Indicia-applying method and apparatus

A carton processing apparatus and method can be used to reduce inventory of pre-printed or pre-labeled cartons. The carton processing apparatus can use a stacked inventory of unassembled cartons in a first planar orientation. A carton can be picked from the inventory, rotated from the first planar orientation to a print plane, and transported near a carton coding device, such as an ink jet printer, which can apply indicia to the carton. The processed carton can be further rotated or provided to a downstream device or process.

BACKGROUND

Packaging materials such as cartons come in countless shapes, sizes, and materials. Cardboard cartons, in particular, are in widespread use for containing everything from raw materials to finished goods, such as diapers, foodstuffs, books, or appliances, and various things in between.

Many cartons contain some sort of printed graphic or text to indicate source or origin, or to identify carton contents. In some scenarios, pre-printed cartons can arrive at a manufacturer's point of production. The manufacturer can fill the pre-printed cartons, and ship the filled cartons to customers. In other scenarios, substantially blank cartons can arrive at the manufacturer's point of production. The manufacturer can fill the substantially blank cartons, label the cartons, and ship the filled and labeled cartons to customers.

Carton information can be applied to a carton as a step in a manufacturing production line. For example, an operator can apply a stamp or place an adhesive-backed label to a cardboard carton, such as to indicate carton weight or contents. In an automated production line scenario, a filled carton can pass an automatic labeling device, such as a printer, to have carton information applied to the carton.

Several methods and apparatus have been developed seeking to optimize the application of carton information to cartons in an automated packaging environment, but such methods and apparatus have fallen short. For example, Bowman et al., in U.S. Pat. No. 6,164,040, entitled “CARTONER WITH INK JET CODER,” refers to dispensing cartons along a single plane pathway past multiple ink jet print heads to apply carton information. As another example, Sugahara, in U.S. Patent Application No. 2010/0060693, entitled “PRINTER,” refers to a printing apparatus that can print on a first surface of a printing medium, turn the medium upside down, and print on a rear surface.

OVERVIEW

A carton processing apparatus and method can be used to reduce inventory of pre-printed or pre-labeled cartons. The carton processing apparatus can be configured to use a stacked inventory of substantially unassembled cartons in a first planar orientation. An unassembled carton can be picked from the inventory, rotated from the first planar orientation to a print plane, and transported near a carton coding device, such as an ink jet printer, which can apply indicia including information to the carton. The indicia-bearing carton can be further rotated or otherwise provided to a downstream device or process.

This patent document describes, among other things, apparatus, methods, machine-readable media, or other techniques that can involve receiving one or more substantially unassembled carton blanks, manipulating a substantially unassembled carton blank, such as to orient a carton blank in a print plane, applying indicia to a substantially unassembled carton blank, and optionally further manipulating a substantially unassembled carton blank. The techniques can involve receiving a series of carton blanks, such as to provide a substantially constant supply of indicia-bearing cartons to a downstream device or process, such as an automated carton assembly or carton packing device.

The techniques described and illustrated herein can be directed toward optimizing a manufacturing process and reducing an inventory of pre-printed or pre-labeled cartons. In previous examples, a manufacturer oftentimes purchased pre-printed cartons from a carton supplier for containing a particular line of goods. If the particular line of goods was to be supplied to several different customers, and each customer had its own carton labeling requirements, the manufacturer was required to purchase several different pre-printed cartons from the carton supplier. Thus, the present inventor has recognized, among other things, that a problem to be solved can include reducing an inventory of pre-printed or pre-labeled cartons. The present subject matter can provide a solution to this problem, such as by applying carton indicia to a substantially unassembled blank carton at a point of production. For example, carton indicia, such as to designate carton contents and destination information, can be applied to a carton immediately before the carton is filled and sent to an export area. In an example, a substantially unassembled blank carton can be retrieved from a carton inventory, rotated from a horizontal plane to a vertical plane, and coded, such as using a printing or labeling device. In an example, the carton inventory can include a magazine of substantially horizontally oriented, unassembled cardboard cartons.

This Overview is intended to provide non-limiting examples of the present subject matter. It is not intended to provide an exclusive or exhaustive explanation. The Detailed Description is included to provide further information about the present subject matter.

DETAILED DESCRIPTION

FIGS. 1A and 1Billustrate generally examples of a packaging carton.FIG. 1Aillustrates generally an example of an unassembled carton111, such as a cardboard carton or box that, when assembled, can substantially retain contents. In this document, the term “unassembled” as it relates to a carton is used to refer to an unexpanded carton and/or a carton that is coupled along an edge or corner, but which lies substantially flat in a planar configuration. That is, when an unassembled carton111is formed into an assembled carton112, the assembled carton112can have four sides, a sealable bottom, and a sealable top. In the example ofFIG. 1A, the carton111can have at least four faces and eight flaps. The faces A and B can form exterior side walls of the carton when assembled. The flaps D and F can be interior flaps of the carton when assembled. The flaps C and E can be exterior flaps of the carton when assembled. In an example, the unassembled carton111can have dimensions of about 3 by 2 by 0.05 feet. In an example, the unassembled carton111can have dimensions of about 3 by 2 by 0.02 inches. The present invention can be configured to process cartons and other substantially flat substrates that are larger or smaller than these dimensions.

FIG. 1Billustrates generally an example of an assembled carton112. The assembled carton112can be formed from the unassembled carton111. For example, the faces A and B, and the flap C inFIG. 1Bcan correspond to the faces A and B, and the flap C inFIG. 1A.

The assembled carton112can include carton indicia on any one or multiple sides of the carton. Carton indicia can include information such as the contents of the carton, the manufacturer of the carton contents, the manufacturer of the carton, the origin of the carton contents, address information, bar code information, or practically any other information that can be represented using text or graphics. Such carton indicia can be printed directly on to the carton substrate (e.g., cardboard, paperboard, plastic, etc.). In an example, carton indicia can be printed on an intermediate substrate, such as a label, for application to a carton.

