US3838632A - Method and apparatus for making corrugated containers of longitudinally corrugated strips on continuous basis - Google Patents

Method and apparatus for making corrugated containers of longitudinally corrugated strips on continuous basis Download PDF

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US3838632A
US3838632A US00280210A US28021072A US3838632A US 3838632 A US3838632 A US 3838632A US 00280210 A US00280210 A US 00280210A US 28021072 A US28021072 A US 28021072A US 3838632 A US3838632 A US 3838632A
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corrugated
mandrel
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core
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H Miyake
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Kk Osaka ja
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B31MAKING ARTICLES OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER; WORKING PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31FMECHANICAL WORKING OR DEFORMATION OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
    • B31F1/00Mechanical deformation without removing material, e.g. in combination with laminating
    • B31F1/20Corrugating; Corrugating combined with laminating to other layers
    • B31F1/22Making webs in which the channel of each corrugation is longitudinal with the web feed
    • B31F1/225Making webs in which the channel of each corrugation is longitudinal with the web feed combined with uniting the corrugated web to flat webs; Making corrugated-web structures
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00Layered products having a general shape other than plane
    • B32B1/02Receptacles, i.e. rigid containers, e.g. tanks
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B1/00Layered products having a general shape other than plane
    • B32B1/08Tubular products
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04Interconnection of layers
    • B32B7/12Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00Containers; Receptacles
    • B32B2439/40Closed containers
    • B32B2439/62Boxes, cartons, cases
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2553/00Packaging equipment or accessories not otherwise provided for

Abstract

The present invention relates to a method and apparatus for making corrugated cardboard container blanks of longitudinally corrugated cardboard based on a new idea of producing stitchless corrugated container blanks on a continuous basis. An elongated strip of corrugated cardboard is formed, the corrugations of the core ply of which extend longitudinally. The face plies are laterally offset in opposite directions so as to form stepped edges at both sides of the strip. Transverse and longitudinal folds or creases and slots are formed in the strip and the strip is formed into a tube by joining the stepped edges on a mandrel which is gradually flattened, and individual stitchless corrugated container blanks can then be cut off the flattened tube.

Description

United States Patent [191 1111 3,838,632

Miyake Oct. 1, 1974 [5 METHOD AND APPARATUS FOR MAKING 3,444,792 5/l969 Thesing et al 93/82 x CORRUGATED CONTAINERS .OF 3,732,790

LONGITUDINALLY CORRUGATED STRIPS ON CONTINUOUS BASIS Inventor: Hajime Miyake, Osaka, Japan Assignee: Kabushiki Kaisha, Osaka, Japan Filed: Aug. 14, 1972- Appl. No.: 280,210

US. Cl. 93/94 PS, 93/36 R, 93/82 Int. Cl B3lb 17/74 Field of Search 93/94 PS, 94 R, 82, 36 R,

I 93/36 MM References Cited UNITED STATES PATENTS 7/l959 Mann 93/94 R 4/1960 Molla 93/94 R 6/1964 Elliott 93/94 PS 5/1973 Miyake et al. 93/94 R Primary ExaminerRoy Lake Assistant Examiner.lames F. Coan Attorney, Agent, or Firm-Wenderoth, Lind & Ponack [5 7 ABSTRACT The present invention relates to a method and apparatus for making corrugated cardboard container blanks of longitudinally corrugated cardboard based on a new idea of producing stitchless corrugated container blanks on a continuous basis. An elongated strip of corrugated cardboard is formed, the corrugations of the core ply of which extend longitudinally. The face plies are laterally ofi'set in opposite directions so as to form stepped edges at both sides of the strip. Transverse and longitudinal folds or creases and slots are formed in the strip and the strip is formed into a tube by joining the stepped edges on a mandrel which is gradually flattened, and individual stitchless corrugated container blanks can then be cut off the flattened tube.

8 Claims, 53 Drawing Figures PATENIE ncI 1:924

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METHOD AND APPARATUS FOR MAKING CORRUGATED CONTAINERS OF LONGITUDINALLY CORRUGATED STRIPS ON CONTINUOUS BASIS This invention relates to a method of making corrugated container blanks, more particularly to an integrated method of making so-called longitudinally corrugated strips strips in which the flutes of the core ply extend in the longitudinal direction of the strip and making flat folded corrugated container blanks therefrom and a manufacturing apparatus for the above integrated method.

In the prior art of making so-called transversely corrugated cardboard strips as shown in FIG. 36 a, flutes are formed at right angles to the direction of elongation of the strip which is conventional in the present technique of corrugated cardboard making. This involves spoiling of the paper fiber and finished containers of such cardboard do not have sufficient strength because the direction of the fibers in the corrugated core ply and face plies superposed thereon are at a right angle with the top-to-bottom direction of a container. In the process of making corrugated cardboard containers, joining of the ends of the corrugated cardboard strip is effected by either stitching or pasting. In the case of stitching, the joint strength is weak because it is partial joined and the cardboard is damaged by the stitching. On the other hand, where only the surface of an outer face ply and an inner face ply of the container are pasted together, with the corrugated core ply left unpasted, such a joint is easy to split. Thus the joint has been the weakest portion of the conventional corru gated container.

