WO2011055361A1

WO2011055361A1 - Method and apparatus for manufacturing collapsible cardboard boxes

Info

Publication number: WO2011055361A1
Application number: PCT/IL2010/000906
Authority: WO
Inventors: Mordechai Kleiner
Original assignee: Mordechai Kleiner
Priority date: 2009-11-04
Filing date: 2010-11-01
Publication date: 2011-05-12
Also published as: IL201927A0

Abstract

A continuous production line for manufacturing collapsible boxes, the production line comprising a construction assembly adapted to fold and assemble a cardboard sheet to construct a regular, serviceable box and a collapsing assembly adapted to collapse such regular cardboard boxes. The construction assembly comprises a linearly movable pressing device comprising a bottom platform and adapted to move downwards while pressing the bottom platform against a bottom panel of the cardboard sheet and the collapsing assembly comprises at least two collapsing mechanisms adapted to grasp the constructed box at two sides thereof and to apply pressure on the two sides, such as to collapse the grasped constructed box to form a collapsed box resulting in smaller dimensions and convenient to store and ship.

Description

METHOD AND APPARATUS FOR MANUFACTURING

COLLAPSIBLE CARDBOARD BOXES

Field of the Invention The invention relates to methods, apparatus and production line for producing cardboard boxes in general and to the manufacturing of collapsible cardboard boxes using automated processes in particular.

Background of the Invention

Many types of packaging boxes, such as cardboard boxes, are known in the packing industry market. Nevertheless, the existing types of boxes, particularly cardboard boxes, generally suffer from lack of adequate strength and thus the weight of materials that can be packed or stored within these boxes is limited.

Attempts of adding strengthening structures to the common packaging boxes, typically result in an undesired increase of the volume and/or the weight of the boxes. In addition the manufacturing of the boxes themselves as well as their shipment is complicated and volume consuming.

Currently the variety of cardboard boxes manufactured by using automated processes can generally be divided into two main groups: "RSC" type cardboard boxes and "Tray" type cardboard boxes. Cardboard boxes of the "RSC" type can be manufactured from cardboard sheets using automated processes and are foldable after manufacturing. The folded boxes can be piled in a relatively volume saving manner (relative to unfolded ones). However, the end user is required, in addition to opening the boxes to their unfolded (usable box) state, to also secure the bottom and the side panels of the re-constructed (unfolded) box by implementing additional means, such as applying hot melt type of adhesive, adhesive tape or stapling devices. The "Tray" type cardboard boxes do not require any securing means to be applied by the end user but upon being manufactured, the "Tray" type boxes (of previous art) cannot be folded - and therefore require high volume for their shipment to the end user, resulting in high costs.

Thus, there is a need for a continuous production line for manufacturing collapsible boxes that would enable high speed, manufacturability of collapsible (foldable) cardboard boxes using automated processes that have, on a one hand, high strength characteristics, and on the other hand, wou Id be easy to pack, transport and unfold (re-construct) without requiring the use of any additional securing means at the end user level.

Summary of the Invention Herein after we provide an overview of the subject matter disclosed below, but it should not be construed, however as limiting the invention to any features described in this summary section.

Some embodiments of the invention are generally directed to methods or apparatus, others to the production line for manufacturing collapsible boxes.

In one aspect, the present invention constitutes a continuous production line for manufacturing collapsible cardboard boxes. The production line comprises a construction assembly adapted to be fed continuously with discrete prefabricated cardboard sheets having collapsing lines. The construction assembly is further adapted to assemble the cardboard sheets into constructed boxes. A continuous production line in accordance with this aspect of the invention comprises in addition a collapsing assembly adapted to collapse the constructed boxes along the collapsing lines. The collapsing assembly comprises at least two collapsing mechanisms adapted to grasp the constructed box at two opposing side panels thereof and to apply pressure on those two opposing side panels, such as to collapse the grasped constructed box along its collapsing lines.

In yet another aspect of the present invention, the invention embodied in the cardboard sheet which is adapted to be used for the construction of a collapsible box in a continuous production line for the manufacturing of collapsible cardboard boxes in accordance with the invention.

In another aspect of the present invention, there is embodied in it a general method for continuously manufacturing collapsible cardboard boxes. The method comprises the steps of continuously feeding a construction assembly with discrete prefabricated cardboard sheets having collapsing lines; assembling the cardboa rd sheets into constructed boxes within the construction assembly while continuously moving the discrete prefabricated cardboard sheet to be assembled, in a linearly downward directed movement; inserting the constructed boxes into a collapsing assembly; and within the collapsing assembly - sequentially (one after the other) grasping the constructed boxes at two of its opposing side panels and applying pressure on the two opposing side panels, such as to collapse the grasped constructed boxes along their collapsing lines.

