Classifications

• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
  • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
  • B65D5/00—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper
  • B65D5/02—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body
  • B65D5/0281—Rigid or semi-rigid containers of polygonal cross-section, e.g. boxes, cartons or trays, formed by folding or erecting one or more blanks made of paper by folding or erecting a single blank to form a tubular body with or without subsequent folding operations, or the addition of separate elements, to close the ends of the body the tubular body presenting double or multiple walls
• • 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
  • B31B2105/00—Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs
• • 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
  • B31B2105/00—Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs
  • B31B2105/001—Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs made from laminated webs, e.g. including laminating the webs
• • 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
  • B31B2105/00—Rigid or semi-rigid containers made by assembling separate sheets, blanks or webs
  • B31B2105/002—Making boxes characterised by the shape of the blanks from which they are formed
  • B31B2105/0027—Making boxes from blanks consisting of side wall panels integral with a bottom panel and additional side wall panels
• • 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
  • B31B2110/00—Shape of rigid or semi-rigid containers
  • B31B2110/30—Shape of rigid or semi-rigid containers having a polygonal cross section
  • B31B2110/35—Shape of rigid or semi-rigid containers having a polygonal cross section rectangular, e.g. square
• • 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
  • B31B2120/00—Construction of rigid or semi-rigid containers
  • B31B2120/50—Construction of rigid or semi-rigid containers covered or externally reinforced
• • 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

Definitions

• bins Large format containers, generally referred to as "bins", are used to hold a variety of materials, usually for transport but also for retail display. Because more than 95% of all products in the US are shipped in corrugated boxes, and because of the cost advantages associated with this form of packaging, most bins are constructed from corrugated paperboard. But while about 90% of all corrugated paperboard is single wall, the relatively large dimensions of bins in conjunction with the nature of the goods being placed in the bins require the additional strength provided by multiple wall construction.
• an improved bin and related manufacturing process would use easy-to-create/source single wall corrugated material, would use minimal amounts of adhesive during the converting process, would require minimal human effort before, during and after the converting process, would generate minimal waste, and would require minimal handling, among other requirements. While such needs exist, heretofore, such needs have not been met.
• Methods according to the invention are directed to creating multi-walled containers from a corrugated material with minimal intentional waste, wherein the containers are formed from a single sheet or preferably a continuous web of corrugated material, such as single wall corrugated board, or double wall corrugated board (whether single or dual arch).
• Methods according to the invention cause the sheet or web of corrugated material to engage a wrapping mandrel, which creates the physical form of the container during the folding and attaching (e.g., gluing) process.
• Methods according to the invention also involute flap precursors to establish a container wall, thereby dispensing with the common method of gluing an "inner box" to the container.
• Articles produced by method embodiments of the invention are characterized as having at least one container wall comprised from a pair of opposing flap precursors that are attached or otherwise permanently associated with a conventional sidewall of the container.
• articles produced by method embodiments of the invention include, alone or in combination, unstressed vertical folds at corner edges, interlocking/intermeshing flap precursors, corner stress relief features and others that will become apparent from this specification.
• multi-walled containers are usually large, e.g., from approximately 40" or about 1 meter in width/side. At this scale, conventional large, multi-walled container blanks would be very large, approaching 15 feet or about 4.5 meters in length, but according to the invention, blanks for the various embodiments might approach 30 feet or about 9 meters in length.
• container embodiments of the invention were formed using traditional construction methodologies, e.g., one apparatus manufactures the blanks, the blanks are then moved to storage, and then moved to a converting or box making machine, storage, transport and handling of such large format blanks would present a daunting challenge (batch transportation of 30 foot blanks is not easy) .
• a continuous process wherein a web or constant source of material is fed into a converting or box making machine, all material batch handling requirements that would otherwise be associated with conventional blank-based box making procedures can be eliminated.
• Methods of making containers according to the invention utilize in- or out- folded flap precursors to establish a container wall, in particular between an outer wall and an inner wall of a manufactured container.
• flap precursors of a blank used to create the container are dimensioned to either individually, or in combination, create a sidewall.
• opposing flap precursor are folded toward each other, and attached, such as by adhesive, to the panel from which they extended. Once folded and adhered, these flap precursors collectively form an additional sidewall of the container.
• Methods according to the invention in yet another respect comprise creating a multi-walled container that has a generally unstressed vertical fold at all corner edges.
• the resultant container's relaxed state is that of its in-use form.