Furthermore, in the prior method of making corrugated containers, at first corrugated cardboard of a certain standard size is made and then parts necessary for making containers are measured and cut out of the cardboard. This involves a large amount of waste. According to the prior method of making transversely corrugated strips, it was impossible to integrate the process of manufacturing corrugated cardboard directly with the process of making corrugated container blanks because the direction of the core ply flutes at the time of making corrugated cardboard is at right angles to the direction of the corrugations in the finished corrugated cardboard containers. In the process of making corrugated container blanks, it is necessary to install a singlefunction machine for each process, i.e., a slitter, a slotter, a gluer, a stitcher, a die cutter, and so on, and corrugated cardboard has to be carried to each machine for processing. This not only requires a large factory area but also exployment of many workers.

As shown in FIG. 36 b, so-called longitudinally corrugated cardboard has the flutes in the core ply parallel with the direction of the paper fiber. This'involves no spoiling of the paper fiber and makes it possible to utilize the strength in the longitudinal direction which is an essential object of corrugated cardboard, thereby improving the top-to-bottom compressive strength of corrugated containers to a great extent. Moreover, if the flutes of the core ply of the corrugated cardboard are kept in the longitudinal direction, ranging from the first corrugating process up to the last container blank making process, it is possible to mass-produce corrugated container blanks by a continuous process using simple apparatuses.

A primary object of the present invention is to provide a method and an apparatus for making flat folded stitchless corrugated container blanks on a continuous production basis, by making an elongated strip of longitudinally corrugated cardboard, making the strip into a tubular body, and further making the tubular body into stitchless corrugated container blanks.

Various apparatuses for making longitudinally corrugated cardboard have so far been devised, for example, a method of feeding a core ply into a shaping disk with the space between teeth narrowed gradually and pressing it by a roller and a method of arranging upper and lower endless belts in a line with the space therebetween narrowed gradually. However, while the former has such disadvantage that the core ply breaks easily during operation due to the high resistance of such core plies to pulling, the latter can cause irregularity in the corrugations due to the elasticity of belts with resultant irregularity in the quality of the finished goods. Due to such disadvantages, these methods have not been employed in practice.

With the above in view, studies have been made of a new method of making longitudinally corrugated cardboard, based on the principle that a core ply is inserted between groups of rotatably supported balls to be cor: rugated on semicircular contact lines which are formed by contact with the balls and the freedom in the transverse direction can be obtained due to the groups of balls being rotatably supported.

This new method has been developed successfully and has overcome the above-mentioned disadvantages.

The present invention uses this new method.

Another object of the present invention is to produce corrugated container blanks having a joint which presents a good appearance in which both face plies and a corrugated core ply overlap one another properly and v are well joined.

A further object of the present invention is to provide an economical method in which face plies and a core ply to be corrugated are cut in a desired width at the start of production and are immediately transferred to the edge joining process, thereby eliminating the loss of material.

The nature and advantages of the present invention will be understood more clearly from the following description made with reference to the accompanying drawings, in which:

FIG. 1, parts A-H and El-E4 are diagrams showing processing procedures at each stage of the process of making a container blank, part (A) being a transverse cross-sectional view of a longitudinally corrugated cardboard, parts B, C, D, E, F, G and H being partly sectional perspective views respectively, and E, through B, being cross sectional views illustrating a corrugated cardboard on lines A-A, B-B, H-I-I, E,E E.,E respectively.

FIG. 2 is a perspective view showing a core ply of longitudinally corrugated cardboard at the position encircled with chain line in FIG. 4.

FIG. 3 is a plan view of an apparatus for making corrugated container blanks continuously, according to the present invention.

FIG. 4 is a side elevation view of the apparatus shown in FIG. 3.

FIG. 5 is a side elevation view of an apparatus for shaping corrugated strips according to one embodiment of the present invention.

FIG. 6 is a plan view of the apparatus shown in FIG.

FIG. 7 is a front elevation of corrugation forming rollers of the apparatus of FIG. 5.

FIG; 8 is a sectional view taken along line M-M in FIG. 5.

FIG. 9 is a partial sectional view on an enlarged scale taken along line J--.[ in FIG. 5.

FIG. 10 is a partial sectional view on an enlarged scale taken along line K-K in FIG. 5.

FIG. 11 is a sectional view of a part of FIG. 8, on an enlarged scale.

FIG. 12 is an elevation view,-partly in section and on an enlarged scale, showing a part of the lower ball supporting rod.

FIG. 13 is a plan view of FIG. 12.

FIG. 14 is a sectional view taken along line NN of FIG. 12.

FIG. 15 is a sectional view taken along line 0-0 of FIG. 12.

FIG. 16 is a front elevation view, partly in section, of the device for making transverse folds or creases.

FIG. 17 is a sectional side view of a main part of the device for making transverse folds or creases.

FIG. 18 is a front elevation view, partly in section, of

a main part of the device for making transverse folds or creases.

FIG. l9-is a front elevation view, partly in section, of the device to make slot.

FIG. 20 is a sectional side viewof a main part of the device to make slot.

FIG. 21 is a transverse sectional elevation of a main part of the device to apply adhesive.

FIG. 22 is a transverse sectional view, on an enlarged scale, showing the edges of the longitudinally corrugated cardboard.

FIG. 23 is a broken sectional view of the heating device provided in the mandrel.

