Methods and apparatus for forming a container

An apparatus for forming a container includes a frame, and a forming station coupled to the frame. The forming apparatus includes a plurality of folding plows configured to fold portions of a blank to form a container. The apparatus also includes a transfer assembly including a plurality of containment bars for supporting the container in a formed state. The containment bars facilitate retaining the formed state of the container while the transfer assembly transfers the container to an operator.

BACKGROUND OF THE INVENTION

This invention relates generally to forming a container, and more particularly, to methods and apparatus for forming a container.

Many businesses are required to package materials before shipping the materials to other locations. Specifically, these businesses package products into containers for shipping and transportation. In at least some of these cases, the products are packaged in corrugated containers. In such a case, an operator manually erects and loads a corrugated paperboard carton from collapsed, partially assembled box blanks. One type of blank commonly used for packaging materials is a regular slotted container type commonly known as an R.S.C. type container. This type of blank requires folding of major and minor flaps at both the upper and lower ends of the blank to form the top and bottom walls of the container. The R.S.C. type blank often times includes four top wall flaps and four bottom wall flaps. When folded over, at least a portion of the four flaps overlap each other, thus leading to a container having additional thickness when compared to containers having only a single layer of corrugated paperboard material.

In at least some known applications, an operator must manually erect the container without the use of a forming machine by folding the flaps and sealing both the top and bottom walls of the container. As such, time and materials are required to form the container prior to the operator being able to load the materials into the container.

In response to the additional labor costs required to form such containers, at least some known folding machines have been developed to aid in the forming of such containers from R.S.C. type blanks. These known folding machines fold and secure the four bottom flaps with tape, staples, or glue, and then direct the container to the operator for loading.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, an apparatus is provided for forming a container. The apparatus includes a frame, and a forming station coupled to the frame. The forming apparatus includes a plurality of folding plows configured to fold portions of a blank to form a container. The apparatus also includes a transfer assembly including a plurality of containment bars for supporting the container in a formed state. The containment bars facilitate retaining the formed state of the container while the transfer assembly transfers the container to an operator.

In another aspect, a container packing system is provided for packing a container formed from a blank. The blank includes a bottom panel defining a footprint of the container, a plurality of end panels having minor flaps extending therefrom, and a plurality of side panels, wherein the end panels and the side panels form the sidewalls of the container. The container packing system includes a frame, a blank hopper coupled to the frame and configured to house at least one blank, and a forming station configured to receive a single blank from the blank hopper. The forming station includes minor flap folding plows configured to fold the minor flaps, end panel folding plows configured to fold the end panels, and side panel folding plows configured to fold the side panels. The forming station is configured to form the blank into a container. The container packing system also includes a transfer assembly including a container support assembly for supporting the container in a formed state. The transfer assembly is configured to transfer the container support assembly to an operator. The container packing system also includes an operator loading station for packing items into the formed container.

In a further aspect, a method is provided for packing a container. The method includes providing at least one blank having a predetermined pattern, directing the blank through a forming station having a plurality of plow fingers oriented to contact corresponding portions of the blank when the blank is directed through the forming station, and folding portions of the blank using the plow fingers to form a container. The method also includes supporting the formed container with a container support assembly such that the formed container retains the formed state, transferring the container from the forming station to an operator loading station using a transfer assembly, and packing the container with at least one item.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1is an exemplary solid bottom, top load corrugated blank10that may be used within a container packing system as described herein. In the exemplary embodiment, blank10is fabricated from a corrugated material and is formed into a plurality of panels having fold lines defined between each of the panels. Blank10includes a bottom panel12. In the exemplary embodiment, bottom panel12is rectangular, however, other patterns or shapes may be utilized in alternative embodiments. Bottom panel12defines the footprint of container when formed.

Blank10also includes end panels14extending along opposite sides of bottom panel12. In the exemplary embodiment, end panels14extend along the entire length of the side of bottom panel12. A fold axis is positioned between each end panel14and bottom panel12. In the exemplary embodiment, blank10includes minor flaps16extending along opposite sides of each end panel14. Specifically, minor flaps16extend from each side of end panels14and include a fold axis positioned between each minor flap16and corresponding end panel14.

Blank10includes a front side panel18and a rear side panel20extending along opposite sides of bottom panel12. In the exemplary embodiment, side panels18and20extend along the entire length of each side of bottom panel12. A fold axis extends between bottom panel12and each side panel18and20. In the exemplary embodiment, blank10includes a front top lid panel22extending along the side of front side panel18, and a rear top lid panel24extending along the side of rear side panel20. A fold axis extends between each side panel18or20and corresponding top lid panels22or24. In the exemplary embodiment, blank10includes tuck flaps26extending along opposite sides of each top lid panel22and24. A fold axis extends between each top lid panel22and24and each corresponding tuck flap26.

FIG. 2is a perspective view of an exemplary embodiment of a container packing system100in accordance with one embodiment of the instant invention. In the exemplary embodiment, system100includes a blank hopper assembly102, a forming station104, a blank pick mechanism106, an upper plow assembly108, a lower plow assembly110, a transfer assembly112, and an operator loading station114. System100facilitates forming a container, also referred to hereinafter as a tray, and directing the formed container to an operator116for loading with items, such as, for example, food items. System100also facilitates retaining the folded form of the container while operator116packs the items into the container. Specifically, system100facilitates retaining the folded form of the container while operator116is packing the container without the use of adhesive, glue, or other chemical or mechanical fasteners to form the container.