Brief Description of Figures

Examples illustrative of embodiments of the invention are described below with reference to figures attached hereto. In the figures, identical structures, elements or parts that appear in more than one figure are generally labeled with the same number in all the figures in which they appear. Dimensions of components and features shown in the figures are generally chosen for convenience and clarity of presentation and are not necessarily shown to scale.

Figure No.lA shows a schematic plan view of a cardboard sheet used to construct a collapsible box in accordance with some embodiments of the present invention.

Figure No. IB shows a schematic plan view of a different cardboard sheet used to construct a collapsible box, in accordance with other embodiments of the present invention.

Figure No. 2 shows a schematic view of a manufacturing line of collapsible boxes, in accordance with certain embodiments of the invention.

Figure No. 3 shows a schematic view that presents a part of a manufacturing line of collapsible boxes, in accordance with additional (different) embodiments of the present invention.

Figure No. 4 shows a schematic view that presents a part of a manufacturing line of collapsible boxes, in accordance with yet other embodiments of the invention.

Figure No. 5 shows a schematic view of other parts of a manufacturing line of collapsible boxes, in accordance with various additional embodiments of the present invention.

Figure No. 6 shows a schematic view in perspective of a collapsed box, in accordance with some embodiments of the invention.

Detailed Description of Preferred Embodiments

In the following description, various aspects of the invention will be described. For the purpose of explanation, specific configurations and details are set forth in order to provide a thorough understanding of the techniques. However, it will also be apparent to any professional skilled in the art that the techniques may be practiced without specific details being presented herein. Furthermore, well-known features might be omitted or simplified in order not to obscure the descriptive aspects of the techniques.

Reference is made to Figures No. 1A and No. IB that show schematically a plan view of pre-shaped cardboard sheets used to construct collapsible boxes, in accordance with some embodiments of the this innovative invention.

Cardboard sheet 100 includes a bottom panel 102 shown as having an essentially rectangular shape, but can also have various and other different shapes, such as for example, a square. Bottom panel 102 includes four foldable edges: right foldable edge 114, left foldable edge 120, front foldable edge 122 and rear foldable edge 124.

Bottom panel 102 further includes two sets of collapsing lines: right set of collapsing lines 104 and left set of collapsing lines 106. Each one of the sets of collapsing lines right set of collapsing lines 104 and left set of collapsing lines 106 includes three collapsing lines, but may also include any other number of collapsing lines, such as 1, 2, 3, 4 or more collapsing lines. The right set of collapsing lines 104 extends from rear right corner 108 of bottom panel 102 towards a central area 110 of bottom panel 102 "and angle" (at approximately 90 degrees) towards a front right corner 112 of bottom panel 102, such that collapsing lines 104 form a triangle pattern together with right foldable edge 114 of bottom panel 102. Left set of collapsing lines 106 extend from rear left corner 116 of bottom panel 102 towards a central area 110 of bottom panel 102 and angle (at approximately 90 degrees) towards a front left corner 118 of bottom panel 102, such that collapsing lines 106 form a triangle pattern together with left foldable edge 120 of bottom panel 102.

Two opposing side panels, right side panel 126 and left side panel 128 are disposed on the right and left sides of bottom panel 102, along right foldable edge 1 14 and left foldable edge 120, respectively. Right side panel 126 and left side panel 128 include gripping holes 130 and 132, respectively.

Both right side panel 126 and left side panel 128 are adapted to receive an adhesive material, such as glue, adhesive strips or any other material. The adhesive material might be disposed onto right side panel 126 and left side panel 128 in any form or pattern, for example, as shown in Figure IB, along "glue lines" 126a, 126b, 126c, 126d, 126e, 126f, 126g and 126h and along "glue lines" 128a, 128b, 128c, 128d, 128e, 128f, 128g and 128h. According to some embodiments, part of the glue lines might include "cold glue" (a glue of the type that requires relatively long time for curing) and part of the glue lines might include "warm glue" (a glue that is applied while being in a hot state and cures rapidly upon cooling off).