FIG. 24 is a sectional side view of the corrugated board feeding device provided outside the rectangular mandrel.

FIG. 25 is a transverse sectional view of the feeding device shown in FIG. 24.

FIG. 26 is a front view of a main part of the feeding device provided at the flat part of the mandrel.

FIG. 27 is a sectional side elevation view of the severing device.

FIG. 28 is a transverse sectional .view of a corrugated cardboard tubular body illustrating overlapping of edges.

FIG. 29 is a sectional view, on an enlarged scale, of the part of the body encircled with chain line in FIG. 28.

FIG. 30 is a sectional view of a corrugated cardboard tubular body illustrating overlapping of edges according to another embodiment of the present invention.

FIG. 31 is a sectional view, on an enlarged scale, of the part of the body encircled with chain line in FIG. 30. FIGS. 32a and b are transversely sectional perspective views, respectively, of a longitudinally corrugated cardboard.

FIG. 33, parts PP are transverse sectional diagrams taken on corresponding section lines in FIG. 34 to illustrate folding of a corrugated cardboard along the sides of the mandrel.

FIG. 34 is a side elevation view of the device for making longitudinally corrugated cardobard.

FIG. 35 is a transverse elevation of a main part of the device to apply adhesive. FIGS. 36a and b are perspective diagrams for showing a comparison of corrugated cardboard manufactured process by the conventional method and the method according to the present invention.

The process of producing the flat folded corrugated container blanks according to this invention will be explained hereinafter.

FIG. 1 shows a corrugated coardboard 4 comprising face plies 1 and 2 which are fed in parallel with each other from mill roll stands and between which a corrugated core ply 3,'the corrugations of which extend in the direction of the length of the strip as it moves through the machine is positioned.

The face plies l and 2, and the corrugated core ply 3 have the same width. However, the face plies l and 2 are laterally offset in-opposite directions in such a manner that stepped edges and 7b are formed. While the corrugated cardboard 4 is fed on a supporting plate 16 in the direction of the arrow I shown in FIG. 1 B,transverse folds or creases 18 are applied by a transverse creasing device 46 shown inFlG. 3. Longitudinal folds or creases 19 are applied next by a longitudinal creasing device 56 as shown in FIG. 3 C. Slots 20 are made on said longitudinal folds or creases 19 at regular intervals of length, as shown in heavy lines in FIG. 3 D, by a slotting device 59. The corrugated cardboard strip 4 treated according to the above processes is fed onto a mandrel 17 comprising a tubular part 17a to form a tube having a rectangular section, an intermediate part 17b which follows said tubular part and changes gradually into a flat form and a flat part 17c. By said mandrel 17, the cardboard is bent downwardly at longitudinal folds or creases 19b and 190 as shown in FIG. 1 (B A corrugated tube 5 as shown in FIG. 1 (E) is formed by the cardboard being bent at the longitudinal folds or creases 19a and 19d to conform to each face of the mandrel 17 'as shown in FIG. 1 E E and causing the edge 7b to overlap the edge 7a for forming a joint 7c. Said tube 5 is, as shown in FIG. 1 F as it passes along the intermediate part 17b of said mandrel, gradually flattened and after passing over the flat portion 170 of the mandrel, becomes a flat folded tube 6, as shown in FIG. 1 G, which is then severed by a severing device on a severing line 139 at the middle of the length of each slot 20, whereby individual flat folded container blanks are obtained.

A description will now be given of an apparatus to produce the folded container blanks of thepresent invention.

The plain face plies 1 and 2 are drawn out from mill roll stands 8 and 9 respectively, and the face ply 1 then is passed through an adhesive applicator roll 11a, 21 support roll 11 and guiding rolls 12a and 12b, and the face ply is passed through an adhesive applicator roll 13a, a support roll 13b and guiding rolls 12a and 12b. The corrugated core ply 3 the corrugations of which are made by a corrugation forming device 23 to be described later, is fed by pulling rollers 36 and 37 in the direction of passage of the elongated cardboard strip and then is passed through adhesive applicator rollers 14a and 14c, support rolls 14b and 14d and guiding rolls 12a and 12b. The three plies passed through said guiding rolls are combined on a support plate 16 with the face plies l and 2 offset in opposite directions relative to the core ply 3 so that stepped parts are formed at the edges of strip 4, thereby forming an elongated strip of longitudinally corrugated cardboard 4. Numerals a, 15b and 150 designate edge detectors for the face plies and the corrugated strip. Signals detected by said edge detectors 15a, 15b and 15c are transmitted to a support mechanism for said supplies of face plies l and 2 and the corrugated core ply 3 (not shown in the drawings), comprising an automatic regulating device which adjusts said support mechanism at right angles to the direction of passage of the strip and for accurately controlling the size of the stepped edges 7a and 7b when said face plies 1 and 2 and said corrugated core ply are combined.