Unique carton indicia can be applied to each carton in a series of unassembled cartons111or assembled cartons112. For example, actual net weight information can be applied to each of a series of cartons, such as after the cartons are filled with different amounts of a particular product. In an example, unique carton indicia can be applied to each of a series of cartons such as to designate different contents.

FIG. 2illustrates generally a portion of an apparatus200that can include a carton transport device110. The carton transport device110can be configured to retrieve, receive, or retain a carton, such as a cardboard carton (e.g., the unassembled carton111) or other substantially flat substrate. The carton transport device110can include one or more suction devices113, peripheral positioners114, or a central positioner117. The carton transport device110can include a hinge106, such as to permit rotation of a top portion of the carton transport device110. In an example, the carton transport device110can include a sensor116. In an example, the carton transport device110can be movably coupled with a track and conveyor105.

In an example, the carton transport device110can include a suction device113. The suction device113can include a vacuum-actuated suction cup, such as can be used to adhere to uneven or porous surfaces like cardboard or paperboard. Multiple suction devices113can be included on the carton transport device110, such as to accommodate various lift force requirements. For example, a large unassembled carton111(e.g., a 36 ounce carton) can be transported using the carton transport device110with two or more suction devices113. The lift force of the suction device113can be influenced by the diameter of the suction cup, the strength of the actuating vacuum, or the suction cup material, among other variables. The suction device113can include an elastic level adjustment, such as to compensate for uneven carton surfaces. In an example, one or more suction devices can be configured to contact a carton face, such as one or more of the carton faces A or B on the unassembled carton111ofFIG. 1A.

In an example, the carton transport device110can include the peripheral positioner114or the central positioner117. The peripheral positioner114can include a rubber stopper, and several peripheral positioners can be used with the carton transport device110, such as in several different locations, to substantially brace a carton or other substrate (e.g., the unassembled carton111). For example, peripheral positioners114can be located in several locations corresponding with the flaps of the unassembled carton111, such as to prevent the flaps from moving or folding during carton transport. The central positioner117can be similarly used to brace a carton or other substrate, such as in a central portion of the unassembled carton111(e.g., at carton face A). In an example, the peripheral positioners114or the central positioner117can be a moderate durometer (e.g., 70 Shore A) rubber material, and can have a diameter of about 1 inch.

The carton transport device110can include a sensor116. The sensor116can include an optical sensor or a mechanical sensor, among other sensors, such as can be configured to detect the presence of a carton on the carton transport device110. For example, the sensor116can be an optical sensor configured to provide an electrical signal when a carton (e.g., the unassembled carton111) obstructs light from reaching the sensor116. The sensor116can be a mechanical sensor configured to physically actuate when a carton (e.g., the unassembled carton111) is coupled to the carton transport device110, such as subsequent to vacuum-actuation of the suction devices113.

The carton transport device110can include a hinge106. The hinge106can enable at least a portion of the carton transport device110, such as a top portion, to rotate. The unassembled carton111can be coupled to the carton transport device110, such as using the suction devices113. The top portion of the carton transport device110can be continuously rotatable, such as from an initial orientation to a non-coplanar second orientation. Consequently, the unassembled carton111coupled to the carton transport device110can be rotated, such as from an initial planar orientation (e.g., a horizontal orientation) to a second planar orientation (e.g., a vertical orientation).

A lower portion of the carton transport device110can be coupled with a track and conveyor105. The track and conveyor105can be configured to carry the carton transport device110along a path, such as a substantially linear path. Other paths including bends, turns, or changes in elevation along the track can also be used. In an example, the track and conveyor105can include a linear track and motor. The motor can include a brushless servo motor, such as with an encoder to provide information about a location of the carton transport device110. The motor can be configured to transport the carton transport device110along the track and conveyor105, such as at a substantially constant velocity. The carton transport device110can be transported along the track and conveyor105in any orientation, such as a horizontal, vertical, or intermediate angled orientation. The motor can be coupled to the track or the carton transport device110.

In an example, the track can include a linkage or a belt drive. In some examples, multiple carton transport devices110can be disposed on the track, which can be formed into a continuous loop. In such an example, one or more carton transport devices110can be fixedly coupled to the track, and the track can be driven by a track motor, such as in a tank-wheel configuration.

The hinge106can enable a portion of the carton transport device110to rotate in a direction perpendicular to a direction of travel of the carton transport device110. For example, where the track and conveyor105include a substantially linear track (e.g., a horizontal track), the rotatable portion of the carton transport device110can rotate about a direction perpendicular to the length of the track.

In an example, the carton transport device110can use a non-hinged mechanism to rotate the entire carton transport device110or a portion of the carton transport device110, such as perpendicular to a direction of travel. For example, a pneumatic or hydraulic manipulation mechanism can be used to lift or adjust a top portion of the carton transport device110, such as in a rotational direction. In an example, the track and conveyor105can include a turn or twist, such as parallel to the direction of travel. The carton transport device110can be fixedly coupled to the track and conveyor105and can travel along the turned or twisted track and conveyor105. Consequently, the carton transport device110can be rotated, such as by a rotational amount that is the same as the rotational turn or twist of the track and conveyor105.

FIG. 3illustrates generally a portion of an apparatus300that can include the carton transport device110in a first rotational orientation and a carton coding device120. The carton transport device110can be coupled to the track and conveyor105, such as including a substantially linear track. The unassembled carton111can be coupled to the carton transport device110, such as in a horizontal orientation. The carton transport device110can carry the unassembled carton111from at least one end of the track to an opposite end.

