Abstract:
An apparatus for forming packages of pre-cooked meals. The package comprises a tray enclosed at least partially by a card sleeve having top and bottom faces and two opposing side walls. The forming apparatus includes a series of forming tools mounted for movement at spaced intervals and each forming tool is provided for the reception of a sleeve in a blank flattened form. As the sleeve is introduced into the forming tool the sleeve is moved to the erected condition, the tray is inserted in the erected sleeve and the formed package removed from the forming tool.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
   This is an United States Application entitled “Packaging Apparatus” claiming priority to British Application No. 0206151.3 filed 15 Mar. 2002. 
   BACKGROUND OF THE INVENTION 
   The invention to which this application relates is apparatus and a method for erecting a packaging sleeve from a blank, folded substantially flat condition to an in-use condition for subsequent insertion of an article, most typically a tray, therein to form a package. 
   Reference hereonin is made to the insertion of an article in the form of a tray but this reference does not limit the invention for use solely with a tray. In addition reference to a sleeve incorporates many different designs of sleeve, examples of which are provided herein in a non-limiting manner. 
   Particularly, although not necessarily exclusively, the sleeve is what is known as a 5-fold sleeve formed from card and having a top face, bottom face, and two opposed side walls joining said top and bottom faces and with one of the side walls having an intermediate elongate fold line. The sleeve, when erected, defines a passage with an opening at each end thereof into which a tray can be inserted. Typically, two of the fold lines define the corners between the front face and side walls, two fold lines define the corners between the side walls and the bottom face, with the fifth fold line located intermediate the corner fold lines of one of the side walls. When provided in the folded or blank condition as referred to herein, the free ends of the sleeve are already joined together, typically by gluing, in an overlapping manner, said join typically but not always, positioned at or adjacent one of the side walls. 
   Typically, the packages are provided as retail packs, provided to hold a foodstuff such as a frozen or chilled foodstuff for purchase in a retail outlet and subsequently, by removal of the sleeve, and typically an enclosing film, the foodstuff can be eaten or first cooked in the tray at home. 
   Large numbers of said packages are sold on a daily basis and conventionally the packages are formed manually or automatically using appropriate machinery. In each case there is a significant problem in terms of the relatively slow throughput of the packages due to the package forming process and apparatus, if any. If a manual process is used, the sleeve is moved from a blank to an erected form by hand and the tray inserted into the sleeve passage through one of the openings. In an automatic process the sleeve is moved from a blank to an erected form by the provision of mechanical fingers which locate on the bottom face of the blank and pull the same downwards and away from the top face and so move the sleeve into a former into which the tray can then be inserted either manually or by automatic pushers. In one embodiment, the fingers include suction means such as vacuum pads to locate and move the sleeve. 
   Thus, if the process is performed manually, the same is intensive in terms of personnel and, if performed automatically, the process is slow due to the fact that no continuous forming operation occurs. Other automated package forming apparatus is known but tends to relate to the erection of boxes from blanks rather than sleeve blanks and, as such, is not applicable or usable in practical terms as is evidenced by the conventional apparatus and methods currently used for sleeves. One box blank erecting apparatus is disclosed in U.S. Pat. No. 2,900,880 where a box with right angled side faces with respect to the front and bottom faces is formed. 
   SUMMARY OF THE INVENTION 
   The aim of the present invention is to provide a package forming apparatus and forming tool for use therewith, which allows the formation of a package comprising an erected sleeve with an article placed therein and to allow the package to be formed efficiently and reliably while also improving the speed and throughput of the same. 
   In a first aspect of the invention there is provided apparatus for the formation of a package, said package comprising a sleeve having at least top and bottom faces and opposing side walls, and an article which is inserted in the sleeve when in an erected condition to form the package, said sleeve movable between blank and erected conditions and characterised in that said apparatus includes placement means to move a sleeve in a blank condition for placement into a forming tool and said sleeve is moved to the erected condition by insertion of the same into the forming tool, said forming tool mounted for movement on drive means along a path, and once erected, the article is inserted into the sleeve. 
   Typically the formation of the package as described is repeated for successive sleeve blanks as they are removed from a store magazine and the articles are a series of trays including foodstuffs therein and which foodstuffs may be sealed in the tray. 