Two opposing panels, front panel 134 and rear panel 136 are disposed on the front and rear sides of bottom panel 102, along front foldable edge 122 and rear foldable edge 124, respectively. Front panel 134 has two flaps: front right flap 138, disposed along front right (FR) foldable line 142 and front left flap 140 disposed along front left (FL) foldable line 144. Rear panel 136 also has two flaps: rear right flap 150, disposed along rear right (RR) foldable line 154 and rear left flap 152 disposed along rear left (RL) foldable line 156.

Upon unfolding and "constructing" (reassembling) the collapsible box from cardboard sheet 100, the adhesive material on right side panel 126 is adapted to bind to the back planes (not shown) of front right flap 138 and rear right flap 150; and the adhesive material on left side panel 128 is adapted to bind to the back planes (not shown) of front left flap 140 and rear left flap 152.

In addition, each of front right flap 138 and rear right flap 150 has a recess, namely, recess 146 and recess 158, adapted to align with gripping holes 130 upon constructing (reassembling) the collapsible box from cardboard sheet 100, and thus enables (allows) the user of the box to insert his/her hands into the holes in order to carry it. Similarly, each of front left flap 140 and rear left flap 152, has a recess, namely, recess 148 and recess 160, adapted to align with gripping holes 130 upon construction of the collapsible box from cardboard sheet 100.

Right side panel 126 includes collapsing line 127, located approximately in the center thereof, essentially perpendicular to foldable edge 114.

Left side panel 128 includes collapsing line 129, located approximately in the center thereof, essentially perpendicular to left foldable edge 120.

Reference is now made to Figure No. 2, that shows schematically a manufacturing line 200 of collapsible boxes (such as boxes manufactured from a pre-shaped cardboard sheets as described hereinabove while referring to figures No. 1A and No. IB), in accordance with several embodiments of the present invention.

Manufacturing (production) line 200 includes five assemblies: preliminary (introduction or input end) assembl y 202, construction assembl y 204, a first conveyor assembly 206, collapsing assembly 208 and a second conveyor assembly, 210. Manufacturing line 200, in accordance with several selected (actual) embodiments, might be a continuous manufacturing line.

The continuous manufacturing line, according to some specific embodiments, might be a production line that includes two or more production units (assemblies), wherein the product of one such unit (assembly) is sequentially transferred to another unit (assembly) of the manufacturing line 200 for further treatment. The production assemblies might be adjacent one to the other. The product of one assembly might be transferred to another assembly in a continuing (advancing) operation and essentially without delay.

Preliminary / input end assembly 202 is used for feeding the line with cardboard sheets (such as cardboard sheet 100 of Figure 1) that are used in the construction of the collapsible boxes. As seen in figure No. 2., cardboard sheet 300 (which is similar to cardboard sheet 100 of Fig. No. 1) is introduced into manufacturing line 200, using preferably motor 500 (or optionally any other means). Cardboard sheet 300a is shown in an already further advanced point in the manufacturing line 200 than cardboard sheet 300. Preliminary (Input End) assembly 202 also includes glue pump 510 (cold and/or warm glue) and glue dispenser 520 adapted, for example, to apply glue (cold and/or warm), according to a predetermined pattern, on right side panel 426 and left side panel 428 of cardboard sheet 300a (similar to right side panel 126 and left side panel 128 of cardboard sheet 100 of figure No. 1). The application of glue might be performed during the progression of the cardboard sheets towards construction assembly 204.

After the application of glue, the cardboard sheets are moved to construction assembly 204 which is adapted to fold and assemble (such as connect, glue, tape or the like) the cardboard sheets (such as cardboard sheets 300a, 300b, 300c, 300d and 300e) so as to form the constructed boxes 600, having the desired design and strength. Detailed view of preliminary / input end assembly 202 and construction assembly 204 is found in Figure 3, hereinbelow.

The constructed boxes are then transferred by first conveyor assembly 206 to collapsing assembly 208 which is adapted to collapse the constructed boxes 600 and to convert them into collapsed boxes 700.

Collapsing assembly 208 includes collapsing mechanism 602 adapted to grasp one of constructed boxes 600 and collapse it. The same collapsing mechanism 602 is also shown grasping one of the constructed boxes 600 (labeled as 602') and in a closed position, collapsing the box (labeled as 602"). Detailed view of collapsing assembly 208 is found in figure No. 4, hereinbelow.

Collapsed boxes 700, which are now reduced in volume, are then transferred by second conveyor assembly 210 to piling, storage, and/or shipment. Due to their reduced form, collapsed boxes 700 can be conveniently piled at ease, stocked or shipped - and afterwards, prior to their use for packaging or carrying various objects, they can readily be reconstructed back to regular boxes - manually or by using automated processes.

Figure No. 3 shows a closer view of preliminary (input end) assembly 202 and construction assembly 204 of manufacturing line 200 shown in Fig. No. 2. Cardboard sheet 300 (which is similar to cardboard sheet 300 of Fig. No. 2 and to cardboard sheet 100 of Figure 1) is inserted/ fed into manufacturing line 200 (not fully shown), using motor 500 (or optionally any other means). Cardboard sheet 300a is shown already at a further advanced stage in the manufacturing line than cardboard sheet 300. Preliminary / Input End assembly 202 also includes glue pump 510 (cold and/or warm glue) and glue dispenser 520 adapted to apply glue (cold and/or warm), for example, according to a predetermined pattern, on right side panel 426 and left side panel 428 of cardboard sheet 300a (similar to right side panel 126 and left side panel 128 of cardboard sheet 100 of figure No. 1), wherein the arrow on cardboard sheet 300a indicates the direction of the progression of the cardboard sheets. The application of glue might be performed during the progressing run of the cardboard sheets towards construction assembly 204.

After the application of the glue, the cardboard sheets are moved to construction assembly 204 which is adapted to fold and glue the cardboard sheets (such as cardboard sheets 300 and 300a) so as to form the constructed boxes 600, having the desired design and strength. Cardboard sheet 300b is showing within construction assembly 204 when pressing device (or in other word- plunger) 530 presses downwards against bottom panel 102b (not shown). Pressing device 530 comprises a bottom platform 532 and two side platforms 533 essentially perpendicular to bottom platform 532.

Pressing device 530 is adapted to linearly move in a downwards direction while pressing bottom platform 532 against bottom panel 102b of cardboard sheet 102b.

Pistons 534 located in the vicinity of front right flap 138b, front left flap 140b, rear right flap 150b and rear left flap 152b are adapted to push front right flap 138b, front left flap 140b, rear right flap 150b and rear left flap 152b upwards in a direction opposing the pressing direction of pressing device 530 to conform cardboard sheet 300b to the box shape dictated by box model 532.

Cardboard sheet 300c is depicted after compressing and fitting the flaps. Cardboard sheet 300d shows the next step, which can also be performed simultaneously with the previous step (compression and fitting), that includes pushing the back surfaces of right side panel 426 and left side panel 428 towards the center of the box and tightening the glue. This is being performed by tightening device 536.

Professionals in the field will recognize that a rather characteristic feature of construction assembly 204 is that it reconstructs the box while implementing a continuance downwards directed movement of pressing device (plunger) 530 that continually engages the pre-fabricated and already glue applied cardboards sheet.

The result is the box, shown as constructed box 300e. Constructed box 300e includes: bottom panel 402 (similar to bottom panel 102 of Figs. 1A and IB), having right set of collapsing lines 404 and left set of collapsing lines 406 (not shown, but are similar to right set of collapsing lines 104 and left set of collapsing lines 106 of Figs. 1A and IB), front panel 434 and rear panel 436 (similar to front panel 134 and rear panel 136 of Figs. 1 A and IB), right side panel 426 and left side panel 428, rear right (RR) foldable line 454 (similar to rear right (RR) foldable line 154 of Figs. 1A and IB), rear left (RL) foldable line 456 (similar to rear left (RL) foldable line 154 of Figs. 1A and IB), front right (FR) foldable line 442 (similar to front right (FR) foldable line 142 of Figs. 1A and IB), and front left (FL) foldable line 444 (similar to front left (FL) foldable line 144 of Figs. 1A and IB).

Reference is now made to Figure No. 4. Fig. No. 4 shows schematically the first conveyor assembly 206, collapsing assembly 208 and second conveyor assembly 210 manufacturing line 200 of Figure 2, in accordance with some embodiments of the invention.

Constructed boxes 600, which are formed by the process described in detail in

Figure 3 (cardboard sheets 300a, 300b, 300c, 300d and 300e), are transferred by first conveyor assembly 206 to collapsing assembly 208 which is adapted to collapse the constructed boxes 600 (similar to constructed box 300e) and to convert them into collapsed boxes 700.

Collapsing assembly 208 (also shown in Figure No. 5) includes two collapsing mechanisms 602 adapted to grasp a constructed box 600 (that has reached the end of conveyor assembly 206) at the two sides of the constructed box (at right side panel 426 and left side panel 428) and collapse it.

The same collapsing mechanisms 602 are also shown in a grasping position, grasping constructed box 600 (the grasping position of collapsing mechanisms 602 is labeled as 602').

The same collapsing mechanisms 602 are also shown in a closed position collapsing the grasped constructed box 600 (the closed position of collapsing mechanisms 602 is labeled as 602").

Each of the two collapsing mechanisms 602 (602a and 602b) include elongated collapsing blades 630a and 630b, respectively, adapted to apply pressure on right side panel

426 and left side panel 428 of constructed box 600 (similar to constructed box 300e of Fig. No. 3), respectively.

For example, according to some embodiments, the pressure may be applied by collapsing blade 630a on right side panel 426 along collapsing line 427 (similar to collapsing line 127 of Figs. 1A and IB), located approximately between (and parallel to), rear right (RR) foldable line 454 and front right (FR) foldable line 442 and collapsing blade 630b on left side panel 428 along collapsing line 429 (similar to collapsing line 129 of Figs. 1A and IB), located approximately between (and parallel to) rear left (RL) foldable line 456 and front left (FL) foldable line 444. According to yet another embodiment, the pressure may be applied by collapsing blades 630b on right side panel 426 along collapsing line 427 and by collapsing blades 630a on left side panel 428 along collapsing line 429.

Upon application of such pressure, constructed box 600 (similar to constructed box 300e of figure No. 3) collapses along collapsing lines 427 and 429, so that collapsing lines

427 and 429 are pushed towards one another, rear right (RR) foldable line 454 and front right (FR) foldable line 442 are brought together, essentially parallel and adjacent to each other and rear left (RL) foldable line 456 and front left (FL) foldable line 444 are also brought together, essentially parallel and adjacent to each other. Upon collapsing, front panel 434 and rear panel 436 are also brought together essentially overlapping each other, and bottom panel 402 folds downwards (and outwards), along right set of collapsing lines 404 and left set of collapsing lines 406. The collapsed box is labeled as collapsed box 700 (shown in detail, in Fig. No. 6). Collapsing assembly 208 further includes flat ramp 640 located near collapsing blades 630a and 630b (for example, as shown in figure 5, near the lower parts of collapsing blades 630a and 630b, the lower parts of collapsing blades 630a and 630b are the parts facing downwards, towards the ground). Flat ramp 640 might be adapted to perform either one or both of the following functions:

a) supporting the bottom panel of the constructed box (such as constructed box 600), which is fed / inserted to the collapsing assembly by the first conveyor assembly (such as collapsing assembly 208 by first conveyor assembly 206 of figures. No. 2 and No. 4), the constructed box may be supported by flat ramp 640 until collapsing blades 630a and 630b are grasping the box (such as in 602' grasping position of collapsing mechanisms 602); and b) when (or shortly before) collapsing blades 630a and 630b are closing to their closed positions 602", flat ramp 640 might be adapted to move aside from the position of carrying (supporting the bottom panel of) the constructed box in order to make room for the bottom panel of the constructed box to collapse downwards (as shown, for example, in Fig. No. 4, wherein upon collapsing of the constructed box bottom panel 402 folds downwards, along a right set of collapsing lines 404 and left set of collapsing lines 406). When collapsing blades 630a and 630b apply pressure on the right side panel and left side panel of the constructed box (for example, right side panel 426 and left side panel 428 of constructed box 600) to induce the collapse, flat ramp 640 may be adapted to push (apply pressure) against the front panel or rear panel of the collapsing box (such as front panel 434 and rear panel 436 of constructed box 600) in order to improve the performance of collapsing the box.

Collapsed boxes 700, which are now flattened and reduced in volume, are then transferred by second conveyor assembly 210 to piling, storage, and/or shipment. Due to their reduced form collapsed boxes 700 can easily be piled, stocked or shipped and afterwards, prior to their use for packaging or carrying various objects they can readily be reconstructed manually or by automated means - becoming once more collapsible cardboard boxes.

Reference is now made to Figure. No. 6, which schematically shows a perspective view of collapsed box 700, in accordance with some embodiments of the invention. Collapsed box 700 includes:

- folded bottom panel 702 (similar to bottom panel 102 of Figs. 1A and IB and bottom panel 402 of Figure 3, but in a folded position), folded along right set of collapsing lines 704 and left set of collapsing lines 706 (similar to right set of collapsing lines 104 and left set of collapsing lines 106 of Figs. 1A and IB and right set of collapsing lines 404 and left set of collapsing lines 406 of Figure 3, but in a folded position);

- front panel 734 and rear panel 736 (similar to front panel 134 and rear panel 136 of Figs. 1 A and IB and front panel 434 and rear panel 436 of Figs. 3) but essentially adjacent to and overlapping each other;

- right side panel 726 and left side panel 728 (similar to right side panel 126 and left side panel 128 of Figs. 1A and IB and right side panel 426 and left side panel 428 of Figs. 3), each folded along collapsing line 727 and collapsing line 729, respectively, (similar to collapsing line 127 and collapsing line 129 of Figs. 1A and IB and collapsing line 427 and collapsing line 429 of Fig. No. 3);

- rear right (RR) foldable line 754 (similar to rear right (RR) foldable line 154 of Figs. 1A and IB and rear right (RR) foldable line 454 of Figure 3), rear left (RL) foldable line 756 (similar to rear left (RL) foldable line 156 of Figs. 1A and IB and to rear left (RL) foldable line 456 of Figure 3), front right (FR) foldable line 742 (similar to front right (FR) foldable line 142 of Figs. 1A and IB and to front right (FR) foldable line 442 of Figure 3), and front left (FL) foldable line 744 (similar to front left (FL) foldable line 144 of Figs. 1 A and IB and to front left (FL) foldable line 444 of Figure 3), such that rear right (RR) foldable line 754 and front right (FR) foldable line 742 are essentially parallel and adjacent to each other, and rear left (RL) foldable line 756 and front left (FL) foldable line 744 are also essentially parallel and adjacent to each other; and

- four foldable edges: right foldable edge 714 (similar to right foldable edge 1 14 of Figs. 1A and IB), left foldable edge 720, (not shown, similar to left foldable edge 120 of Figs. 1A and IB), front foldable edge 722 (similar to front foldable edge 122 of Figs. 1A and IB), and rear foldable edge 724 (not shown, similar to rear foldable edge 124 of Figs. 1A and IB), wherein, right foldable edge 714 and left foldable edge 720 essentially form a V shape.

Furthermore, in view of what was described above while referring to the accompanying figures, any professional would understand that in the invention presented above, it is also described and assimilated an aspect of a general method for continuously manufacturing collapsible cardboard boxes. The method includes the steps of - Continuously feeding a construction assembly (such as 204, see Fig. No. 2) with discrete prefabricated cardboard sheets (such as cardboard sheets 300 and 300a, ibid) having collapsing lines; and

assembling the cardboard sheets into constructed boxes within the construction assembly while continuously moving the discrete prefabricated cardboard sheet to be assembled in a linearly downward directed movement; and

Inserting the constructed boxes (such as 300e) into a collapsing assembly (such as 208); and

within the collapsing assembly, sequentially (one by one) grasping the constructed boxes at two opposing side panels thereof and applying pressure on the box's two opposing side panels, such as to collapse the grasped constructed boxes along its collapsing lines.

The method may be further characterized by additional optional features, such as -

The step of assembling the cardboard sheets into constructed boxes within the construction assembly, might comprise:

moving downwards a pressing device (or in other words - a plunger), (such as pressing device 530), comprising a bottom platform (such as 532) and two side platforms (533) essentially perpendicular to said bottom platform, wherein moving downwards the pressing device is performed while continually engaging the pre-fabricated cardboard (for example - by pressing the bottom platform against a bottom panel of the cardboard sheet); and

Pushing the flaps of the cardboard sheet upwards to construct (form) the cardboard sheet to a box shape; and

pressings the panels of the cardboard sheet against two side platforms of the pressing device, and tightening the side panels to the side flaps to form the constructed box, wherein one or more of the side panels are (optionally), at least partially pre-covered with an adhesive material.

The application of the adhesive material may be performed on the side panels of the cardboard sheets prior to assembling the cardboard sheets into constructed boxes (e.g. - a combination of strips of "hot-melt" quick curing glue for keeping the just constructed box from dismantling along side strips of "cold" type of glue that required an extended time and pressure for curing). The method might be further characterized by additional optional features, namely -

The step of grasping the constructed box at two opposing side panels thereof and applying pressure on the two opposing side panels may comprises:

horizontally moving two collapsing blades (such as 630a and 630b) against each other along a common axis, to simultaneously grasp and apply pressure along collapsing lines pre-formed on the two opposing side panels of the constructed box.