In an example, the carton transport device110can carry the unassembled carton111near the carton coding device120. The carton coding device120can include one or more devices operable to apply information to a substrate (e.g., the unassembled carton111) carried by the carton transport device110. For example, the carton coding device120can include one or more print heads, such as an impact print head (e.g., a dot matrix print head), a thermal ink print head, an ink jet print head (such as including an integral or piezo print head), a drum print head, or a laser print head, among others. The one or more print heads can have the same or different characteristics, including resolution, speed, color capacity, and memory, among others.

In an example, the carton coding device120can be a label application device. For example, the carton coding device120can be an automatic label applicator, such as can be used to apply pre-printed labels to the unassembled carton111or other substrate. The carton coding device120can include a label application device that can print label information on to a label just prior to the label application. In some carton processing examples, such as where very porous or very smooth carton substrate surfaces are used, labeling a carton or other substrate with an adhesive-backed label can be more effective than applying ink directly to the substrate surface.

In the example ofFIG. 3, the carton coding device120can include at least two ink jet print heads122. The ink jet print heads122can be independently positioned, such as in a horizontal or vertical plane. In an example, a first ink jet print head122can print in multiple colors (e.g., cyan, magenta, etc.) over a first area (e.g., 3 inch height) at a first resolution (e.g., 180 dots per inch (dpi)). A second ink jet print head122can similarly print in multiple colors over the first area at the first resolution. One or more additional print heads can be included, such as can be configured to print with different colors, over different areas, or at different resolutions.

In an example, the first ink jet print head122can be configured to apply indicia over a first portion of a carton, such as from a bottom edge of a carton (e.g., a location 0 inches inFIG. 1A) to an intermediate portion of a carton face (e.g., a location +3 inches inFIG. 1A). The second ink jet print head122can be configured to print a second portion of the carton, such as from the intermediate portion of the carton face (e.g., the location +3 inches inFIG. 1A) to an upper print edge of a carton (e.g., the location +6 inches inFIG. 1A). In an example, the first and second ink jet print heads122can be configured to print over the same portion of a carton (e.g., the first portion of a carton), such as using different colors or types of ink, or at different resolutions.

FIG. 4illustrates generally a portion of an apparatus400that can include the carton transport device110in a second orientation and the carton coding device120. In an example, the ink jet print heads122can be configured to print in a plane that is different than an initial plane of the unassembled carton111. For example, the ink jet print heads122can be configured to print in a substantially vertical plane, and an initial plane of the unassembled carton111can be a substantially horizontal plane. To accommodate the configuration of the print heads, the unassembled carton111can be rotated from an initial orientation (e.g., a horizontal orientation) to a vertical orientation, such as using the carton transport device110and the hinge106.

In an example, a top portion of the carton transport device110can be configured to rotate while the carton transport device110is at rest or in motion. For example, the carton transport device110can begin in a first orientation (e.g., a substantially horizontal orientation) and can accelerate along the track and conveyor105, such as until a print velocity is reached. The carton transport device110can rotate its top portion, such as to a vertical orientation, while the carton transport device110is at rest, accelerating, or after attaining a print velocity.

In an example, a top portion of the carton transport device110can be fully rotated from a horizontal to a vertical orientation before a leading edge of the unassembled carton111, such as coupled to the carton transport device110, enters a print region118. The print region118can include an area wherein the ink jet print heads122can be configured to apply carton indicia to the passing unassembled carton111. The carton transport device110can be configured to rotate the top portion to return to an initial (e.g., horizontal) orientation after the ink jet print heads122have applied the carton indicia to the unassembled carton111, such as after a trailing edge of the unassembled carton111exits the print region118.

In an example, carton location information can be used to determine when or if the top portion of the carton transport device110can be rotated. For example, an encoder coupled to the track and conveyor105can provide the carton location information to the carton transport device110. Mechanical or optical sensors, such as at or near the carton coding device120, can provide the location information to the carton transport device110. A combination of encoder information and sensor information can be used to provide the carton location information and to indicate if the top portion of the carton transport device110can be rotated, such as without interfering with another portion of the carton processing device.

FIG. 5illustrates generally a portion of an apparatus500that can include the carton transport device110and multiple carton coding devices. For example, the apparatus500can include all of the features of the apparatus400, including a first carton coding device120A and a second carton coding device120B. The first and second carton coding devices120A and120B can include ink jet print heads122A and122B, respectively. The first and second carton coding devices120A and120B can include other types of printing or coding devices, such as can be used to apply carton indicia to a carton or other substrate.

In the example ofFIG. 5, the carton transport device110can be configured to carry the unassembled carton111through the print region118when the unassembled carton111is in a substantially vertical orientation. The print region118can include any area over which the first and second carton coding devices120A and120B are capable of applying carton indicia to the unassembled carton111. For example, the first carton coding device120A can be configured to apply carton indicia to a first side of the unassembled carton111(e.g., faces A and B, and flaps C, D, E, and F inFIG. 1A) and the second carton coding device120B can be configured to apply carton indicia the an opposite side of the unassembled carton111.

In the example ofFIG. 5, the first and second carton coding devices120A and120B can be placed on opposite sides of the track and conveyor105and the carton transport device110. The first carton coding device120A can be configured to apply carton indicia to face A of the unassembled carton111, and the second carton coding device120B can be configured to apply carton indicia to flap G of the unassembled carton111(see, e.g.,FIGS. 1A and 1B). In an example, the first and second carton coding devices120A and120B can be placed on the same side of the track and conveyor105and the carton transport device110, such as to print on only one side of the unassembled carton111. The first carton coding device120A can be configured to print over a lower portion of the unassembled carton111(e.g., flaps E and F) and the second carton coding device120B can be configured to print over an upper portion of the carton (e.g., flaps C and D). Thus, the printable area of the carton can be extended by adding additional carton coding devices.