   In a preferred embodiment the sleeve blanks are moved from the store to be positioned in the forming tool by rotation of the placement means. Typically in the movement the sleeve rotates about at least 180 degrees but more typically at least 240 degrees. 
   Typically the forming tools are mounted in a spaced manner along a drive means, said drive means having a forward path during which the blanks are erected, the article inserted and the package removed, and a return path by which the forming tools are returned to a start position for the reception of a new sleeve blank. 
   In one embodiment the drive means has a linear forward path and a return path. 
   Preferably, a number of said forming tools are located at spaced intervals on the drive means for linear movement. Typically, upon the removal of the formed package, each forming tool is moved to a start position to repeat the forming operation for the next sleeve blank inserted therein, and so on, thus providing a continuous package forming apparatus. 
   Typically, the sleeve blanks are held in a store magazine for feeding to the rotational placement apparatus which presents each blank in turn for insertion into a respective forming tool, as it passes the location for the presentation of the blank by the placement tool. 
   Typically, the drive mechanisms for the rotational placement apparatus and the forming tool drive means are mechanically linked so as to be synchronised, thereby ensuring that each sleeve blank is inserted into a respective forming tool in the required position and path as the forming tools move. It is preferred that the forming tools move continuously or at least move continuously in the vicinity of the placement means as the relative movement between the placement means in a first direction and the forming tool cause the commencement of erection of the sleeve blank. 
   Typically, the sleeve blank is inserted into the forming tool with the intermediate fold line folded to lie outwardly of the blank such that the side surface with the intermediate fold line first contacts with the forming tool. 
   In one embodiment, erection fingers and/or a bar are provided to further assist the erection of the sleeve blank, and retain the sleeve in the forming tool. In one embodiment said fingers may make first contact with the blank prior to the forming tool. 
   In order to aid the removal of the formed package from the forming tool, removal means may be provided to locate with the formed package and to carry the same away from the forming tool at the end of the package forming path. In a preferred embodiment, at least one, but preferably two, driven removal belts are provided and positioned with respect to the forming tool such that as the package in the tool reaches the belts, the belts contact and support the moving package in a first direction as the forming tool turns on the drive means to commence its return path. The formed packages can then be moved to a packing or storage location by the drive belts. Further removal means in the form of mechanical fingers may also be provided. 
   Typically the forming tool includes a base, and first and second opposing side walls, said side walls lying perpendicular to the direction of travel of the forming tools on the drive means. In one embodiment the rear side wall, as the forming tool is moving along the forward path, is first contacted by the sleeve blank from the placement means and, yet further by the side wall of the blank which includes the intermediate fold line. 
   Typically the rear side wall can be formed to suit particular sleeve forming requirements and can include any or any combination of an angled portion and/or vertical portion, and/or a lip at the free edge of the said side wall. 
   Typically the forming tool can be attached to the drive means by releasable location means mounted on a plate, said plate having location means for location with respect to the drive means plate and wherein one of the location means is slotted for location on a peg by movement of the plate in a first direction, and the second location means is slotted so as to allow location on a second peg by movement in a second direction by rotation about the first peg. Typically the second peg is provided to receive locking means so as to retain the forming tool in location. 
   Typically the forming tools are provided in sets, each set provided to allow the formation of a particular sleeve design. 
   In one embodiment the article inserted into the erected sleeve is a tray, said tray, with foodstuffs therein, moved into the sleeve while the sleeve is retained in the forming tool. In one embodiment the tray is manually inserted. Alternatively and preferably, automatic feed means are provided to allow the trays to be moved to be inserted into the erected sleeves in a direction perpendicular to the movement of the forming tools along the drive means. Preferably the insertion occurs as the forming tools continue to move along the forward path of the drive means and yet further the movement means for the tray are synchronised with the movement of the forming tools on the drive means. 
   In a further aspect of the invention there is provided apparatus for the formation of a package, said package comprising a sleeve having at least top and bottom faces and opposing side walls, and an article which is positioned in the sleeve when in an erected condition to form the package, said sleeve movable between blank and erected conditions and characterised in that said apparatus includes a store of sleeves in a blank form, placement means to select and move a sleeve from the store for placement into a forming tool, said forming tool mounted for movement along a path and said blank retained by the placement tool as contact is made with the forming tool with relative movement between the forming tool and placement means to at least partially erect the sleeve whereupon the sleeve is released by the placement means and positioned in an erect form in the forming tool whereupon the tray is placed to lie within the sleeve and the formed package removed from the forming tool. 
