Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B31—MAKING 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
  • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B31—MAKING 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
  • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
  • B31B50/26—Folding sheets, blanks or webs
  • B31B50/28—Folding sheets, blanks or webs around mandrels, e.g. for forming bottoms
  • B31B50/30—Folding sheets, blanks or webs around mandrels, e.g. for forming bottoms the mandrels moving
  • B31B50/32—Folding sheets, blanks or webs around mandrels, e.g. for forming bottoms the mandrels moving in circular paths
  • B31B50/322—Folding sheets, blanks or webs around mandrels, e.g. for forming bottoms the mandrels moving in circular paths the mandrels extending radially from the periphery of a drum
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B31—MAKING 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
  • B31B—MAKING CONTAINERS OF PAPER, CARDBOARD OR MATERIAL WORKED IN A MANNER ANALOGOUS TO PAPER
  • B31B50/00—Making rigid or semi-rigid containers, e.g. boxes or cartons
  • B31B50/60—Uniting opposed surfaces or edges; Taping
  • B31B50/64—Uniting opposed surfaces or edges; Taping by applying heat or pressure, e.g. by welding

Definitions

• the present invention relates to a bottom forming apparatuses for cartons. Specifically, the present invention relates to a bottom forming apparatus for a carton having portions of the bottom elevated to protect the raw paperboard edges from damage and absorption of moisture.
• the raw paper edges are a by-product of the composition of the carton blank.
• the carton blank is cut and scored from a sheet of coated fiberboard material.
• the coated fiberboard material is usually composed of three layers, and may have a barrier layer juxtaposed between fiberboard layers.
• the exposed surfaces of this sheet are coated with a polymer material such as polyethylene.
• the coating does not extend to the edges which are thus left uncoated, and partially unprotected at least to moisture and sensitive to 2 damage.
• these raw. paper edges are most prevalent at the bottom of the carton. If moisture is absorbed into the raw paper edges, the water may be absorbed throughout the fiberboard interior layer, which due to its cellulose-like nature, has a strong affinity for liquids. This absorption of moisture may compromise the integrity of the carton thereby rendering it defective.
• Fujikawa et al U.S. Patent No. 5,222,667, for a Container Made Of Paper- Base Laminate, similarly discloses a carton having an inverted V-shaped bottom to provide greater stability to the carton.
• the raw paper edge of panel 27 is not inverted and is susceptible to moisture absorption since the N-shaped inversion begins at the raw paper edge and since the inversion must be centered to provide stability to the carton.
• the present invention resolves the problem of absorption of moisture through raw paperboard edges by providing a carton having the raw paper edges elevated in order to protect the raw paperboard edges and reduce the susceptibility of moisture absorption.
• the present invention is able to accomplish this without adversely affecting the carton.
• One aspect of the present invention is a bottom forming apparatus having a sealing plate and a mandrel cap formed to elevate the raw paperboard edges of the carton.
• the mandrel cap has a recess with an angled edge corresponding to the placement of the raw paperboard edge of the bottom of a carton.
• the angled edge may have the angle downward to form a beveled edge.
• the sealing plate has a first elevated portion partitioned into two sections, a traversal section and an edge section which mate with the recess area and angled edge of the mandrel cap to form the elevated portions.
• the sealing plate may also have a second elevated portion thereon.
• sealing plate for elevating the bottom of cartons having different bottom configurations.
• Another aspect of the present invention is a method for forming a carton having an elevated bottom.
• FIG. 1 is a schematic view of a packaging machine for producing cartons having an elevated bottom.
• FIG. 2 is an isolated schematic view of a bottom forming assembly of the present invention.
• FIG. 3 is a bottom perspective view of one embodiment of a carton fabricated from bottom forming assembly of the present invention.
• FIG. 4 is an isolated top perspective view of a mandrel cap of the present invention.
• FIG. 5 is a top plan view of the mandrel cap of FIG. 4.
• FIG. 6 is an isolated top perspective view of a preferred embodiment of a sealing plate of the present invention.
• FIG. 7 is a side plan view of the sealing plate of FIG. 6.
• FIG. 8 is a top plan view of the sealing plate of FIG. 6.