FIG. 6illustrates generally a portion of an apparatus600that can include the carton transport device110, the carton coding device120, and a carton inventory holder150. The apparatus600can include a complete carton processing apparatus, wherein an inventory of carton blanks211can be received at an input portion of the apparatus, and a processed carton (e.g., a carton containing carton indicia) can be provided at an output portion of the apparatus. The output portion of the apparatus can include a downstream device or process160, such as an automatic carton assembly device, or a second carton inventory.

In the example ofFIG. 6, the carton inventory holder150can include an inventory of carton blanks211, such as including a stack of one or more unassembled cartons (e.g., including the unassembled carton111). In an example, the carton inventory holder150can include an inventory of carton blanks211such as including a magazine of substantially assembled cartons. In an example, the apparatus600can be configured to process any substrate that can be held in the carton inventory holder150, such as can include substrates with at least one substantially planar portion, such as including substantially flat sheets of paper, cardboard, or plastic, among other materials. The carton inventory holder150is further discussed below in the discussion ofFIG. 7.

The carton inventory holder150and the inventory of carton blanks211can be accessed using a carton retrieval transport device130. The carton retrieval transport device130can include some or all of the features of the carton transport device110, such as including the suction device113, the peripheral positioner114, the central positioner117, the hinge106, or the sensor116, among other features. The carton retrieval transport device130can be transported in a first plane (e.g., a horizontal plane) along a retrieval track and conveyor115, such as can be similar to the track and conveyor105. The carton retrieval transport device130can be further transported in a second plane (e.g., a vertical plane), such as using a pneumatic cylinder or other mechanical transport device. For example, in a carton pick-up position140, the carton retrieval transport device130can be located substantially above the inventory of carton blanks211. The carton retrieval transport device130can be lowered in a vertical direction using the pneumatic cylinder such that the suction devices113can contact a first carton blank, such as an unassembled carton blank (e.g., the unassembled carton111). Vacuum actuation of the suction devices113can secure the unassembled carton blank to the carton retrieval transport device130. The carton retrieval transport device130and the attached unassembled carton blank can then be transported, such as to a carton handoff position141.

In an example, the handoff position141can be a position where the carton retrieval transport device130is positioned substantially above the carton transport device110, such that the unassembled carton blank can be transferred from the carton retrieval transport device130to the carton transport device110. The carton retrieval transport device130can be actuated in a vertical direction, such as to bring the unassembled carton blank down to the carton transport device110. The carton transport device110can also be movable in a vertical direction, such as to facilitate a handoff at the handoff position141. The carton retrieval transport device130can return to the carton pick-up position140, such as after releasing the unassembled carton blank to the carton transport device110.

After the unassembled carton blank is transferred to the carton transport device110, such as at the handoff position141, carton indicia can be applied to the carton, such as using the apparatus400or the apparatus500. In the example ofFIG. 6, a verification device125can be used to verify the applied carton indicia, such as the carton indicia applied using the carton coding device120. The verification device125can be disposed along the track and conveyor105subsequent to the carton coding device120.

The carton coding device120can be configured to print bar code information on a first face of the unassembled carton111. The verification device125can be configured to verify the readability of the bar code, such as immediately after the carton coding device120applies the bar code information. The verification device125can be any sort of optical scanner, including any machine vision scanner capable of recognizing text, graphics, or other printed codes or indicia.

In an example, the carton transport device110and an attached carton can be transported along the track and conveyor105to a terminal carton position142, such as subsequent to the print region118. The processed carton can be provided to a downstream device or process160for subsequent printing, assembly, or other manipulation or processing.

In an example, the processed carton can be provided to a second carton inventory using a second carton retrieval transport device that can effectively mirror the carton retrieval transport device130. For example, the second carton retrieval transport device can be configured to receive the processed carton (e.g., the unassembled carton111including the carton indicia applied by the carton coding device120) at the terminal carton position142. The second carton retrieval transport device can, for example, transport the carton to an inventory of processed cartons, such as a stacked inventory of cartons with printed carton indicia. In an example, the inventory of processed cartons can be collected using a processed carton inventory holder152(seeFIG. 8) that can functionally mirror the carton inventory holder150.

The apparatus600can be controlled at least in part using a control circuit170. The control circuit170can include a processor circuit, and a processor-readable medium including instructions to operate the apparatus600. In an example, the processor-readable medium can include instructions to operate the apparatus600according to the examples ofFIGS. 9-13. The control circuit170can be communicatively coupled to any one or more of the elements of the apparatus600, among other elements, such as using a communicative data coupling180. The discussion ofFIG. 8, below, further describes the interface of the control circuit170with the elements of the apparatus600.

FIG. 7illustrates generally a portion of an apparatus700that can include the carton inventory holder150. In an example, the carton inventory holder150can include an operational portion153and a staging portion154. The operational portion153can include a stack of one or more unassembled carton blanks, such as the inventory of carton blanks211. The operational portion153can be located at the carton pick-up position140to facilitate an exchange of a blank carton from the inventory to the carton retrieval transport device130.

In an example, the inventory of carton blanks211can be disposed on a carton riser159that can be used to maintain an upper planar edge of the inventory of carton blanks211. For example, when the inventory of carton blanks211is at full capacity, the carton riser159can be retracted such that the inventory of carton blanks211does not rise above a particular horizontal plane. As the inventory of carton blanks211is depleted, such as during operation of the apparatus600, the carton riser159can elevate the inventory of carton blanks211to maintain the uppermost carton blank in the particular horizontal plane. The particular horizontal plane can include a plane from which the carton retrieval transport device130is configured to retrieve a carton from the inventory of carton blanks211.