• each vertical corner of a four-sided container is less susceptible to tearing and breakage during use, as is common in the prior art.
• handling and storage of the resulting containers is enhanced since no vertical corner in the four sided configuration, for example, undergoes substantially greater than a 90° bend from its "use" geometry to its "knocked down" geometry.
• corner edge when such a corner edge is under induced stress, it is not usually subject to dynamic loads; it is in a folded and likely stored state. In contrast, when the container is most likely subject to dynamic loads such as during use and transportation of goods, these corner edges are in their nominal, generally unstressed geometry. This configuration also facilitates restoration of the container shape from the "knocked down" geometry, which for large format containers can be quite a meaningful advantage over the prior art.
• a corner stress relief feature is created at the intersection of a flap joint and a panel joint, preferably on the outermost panels and flaps, by selective material removal. Because this intersection would otherwise undergo bidirectional manipulation (panel folding and flap folding), select removal of material from this intersection permits a greater degree of articulation and delocalizes stresses that would otherwise occur at a highly specific location. In one series of embodiments, a roughly circular piece of material is removed at and/or near the fold intersections. The resulting blank and/or container precursor would then incorporate this feature as a structural element thereof.
• a slit for separating two flaps or flap portions be offset from a score to facilitate bending of two adjacent panels.
• the offset which preferably occurs with respect to the outer panels and flaps, is preferably approximately equal to the thickness dimension of the material (web or blank) used to construct the container, such as when a three wall container is created.
• each flap will have a width dimension that is different (longer or shorter) than the width dimension of the panel width from which it extends.
• the wider outer flaps will extend to the outer edge of the container, and the inner flaps will fully extend over the intermediate and inner layer, thereby providing additional stacking strength and making full use of, and contact with, the outer panel(s) of the container.
• articles resulting from the practice of the various method embodiments comprise a single blank for forming a multiple sidewall container, container precursor, as well as the resulting container.
• the blank defines a longitudinal direction from a first end to a second end, and comprises an inner panel forming inner sidewalls of the container when assembled, wherein the inner panel has a plurality of inner panel portions, each inner panel portion being contiguous with any adjacent inner panel portion and each inner panel portion making up one inner sidewall of the container when assembled.
• the blank further comprises at least one pair of flap precursors, which may comprise opposing middle flaps extending from the inner panel to a distal edge, wherein the sum of the average lateral lengths of the pair of flap precursors from their intersection with a panel to a distal edge is equal to or less than the lateral length of the panel from the intersection of a first opposing flap precursor to the intersection of a second opposing flap precursor.
• each flap precursor or middle flap preferably has a plurality of flap portions, each flap portion being contiguous, or discrete but adjacent, with any adjacent flap portion and each opposing pair of flap portions making up one sidewall of the container when assembled.
• the blank comprises, in three layer sidewall embodiments, an outer panel extending longitudinally from the inner panel forming outer sidewalls of the container when assembled, wherein the outer panel preferably has a plurality of outer panel portions, each outer panel portion being contiguous with any adjacent outer panel portion and each outer panel portion making up an outer sidewall of the container when assembled. If additional intermediate sidewalls are desired, then the outer panel will preferably extend from a last intermediate panel. In the described three sidewall embodiment, such (an) intermediate panel(s) is/are located longitudinally between the inner panel and the outer panel.
• container embodiments of methods according to the invention comprise containers wherein the combined average lateral widths of the flap precursors are equal to or less than the lateral width of the panel from which they extend.
• the flap precursors may constitute either the inner or intermediate panel, and the panel from which they extend may constitute the other panel.
• the resulting involuted structure can then function as sidewalls when the container precursor is assembled into the container.
• the skilled practitioner will of course realize that as the geometries of the distal edges vary, so may the lateral length determinations.
• the combined lengths are described in terms of "average", it is within the scope of the invention to include any geometry that will not result in an overlapping condition when the opposing flaps are involuted and brought into relative proximity with one another.
• an interlocking or inter- meshing pair of opposing flap precursor edges are formed, such as by die cutting.
• stresses at what would otherwise be localized at a butt joint after involution and formation of the container are dispersed over a longer edge and larger area of adjacent sidewall of the container when in use. This is especially important when maximizing burst and vertical compression strength values.
• Industrial implementations of the invention comprise a plurality of stations wherein various treatments are applied to a blank or continuous web of material in order to create a container.