• FIG. 9 is a side plan view of a sealing plate and mandrel cap of the present invention engaging a carton to form an elevated bottom.
• FIG. 10 is a top perspective view of an alternative embodiment of a sealing plate of the present invention.
• FIG. 11 is a top perspective view of an alternative embodiment of a sealing plate of the present invention.
• FIG. 12 is a top perspective view of an alternative embodiment of a sealing plate of the present invention. 5
• FIG. 13 is a top plan view of the sealing plate of FIG. 12.
• FIG. 14 is a top perspective view of an altemative embodiment of a sealing plate of the present invention.
• FIG. 15 is a top plan view of the sealing plate of FIG. 14.
• FIG. 16 is a top perspective view of an altemative embodiment of a sealing plate of the present invention.
• FIG. 17 is a top plan view of the sealing plate of FIG. 16.
• a packaging machine for forming, filling and sealing cartons is generally designated 20.
• One example of such a machine is a TETRA REX® packaging machine available Tetra Pak, Inc. of Chicago, Illinois.
• a plurality of carton blanks 22 are fed from a magazine 21 to a bottom forming station 25of the machine 21.
• each of the carton blanks 22 is erected to a partially- formed state wherein the top and bottom of the carton is open.
• the bottom of the carton is formed at a number stations. First, an erected carton blank 21 is placed upon a mandrel 26.
• the mandrels 26a-f rotate about a turret 27. Although six mandrels are shown, other configurations have five or four mandrels rotating about a turret 27.
• the bottom panels of each carton are pre-folded at a pre-folding station 28, and then heated at a heating station 29.
• the bottom panels are then heat sealed together at a sealing station 30.
• the sealing of the bottom panels is accomplished by pressing a sealing unit 50 against the bottom panels as they lie on a mandrel 26, and specifically a mandrel cap 40.
• the carton 100, with its bottom sealed, is then ejected from the mandrel 26 onto a conveyor 32 for further processing on the packaging machine 20.
• the elevated bottom is formed at the sealing station 30 by an unique sealing plate 50 and an unique mandrel cap 40.
• the bottom of the carton 100 has an elevated portion 120 bounded by substantially planar portions 160 and 162.
• the planar portions 160 and 162 are substantially perpendicular to side panels 112a, 112b and 112c and 112d, not shown.
• the planar portions 160 and 162 contact the conveyor belt 7
• elevated portion 120 is elevated above the belt 154 and any moisture thereon. The same applies during distribution whether in a crate or a shelf at a store.
• the elevated portion 120 is further defined by angled portions 164 and 166 and elevated planar portion 170.
• the elevated planar portion 170 is further defined as elevated planar portion 170a and elevated planar portion 170b.
• the elevated planar portion 170a substantially includes a portion of panel 132b while elevated planar portion 170b includes a portion of panel 132d.
• the exposed raw paper edge 140a extends across the bottom of the carton 100, from the end of panel 112 a to the end of panel 112c, not shown.
• the elevated portion 120 extends across the bottom of the carton 100.
• the elevated portion 120 may be centered on the bottom of the carton 100 with planar portions 160 and 162 being equal in area to each other. However, those skilled in the pertinent art will recognize that planar portions 160 and 162 may be unequal and elevated portion 120 may be uncentered without departing from the scope and spirit of the present invention.
• Elevated portion 170a, angled portion 164 and planar portion 160 may all be part of bottom panel 132b. Also, elevated portion 170b, angled portion 166 and planar portion 162 may all be part of bottom panel 132d.
• the exposed edge 140b is substantially perpendicular to exposed edge
• a side elevated portion 120a elevates this exposed edge 140b thereby preventing moisture absorption as with exposed edge 140a.
• the side elevated portion 120a has an angled portion 172 which engages planar portion 160, side panel 112a, and angled portion 164.
• the secondary elevated portion 180 prevents loss of elevation in the center of the bottom of the carton 100 during transportation from a packaging machine to the retailer/wholesaler to the consumer.
• the center of the bottom of the carton 100 is most susceptible to deelevation from the weight of the product.
• the weight of the product in the carton 100 is focused on the center of the bottom of the carton 100, and thus it is necessary to provide greater elevation in this area.
• This greater elevation is provided by the secondary elevated portion 180 which compensates for gravitational forces exerted by the product on the center of the bottom of the carton 100.