The operational portion153of the carton inventory holder150can include several carton positioning features. For example, the operational portion153can include an operational carton inventory alignment wall155, a first carton aligner156, and a second carton aligner157. These three alignment features can be used to secure and maintain an initial carton alignment, such as of an uppermost carton in the inventory of carton blanks211. The carton retrieval transport device130and the carton transport device110can maintain the initial carton alignment such that no additional carton alignment adjustments are required prior to an application of the carton indicia (e.g., using the carton coding device120). Various sensors (e.g., the sensor116, such as an optical sensor) can be used to verify carton alignment, such as before the control circuit170instructs the carton retrieval transport device130to retrieve a carton from the inventory of carton blanks211.

In an example, the staging portion154of the carton inventory holder150can include carton alignment features such as a staging carton inventory alignment wall158. The staging portion154can maintain a secondary carton blank inventory311, such as can be used to replenish the inventory of carton blanks211. For example, when a final carton blank is removed from the inventory of carton blanks211(e.g, as determined using the control circuit170and the sensor116), the secondary carton blank inventory311can be advanced from the staging portion154to the operational portion153of the carton inventory holder150. The secondary carton blank inventory311can be automatically advanced using the carton inventory track151, such as can be controlled by the control circuit170. Thus, the secondary carton blank inventory311can be loaded on to the fully retracted carton riser159, and can be aligned using the operational carton inventory alignment wall155, and the first and second carton aligners156and157. In an example, the secondary carton blank inventory311can be manually or automatically replenished at any time.

In an example, the operational portion153and the staging portion154can maintain inventories of similarly or differently sized cartons or other substrates. The control circuit170can be used to adjust features of the apparatus, such as to accommodate changes from a first carton shape to a second carton shape. For example, the secondary carton blank inventory311can include cartons that differ in size, shape, or weight from an exhausted inventory of carton blanks211. When the secondary carton blank inventory311advances to the operational portion153, the control circuit170can adjust, among other elements, the carton pick-up position140, or the suction devices113of one or more of the carton retrieval transport device130or the carton transport device110, to accommodate the change in carton inventory (e.g., the vacuum applied to the suction devices113can be increased to accommodate a heavier carton).

FIG. 8illustrates generally a block diagram that can include a carton processing apparatus800. In the example ofFIG. 8, the control circuit170can be communicatively coupled to any one or more of the carton inventory holder150, the carton retrieval transport device130, the retrieval track and conveyor115, the track and conveyor105, the carton transport device110, the carton coding device120, the verification device125, the downstream device or process160, the processed carton inventory holder152, or the suction devices113A or113B, among other devices. The control circuit170can be communicatively coupled to other devices, such as can be configured to interface with the apparatus600, including an air supply (e.g., to supply the vacuum to actuate the suction devices113), or a process flow controller to determine when the carton retrieval transport device130can retrieve a carton from the carton inventory holder150, or when to provide a processed carton to the downstream device or process160.

In an example, the control circuit170can be communicatively coupled with a carton indicia driver, such as can be used to provide instructions to the carton coding device120about the information to be applied to one or a series of cartons. The carton indicia driver can provide unique information (e.g., a serial number) to each carton in a series. For example, the carton indicia driver can provide unchanging information to be applied to each carton in a batch of cartons. In an example, the control circuit170can be coupled to one or more other devices using the communicative data coupling180, such as using a wireless data communication coupling, or a wired data communication coupling (e.g., CAT V).

FIG. 9illustrates generally an example900that can include applying carton indicia to a carton. In an example, a first carton can be received at910. The first carton can be received from the inventory of carton blanks211, such as using the carton retrieval transport device130. In an example, the first carton can be manually received by the carton transport device110. The first carton can be received in any orientation, such as a horizontal orientation. For example, the first carton can be the unassembled carton111, and it can be received by a top surface of the carton transport device110. The first carton can be secured to the carton transport device110using the suction device113. The first carton received at910can be retained by the carton transport device110, such as according to the discussion ofFIGS. 2 and 3.

At930, the first carton can be rotated. In an example, the first carton can be rotated using a rotatable portion of the carton transport device110, such as a hinged top portion of the carton transport device110. The first carton can be rotated by any amount, such as by a few rotational degrees or by 90 degrees or more. The extent of the rotation can be determined by the functional limitations of a carton transport hinge (e.g., the hinge106) or the track and conveyor105, among other functionally limited devices. See, for example, the discussion atFIG. 2regarding the rotation of the carton transport device110.

In an example, the first carton can be rotated at930from an initial orientation (e.g., a horizontal carton orientation) to a print orientation (e.g., an orientation that is the same as or different than the initial orientation, such as a vertical carton orientation). For example, the first carton can be rotated at930from the initial orientation illustrated generally inFIG. 3to the different second orientation illustrated generally inFIG. 4.

In an example, the first carton can be rotated at930at a first rotational rate. The first rotational rate can be adjusted to minimize carton shifting and maximize carton throughput, such as through the carton processing apparatus600. The rate can depend upon several features of the first carton, such as the carton weight, size, and shape. The rate can further depend upon several features of the carton transport device110, or the track and conveyor105, among other features. See, for example, the discussion atFIGS. 2,3, and4regarding the functional elements of the carton transport device110, and the rotation of the carton transport device110.

At950, carton indicia can be applied to the first carton. For example, carton indicia, such as including text or graphics, can be applied to the first carton (e.g., the unassembled carton111) using the carton coding device120. The carton indicia can be applied to the first carton when the first carton is in a different rotational orientation than an initial rotational orientation. The carton indicia can be applied using any of the carton coding devices described above, such as in the discussions ofFIGS. 3 through 6.

In an example, carton indicia applied at950can be applied to at least one side of the unassembled carton111. For example, the carton indicia can be applied to the carton faces A, B, and C, such that the carton indicia can appear on more than one side of the carton when assembled (seeFIGS. 1A and 1B). Importantly, the carton indicia can be applied to a single plane of the of the unassembled carton111, and the carton indicia can correspond to multiple different planes of the carton after assembly, such as including a first carton plane (e.g., occupied by carton face A), a second carton plane (e.g., occupied by carton face B), or a third carton plane (e.g., occupied by carton face C), among other carton planes.