Numeral 21 in FIG. 3 denotes a steam supply device which, when a flat core ply drawn out from a reel 10, passes therethrough, sprays steam thereon from a nozzle 22 (FIG. 5) so as to humidify said core ply to a constant degree of moisture content. Numeral 23 denotes a core ply guide means (FIG. 5) which passes said core ply L between an upper ball supporting rod group and a lower ball supporting rod group so that the pitch of the flutes made by said groups becomes gradually smaller. Numeral 24 denotes upper ball supporting rods which are arranged regularly in a plane and at regular intervals, the space between adjacent rods being made gradually narrower in the direction of passage of the strip (arrow 1). Numeral 25 denotes lower ball supporting rods, each of which is arranged below a corresponding upper ball supporting rod. The upper surface of said upper ball supporting rods 24 is secured to fixing means 26a, 26b, 26f and the lower surface of said lower ball supporting rods 25 is secured to fixing means 27a, 27b, 27f and said two fixing means are supported by legs 28a, 28b and 280. A ball 29 (FIG. 9) made of an abrasion resistant material, such as steel or nylon, is inserted in a conical-shaped groove 30 which is provided at the end of each supporting rod 24 and 25, the upper half of said ball 29 being held by a metallic cover piece 31 fixed to the supporting rods 24 and 25 so as to prevent said ball from slipping off. The fixing means 26a, 26b, 26f securing the upper ball supporting rods 25 are provided with a fixing piece 32 at both ends thereof which is secured to the side 33 of said fixing means 27a, 27b, 27f by a bolt 34. Numeral 35 denotes a corrugation forming roller which sets corrugations by heating while pulling the core ply L. Male and female pulling rolls 36 and 37 respectively have on the surface thereof flute-shaped grooves meshing with each other and steam is supplied by a pipe 38 thereto and condensate is exhausted by a drain pipe 39 secured to a drain pipe inside of said roll. Said pulling rolls 36 and 37 rotate while being supported by bearings 40 and 41 and are connected, by a rotating connector 42, to said fixed pipe 38 and the drain pipe 39. Numerals 43 and 44 denote gears meshing with each other and secured to the shafts of said pulling rolls 36 and 37 and numeral 45 denotes a driving gear.

A description will now be given of the process of forming the core ply L into a corrugated core ply 3. The core ply L passed through the steam supply device 21 is inserted between balls 29 carried by the upper supporting rods 24 and the lower supporting rods 25 as illustrated in FIG. 9 showing a section at the position J-J of FIG. 6 so as to be corrugated. The space between the supporting rods 24 and 25 is made narrower in the direction of movement of.the ply so that as the core ply L proceeds forward, the pitch P of the flutes becomes gradually smaller, the pitch P of the flutes at the foremost position M-M being as shown in FIG. 11. The corrugated core ply L having such pitch of the flutes is pulled as it is sandwiched between grooves of the corrugation forming roller 35 and the corrugations are set by the heated pulling rolls 36 and 37 to such a degree that they are free from deformation. By the above-mentioned process, the core ply L is continuously fed from the corrugation forming roller 35 in the form a longitudinally corrugated ply 3 as shown in FIG. 3.

Numeral 16 denotes a flat supporting plate the terminal end (left-hand of FIG. 3) of which comes close to the mandrel 17, and which is held by legs 138. This plate supports the corrugated cardboard strip 4 horizontally thereon and passes said cardboard 4 through the processes of transverse creasing, longitudinal creasing, slotting and the like.

A creasing roll 48 of a device 46 for making transverse folds or creases (FIG. 16 and FIG. 17) is supported by a shaft 50 by means of a spring 49 provided at both ends of said roll and is attached rotatably to a bracket which is fixed to a support. A gear 51 is provided at one end of said shaft 50. By a gear meshing with said gear 51, power from a motor 53 is transmitted to the creasing rolls 48 by means of a reduction gear 54. Provided on the surface of the creasing roll is a blade 55 which compresses the corrugated cardboard 4 between itself and the supporting plate 16 during the rotation of the creasing roll, thereby forming transverse folds or creases 18. Since the corrugated board 4 is pulled at a constant speed, if the diameter and the r.p.m. of the creasing roll 48 are properly designed and adjusted (adjustment of the r.p.m. is made by means of the reduction gear 54), the size of the finished goods or folded container blanks 150 can be changed as desired. For this purpose, several-step change gears are preferably provided in the reduction gear 54. The transverse creasing device is driven by a separate motor in the example of FIG. 16', however, the transverse creasing, as described later, has a close relation with the slotting process and the severing process so that if a transverse creasing device, a slotting device and severing device are driven synchronously, irregularities which might occur in each process can be avoided.

A device 56 (FIG. 18) is provided to make longitudinal folds or creases continuously in the corrugated board 4 for enabling it to be formed into a tube by lapping the corrugated board 4 about the mandrel 17. A shaft 58 to which four disks 57 having sharp circumferential edge are fastened at regular intervals can be supported rotatably in bearings at both ends thereof and be connected to a motor for rotation. The interval between disks 57 can be changed, depending on the desired container shape.

A device 59 (FIG. 19, FIG. 20) is provided to make slots intermittently in longitudinally creased parts of the corrugated board and comprises four disks 62 on a shaft 61 supported rotatably on a bracket 60, and rotatable blades 63 secured to said disks. Openings 65 are provided in a base 64 through which grooved slotting rolls 66 rotatably fixed to a shaft 67 are exposed opposite the respective rotating blades 63. A gear 68 is provided at one end of the shaft 61, to which gear power is transmitted from a motor 70 through a reduction gear 71 and a gear 72.

A device 73 is, as shown in FIG. 21, provided to apply adhesive to both stepped edge portions 7a and 7b of the corrugated board 4. A stepped adhesive applicator roll 74 which conforms to the stepped form of the edge portions 7a and 7b of the corrugated cardboard 4, is arranged opposite a supporting roll 75 and both rolls are driven by a suitable power means. The corrugated cardboard 4 is fed between these rolls so that adhesive is continuously applied thereto by the adhesive applicator 74. To this adhesive applicator, an adhesive tank, a doctor roll, a cleaning roll (none of which are shown) and the like are associated with the rolls so that pasting is effected uniformly. The detailed explanation of this device is omitted here since it is conventional.

The mandrel 17 has the corrugated cardboard 4 folded around the outer surface thereof to form a tube. The cross-section of the mandrel 17 supported and fixed by a leg 76 as shown in FIG. 3 is rectangular at lines E,-E,, E E E-E, is elliptical on line FF and substantially around line GG.

Around the mandrel are provided levelling rollers 77a, 77b, 77c, 79a, 79b, 81a and 81b at the upper and lower sides thereof and levelling rollers 78a, 78b, 80a, 80b at the sides thereof, respectively, to shape the corrugated cardboard 4 to the mandrel 17. Following these levelling rollers in the direction of movement of the tube is a pressing roller 83 which presses the overlapped edge portions 7a and 7b of the corrugated cardboard 4 together thereby forming a corrugated tube 5. At the pressing roller section, heat is applied to dry the overlapped edges of tube 5. As a heating means, an electrothermic or the steam type heater is most preferable, and steam heating apparatus as shown by 84 in FIG. 23 is disclosed for the embodiment of the present invention. A steam supplying pipe 85, which has a helical portion 88 in the mandrel and has a drain pipe 89, is connected at one end 86 to a steam generator (not shown in the drawings).

A device 91 (FIG. 24, FIG. 25) is provided to feed the corrugated cardboard 4 and the tube continuously and is provided near the pressing roller 83at the portion where the corrugated cardboard 4 is finished into a tube at the end of the mandrel.

The device has four driving elements, one on each face of the mandrel, and each comprising a driving roller 95 rotatably mounted on a supporting shaft 94 which is fixed to a support 93 and a driven roller 97 is rotatably mounted on a supporting shaft 96, and an magnetic endless belt 98 extending between said driving roller and said driven roller and stretched outwardly by means of a tension roller 100. The tension of the endless belt 98 is adjusted by an adjusting bolt 101 which is connected to said shaft 96. The driving roller 95 of each driving element is connected to the other driving rollers by means of a bevel gear 102 and bevel gear 109 connects one bevel gear 102 to a motor 103 for driving the driving rollers simultaneously.

A feeding device 120 is provided at the flat portion of the mandrel 17 shown in FIG. 3 and FIG. 4 on the line 6-6. Fixed to roller shafts 122 and 123 which are rotatably supported on a bracket 121, are feeding rollers 124 and 125 which have a non'skid surface (for example, a coating of rubber or the like) on the surfacegears 126 and 127 having the same pitch for rotating both feeding rollers at the same speed.

A severing device 130 shown in FIG. 27 is provided to sever from the folded corrugated tube 6 cardboard container blanks of uniform length. Fixed to a stud 131 are two guiding plates 132 on each of which a severing knife 133 is slidably mounted within a groove 134. The severing knives are constantly urged to move outwardly by springs 135a around armatures of solenoid l35, the armatures being connected to arms projecting fromthe ends of the severing knives 133. Upon energization of said solenoid, the severing knives 133 are drawn toward each other and the blade 136 thereof cooperate to sever from the folded tube 6 flat folded cardboard blanks of uniform length, which are fed to a stacking device 140.

A stacking device 140 (FIG. 3, FIG. 4) stacks and sends the folded cardboard blanks to be packed.

A description of the method of overlapping the edge portions 70 and 7b of the corrugated cardboard will now be given. Methods of overlapping the corrugated strip 3 and of abutting it are shown in FIG. 28 and FIG. 29, and in FIG. 30 and FIG. 31, respectively. In the former, the edges of the corrugated core ply 3 and'the face plies 1 and 2 superposed thereon to form the stepped edges are each overlapped. The edges of the corrugated strip 3 are overlapped in such a fashion that a convex portion of one flute is overlapped by the convex portion of another flute and a concave portion of one by a concave portion of another. For that purpose, adhesive is applied to the edge portions 7a and 7b as shown in FIG. 20. In the latter case, the face plies are overlapped but the corrugated ply 3 has the edges abutted.

The apparatus for forming a corrugated tube 5 from one sheet of double faced corrugated cardboard 4 has been described hereinbefore but a similar corrugated tube can be made from two strips of corrugated cardboard, each of which is bent and then secured to the other. This embodiment isshown in FIG. 32 FIG. 35, especially the different features from those in the first described embodiment.

In this embodiment two sets of the devices up to the guiding rollers 12a and 12b on the mandrel shown in FIG. 3 and FIG. 4, are provided for forming corrugated cardboard strips 141 and 1142 which are one half the width of the corrugated cardboard 4 by superposing face plies l and 2 and a longitudinally corrugated core ply 3.