• methods of forming a container according to the invention will begin with an appropriately sized "blank" as that term has been previously defined. Selection of the features to be incorporated into the container will determine the presence and order of methods and apparatus used to form the intended container. For the purpose of illustration only, a basic construction of a triple wall, four sided container will initially be described below.
• flap precursors are adhered to associated panels as previously described and the container precursor is subject to involution. During the involution of the container precursor, panels forming adjacent layers are brought into compressive contact, and adhered to one another to form the container, which is subsequently removed and optionally "knocked down".
• Fig. 1 is a perspective view of a first embodiment of the invention shown in a generally assembled state
• Fig. 2 is a detailed perspective view of a portion of the double liner corrugated material used in the construction of the first embodiment
• Fig. 3 is a plan view of the first embodiment with the upper flaps shown in phantom to better illustrate the layering of the corrugated material;
• Fig. 3a is a detailed plan view of a corner of the embodiment shown in Fig. 3;
• Fig. 4 is a plan view of a "blank" used to form the first embodiment of the invention
• Fig. 5 is a detailed plan view of a stress relief feature and vertical crush resistance geometry feature of the first embodiment of the invention
• Fig. 6 is a perspective view of a first step in forming a multi-walled container using the "blank” of Fig. 4 where the middle flaps are folded into close proximity to form a middle sidewall of corrugated material;
• Fig. 7 is a perspective view of a second step in forming a multi-walled container using the "blank" of Fig. 4;
• Fig. 8 is a perspective view of a third step in forming a multi-walled container using the "blank” of Fig. 4 where the combined inner panel and middle flaps are involuted;
• Fig. 9 is a perspective view of a fourth step in forming a multi-walled container using the "blank” of Fig. 4 where an inner glue tab is attached to an inner panel, thereby forming a basic container shape;
• Fig. 10 is a perspective view of a fifth step in forming a multi-walled container using the "blank” of Fig. 4 where the outer panels are wrapped around the basic container of Fig. 9;
• Fig. 11 is a perspective view of a sixth step in forming a multi-walled container using the "blank" of Fig. 4 where an outer glue tab is attached to an outer panel, completing formation of the first embodiment;
• Fig. 12 is a detailed perspective view of a stress relief feature shown in Fig. 5 when the "blank" of Fig. 4 is converted into the container of Fig. 11 , and the upper and lower flaps are folded inward;
• Fig. 13 is a plan view of a system for receiving converted blanks and creating assembled containers there from;
• Fig. 14 is an isometric view of a folding and gluing station, which is part of the system shown in Fig. 13;
• Fig. 15 is a perspective view of an up-winder, which is part of the system shown in Fig. 13;
• Fig. 16 is a schematic elevation view of the rotator portion of the up-winder shown in Fig. 15 wherein the relative movement of the four mandrel bars are shown.
• Container 20 comprises "blank" 22, which is preferably constructed from a double lined, single wall corrugated material such as 5 /i 6 n L flute corrugated board shown in Fig. 2.
• container 20 has dimensions of about 42" H x 48" W x 40" D, while blank 22 has maximum dimensions of about 355" L x 83" W.
• container 20 has triple sidewalls and single overlapping bottom and top flaps.
• container blank 22 is a unitary piece of corrugated material, such as of the type shown in Fig. 2, with the direction of corrugation running laterally. From a single sheet, selected scores, cuts and perforations are carried out, such as by rotary die cutter(s) or other means appreciated by the skilled practitioner.
• Each container blank 22 then comprises inner panel 40, opposing middle flaps 50, outer panel 60, and a plurality of end flaps 70.
• Container blank 22 preferably further comprises inner tab 30 and optional outer glue tab 80.
• the observed sides of all panels and flaps are as indicated, with the reverse side being numbered similarly, but within the one hundred series.
• inner panel 140 the reverse side of inner panel 40, for example, is labeled as inner panel 140.
• Inner panel 40 comprises inner panel portions 42, 44, 46 and 48, separated by scores 34a, 34b, and 34c.
• Inner tab 30 extends longitudinally from inner panel portion 42, and is separated there from by score 32.
• middle flaps 50 Extending laterally outwardly from inner panel portions 42, 44, 46 and 48, and defined in part by slit-scores 43a/b, 45a/b, 47a/b and 49a/b, and by scores 34a, 34b, and 34c (as well as edges 51a/b, and slits 73a and 73b), are respective middle flaps 50, identified in this embodiment as middle flap portions 52a/b, 54a/b, 56a/b and 58a/b.
• each "flap" 50 may comprise physically discrete flap portions (as are end flaps 70, discussed below), visually discrete flap portions as illustrated herein, or may be wholly contiguous (no scoring). Because it is only necessary to form a wall or layer within container 20, there is no intrinsic need to form physically discrete flap portions as long as those portions of blank 22 that fold to meet the opposing portions of blank 22 can result in the creation of such wall or layer.
• each middle flap portion are characterized by chevron edges 53a/b, 55a/b, 57a/b and 59a/b, again as shown best in Fig. 4.
• chevron edges 53a/b, 55a/b, 57a/b and 59a/b will beneficially delocalize burst and column compression stresses that may occur after assembly and use of container 20, as will be described in later detail below.
• curvilinear edges or rectilinear edges such as repeating square or saw-tooth geometries are considered desirable.
• it is not necessary to the operation or constitution of the embodiments of the invention to incorporate such non-linear edges, and a linear edge will provide benefits as herein described.
• outer panel 60 comprises outer panel portions 62, 64, 66 and 68, separated by scores 38a, 38b, and 38c; outer panel portion 62 is separated from inner panel portion 48 by score 36.
• Outer glue tab 80 extends longitudinally from inner panel portion 42, and is separated there from by score 82.
• outer panel portions 62, 64, 66 and 68 Extending laterally outwardly from outer panel portions 62, 64, 66 and 68, and defined in part by point-to-point scores 63a/b, 65a/b, 67a/b and 69a/b, and by slits 73a/b, 75a/b, 77a/b and 79a/b (as well as edges 71a/b), are respective end flaps 72a/b, 74a/b, 76a/b and 78a/b, as shown.
• the lateral width (or as assembled, the height) of outer panel 60 is greater than that of inner panel 40. This increased dimension addresses the consequence of the increased external dimensions as container 20 is formed (discussed and shown below). Similarly, the longitudinal length (or as assembled, the width and depth) of outer panel 60 is greater than that of inner panel 40. Those persons skilled in the art will appreciate that the increases are related to the number of walls used to form the container, as well as the thickness of the material comprising the walls.
• Fig. 5 illustrates two features of the subject embodiment, namely, stress relief feature 90, which is characterized as a hole of approximately 0.375" diameter, and flap offsets.
• stress relief feature 90 which is characterized as a hole of approximately 0.375" diameter
• flap offsets It is well known in the art that flaps on containers frequently tear at the exposed edge interface between the flap and a sidewall panel. This is due in part to the effect of the three edge corner present on the underside of the flap: the three edge corner causes a crushing of the flap at its edge, thereby compromising the structural integrity of the flap and related structure. This consequence, in conjunction with the inherent weakness of the material at this position, often invites mechanical failure during repeated use or operation of the flap.
• a hole and preferably, but not necessarily, a round or circular hole
• the three edge corner will not directly impinge upon the underside of the flap.
• additional stress relief features may be employed with respect to interior or middle walls, as the case may be.
• FIG. 5 Also shown in Fig. 5 is an offset with respect to the slits separating adjacent flaps 70 and the point-to-point scores separating adjacent outer panel 60.
• flaps 70 have differing dimensions when compared to their companion panels. Because flaps 70 form end walls as opposed to sidewalls, there is no need for such symmetry.
• flaps 70 form end walls as opposed to sidewalls, there is no need for such symmetry.
• flaps 70 will be positioned orthogonal to the sidewalls comprising inner panel 40, middle flaps 50 and outer panel 60, the dimensionally larger flaps will extend over the entire exposed edges of outer panels 60 when container 20 is in the assembled configuration.
• the consequence of this arrangement is that all exposed vertical sidewall edges can be "covered” by the end flaps, and that vertical compression loads can be evenly distributed to the end flaps. See also Fig. 11.
• Figs. 6-12 the assemblage of container 20 is shown in detail.
• Completed blank 22, as described in Fig. 4 emerges from a converting machine and enters a folding and gluing section of the process.
• co- joined middle flap portions 52a, 54a, 56a and 58a, and 52b, 54b, 56b and 58b are down folded 180°, along slit-scores 43a, 45a, 47a and 49a, and 43b, 45b, 47b and 49b to join in surface-to-surface area contact with respective inner panel portions 42, 44, 46 and 48 as shown in Fig. 6.