FIG. 10illustrates generally an example1000that can include applying carton indicia to a rotated carton. In an example, a first carton can be removed from a carton blank inventory at1020. For example, the first carton (e.g., the unassembled carton111) can be removed from the inventory of carton blanks211in the operational portion153of the carton inventory holder150. The first carton can be removed using the carton retrieval transport device130, and can be transferred to the carton transport device110for further processing at the carton handoff position141. In an example, the first carton can be removed using the carton transport device110, or can be manually placed on the carton transport device110. The first carton removed at1020can be in an initial carton orientation.

At1030, the first carton can be rotated. The first carton can be rotated according to the discussion at930, such as using the carton transport device110. In an example, the first carton can be rotated at1030from an initial carton orientation to a print orientation that is substantially orthogonal to the initial orientation. At1050, carton indicia can be applied to the first carton. The carton indicia can be applied according to the discussion at950, such as using the carton coding device120. In an example, the carton indicia can be applied while the carton transport device110carries the first carton through a print region (e.g., the print region118) of one or more ink jet print heads122on the carton coding device120.

At1056, the first carton can be rotated. For example, where the first carton was rotated from an initial carton orientation to a print orientation at1030, the first carton can be rotated to the initial carton orientation at1056. In an example, the first carton can be rotated to a final orientation that is different than the initial orientation and the print orientation. A downstream device or process160can be configured to receive the first carton in an intermediate orientation, such as rotated 45 degrees from a vertical orientation. In such an example, the carton transport device110can be configured to rotate the first carton to 45 degrees at1056. At1060, the first carton can be provided to the downstream device or process160, such as an automatic carton assembler or case packer.

FIG. 11illustrates generally an example that can include determining a status of an operational inventory of cartons. In an example,FIG. 11can describe a portion of the carton inventory holder150as shown inFIG. 7. At1102, an operational inventory of unassembled, substantially blank cartons can be provided. The operational inventory can include the inventory of carton blanks211, such as can be disposed in the operational portion153of the carton inventory holder150. At1104, the operational inventory can be substantially aligned, such as using the operational carton inventory alignment wall155, the first carton aligner156, or the second carton aligner157, among other alignment devices. The operational inventory alignment can be verified, such as using a sensor coupled to one or more of the alignment devices, or using optical sensors to determine a carton position or carton inventory position. Information obtained or received from such sensors can be interpreted using the control circuit170.

At1106, a secondary inventory of unassembled, blank cartons can be provided. In an example, the secondary inventory can include the secondary carton blank inventory311, such as can be disposed in the staging portion154of the carton inventory. The secondary inventory can be substantially aligned, such as using the staging carton inventory alignment wall158. The operational inventory and the secondary inventory can include the same or different carton materials. For example, the operational inventory can include a stack of unassembled carton bottoms, and the staging inventory can include a stack of unassembled carton lids. In an example, the operational inventory and the secondary inventory can include a magazine of unassembled cartons111, wherein the operational inventory includes cartons of a first size and weight, and the secondary inventory includes cartons of a different second size and weight.

At1122, a blank carton can be obtained from the operational inventory. In an example, the blank carton can be obtained from the operational inventory such as from the inventory of carton blanks211. The blank carton can be obtained from the top of a stack of unassembled cartons111. The blank carton can be obtained using the carton retrieval transport device130, and can be transferred to the carton transport device110, such as at the carton handoff position141, for further processing. In an example, the blank carton can be removed using the carton transport device110, or can be manually placed on the carton transport device110. The blank carton can be obtained at1122in an initial blank carton orientation.

At1150, carton indicia can be applied to the blank carton, such as using the carton coding device120. The carton indicia can be applied such as according to the discussion at950. At1160, the processed carton can be provided to the downstream device or process160, such as according to the discussion at1060.

At1161, the operational inventory can be analyzed for remaining blank cartons. For example, the control circuit170can be configured to analyze the operational inventory for remaining blank cartons after each application of carton indicia to a blank carton. The control circuit170can be configured to determine the presence or absence of a blank carton, such as in the operational portion153of the carton inventory, using information from one or more sensors disposed near the operational inventory.

In an example, at1161, the control circuit170can determine that the operational inventory is not exhausted, and that cartons remain in the inventory of blank cartons211. Accordingly, the carton processing apparatus (e.g., the apparatus600) can continue to operate, such as by obtaining a subsequent blank carton from the operational inventory at1122. This process can repeat until the operational inventory is exhausted, or until some other intervention of the control circuit170or an operator.

In an example, at1161, the control circuit170can determine that the operational inventory is exhausted, and that no cartons remain in the inventory of blank cartons211. Accordingly, if a secondary carton blank inventory311is available, the secondary inventory can be advanced into the operational inventory position at1162. For example, the secondary carton blank inventory311can be conveyed, such as along the carton inventory track151, and placed upon the carton riser159, such as to provide an operational inventory of unassembled, blank cartons at1102. The carton riser159can elevate this newly-arrived carton blank inventory to an operational position, such as can be accessible by the carton retrieval transport device130. One or more carton alignment devices (e.g., the first and second carton aligners156and157) can be configured to automatically align the newly-arrived carton blank inventory, such as at1104.

FIG. 12illustrates generally an example that can include rotating a carton between horizontal and vertical orientations and applying information to the carton. In an example, an unassembled carton111, such as oriented in a horizontal plane, can be removed from a carton blank inventory at1222(e.g., the inventory of carton blanks211). Removing the horizontally-oriented unassembled carton111can be performed such as according to the discussion at1022, such as using the carton retrieval transport device130. At1230, the unassembled carton111can be rotated to a vertical plane, such as using the hinged top portion of the carton transport device110. The unassembled carton111can be coupled to the carton transport device110, such as via a vacuum force provided via the suction device113B, or via a grip force. The control circuit170can be configured to initiate or release a vacuum or grip force such as in response to information about a carton presence that can be received from the one or more sensors116.

