against the upright flap of the box and folds it downwards through 180°. The folding bar's final position is labelled 54. The line of the fold is defined by the top edge of the side wall 50. Actuator 53 is then extended which raises the folding bar 52 and releases its grip on the folded flap of the box.

A conveyor or other means then transports the box into Stage 2 of the apparatus. At the start of Stage 2 the height adjusting actuator 60 is set for the height of the box and actuator 58 is extended which causes folding bar 57 to be at the uppermost portion of its range of motion. Actuator 58 is then contracted which causes folding bar 57 to rotate downwards towards the bottom of its range of motion.

It abuts against the flap of the box and folds it downwards through 180°. This causes the box to fold across a line across the top of the side wall producing fold 21. The folding bar moves to its final position 59 at which point the lid flap has been folded through 180°. Actuator 58 then begins to extend which causes folding bar 57 to release its grip of the box lid flap.

The box is then moved into Stage 3 of the apparatus by a conveyor or other means. At the start of Stage 3 the lifting and grabbing means is at the lower, open portion of its range of motion. Cam mechanism 65 begins to rotate upwards which 244433 causes the holding means 64 to begin to close and move upwards. Holding bars 64 abuts against and grabs the folded lid flaps of the box. This has the effect of pressing the lid flaps against the sides and bottom of the completed box. The grabbing and lifting means moves upwards and the completed box passes through the non-return gates 66 and 67. Cam 65 begins to move downwards, therefore, the holding and grabbing means releases its grip and moves downwards. When a box enters the nonreturn gates the boxes already in the stack are held firmly by holding bars 70 and 71 by means of the extension of actuators 72 and 73. The causes the box entering the stack to abut against the bottom most box in the stack. This causes the flaps of the bottom most box to be pressed hard against the bottom of the box. When a predetermined number of boxes are in the stack actuators 72 and 73 are contracted to release the hold of the boxes and actuator 76 is extended which causes the abutment device 75 to push the stack of boxes out of Stage 3.

Thus it can be seen that at least in the preferred of the invention a method of forming a package and an apparatus therefor are provided. The method of manufacturing the package involves a folding step whereby the lid flaps are folded through an angle of around 180°. This serves to "deaden the memory" in the corrugations of the corrugated board forming the package so that the lid flaps tend to stay open when the package is being loaded with produce on-line for example. Furthermore, this prefolding step helps to hold the lid flaps under the package when a stack of packages is required with the lid flaps positioned under the base of each of the packages.

The requirement to prefold the lid flaps is necessitated because of the use of corrugated board having a twin or multi-ply medium which tends to resist folding to a greater extent than other types of corrugated board.

Claims (9)

WHAT WE CLAIM IS: 244433

1. A method of preparing and presenting containers for use, said containers being of a kind having a substantially rectangular base with upstands from each of one pair of walls to penetrate an opening/openings of top closing flaps "hinged" from the other pair of walls, (I) (A) where the height of the walls is greater than or of a similar dimension to the distal extent of each closing flap (i) machine folding each of the top closing flaps outwardly against the wall from which each is integral and from which it is to hinge (eg using about a 180° fold at the intended hinging line of fold for closing purposes), and (ii) closing the top closing flaps of the container, OR (B) where the wall height is less than the distal extent of each closing flap (i) machine folding each of the top closing flaps substantially centrally of its distal edge and the intended hinging line of fold for closing purposes, such folding preferably being at about 180° outwardly of the container and (ii) machine folding each of the top closing flaps against the wall with which it is integral and from which it is hinged at the intended hinging line of fold for closing purposes (eg a fold of about 180°) while allowing the distal region outwardly of said first mentioned machine fold to underlie the base of the container, AND (II) machine stacking each said container with like presented containers from below.

2. A method of preparing and presenting containers for use as claimed in Claim 1 wherein said upstands are dependent from ends of the container.

3. A method of preparing and presenting containers for use as claimed in any one of Claims 1 or 2 wherein container has the walls and closing flaps formed of a -16- 244433 corrugated paper/board (laminated or not) where the corrugations run parallel to the intended hinging fold.

4. A method of preparing and presenting containers for use as claimed in any one of the preceding claims wherein prior to step (I) the closing flaps are in the same plane as the wall from which they depend.

5. A method of forming or presenting a package for use, said package having a base, four side walls and a pair of lid flaps extending from a pair of said side walls, a longitudinal fold line provided between said lid flaps and said side walls, comprising the steps of: initially providing said lid flaps in the same plane as said side walls; machine folding said lid flaps outwardly about said fold line through an angle of about 180°; and machine closing said lid flaps; or positioning the distal longitudinal parts of said lid flaps under said base and forming a stack of said packages.

6. Apparatus for preparing and presenting containers for use, said containers being of a kind having substantially rectangular base with upstands from each of one pair of walls to penetrate an opening/openings of top closing flaps "hinged" from the other pair of walls, comprising: (I) (A) where the height of the walls is greater than or of a similar dimension to the distal extent of each closing flap (i) a machine folding apparatus for folding each of the top closing flaps outwardly against the wall from which each is integral and from which it is to hinge (eg able to fold said top closing flaps through 180° at the intended hinging line or fold for closing purposes), and 24443 (ii) a lid flap closing means for closing the top closing flaps of container; or (B) where the wall height is less than the distal extent of each closing flap (i) a first machine folding apparatus for folding each of the top closing flaps substantially centrally of its distal edge and the intended hinging line or fold for closing purposes, such folding preferably being at about 180° outwardly of the container and, (ii) a second machine folding apparatus for folding each of the top closing flaps against the wall with which it is integral and from which it is hinged at the intended hinging line of fold for closing purposes (eg a fold of about 180°) while allowing the distal region outwardly of said first mentioned machine fold to underlie the base of the container, AND (II) a stacking apparatus for stacking each said container with the like presented containers from below.

7. Apparatus for forming or presenting a package for use, said package having a base, four side walls and a pair of lid flaps extending from said side walls with a longitudinal fold line between said lid flaps and said side walls, comprising; an advancing mechanism for advancing a partly or completely assembled package or packages having said lid flaps in the same plane as said side walls, at least one pair of side rails provided at a predetermined height, wherein said package advances substantially between said side rails in use, and a folding apparatus for folding said lid flaps over said side rails through an angle of about 180° and either (i) an apparatus for closing said lid flaps; or (ii) a second folding apparatus for folding distal ends of said lid flaps under said base.

8. Apparatus for preparing and presenting containers for use as claimed in Claim 7 wherein said side rails are height adjustable. -18- <^4433

9. Apparatus for preparing and presenting containers for use as claimed in any one of Qaims 7 or 8 wherein said apparatus includes a stacker for stacking a plurality of said packages in a stack of predetermined height DATED THIS DAY OF tic A.J. gAB^SQN ^E^F^RTHHAPPUCANT -19-