A flat ramp (such as 640) can be utilized for supporting the bottom of a constructed box upon inserting the constructed box into the collapsing assembly; and

The flat ramp might be moved aside once the constructed box is grasped, thus enabling the collapsing downwards of the bottom panel of the box, along one or more preformed collapsing lines.

The method may further comprise a step of applying pressure against a front panel or a rear panel of the collapsing box in order to facilitate the collapsing of the constructed box.

Therefore, in view of the preferred embodiment as described hereinabove with reference to the accompanying figures, any professional will appreciate that the continuous production line for the manufacturing of collapsible cardboard boxes, the cardboard sheet adapted to be used for the construction of a collapsible box in such continuous production line, and the method for continuously manufacturing collapsible cardboard boxes (as described), constitute an appropriate and innovative solution to the challenges of providing a continuous production line for the manufacturing of collapsible boxes that will enable high speed producing collapsible cardboard boxes (namely manufacturing collapsible (foldable) cardboard boxes by automated processes) that have, on the one hand, high strength characteristics, and on the other hand, are easy to pack, transport and unfold (re-construct) without requiring the use of additional securing means at the end user level.

The invention has, so far, been described using various detailed descriptions of embodiments thereof, that are provided by way of example and are not intended to limit the scope of the invention. The described embodiments might comprise different features, not all of which are required in all the embodiments variants of the invention. Some embodiments of the invention utilize only some of the features or possible combinations of the features. Variations of embodiments of the invention that are described and embodiments of the invention comprising different combinations of features noted in the described embodiments would occur to professionals skilled in the art. It to be noted that the scope of the invention is limited only by the claims and that the claims be interpreted to include all such variations and combinations.

Claims

CLAIMS What is claimed is:

1. A continuous production line for manufacturing collapsible cardboard boxes, wherein the production line comprises:

a construction assembly adapted to be continuously fed with discrete prefabricated cardboard sheets havin g collapsing lines, wherein said construction assembly is further adapted to assemble said cardboard sheets into constructed boxes; and a collapsing assembly adapted to collapse said constructed boxes along said collapsing lines. Said collapsing assembly comprises:

at least two collapsing mechanisms adapted to grasp a constructed box at two opposing side panels thereof and to apply pressure on said two opposing side panels, such as to collapse said grasped constructed box along said collapsing lines.

2. The production line of claim 1, wherein said construction assembly also comprises: a linearly movable pressing device comprising a bottom platform and two side platforms essentially perpendicular to said bottom platform, wherein said pressing device is adapted to move downwards while pressing said bottom platform against a bottom panel of said cardboard sheet; and

at least one piston means adapted to push side flaps of said cardboard sheet upwards to form said cardboard sheet into a box shape;

at least one tightening device comprising at least two platforms adapted to press said side panels of said cardboard sheet against said two side platforms of said pressing device, and tighten said side panels unto said side flaps so as to form said constructed box, wherein one or more of said side panels are, optionally at least, partially covered with an adhesive material.

3. The production line of claim No. 2, further comprising a Preliminary / Input End assembly adapted to continuously feed said discrete prefabricated cardboard sheets to the construction assembly.

4. The production line of claim No. 3, wherein said preliminary / input end assembly comprises an array of glue dispensers adapted to apply glue on said side panels of said cardboard sheets.

5. The production line of claim No. 4, wherein said array of glue dispensers comprises at least one hot melt glue dispenser and at least one cold glue dispenser.

6. The production line of claim No. 1, wherein each of said two collapsing mechanisms comprises:

a collapsing blade, adapted to grasp and apply pressure along collapsing lines preformed on a side panel of said constructed box - wherein said two collapsing mechanisms are adapted to move horizontally against each other along a common axis to simultaneously grasp and apply pressure along said collapsing lines pre-formed on said two opposing side panels of said constructed box.

7. The production line of claim No. 6, wherein said collapsing assembly further comprises a flat ramp adapted to:

support said bottom of said constructed box upon inserting said box into said collapsing assembly; and

move aside once said two collapsing mechanisms that grasped said box, thus enable said collapsing downwards action of said bottom panel of said box, along one or more pre-formed collapsing lines.

8. The production line of claim No. 7, wherein said flat ramp is further adapted to apply pressure against a front panel or a rear panel of said collapsing box in order to facilitate collapsing said constructed box.

9. The production line of claim No. 1, further comprising a first conveyor assembly adapted to transfer said constructed boxes formed by said construction assembly to said collapsing assembly.

10. The production line of claim No. 1, further comprising a second conveyor assembly adapted to transfer said collapsed boxes collapsed by said collapsing assembly to piling, storage, shipment or any combination thereof.

11. The production line of claim No. 1 , wherein the cardboard sheet of material comprises:

a folded bottom panel adapted to be folded, upon collapsing of the constructed box, along a right set of collapsing lines and a left set of collapsing lines; and a front panel and a rear panel adapted to essentially overlap one another, upon collapsing of said constructed box; and

a right side panel and a left side panel each comprising collapsing line essentially at their center; and

a rear right (RR) foldable line, rear left (RL) foldable line, front right (FR) foldable line, and front left (FL) foldable line, such that, when the constructed box collapses, said rear right (RR) foldable line and said front right (FR) foldable line are essentially parallel and adjacent to each other, and said rear left (RL) foldable line and said front left (FL) foldable line are essentially parallel and adjacent to each other; and

four foldable edges: a right foldable, a left foldable edge, a front foldable edge, and a rear foldable edge, wherein, when said constructed box collapses, said right foldable edge and said left foldable edge form essentially a V shaped pattern.

12. A cardboard sheet adapted to be used for constructing a collapsible box in a continuous production line for manufacturing collapsible cardboard boxes in accordance with claim No. 1, wherein said cardboard sheet comprises one or more collapsing lines in a bottom, side panel, front panel, rear panel or any combination thereof.

13. The cardboard sheet material of claim 12, comprising:

a folded bottom panel adapted to be folded, upon collapsing of said constructed box, along a right set of collapsing lines and a left set of collapsing lines; and

a front panel and a rear panel adapted to essentially overlap one another, upon collapsing of said constructed box; and

a rear right (RR) foldable line, rear left (RL) foldable line, front right (FR) foldable line, and front left (FL) foldable line, such that, upon said constructed box collapses, said rear right (RR) foldable line and said front right (FR) foldable line are essentially parallel and adjacent to each other, and said rear left (RL) foldable line and said front left (FL) foldable line are essentially parallel and adjacent to each other; and four foldable edges: a right foldable, a left foldable edge, a front foldable edge, and a rear foldable edge, wherein, when said constructed box collapses, said right foldable edge and said left foldable edge essentially form a V shaped pattern

14. A method for continuously manufacturing collapsible cardboard boxes, wherein this method comprises:

continuously feeding a construction assembly with discrete prefabricated cardboard sheets having collapsing lines;

assembling said cardboard sheets into constructed boxes within said construction assembly while continuously moving above cited discrete prefabricated cardboard sheets to be assembled, in a linearly downward directed movement; and

inserting said constructed boxes into a collapsing assembly; and

within said collapsing assembly, sequentially grasping said constructed boxes at two opposing side panels thereof and applying pressure on said two opposing side panels, such as to collapse said grasped constructed boxes along said collapsing lines.

15. The method of claim No. 14, wherein said step of assembling said cardboard sheets into constructed boxes within said construction assembly comprises:

a pressing device moving downwards comprising a bottom platform and two side platforms essentially perpendicular to said bottom platform, wherein moving downwards said pressing device is performed while pressing said bottom platform against a bottom panel of said cardboard sheet;

pushing side flaps of said cardboard sheet upwards to conform the cardboard sheet to a box shape; and

pressings side panels of said cardboard sheet against two side platforms of said pressing device, and tightening said side panels to said side flaps to form the constructed box, wherein one or more of said side panels are optionally at least partially covered with an adhesive material.

16. The method of claim 14, further comprises a step of applying glue on said side panels of said cardboard sheets prior to assembling said cardboard sheets into constructed boxes.

17. The method of claim 14, wherein the step of grasping said constructed box at two opposing side panels thereof and applying pressure on said two opposing side panels comprises:

horizontally moving two collapsing blades against each other along a common axis, to simultaneously grasp and apply pressure along collapsing lines pre-formed on said two opposing side panels of said constructed box.

18. the method of claim 17, further comprising:

a step of using a flat ramp, supporting the bottom of a constructed box upon inserting said constructed boxes into said collapsing assembly; and

moving said flat ramp aside once said constructed box is grasped, thus enabling the collapsing downwards of the bottom panel of said box, along one or more preformed collapsing lines.

19. the method of claim 18, further comprising a step of applying pressure against a front panel or a rear panel of the collapsing box in order to facilitate a collapsing action of said constructed box.