The corrugated strips 141 and 142 are fed to an apparatus for making flat folded blanks for box-shaped containers which comprises a series of devices, i.e., a transverse creasing device, a longitudinal creasing device, a slotting device, a feeding device, a folding and overlapping device and a severing device.

These devices are the same as those in the first embodiment, except that two sets of the transverse creasing device, the longitudinal creasing device and the slotting device are provided, one above and one below the mandrel, so that a detailed description thereof is omitted here. The corrugated strips 141 and 142, after having longitudinal creases 19b and and a slot 20 formed therein, are fed to an adhesive applying device 167 at the same time. In this device, which different from the that earlier described embodiment, the stepped edge portion 7a and 7b of both strips are each continuously coated by means of an adhesive applying roller 190 and a support roller 191 as shown in FIG. '33 and after that the corrugated strips 141 and 142 are fed to the mandrel 17. The adhesive coated corrugated strips 141 and 142 are folded and overlapped at the edges in the steps shown in parts P P P P of FIG. 33. The central portion of each corrugated strip 141 and 142 between the longitudinal creases 19b and -19c is placed in contact with the respective upper and lower faces of the mandrel 17 and leveling rollers 170, 171, 172 and 173 provided along the mandrel 17, fold portions 143 and 146 of the corrugated strips 141 into close contact with the mandrel l7, and then fold portions 144 and 145 against the mandrel. By this method, a corrugated tube 147 is formed with the edge 143 of the corrugated strip 141 being overlapped by the edge 145 of the corrugated strip 142 and the edge 146 being overlapped by the edge 144. As can be seen from the section of said tube in FIG. 30, two edge overlapping portions 148a and 148b are formed. The thus formed tube 147 is pressed by pressing rollers 174, 175, 176a, 176b, 177, 178a and 178 b, is fed forward and is heated and dried by a heater in the mandrel, is .gradually flattened, and is severed in the desired lengths by a severing device, whereby folded corrugated blanks for boxshape containers are formed and said blanks are fed to a stacking device. By these devices, box-shape folded cardboard containers 200 are made continuously from one corrugated board. Numerals 160 and 161 in FIG. 34 denote upper and lower support plates respectively, numerals 162 and 163 denote guiding rollers, numeral 164 denotes a transverse creasing device, numeral 166 is a slotting device, numeral 167 is an adhesive applying device, numerals 168a and 168b are support rollers, and parts P P P and P of FIG. 33 are sections on.

lines -P P P -P P P and P'P in FIG. 34 respectively.

There has been described a method and an apparatus for making flat folded blanks for corrugated containers continuously from a longitudinally extending corrugated cardboard strip which is made by continuously superposing between face plies on a longitudinally corrugated strip. However, flat folded blanks for rectangular cross-section tubular containers can also be made by omitting the transverse creasing step and the slotting step. By increasing the number of creases and by changing the cross-sectional shape of the mandrel l7, hexagonal-, octagonaland tubular-shape folded corrugated cardboard containers can also be made. Recently the market demand for folded corrugated containers is overwhelmingly for rectangular cartons. As the thermal drying conditions are the most important element for manufacturing corrugated cardboard having well adhered corrugations on a high speed manufacturing basis, a dryer using infrared rays or heated air can be provided at the position 300 in FIG. 4, so as to compensate for loss of heat instantly and thereby minimize the decrease in temperature.

The present invention is, as above described, a method and apparatus for manufacturing folded corrugated cardboard which undergoes processes which form it into a tube, which is made gradually flat and severed into individual containers, whereby containers of a certain size which are tough and fit for packing oranges, eggs or vegetables can be manufactured efficiently on a continuous processing and mass production basis.

The method and apparatus according to the present invention, therefore, have the following various advantages; v

l. The apparatus can be made compact in size and in one unit, since continuous operation is possible.

2. The cost for installing the manufacturing apparatus and the labor cost for operating the same are very small.

3. The material loss is reduced to nearly zero and inexpensive corrugated containers can be obtained.

4. Corrugated box-shape containers having a large compressive strength can be obtained.

5. Corrugated containers having excellent joint strength are produced comprising face plies and a corrugated core ply which are superposed on one another and are overlapped completely at each edge thereof.

6. In the manufacturing apparatus, the device for feeding can bemade simple, taking advantage of the fact that corrugations are formed in the direction of passage of the strip through the machine so that the strip is strong in said direction when it is fed on the support plate and on the mandrel.

We claim:

1. A method of continuously producing flat folded corrugated container blanks, comprising the steps of:

making an elongated strip of corrugated cardboard having a corrugated core ply the corrugations of which extend longitudinally thereof and having face plies on the opposite faces of said core ply with one face ply laterally offset in one direction relative to the core ply and the other face ply laterally offset in the opposite direction relative to the core ply;

moving said strip of corrugated cardboard longitudinally along an elongated mandrel and folding the strip around the mandrel to form a tube of the corrugated cardboard in which the corrugations of the core ply extend in the direction of the length of the tube, and adhering the edges of the offset face plies and the edges of the core plies to each other; flattening said tube; and

severing the flattened tube into desired lengths.

2. A method as claimed in claim 1 further comprising the steps of creasing, scoring and slotting said flattened tube for forming carton blanks from the said lengths.

3. A method as claimed in claim 1 in which the step of adhering the edges of the offset plies and the edges of the core plies comprises adhering the inner surface of the edge of each face ply which projects beyond the core ply to the outer surface of the edge of said face ply beyond which the core ply extends.

4. A method as claimed in claim 3 in which the corrugations at one edge of the core ply are interfitted with the corrugations at the other edge of the core ply.

5. A method as claimed in claim 3 in which the corrugation at one edge of the core ply is abutted against the corrugation at the other edge of the core ply.

6. An apparatus for producing flat folded corrugated container blanks, comprising:

a corrugating means for receiving a strip of flat core ply stock and forming in it corrugations extending longitudinally of the strip to form a strip of core P y; a support plate for receiving the strip of core ply;

Claims (8)

1. A method of continuously producing flat folded corrugated container blanks, comprising the steps of: making an elongated strip of corrugated cardboard having a corrugated core ply the corrugations of which extend longitudinally thereof and having face plies on the opposite faces of said core ply with one face ply laterally offset in one direction relative to the core ply and the other face ply laterally offset in the opposite direction relative to the core ply; moving said strip of corrugated cardboard longitudinally along an elongated mandrel and folding the strip around the mandrel to form a tube of the corrugated cardboard in which the corrugations of the core ply extend in the direction of the length of the tube, and adhering the edges of the offset face plies and the edges of the core plies to each other; flattening said tube; and severing the flattened tube into desired lengths.
2. A method as claimed in claim 1 further comprising the steps of creasing, scoring and slotting said flattened tube for forming carton blanks from the said lengths.
3. A method as claimed in claim 1 in which the step of adhering the edges of the offset plies and the edges of the core plies comprises adhering the inner surface of the edge of each face ply which projects beyond the core ply to the outer surface of the edge of said face ply beyond which the core ply extends.
4. A method as claimed in claim 3 in which the corrugations at one edge of the core ply are interfitted with the corrugations at the other edge of the core ply.
5. A method as claimed in claim 3 in which the corrugation at one edge of the core ply is abutted against the corrugation at the other edge of the core ply.
6. An apparatus for producing flat folded corrugated container blanks, comprising: a corrugating means for receiving a strip of flat core ply stock and forming in it corrugations extending longitudinally of the strip to form a strip of core ply; a support plate for receiving the strip of core ply; adhesive applicator means between the corrugating means and the support plate for applying adhesive to the top portions of the corrugations on both sides of the core ply; face ply feed means adjacent the support plate for feeding a face ply against the lower surface of the core ply as it moves onto the suppOrt plate and for feeding a face ply against the upper surface of the core ply as it moves onto the support plate to form a strip of corrugated cardboard, said face ply feed means including edge detectors for detecting and controlling the direction of feed of the face plys for offsetting one of the face plys in one lateral direction relative to the core ply and offsetting the other face ply in the opposite lateral direction relative to the core ply; a mandrel extending in the same direction as said support plate from the end of the support plate opposite the end adjacent to the corrugating means, said mandrel having a generally rectangular cross section tubular part adjacent the support plate, a flat part at the end remote from the support plate, and an intermediate part tapering gradually from the tubular part to the flattened part; an adhesive applicator adjacent the tubular part of the mandrel for applying adhesive to the edges of the corrugated cardboard; corrugated cardboard bending means along said tubular part of said mandrel for bending the strip of cardboard longitudinally around said mandrel and overlapping the edges thereof for forming a tube of the corrugated cardboard; cardboard pressing means along said mandrel for pressing the overlapped edges of the cardboard; feed means along said mandrel for engaging said tube of corrugated cardboard and feeding it along said mandrel; and transverse cutting means at the end of said mandrel for cutting lengths of said tube of corrugated cardboard from said tube.
7. An apparatus as claimed in claim 6 further comprising slitting means and creasing means along said support means between said face ply feeding means and said mandrel for slitting the cardboard and creasing it for providing flaps and fold lines in the finished blanks.
8. An apparatus as claimed in claim 6 in which said corrugating means comprises a plurality of groups of balls the size of the corrugations to be formed in the core ply stock, each group of balls having a plurality of upper side by side rows of balls and lower side by side rows of balls, the rows extending in an inwardly converging direction along the direction of length of the core ply, the rows of balls in the upper row being positioned between the rows of balls in the lower row, the groups of balls being spaced in the direction of length of the core stock and the rows in the successive groups being closer together and the upper balls in the successive groups being closer to the lower balls with the balls in the last successive group being substantially side by side.
US00280210A 1971-08-17 1972-08-14 Method and apparatus for making corrugated containers of longitudinally corrugated strips on continuous basis Expired - Lifetime US3838632A (en)

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JP (1) JPS5221434B2 (en)
CA (1) CA970193A (en)
DE (1) DE2240505C3 (en)
FR (1) FR2150103A5 (en)
GB (1) GB1410071A (en)

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US3919925A (en) * 1973-04-10 1975-11-18 Akio Hayama Process and equipment for continuous manufacture of corrugated cardboard box
US4469542A (en) * 1982-09-07 1984-09-04 Tetra Pak Developpement Method of making a piece of tube from a flat web of flexible material, and apparatus for carrying out the method
US4500381A (en) * 1983-04-20 1985-02-19 Longview Fibre Company Method and apparatus for making multiple ply paperboard
US4623072A (en) * 1985-04-18 1986-11-18 Macmillan Bloedel Limited Corrugated container with foldable flaps
US6042250A (en) * 1998-08-03 2000-03-28 Stragnola; Steven Vincent Horticulture lighting system for providing uniform illumination from an elevated height
US20040206657A1 (en) * 2003-04-15 2004-10-21 Akira Yokawa Packing structure and packing member of corrugated cardboard
US20080060747A1 (en) * 2005-05-12 2008-03-13 Dyne Technology Co., Ltd. Paper tube and method of making the same
WO2010009006A2 (en) 2008-07-12 2010-01-21 Jarl Jensen Retail boxes and method of manufacturing retail boxes
US7678036B1 (en) * 2007-07-10 2010-03-16 Eleftherios Malitas Ripple bottom pizza box and its associated method of construction
US20140231568A1 (en) * 2013-02-21 2014-08-21 The Procter & Gamble Company Fibrous cores
US9266640B2 (en) 2008-07-12 2016-02-23 Jarl Jensen Retail boxes and method of manufacturing retail boxes
US9440772B2 (en) 2015-02-04 2016-09-13 Company Black Llc Support unit
US9440771B2 (en) 2014-11-07 2016-09-13 Company Black Llc Support assembly and components
US9739397B2 (en) 2014-11-07 2017-08-22 Company Black Llc Support assembly and components

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JPS5342986A (en) * 1976-09-28 1978-04-18 Nippon Flute Co Ltd Method of forming board material for corrugated cardboard product
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SE425057B (en) * 1981-01-23 1982-08-30 Lars Johan Teodor Billing Tools for the front tell up of nitspik or expandable nail
DE3117095C2 (en) * 1981-04-30 1983-07-21 Europa Carton Ag, 2000 Hamburg, De
DE4223978A1 (en) * 1992-07-21 1994-01-27 Flexipack Werk Wunderlich Gmbh Process for the production of hollow profiles for packaging purposes, products produced by the process and devices for carrying out the process
JP4800400B2 (en) * 2009-02-10 2011-10-26 ▲高▼塩技研工業株式会社 Convex and convex strip forming apparatus and concave and convex strip forming method for sheet-like workpiece

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US2893436A (en) * 1954-10-12 1959-07-07 Ephraim H Roden Horizontal corrugated paper tube and method of making the same
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Cited By (19)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3919925A (en) * 1973-04-10 1975-11-18 Akio Hayama Process and equipment for continuous manufacture of corrugated cardboard box
US4469542A (en) * 1982-09-07 1984-09-04 Tetra Pak Developpement Method of making a piece of tube from a flat web of flexible material, and apparatus for carrying out the method
US4500381A (en) * 1983-04-20 1985-02-19 Longview Fibre Company Method and apparatus for making multiple ply paperboard
US4623072A (en) * 1985-04-18 1986-11-18 Macmillan Bloedel Limited Corrugated container with foldable flaps
US6042250A (en) * 1998-08-03 2000-03-28 Stragnola; Steven Vincent Horticulture lighting system for providing uniform illumination from an elevated height
US20040206657A1 (en) * 2003-04-15 2004-10-21 Akira Yokawa Packing structure and packing member of corrugated cardboard
US7296680B2 (en) * 2003-04-15 2007-11-20 Funai Electric Co., Ltd. Packing structure and packing member of corrugated cardboard
US20080060747A1 (en) * 2005-05-12 2008-03-13 Dyne Technology Co., Ltd. Paper tube and method of making the same
US8337375B2 (en) 2005-05-12 2012-12-25 Dyne Technology Co., Ltd. Apparatus and method for making tube with polygonal cross-section
US7678036B1 (en) * 2007-07-10 2010-03-16 Eleftherios Malitas Ripple bottom pizza box and its associated method of construction
EP2334566A2 (en) * 2008-07-12 2011-06-22 Jarl Jensen Retail boxes and method of manufacturing retail boxes
WO2010009006A2 (en) 2008-07-12 2010-01-21 Jarl Jensen Retail boxes and method of manufacturing retail boxes
EP2334566A4 (en) * 2008-07-12 2013-04-17 Jarl Jensen Retail boxes and method of manufacturing retail boxes
US9266640B2 (en) 2008-07-12 2016-02-23 Jarl Jensen Retail boxes and method of manufacturing retail boxes
US20140231568A1 (en) * 2013-02-21 2014-08-21 The Procter & Gamble Company Fibrous cores
US9561929B2 (en) * 2013-02-21 2017-02-07 The Procter & Gamble Company Fibrous cores
US9440771B2 (en) 2014-11-07 2016-09-13 Company Black Llc Support assembly and components
US9739397B2 (en) 2014-11-07 2017-08-22 Company Black Llc Support assembly and components
US9440772B2 (en) 2015-02-04 2016-09-13 Company Black Llc Support unit

Also Published As

Publication number Publication date
JPS4829596A (en) 1973-04-19
FR2150103A5 (en) 1973-03-30
DE2240505B2 (en) 1978-05-03
JPS5221434B2 (en) 1977-06-10
CA970193A (en) 1975-07-01
CA970193A1 (en)
DE2240505A1 (en) 1973-02-22
DE2240505C3 (en) 1978-12-21
GB1410071A (en) 1975-10-15

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