• chevron edges 53a/b, 55a/b, 57a/b and 59a/b meet about mid way of inner panel portions 42, 44, 46 and 48.
• the 'serrated' and intermeshing nature of chevron edges 53a/b, 55a/b, 57a/b and 59a/b distribute the joined line over a greater area than a pure straight cut and now appear on the underside of the flat box blank.
• inner tab 30 is up-folded 90° at score 32
• inner panel portion 42 (with middle flap pair 52a/b) is up-folded 90° at score 34a
• inner panel portion 44 (with middle flap pair 54a/b) is up-folded 90°at score 34b
• inner panel portion 46 (with middle flap pair 56a/b) is up-folded 90° at score 34c
• inner panel portion 48 (with middle flap pair 58a/b) is up-folded 90° at score 36, as is shown in Fig. 8.
• All 90° folds are 'up' and therefore away from the surface joint of chevron edges 53a/b, 55a/b, 57a/b and 59a/b.
• the resulting structure is best shown in Fig. 9.
• Adhesive is applied to the intended mating surfaces of outer panel portions 62, 64, 66 and 68, and the up-folding process continues with outer panel portion 62 folding 90° at score 38a, outer panel portion 64 folding 90° at score 38b, outer panel portion 66 folding 90° at score 38c, and outer panel portion 68 folding 90° at score 82, with outer glue tab 80 completing the folding and gluing process.
• This process is best shown in Fig. 10.
• the up- folding process may be accomplished by use of a forming mandrel or other aid.
• the collective effect of the multiple-90 degree folding and gluing process takes the original flat, rigid corrugated board blank, comprising inner tab 30, inner panel 40, middle flaps 50, which form an intermediate panel, and outer panel 60, as well as optional outer tab 80, all as shown in Fig.4, and forms a multi-walled, four sided, finished container/bin, with single wall flaps top and bottom, that has no 'manufacturers - joint', as best shown in Fig. 11. Because the relaxed state (manufacturer's resting position) is the use state of the container, there is a natural tendency of the container to return to its resting position if collapsed.
• Greenfield containers comprised all features of the above-described embodiment while the prior art containers (HP) were constructed from 2 panel layers of double wall corrugated material or 3 panel layers of double wall corrugated material where the panel layers are nested but not adhered to each other.
• containers constructed according to the invention have superior crush resistance (a major factor in container evaluation) over constructions of the prior for comparable weights, or significantly less material usage for comparable crush resistance values.
• methods for making containers according to the invention further increase cost savings by streamlining manufacturing and handling actions.
• construction of multi-walled containers according to various embodiments of the invention has focused on general manipulation of the blank to form container precursors and containers, as exemplified in Figs. 4, and 6-11.
• the following disclosure is directed to a systems approach for mass producing containers according to the invention and practicing related methods.
• the below disclosure describes a process and its variants for mass manufacturing such containers.
• the skilled artisan will appreciate that the disclosed modes and approaches are not exclusive to the creation of containers according to the invention, but represent both general and specific implementations intended to identify presently preferred means for accomplishing those objectives.
• Basic material used for constructing container 20 is derived from a corrugator (not shown) that produces a continuous web of double face, single wall corrugated material.
• the web may be immediately consumed, or may be stored as cut blanks until needed.
• blanks 22 having a total length of about 30 feet (9 meters) are fashioned from the web by cutting, for example.
• the blanks are subject to various slotting, slitting, scoring, and cutting processes as is necessary to form a desired container 20 as previously described.
• various slotting, slitting, scoring, and cutting processes are carried out by a pair of opposing machines, which are supplied with blanks using conventional conveyor means.
• RAPIDBOX machines preferably RAPIDBOX units from Rapidex (a division of the Bobst Group of Switzerland) of Angers, France, create the desired blanks through appropriate programming, which is determined based upon the size and geometry of the intended container.
• the RAPIDBOX machine can accommodate blanks up to 110" x 400" or 2.8m x 10m, which makes it particularly suited for large format container manufacturing such as described herein.
• these processes may be carried out by more dedicated machinery, such as a plurality of various slotting, scoring, slitting and rotary die cutting machines, serially established in the production line. Regardless of how the blanks are processed, the resulting blanks are delivered to folding and gluing stations as will now be described.
• blanks 22 are deposited on receiving platform 210 as best shown in Fig. 13 where after they are conveyed to vacuum assisted overhead conveyors 220 to folding and gluing station 230.