   In accordance with a further aspect of the invention there is provided a forming tool, said tool provided to allow the movement of a sleeve from a blank to an erected form therein, said forming tool having a mounting plate, a base and opposing side walls. 
   Typically, at least one of the side walls has at its upper edge, a lip portion, said lip portion acting as a locating and limiting means for movement of one of the side walls of the sleeve in a direction away from the forming tool and thereby serving to locate the sleeve blank in position during and after formation. Typically, the side wall which has the lip portion is the same side wall which is first contacted by the sleeve blank as it is introduced into the forming tool. 
   In one embodiment, the side walls of the forming tool are angled to match the angles at which the sleeve blank side walls are to lie when erected. The forming tool can either be adjustable to allow parts of the same to be adjusted to suit the particular design of the sleeve to be formed therein or, alternatively, the forming tools are removable from the drive means to allow the appropriately shaped forming tools to be positioned on the drive means to suit the sleeve to be formed at that time. Thus it will be appreciated that any one forming apparatus can be provided to be used with as many sets of forming tools as required to allow the apparatus to be used to form the sleeve blanks of different design. 
   Preferably the width of the forming tool is less than the width of the package so as to be narrower and allow end portions of the sleeve or tray to protrude. These ends can, if required, be picked up on removal means such as a set of belts to remove the formed package from the tool. 

   
     DESCRIPTION OF THE DRAWINGS 
     A specific embodiment of the invention is now described with reference to the accompanying drawings, wherein: 
       FIG. 1A-E  illustrate packages formed in accordance with the invention in perspective in various embodiments; 
       FIG. 2  illustrates apparatus in accordance with the invention; 
       FIG. 3  illustrates a detailed view of one sleeve being formed in accordance with the invention; 
       FIG. 4  illustrates the forming tool of the invention in one embodiment; and 
       FIGS. 5   a–c  illustrate further forms of the forming tool. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Referring firstly to  FIG. 1A-E , there are illustrated several embodiments of a package  2  formed in accordance with the invention. The package, in each case, comprises a tray  4  retained at least partially within a sleeve in an erected form  6 . 
   The sleeve, when erected, comprises a top face  8 , bottom face  10  and two side walls  12 ,  14  which are opposing and which join the top and bottom faces  8 ,  10 . A series of fold lines are provided and located such that fold lines  15 ,  16  define the corners between the top face and side walls, fold lines  18  and  20  define the corners between the bottom face and side walls and fold line  22  is located intermediate the edges of one of the side walls  12 ,  14  as shown. The fold line  22  is provided to aid the formation of the sleeve from the blank condition which is an almost completely flattened condition, as shown in  FIG. 3 , but with the free edges  19 , 21  attached together, and the erected condition shown in  FIG. 1A-E . 
   The difference between the packages of  FIGS. 1A–E  is the different form of the sleeve, with the sleeve design in FIGS.  1 B,D,E of the type referred to as a band. Reference herein to a sleeve should be taken as referring to the designs shown and also any other sleeve designs, each of which can be erected and packed utilizing this invention. 
   The provision of this form of package, typically to allow foodstuffs held in the tray to be purchased and for the foodstuff type to be indicated on the printed material on the sleeve, is well known and the present invention relates to the formation of the packages of this type in an efficient and quick way compared to conventional apparatus and methods. 
   The apparatus for use in accordance with one embodiment of the invention is illustrated in a schematic manner in  FIG. 2 . The apparatus comprises a rotatable placement means located with store means  26 . The sleeve blanks are moved one at a time from the store means  26  in the direction indicated by arrow  25  by the placement means (not shown). The placement means typically include a suction cup which contacts the surface  8  and then rotates the blank as shown by arrow  25  through typically 240° to be deposited on a forming tool. With the sleeve blanks formed inasmuch that no further gluing is required the same are carried by the placement means in a flat form. A plurality of said forming tools  30  are provided on a drive means  32  which causes the forming tools  30  to move along a forward path as indicated by arrow  34  and then a return path, as indicated by arrow  36 , to reach the start position  38  for the reception of a further sleeve blank. The actual erection of the blank in the forming tool is shown in more detail in  FIG. 3  and once the sleeve is erected in the forming tool as illustrated in forming tools  30 ′, the tray  4  can be inserted through the opening  40  defined by the side walls  12 ,  14  and top and bottom faces  8  and  10  so as to be inserted into the sleeve in the erected form and hence form the package. 