• the secondary elevated portion 180 is triangular in shape with its apex 181 near the exact center of the bottom of the carton 100.
• the secondary elevated portion 180 is substantially contained within elevated planar portions 170a and 170b.
• the triangular shaped embodiment of the secondary elevated portion 180 may be rotated any degree from 1-360 degrees, about apex 181 while not departing from the scope and spirit of the present invention.
• the secondary elevated portion 180 may lie entirely within elevated planar portion 170a.
• the secondary elevated portion 180 is partially defined by secondary angled portions 182, 184, 186 and 188.
• the secondary angled portions 182 and 184 form a transition from the secondary elevated portion 180 to elevated planar portion 170a whereas the secondary 9 angled portions 186 and 188 form a transition from the secondary elevated portion 180 to elevated planar portion 170b.
• a mandrel cap 40 of the present invention is shown in FIGS. 4 and 5.
• the mandrel cap 40 has an engagement surface 41a-b that engages with the bottom panels for mating with the sealing plate 50 to form the elevated bottom carton 100.
• the mandrel cap 40 has a first end 42, a second end opposite the first end, and third and fourth ends 44 and 45 as shown.
• the third and fourth ends 44 and 45 may be non-straight as shown or straight.
• the first end may be partitioned into a first portion 42a and a second portion 42b.
• the engagement surface 41 is traversed by a recess 46 that extends from the first end 42 to the second end 43.
• the width of the recess 46 is generally less than the combined area of engagement surfaces 41a-b, however those skilled in the pertinent art will recognize that the width may be equal or larger than such combined area.
• the engagement surface 41 also has an angled edge 47 along the first portion 42a of the first end 42.
• the angled edge 47 connects with the recess 46 at the transition edge 48b.
• Another transition edge 48a lies opposite the first transition edge 48b.
• the mandrel cap 40 may also have an elliptical groove 49.
• FIGS. 6-8 illustrate a preferred embodiment of the sealing plate 50 of the present invention.
• the sealing plate has a pressing surface 51 that lies on a first horizontal plane, and which engages with the bottom panels of a carton 100 and the mandrel cap 40.
• the generally flat pressing surface 51 is interrupted by a first elevated portion 52 which may be partitioned into a traversal section 52a and an edge section 52b.
• the traversal section 52a traverses the pressing surface 51 from a first end 53 of the sealing plate 50 to a second end 54 of the sealing plate 50. 10
• the sealing plate 50 will also have a third end 55 and a fourth end 56.
• the plan- section of the sealing plate 50 may be square, rectangular, circular, triangular or the like.
• the edge section 52b is generally perpendicular to the traversal section 52a, and edge section 52a extends along a portion 53a of the first end 53 of the sealing plate 50.
• the first elevated portion 52 is generally flat and lies on a second horizontal plane above that of the first horizontal plane defined by the pressing surface 51.
• the edge section 52b may lie on a different horizontal plane than the traversal section 52a, and both sections 52a-b may be non-flat surfaces.
• the first elevated portion 52 is interrupted by a second elevated portion 60 that generally lies in the traversal section 52a. Although shown as triangular, the second elevated portion 60 may be of any shape or configuration.
• the second elevated portion 60 is generally flat and lies on a third horizontal plane above the second horizontal plane.
• a second pressing layer 62 may be disposed on the sealing plate 50. The second pressing layer 62 may cover a portion of the traversal section 52a of the first elevated portion 52.
• the second pressing layer 62 will lie above the second horizontal plane but below the third horizontal plane.
• a pressing surface recess layer 63 is generally flat and lies below the first horizontal plane.
• the recess area 63 is defined by the pressing surface 51b, the edge section 52b, the traversal section 52a and the fourth end 56 of the seal plate 50.
• transition edges 64a-i the most important of which are transition edges 64a and 64b which assist in the elevation of the elevated portions 120 and 120a on the elevated bottom carton 100, as shown in FIG. 3.
• a plurality of channel block protrusions 65a-l may be disposed about the sealing plate 50, on the pressing surface 51 , the first elevation 52, the second pressing layer 62 and at the transition edges 64a-i.
• the channel block protrusions 65a-l act to create a further moisture barrier in the carton 100 should the raw paperboard edges 140a and 140b begin to wick.