• This mode of conveyance is desirable over more conventional forms for two reasons. First, it retains full exposure of the underside surface of inner panel 40 (designated inner panel surface 140) and middle flaps 50 (designated middle flaps surface 150), which becomes important during the "up winding" process described below. Second, it accurately retains the specific position of blanks 22 relative to the other apparatus, which is important when precision application of adhesive is necessary.
• any blank 22 from adhesive application means may be selectively deposited or may be applied to the entirety of inner panel surface140 and/or middle flaps surface 150 exposed to a first adhesive means. Selective deposition of adhesive involves the intelligent location of adhesive lines or zones within the bounds of these panels and/or flaps.
• any adhesive application means capable of depositing an intended amount and type of adhesive on any blank 22 is sufficient.
• the illustrated application means and adhesive composition has been chosen in an effort to optimize the production speed of the illustrated process. At roughly 200 feet per minute, the applied adhesive has sufficient time to "set" prior to folding and mating of middle flaps 50 as will now be described.
• middle flaps 50 Once adhesive has been applied to inner panel surface 140 and/or middle flaps surface 150, actuated folding arms cause middle flaps 50 to involute, and middle flaps surface 150 to contact inner panel surface 140 as best shown in Fig. 14.
• a pinch roller combination may be used to compress middle flaps 50 and inner panel 40 together in conjunction with overhead conveyor 160, otherwise the wrapping process described below will generate compressive contact between these two surfaces.
• converted blank 22 has been transformed into precursor 122.
• adhesive must also be applied to the exposed surface of outer panel 60 (and/or the exposed surface of middle flaps 50, which are now on the "underside” of precursor 122).
• second adhesive application means 262 is provided, and selectively applies adhesive to the exposed surface of outer panel 60.
• rotator 276 may already be rotating or may begin rotation after clamp element 271 engagement with tab 30. While a mechanical engagement means is shown, alternative means such as vacuum engagement are contemplated and will be appreciated by the skilled practitioner.
• rotator 276 preferably includes a plurality of folding bars equal in number to the number of container vertical corners, which in this case is four (4). Folding bars in general localize bending stresses during container formation and provide a convenient, low cost and low mass solution to container formation.
• folding bars 272a-d may be hydraulically or mechanically movable on rotator 276, with the only requirement being that the assembly can accept precursor 122, assist in forming container 20 and release container 20 such that another precursor 122 can be engaged therewith.
• winder 270 is constructed to move in the vertical direction (see hydraulic ram 277 linked to pulley system 278 in Fig. 15).
• an external compression element can be applied during winding of the precursor on the mandrel, with the result being compression between the container sidewall layers.
• winder 270 includes bottom support table 275, which has an upper surface approximately at the level of blank 22. By maintaining the last wound panel/tab in compressive contact with support table 275, container 20 will not prematurely “leave” winder 270. In this position, there is sufficient tension precursor 122 that bonding can occur between the surfaces of panels 140 and 150 as well as the surfaces of panels 50 and 60. However, the set time of such adhesive is usually longer than the time it takes to wind precursor 122.
• a "curing" station is needed.
• a carrousel arrangement is used, as is best shown in Fig. 13 wherein further transportation of formed container 20 is sufficiently delayed to permit sufficient time for the adhesive to cure, thereby ensuring that container 20 will not "unwind".
• one, some or all of the folding bars 172a-d may be retracted in such a manner so as to reduce the friction between them and container 20, although such action is not necessary for the removal of container 20.
• an exterior engaging sliding element or other means for removing container 20 from mandrel 170 may then be employed.
• an arm having a plurality of extensible elements is inserted into container 20, the elements extended to compressively contact the inner walls of container 20 (or engage therewith via vacuum assist), and then the arm removed to "pull" container 20 from folding bars 172a-d.
• Support table 285 is used for similar reasons as that for support table 275.
• certain method embodiments of the invention provide for the back folding of outside flaps 70 onto the side panels such as shown in Fig. 15. If such a final configuration is desired, these embodiments of the invention fold the end flaps onto the side panels at the same time that the intermediate flaps are folded.
• outside flaps 70 are not in the extended position, but are placed in compressive contact with the panels 60.
• shorter mandrels and container removing apparatus can be used as the overall height of the container is shorted by the depth of the end flaps. Additionally, in such embodiments, it may be considered desirable to eliminate tab 80 so that the contacting surface is sufficiently planar to avoid binding and/or crushing.

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