At1240, the rotated, unassembled carton111can be transported through a print region (e.g., the print region118) at a constant velocity, such as using the carton transport device110and the track and conveyor105. In an example, at1250, the carton coding device120can be configured to apply carton indicia to the unassembled carton111as it passes through the print region, such as at a constant velocity. In an example, the carton coding device120can be configured to apply carton indicia to the unassembled carton111during an acceleration or deceleration of the carton transport device110along the track and conveyor105. Application of carton indicia at1250can be initiated using the control circuit170, such as in response to receiving an indication of the presence of a carton in the print region.

At1252, the processed carton (e.g., the unassembled carton with carton indicia) can be transported away from the print region, such as using the carton transport device110. In an example, transporting the carton away from the print region can include verifying at least a portion of the carton indicia applied at1250, such as using a verification device125(e.g., a bar code scanner). The processed carton can be transported away from the print region at a constant velocity or under some acceleration.

In an example, a trailing edge of the processed carton can be sensed exiting the print region using a sensor coupled to the control circuit170. Once the trailing edge of the processed carton is detected, the processed carton can be rotated at1256, such as to a horizontal orientation. The processed carton can be rotated to the horizontal orientation using the top rotatable portion of the carton transport device110. At1260, the rotated or processed carton can be provided to a downstream device or process160, such as according to the discussion at1060.

FIG. 13illustrates generally an example that can include transporting a carton using more than one carton transport device. In an example,FIG. 13can illustrate a portion of the apparatus600as a flow chart. At1322, a blank carton (e.g., the unassembled carton111) can be removed from a carton inventory (e.g., the carton inventory holder150, such as including the inventory of carton blanks211) using a first transport device (e.g., the carton retrieval transport device130). Some features of the first transport device are described above in the discussion ofFIG. 2. In an example, the blank carton can be removed from the carton inventory holder150at the carton pick-up position140.

At1324, the blank carton can be transferred to a second transport apparatus, such as the carton transport device110. The blank carton transfer can occur at the carton handoff position141, such as when the carton retrieval transport device130is disposed substantially near the carton transport device110, such that the suction devices113on the carton retrieval transport device130can release the blank carton, and the suction devices113on the carton transport device130can be actuated to receive and retain the blank carton. One or more sensors116can be used to verify a successful handoff of the blank carton between the transport devices.

At1330, the blank carton can be rotated, such as according to the discussion at930, such as using the devices described inFIGS. 2,3, and4. The blank carton can be transported through a print region (e.g., the print region118) at1340, such as according to the discussion at1240. At1350, carton indicia can be applied to the blank carton as it is transported through the print region, such as according to the discussion at1250. The carton indicia applied at1350can include the application of a label to the blank carton. At1360, the processed carton can be provided to a downstream device or process160, such as according to the discussion at1060.

Additional Notes & Examples

Example 1 includes subject matter, such as a method, comprising receiving an unassembled carton in a first planar orientation, rotating the unassembled carton from the first planar orientation to a second planar orientation, which is angled relative to the first planar orientation, transporting the unassembled carton at a velocity in a direction parallel or substantially parallel to the second planar orientation, and printing or labeling indicia on the unassembled carton while the carton is being transported. Example 1 can include subject matter such as the unassembled carton, which can be an unexpanded carton and/or a carton that is coupled along an edge or corner but which can lie substantially flat in a planar configuration. Example 1 can include subject matter such as receiving an unassembled carton using a carton transport device or apparatus, such as using a vacuum or grip force to couple the unassembled carton to the carton transport device.

In Example 2, the subject matter of Example 1 can optionally include rotating the unassembled carton with the indicia from the second planar orientation to an orientation parallel with the first planar orientation.

In Example 3, the subject matter of one or any combination of Examples 1-2 can optionally include receiving the unassembled carton by removing the unassembled carton from an inventory of one or more unassembled cartons. For example, the unassembled carton can be removed from an inventory holder.

In Example 4, the subject matter of one or any combination of Examples 1-3 can optionally include removing the unassembled carton from the inventory holder of one or more unassembled cartons, such as by removing the unassembled carton using a vacuum-actuated device coupled to a transport mechanism.

In Example 5, the subject matter of one or any combination of Examples 1-4 can optionally include removing the unassembled carton from the inventory holder of one or more unassembled cartons, such as by removing the unassembled carton from a stacked inventory of one or more horizontally-oriented unassembled cartons.

In Example 6, the subject matter of one or any combination of Examples 1-5 can optionally include placing the unassembled carton with the indicia in an inventory of printed or labeled unassembled cartons.

In Example 7, the subject matter of one or any combination of Examples 1-6 can optionally include providing the unassembled carton with the indicia to an automated carton assembly device.

In Example 8, the subject matter of one or any combination of Examples 1-7 can optionally include printing carton information on the unassembled carton such that, when assembled, the carton contains carton information on at least two different carton sides.

In Example 9, the subject matter of one or any combination of Examples 1-8 can optionally include rotating the unassembled carton from the first planar orientation to the second planar orientation, such as including rotating the unassembled carton from a horizontal orientation to a vertical orientation.

In Example 10, the subject matter of one Example 9 can optionally include printing carton information on the unassembled carton using an ink jet print head configured to print within a plane parallel to the second planar orientation.

In Example 11, the subject matter of one or any combination of Examples 1-10 can optionally include rotating the unassembled carton from the first planar orientation to the second planar orientation, including rotating the unassembled carton at least about 90 degrees.

In Example 12, the subject matter of one or any combination of Examples 1-11 can optionally include optically reading or verifying the indicia.

In Example 13, the subject matter of one or any combination of Examples 1-12 can optionally include printing or labeling indicia on the unassembled carton, including transporting the unassembled carton at a substantially constant velocity parallel to a print plane of one or more stationary print heads.

In Example 14, the subject matter of one or any combination of Examples 1-13 can optionally include subject matter, such as a method, comprising removing a carton, from an inventory of one or more unexpanded cartons, using a vacuum force, transporting the carton away from the inventory, rotating the carton from an initial plane to a print plane, wherein the print plane is non-parallel to the initial plane, transporting the carton through a print region, including printing indicia on the carton using at least one print head configured to print substantially within the print plane, and reading or verifying the printed indicia using an optical scanning device. Example 14 can include subject matter such as rotating the carton from the print plane to the initial plane or a plane parallel with the initial plane, or transporting the carton away from the printing region.

Example 15 includes subject matter, such as a carton processing apparatus, comprising a carton transport device or apparatus, including a carton retrieval device and a conveyor, the carton retrieval device rotatable between a first planar orientation and a second, non-coplanar orientation and movable, using the conveyor, between a first retrieval device location and a second retrieval device location spaced apart from the first retrieval device location. Example 15 can include subject matter such as a carton coding device configured to apply indicia to a surface of a carton retrieved and retained by the carton retrieval device, or a control circuit, communicatively coupled to the carton transport device, or apparatus, and the carton coding device, the control circuit configured to provide carton location information to the carton coding device.

In Example 16, the subject matter of Example 15 can optionally include the carton retrieval device, which can be configured to obtain an unassembled carton in the first planar orientation, and the carton coding device, which can be configured to apply the indicia to the unassembled carton while the carton retrieval device is in the second planar orientation.

In Example 17, the subject matter of one or any combination of Examples 15 or 16 can optionally include a carton coding device comprising one or more ink jet print heads.

In Example 18, the subject matter of one or any combination of Examples 15-17 can optionally include the carton transport device, or apparatus, which can be configured to carry the carton retrieval device in the second planar orientation, wherein the second planar orientation can be parallel to a printing plane of the one or more ink jet print heads.

In Example 19, the subject matter of one or any combination of Examples 15-18 can optionally include a conveyor that can comprise a substantially linear conveyor track configured to carry the carton retrieval device between the first retrieval device location and the second retrieval device location.

In Example 20, the subject matter of one or any combination of Examples 15-19 can optionally include a carton blank inventory holder, and the carton retrieval device can be configured to retrieve, in the first planar orientation, a carton blank from the carton blank inventory holder.

In Example 21, the subject matter of one or any combination of Examples 15-20 can optionally include a printed or labeled carton inventory holder, and the carton retrieval device can be configured to place a carton including applied indicia in the printed or labeled carton inventory holder.

In Example 22, the subject matter of one or any combination of Examples 15-21 can optionally include an optical verification device that can be configured to read or verify indicia applied by the carton coding device. In an example, the optical verification device can be communicatively coupled to the control circuit.

In Example 23, the subject matter of one or any combination of Examples 15-22 can optionally include an optical verification device, such as including a bar code scanner.

In Example 24, the subject matter of one or any combination of Examples 15-23 can optionally include a carton coding device that can be configured to apply unique indicia to multiple different cartons.

In Example 25, the subject matter of one or any combination of Examples 15-24 can optionally include a carton coding device that can be configured to apply indicia in the form of bar code information to a surface of a carton.

In Example 26, the subject matter of one or any combination of Examples 15-25 can optionally include a carton coding device that can be configured to apply indicia to at least one side of an unassembled carton.

In Example 27, the subject matter of one or any combination of Examples 15-26 can optionally include a carton transport device, or apparatus, that can be configured to provide an unassembled carton including applied indicia to an automatic carton assembly device.

In Example 28, the subject matter of one or any combination of Examples 15-27 can optionally include a second carton coding device. Example 28 can include subject matter such as the first carton coding device that can be configured to apply indicia to a first side of an unassembled carton, and the second carton coding device that can be configured to apply indicia to a second side of the unassembled carton.

In Example 29, the subject matter of one or any combination of Examples 15-28 can optionally include a carton retrieval device, such as comprising a vacuum-actuated device configured to retain a carton, such as a cardboard carton.

In Example 30, the subject matter of one or any combination of Examples 15-29 can optionally include a carton processing apparatus, comprising a first linear transport apparatus, including a first carton transport device and a first linear track, wherein the first linear track can be configured to carry the first carton transport device between a picking position and a handoff position. Example 30 can include a second linear transport apparatus, such as including a second carton transport device and a second linear track, wherein the second linear track can be configured to carry the second carton transport device between the handoff position and a release position, such as including through a print region. Example 30 can include subject matter such as a carton coding device that can be disposed in or near the print region, or a control circuit, such as can be communicatively coupled to any one or more of the carton coding device, the first linear transport apparatus, and the second linear transport apparatus.

In Example 31, the subject matter of one or any combination of Examples 15-30 can optionally include the second carton transport device, which can be configured to operate between an initial planar transport orientation, a print position planar transport orientation that is different from the initial planar transport orientation, and a final planar transport orientation.

In Example 32, the subject matter of one or any combination of Examples 15-31 can optionally include the carton coding device, which can be configured to apply carton information or other indicia to a carton in a plane that is parallel or substantially parallel to the print position planar transport orientation.

These non-limiting examples can be combined in any permutation or combination.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” In this document, the term “unassembled” as it relates to a carton is used to refer to an unexpanded carton and/or a carton that is coupled along an edge or corner but which lies substantially flat in a planar configuration. Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, an apparatus, device, article, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

The above Detailed Description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other embodiments can be used, such as by one of ordinary skill in the art upon reviewing the above description. Also, various features or elements may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.