• FIG. 9 shows a carton 100 having its bottom formed by simultaneous engagement between the sealing plate 50 and the mandrel cap 40.
• the mandrel cap 40 is attached or integrated therewith a mandrel 26.
• the mandrel 26 may also have a plurality of support 73 engaging with the mandrel cap 40.
• the bottom panels 132a-d of the carton 100 are sealed together and embossed to form the elevated portions 120 and 120a.
• the bottom forming may occur at the bottom forming station 30 disposed about the mandrels 26 rotating on the turret 27.
• the carton 100 may be placed onto an isolated mandrel cap 40 and sealing plate 50 for bottom forming before conveyance to further stations on the packaging machine 20.
• FIGS. 10 and 11 are altemative embodiments of the sealing plate.
• the sealing plates 50a-b of FIGS. 10 and 11 are slight variations on the sealing plate 50 of FIG. 6.
• the sealing plates 50a-b are without many of the various elevations of the sealing plate 50 of FIG. 6, most noticeably the second elevated portion 60 on sealing plate 50a.
• FIGS. 12 and 13 represent different views of an altemative embodiment of the sealing plate of the present invention. Similarities between 12 the sealing plate 50 of FIG. 6 and the sealing plate 50c of FIGS. 12 and 13 will utilize the same reference designations.
• the sealing plate 50c has a sixth panel recess 80 disposed on the first elevated portion 52a and a portion of the second elevated portion 60. Although the recess 80 lies below the second horizontal plane of the first elevated portion 52, the recess 80 may have a surface above the first horizontal plane of the pressing surface 51. The intersection 81 of the recess 80 and the second elevated portion 60 may have a surface that lies on the second horizontal plane of the first elevated portion 52.
• the sealing plate 50c is primarily directed at providing an elevated bottom on a TETRA REX® sixth panel skived edge carton.
• FIGS. 14 and 15 represent different views of an altemative embodiment of the sealing plate of the present invention. Similarities between the sealing plate 50 of FIG. 6 and the sealing plate 50d of FIGS. 14 and 15 will utilize the same reference designations.
• the sealing plate 50d is primarily directed at providing an elevated bottom on a carton formed from a low resource carton blank such as the one described in co-pending U.S. Patent Application 08/766,493, filed on December 13, 1996, entitled Stackable Gable Top Carton And Corresponding Top Interlocking Carton Blank which relevant parts are hereby incorporated by reference.
• the sealing plate 50d has the pressing surface 51a-b and first elevated portions 52a-b, although the edge portion 5 lb is not adjacent the traversal portion 52a.
• the sealing plate 50d also has a plurality of second elevated portions 60, 60a, 60 b and 60c which may all lie on the third horizontal plane.
• a plurality of channel protrusions 65 are also dispersed throughout the sealing plate 50d.
• the various elevations also have transition edges between different elevations. 13
• FIGS. 16 and 17 represent different views of an altemative embodiment of the sealing plate of the present invention. Similarities between the sealing plate 50 of FIG. 6 and the sealing plate 50e of FIGS. 16 and 17 will utilize the same reference designations.
• the sealing plate 50e is primarily directed at providing an elevated bottom on a carton formed from a PURE-PAK® carton blank.
• the sealing plate 50e has the pressing surface 51a-b and first elevated portions 52a-b.
• the sealing plate 50e also has a plurality of second elevated portions 60 and 60d which may both lie on the third horizontal plane.
• a plurality of channel protrusions 65 are also dispersed throughout the sealing plate 50e.
• the various elevations also have transition edges between different elevations.
• the second pressing surface 62 extends along the traversal portion 51a and is interrupted by the second elevated portion 60.

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• Making Paper Articles (AREA)
• Cartons (AREA)

Priority Applications (5)

Applications Claiming Priority (4)

Publications (1)

Family

ID=26730559

Family Applications (1)

Country Status (7)

Cited By (2)

Citations (7)

• 1998
  • 1998-10-19 ES ES98953681T patent/ES2243011T3/es not_active Expired - Lifetime
  • 1998-10-19 CA CA002317715A patent/CA2317715C/en not_active Expired - Lifetime
  • 1998-10-19 AU AU11000/99A patent/AU745817B2/en not_active Expired
  • 1998-10-19 DE DE69831099T patent/DE69831099T2/de not_active Expired - Lifetime
  • 1998-10-19 EP EP98953681A patent/EP1064146B1/en not_active Expired - Lifetime
  • 1998-10-19 WO PCT/US1998/022002 patent/WO1999050054A1/en active IP Right Grant
• 2000
  • 2000-06-29 NO NO20003392A patent/NO325837B1/no not_active IP Right Cessation

Patent Citations (7)

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