   At the end of the forward path indicated by arrow  34  each package  2  leaves the forming tool  30  as indicated by arrow  42  for subsequent collection and loading for transit to a retail premises. 
   If the sleeve is relatively narrow, in the form of a band such as in  FIGS. 1B , D, E then the machine will erect these bands as with all designs of sleeve as described and as the tray is pushed through the aperture defined by the erected band, it is moved to contact a back stop. The band can be held on two locators in the forming tool to ensure it stays central in the tool as the tray is pushed through. The removal belts then pick up on the tray that is protruding out of the ends of the tool to remove it from the tool. 
   Turning now to  FIG. 3 , there is illustrated in schematic fashion a detailed use of the apparatus and forming tool in accordance with the invention to form the erected sleeve  6 . The rotatable placement means  24  provides the sleeve blank in the flattened form as indicated, by the reference numeral  44  and guides the sleeve blank which is folded such that the intermediate fold line  22  is the protruding edge of the blank as it moves as indicated by arrow  43 . The sleeve blank  44  is then moved in contact with the forming tool as indicated in broken line  6 ′ onto the side wall  46  of the forming tool  30  so that the intermediate fold line  22  contacts the side wall  46  of the forming tool and, as the forming tool is moving in the direction indicated by arrow  34 , the movement of the blank into the forming tool combined with the movement of the forming tool itself causes the fold line  16  of the blank to locate under the lip portion  48  of the forming tool and in turn, the fold line  18  in corner  50  of the forming tool and in turn, the bottom face  10  contacts with the base  52  of the forming tool and the side wall  14  of the blank with the side wall  54  of the forming tool by which stage the blank is effectively moved to the erected form as illustrated by broken line  6 ″. Guide means  56  can also be provided to force the sleeve into the forming tool as indicated by arrow  58  to ensure that the erected sleeve retains the position within the forming tool and hence reaches the position indicated in  FIG. 2  where the sleeve  6  is erected and held in the forming tool  30  so defines the opening  40  into which the tray  4  can be inserted as indicated by arrow  59 . 
   It should be appreciated that each of these functions are performed as the apparatus continues to move in terms of the rotatable placement means  24  continues to rotate between the store magazine and the forming tool, the drive means  32  continues to move, and the tray feed means as illustrated in  FIG. 2 , move in sequence in accordance with the movement of the forming tools  30  along the drive means. This ability for continuous movement greatly increases the throughput rate of forming the packages. 
     FIG. 4  illustrates one embodiment of forming tool  30  in more detail wherein the forming tool comprises base portion  52 , side walls  46  and  54 , with the side wall  46  being provided with a lip portion  48  used as described previously. The forming tool also includes a mounting plate  60  by which the forming tool can be attached to the drive means plate  61  by location means comprising a first slot  63  for location on a first peg  61  and slot  65  for location on peg  67 . Typically the forming tool  30  can be positioned by first engaging slot  63  on peg  61  and then rotating the tool as illustrated by arrow  69  about peg  61  to engage slot  65  on peg  67 . Typically the peg  67  is threaded to allow the reception of nut  71  to retain the forming tool in position. This therefore means that sets of forming tools can be provided for each design of sleeve to be formed in accordance with the invention with the said sets of forming tools interchangeable with respect to the apparatus and the drive means  32  so that, for example, for a particular production run, the appropriate set of forming tools, with the appropriately formed and angled base  52  and side walls  46 ,  54 , can be fitted to the forming apparatus. 
     FIGS. 5   a, b  and  c  illustrate further embodiments and dimensions of forming tools with alterations to the base  52 , side walls  46  and  54  as appropriate to suit particular sleeve designs. 
   Thus, the invention as herein described allows efficient sleeve erection and package forming in an automated and fast manner. As such the apparatus and method allows commercially beneficial package forming utilising an article in the form of a tray and a sleeve at least partially surrounding the same to be achieved for the first time. 
   While the invention has been described with a certain degree of particularly, it is manifest that many changes may be made in the details of construction and the arrangement of components without departing from the spirit and scope of this disclosure. It is understood that the invention is not limited to the embodiments set forth herein for purposes of exemplification, but is to be limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled.