Abstract:
A case forming machine for assembling erected cases from blanks including a stacking means configured for receiving a supply of blanks, an opening and forming means for erecting the blanks and ejecting erected cases, and the machine is constructed and arranged so that the stacking means is configured for biasing the supply of blanks in a first direction and the forming means is configured so that the blanks are ejected in a second direction. The machine also includes a frame, a stacking apparatus for holding a supply of blanks, an opening and forming apparatus, a vertical blank guide configured to advance the supply of blanks in a first direction, a vertical blank mover for transporting blanks from the stacking apparatus to the opening and forming apparatus, a first minor flap folder and a second minor flap folder, a first major flap folder and a second major flap folder; and a case advancement mechanism attached to the opening and forming apparatus, the case advancement mechanism configured to advance cases in a second direction along the opening and forming apparatus.

Description:
BACKGROUND OF THE INVENTION 
     The present invention relates to a box or case forming machine, and more particularly relates to a case forming machine for use where limited floor space is available. 
     Case forming machines are commonly used for assembling erected cases from flat blanks. Generally, flat blanks are stacked within a stacking apparatus, or hopper, which in turn feeds the blanks to an assembling deck. An assembling apparatus opens the blank to form an open quadrilateral tube, and subsequently closes and seals the bottom flaps. The erected case is then ejected from the machine, ready for use, such as filling with manufactured products. These cases are central to the packaging, shipping and storing needs of commercial enterprises. However, conventional case forming machines are relatively large; and their footprints can consequently consume large areas of valuable floor space in plants, factories, store rooms, and/or other areas in businesses which utilize these machines. 
     Another disadvantage of conventional case forming machines is that they are frequently powered by electrical motors and, as a consequence, are disruptively loud. Often, these larger case formers are not cost efficient because they are expensively built for high volume output which exceeds the needs of smaller businesses. 
     Smaller case forming machines are known in the art, wherein the hopper or stacking apparatus is positioned either adjacent to the deck and assembly apparatus, or is vertically displaced from the deck and assembly apparatus. However, while these machines are smaller in size compared to conventional case forming machines, neither orientation provides a minimal footprint. For example, U.S. Pat. No. 5,393,291 (Wingerter) represents a typical case forming machine. The hopper is positioned adjacent to a case forming deck. Gravity fed, vertically oriented blanks are opened directly from the hopper by a case puller arm that raises out of the assembly deck, grips the blank, and retracts back into the deck, opening the blanks. The hopper is mounted above the ground, but because the hopper feeds the blank onto the deck in the same direction in which the finished product is ejected, the machine still consumes an undue amount of space. 
     U.S. Pat. No. 4,915,678 (Morita) discloses a case forming machine having a similar problem. Morita teaches a hopper positioned adjacent to and above the deck and assembly apparatus, which is further inclined in the direction of the deck and assembly apparatus so that the blanks are gravity fed. This still causes undue consumption of overhead space. 
     It is an object of the present invention to provide an improved case forming machine having low output volume, which also minimizes consumption of floor and overhead space. 
     It is another object of the present invention to provide an improved case forming machine that is quiet and operates simply at slow speed. 
     SUMMARY OF THE INVENTION 
     The above-listed objects are met or exceeded by the present case forming machine, featuring a stacking apparatus configured to orient blanks in a first direction and an opening and forming apparatus configured to eject formed cases in a second direction. The present case forming machine contains a stacking apparatus biased in the first direction by a vertical blank guide mounted to a chain assembly. Blanks are transported vertically to the opening and forming apparatus by a vertical blank mover. The opening and forming apparatus is coupled to a pneumatic cable cylinder and includes a vacuum arm for opening the blanks and a case advancement mechanism to advance cases in the second direction. The stacking apparatus and opening and forming apparatus and vertically displaced from one another and generally parallel to one another, so that the overall configuration of the machine is a generally sideways U-shape. 
     More specifically, the present invention provides a case forming machine including a stacking apparatus configured for receiving a supply of blanks, and an opening and forming apparatus for erecting the blanks and ejecting erected cases. The machine is constructed and arranged so that the stacking apparatus is configured for biasing the supply of blanks in a first direction and the opening and forming apparatus is configured so that the blanks are ejected in a second direction. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side elevational view of the preferred embodiment of the present case forming machine; 
     FIG. 2 is an overhead plan view of the present case opening apparatus; 
     FIG. 3 is a sectional view taken along the line  3 — 3  of FIG.  1  and in the direction generally indicated; 
     FIG. 4 is a fragmentary side elevational view of the machine of FIG. 1; and 
     FIG. 5 is a fragmentary side elevational view of the machine of FIG. 1 showing a later case forming step than shown in FIG.  4 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now to FIG. 1, the preferred embodiment of the present case forming machine is generally designated as  10 . The machine  10  includes a stacking apparatus  12 , or hopper, configured for receiving a supply of blanks, or collapsed cases,  14 , and an opening and forming apparatus  16  for erecting the blanks into formed cases  20  and ejecting the formed cases. The stacking apparatus  12  is biased in a first direction  22  toward a vertical blank mover  24  by a vertical blank guide  26 , and the opening and forming apparatus  16  is biased in a second direction  28  by a pneumatic cable cylinder  30 . It is also contemplated that other fluid powered cylinders, such as hydraulic cylinders, could also be employed. 
     The stacking apparatus  12  is vertically displaced from the opening and case forming apparatus  16 , and the generally rectangular dimensions of each are generally aligned to be parallel with one another. In this way, the stacking apparatus  12  is stacked on top of the opening and forming apparatus  16  to form a generally sideways U-shaped frame  31 . 
     In the preferred embodiment, the supply of blanks  14  is vertically stacked in the stacking apparatus  12 , with upper flaps  32  open toward the ceiling and lower flaps  34  open toward the ground. The drive for the stacking apparatus  12  is a standard stacking apparatus drive known to one of ordinary skill in the art. For example, the hopper assembly for a conventional case forming machine, Little David® Model CF-40T, manufactured by Loveshaw, South Canaan, Pa., employs this type of drive system. The stacking apparatus  12  includes the vertically-oriented biasing member, or vertical blank guide  26 , which orients the supply of blanks  14  vertically. The vertical blank guide  26  is driven on a chain assembly  36 , which advances the supply of blanks  14  in increments equal to the width of one unassembled blank in the first direction  22 . 
     The vertical blank mover  24 , which is preferably a vacuum arm mounted to a vertical track  38  and contains a plurality of vacuum cups  40 , secures and vertically transports a blank  14  from the stacking apparatus  12  to the opening and forming apparatus  16 . The vertical blank mover  24  is vertically disposed between the stacking apparatus  12  and the opening and forming means  16 . A limit switch  42 , disposed adjacent to the vertical blank mover  24 , monitors the removal of a single blank  14  from the stacking apparatus  12 , and signals the vertical blank guide  26  to consequently advance the supply of blanks  14  each by an increment of one blank thickness in the first direction  22 . 
     The vertical blank mover  24  pulls a blank  14  downward from the stacking apparatus  12  to the opening and forming apparatus  16 . A feature of the present invention is that neither the orientation nor the configuration of the blank  14  is altered during transport. The blanks  14  in both the stacking apparatus  12  and within the opening and forming apparatus  16  have two sides. 
     As depicted in FIG. 2, when viewed from above, a first side  46  of the blank  14  faces the second direction  28 , and contains the leading case face  48  and the first case side  50 , continuous with one another and divided by a score  52  which will later form a corner of the erected case  20  (FIG.  5 ). A second side  54  of the blank faces the first direction  22 , and contains the lagging case face  56  and the second case side  58 , continuous with one another and divided by a score  52 ′ which will later form a second corner of the erected case  20 . 
     While in the stacking apparatus  12 , and during its transport to the opening and forming apparatus  16 , the first side  46  of the blank  18  is maintained in an orientation toward the second direction  28 . Likewise, the second side  54  of the blank  14  is maintained in its orientation in the first direction  22  in the stacking apparatus  12  and during its transport to the opening and forming apparatus  16 . This is advantageous in that less space is required for the transport of the blanks  14 , and complex movements during transport are eliminated. Furthermore, the blanks  14  can be aligned and arranged within the stacking apparatus  12  and subsequently transported to the opening and forming apparatus  16  without disrupting the arrangement or alignment of the blanks. 
     In the preferred embodiment, the opening and forming apparatus  16  is conventional and commonly known to one of ordinary skill in the art. For example, a suitable opening and forming apparatus  16  is found in the Little David® Model CF-40T case former manufactured by Loveshaw of New Canaan, Pa. As depicted in FIGS. 2 and 3, at least one vacuum arm  60  pivots toward the blank  14 . Ideally, the vacuum arm  60  contains one or more vacuum cups  40 . When the vacuum arm  60  contacts the first case side  50  of the blank  14 , the arm  60  is energized to create a vacuum bond between the blank  14  and the vacuum cups  40 . Subsequently, the vacuum arm  60  pivots back to its original position, causing the blank  14  to open into an open-ended case  20 . The leading case face  48  of the open case  20  now faces the second direction  28 , and the lagging case face  56  of the open case faces the first direction  22 . 
     Referring now to FIG. 3, once the blank  14  is in the open position, a minor flap folding apparatus, generally designated  63 , is activated and consists of a first minor flap folder  64  and a second minor flap folder  66 . The flap folders  64 ,  66  are also standard and well known to those skilled in the art. Again, for example, a commercially available case forming machine, the Little David® Model CF-40T, utilizes a suitable minor flap folding device. In the preferred embodiment, the minor flap folders  64 ,  66  are pneumatic devices, with first and second folding cylinders  68 ,  70  respectively, fixedly mounted to a base portion  72  of the frame  31  of the case forming machine  10 . However, other known fluid powered cylinders, such as hydraulic cylinders, are contemplated. 
     The first and second minor flap folders  64 ,  66  are opposing hinged structures. More specifically, the first minor flap folder  64  has a top surface  76  and a bottom surface  78 , and the second minor flap folder  66  likewise has a top surface  80  and a bottom surface  82 . The minor flap folders  64 ,  66  depend vertically when they have not been activated, having the first top surface  76  parallel to, horizontally displaced from, and facing the second top surface  80 . When activated, the folding cylinders  68 ,  70  extend to push the flaps  84  upward approximately 90°, so that the first minor flap folder  64  and the second minor flap folder  66  are generally planar with each other, and parallel to the opening and forming apparatus  16 . This upward arcuate motion causes the minor flap folders  64 ,  66  to contact the minor flaps  84  of the case  20 , and exert a force which closes the minor flaps. 
     Once the minor flaps  84  have been closed, the vacuum cups  40  on both the vertical blank mover  24  and the case opening vacuum arm  60  are deactivated. This deactivation allows the vertical blank mover  24  to return to its original position and the case opening vacuum arm  60  rotates away from the opened case  20 . In turn, the horizontal blank mover assembly, designated generally at  86 , is energized. 
     FIGS. 4 and 5 depict the horizontal blank mover assembly  86 , which contains a slide  88  coupled to the pneumatic cable cylinder  30 , and a case advancement mechanism, such as a sliding case pusher  90 . As is well known in the art, the horizontal blank mover assembly  86  is conventional and commonly known to one of ordinary skill in the art. For example, a suitable horizontal blank mover assembly  86  found in the Little David® Model CF-40T case former manufactured by Loveshaw of South Canaan, Pa. In the preferred embodiment, the case pusher  90  is mounted to a sliding carriage  92 , which in turn is mounted to both the pneumatic cable cylinder  30  and the slide  88 . The case pusher  90  has a front face  94  that is vertically aligned with the vertical blank mover  24 . Therefore, the front face  94  contacts the lagging case face  56  of the blank  14  when the blank is lowered to the opening and forming apparatus  16 . It is preferred that the length of the pneumatic cable cylinder  30  corresponds to the length of the slide  88 . 
     A valve (not shown) under the direction of a programmable logic controller (PLC) (not shown) activates the cable cylinder  30  once the minor flap folders  64 ,  66  have closed the minor flaps  84 . When activated, the movement of the cable cylinder  30  causes the sliding case pusher  90  to travel linearly in the second direction  28 , which consequently pushes the partially opened case in the second direction  28 , into a side rail assembly  100 . The side rail assembly  100  preferably contains a first side rail  102  and a second side rail (not shown) for maintaining orientation of the case during the remainder of assembly by exerting an equal force on either side, both the first case side  50  and the second case side  54 . An advantage of the side rail assembly  100  is that it also preferably contains a clamping arm  106  (shown schematically) to adjust the width to the side rails  102  to accommodate cases of different sizes. 
     As the blank  14 , which is now referred to as the case  20 , is pushed in the second direction  28 , a pair of major flaps  122  are closed by a major flap folding apparatus  126 , made up of first and second major flap folders  128 . In the preferred embodiment, the first and second major flap folders  128  are stationary upwardly and forwardly converging rods which progressively engage and fold the major flaps  122  as the opened case  20  is pushed in the second direction  28 . As these major flaps  122  are folded over the already folded minor flaps  84 , a center line  130  (best seen in FIG. 3) is defined by the junction between these two major flaps. 
     Progressing in the second direction  28 , a case sealing apparatus, designated generally at  132 , operates to seal the now closed major flaps  122 . In the preferred embodiment, the case sealing apparatus  132  includes a standard case sealing apparatus known to one of ordinary skill in the art. For example, the commercially available case forming machine, Little David® Model CF-40T, utilizes a suitable case sealing apparatus. The present case sealing apparatus  132  includes a roll of adhesive tape  133  and first and second guide rollers  134 ,  136 , which are coupled to one another. 
     As the case  20  progresses in the second direction  28 , the roll of adhesive tape  133  having an exposed strip of adhesive is positioned immediately prior to the first guide roller  134 . This exposed strip contacts and adheres to the case  20  at a lower portion  138  of the leading case face  48 , which is aligned with the center line  130  at the junction of the folded major flaps  122 . Subsequently, the case  20  contacts the first guide roller  134 , the force of which causes the first guide roller and second guide roller  136  to retract, allowing the case  20  to progress over the rollers in the second direction  28 . The progression of the case  20  having tape adhered thereto pulls additional tape from the roll of adhesive tape  133 , and continues application of the adhesive tape down the center line  130 , finishing at a lower portion of the lagging case face  56 . Additionally, a spring mounted cutting apparatus  135  is mounted to the opening and forming apparatus  16  between the first and second guide rollers  134 ,  136 . As the case  20  passes over this apparatus  135 , the weight of the case depresses the apparatus. After the case  20  has cleared the apparatus  135 , it springs upward and cuts the tape. An advantage of this sealing apparatus  132  is that the center line  130  is held in alignment by the side rail assembly  100 , thus allowing precise sealing of the case  20  after opening and formation of the case. 
     The preferred embodiment of the instant invention is advantageous in that it provides a compact case forming machine having a minimal footprint on the factory floor on which it is installed. By vertically displacing the stacking apparatus  12  from the opening and forming apparatus  16 , minimal floor space is consumed. Moreover, by orienting the blanks  14  in the stacking apparatus  12  in the first direction  22 , and configuring the opening and forming apparatus  16  to operate in the second direction  28 , the stacking apparatus and opening and forming apparatus can be stacked. This unique configuration also eliminates complicated movements in the transport of blanks  14  between the stacking apparatus  12  and the opening and forming apparatus  16 . Lastly, by using pneumatic power to operate the machine  10  reduces the level of noise produced by the machine. 
     While a particular embodiment of the present case forming machine has been shown and described, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.