FIG. 3is a perspective view of blank hopper assembly102(shown inFIG. 2). Hopper assembly102includes a plurality of guide members120coupled to a frame122. Guide members120facilitate positioning blanks10(shown inFIG. 1) within container packing system100(shown inFIG. 2). In the exemplary embodiment, guide, members120are moveable with respect to frame122to accommodate for blanks10of multiple sizes. Guide members120are outwardly tapered proximate a top edge124of each guide member120to facilitate loading of a stack of blanks10into hopper assembly102. In the exemplary embodiment, guide members120include pins126extending outwardly from an inner surface128of each guide member120. Pins126facilitate supporting blanks10within hopper assembly102during operation of system100. As illustrated inFIG. 2, hopper assembly102is positioned proximate a top portion of container packing system100. As such, blanks10are drawn downward to begin the forming process.

FIG. 4is a perspective view of blank pick mechanism106(shown inFIG. 2). Blank pick mechanism106includes a plurality of vacuum cups160positioned a distance apart from each other on a substantially horizontal plane. Vacuum cups160are coupled to a venturi vacuum system (not shown) for creating a vacuum within vacuum cups160. In one embodiment, each vacuum cup160is coupled to an individual vacuum system. In an alternative embodiment, blank pick mechanism106includes a single vacuum cup160. Blank pick mechanism106includes an actuating mechanism162, such as, for example, a pneumatic cylinder. Actuating mechanism162facilitates guiding vacuum cups160in a substantially vertical direction when blank pick mechanism106is in use. Specifically, as illustrated inFIG. 2, blank pick mechanism106is oriented substantially vertically below hopper assembly102and forming station104. In operation, blank pick mechanism106ascends in a direction towards hopper assembly102until vacuum cups160contact blank10(shown inFIG. 1) within hopper assembly102and then descend with a single blank10through forming station104. Specifically, as blank pick mechanism106descends, blank10is directed through forming station104. In an alternative embodiment, blank pick mechanism106is actuated from above blank hopper assembly102such that blank10is forced downward through forming station104. In such alternative embodiment, blank pick mechanism106may include vacuum cups160, or may include another mechanism for coupling pick mechanism106to blank10for forming a container from blank10.

FIG. 5is a perspective view of upper plow assembly108(shown inFIG. 2). Upper plow assembly108forms a portion of forming station104(shown inFIG. 2). Specifically, upper plow assembly108facilitates forming a portion of container from blank10(shown inFIG. 1). Upper plow assembly108includes a first frame member180and an opposite second frame member182. Frame members180and182extend substantially parallel with respect to one another from a front end184to a back end186and are positioned within a substantially horizontal plane. Upper plow assembly108includes a plurality of arms188coupled to frame members180and182. In the exemplary embodiment, arms188are variably positionable and moveable along frame members180and182.

In the exemplary embodiment, upper plow assembly108includes a first minor flap folding plow192, a second minor flap folding plow194, a third minor flap folding plow196, and a fourth minor flap folding plow198. First and second minor flap folding plows192and194are positioned along first frame member180and are separated from one another by a first distance200. Third and fourth minor flap folding plows196and198are positioned along second frame member182and are separated from one another by a second distance202. Additionally, first and third minor flap folding plows192and196are aligned generally across from one another, and second and fourth minor flap folding plows194and198are aligned generally across from one another. Moreover, in the exemplary embodiment, minor flap folding plows192,194,196, and198are positioned on a substantially horizontal common plane.

In the exemplary embodiment, each minor flap folding plow192,194,196, and198includes a first portion204, a second portion206, and a radius portion208extending therebetween. In the exemplary embodiment, first portion204is coupled to and extends substantially perpendicularly from a respective arm188generally inwardly towards the opposite frame member180or182. Second portion206extends obliquely with respect to first portion204and generally extends inwardly towards the opposite frame member180or182and downwardly with respect to first portion204. The position of second portion206with respect to frame members180and182is variably selected by altering the attachment position of first portion204with respect to arm188. Moreover, the orientation of minor flap folding plow192,194,196, and198is variably selected in a predetermined configuration such that minor flap folding plow192,194,196, and198are configured to contact blank minor flaps16(shown inFIG. 1).

In the exemplary embodiment, upper plow assembly108includes a first end panel folding plow210and a second end panel folding plow212. First and second end panel folding plows210and212are aligned generally across from one another within upper plow assembly108. In the exemplary embodiment, each end panel folding plow210and212includes a first portion214, a second portion216, a third portion218, a first radius portion220extending between first and second portions214and216, respectively, and a second radius portion222extending between second and third portions216and218, respectively. In the exemplary embodiment, first portion214is coupled to and extends substantially perpendicularly from a respective arm188generally inwardly towards the opposite frame member180or182. Second portion216extends obliquely with respect to first portion214and generally extends inwardly towards the opposite frame member180or182and downwardly with respect to first portion214. Third portion218extends obliquely with respect to second portion216and generally extends inwardly towards the opposite frame member180or182and downwardly with respect to first portion214and second portion216. The position of second and third portions216and218with respect to frame members180and182is variably selected by altering the attachment position of first portion214with respect to arm188. Moreover, the orientation of end panel folding plows210and212is variably selected in a predetermined configuration such that end panel folding plows210and212are configured to contact corresponding blank end panels14(shown inFIG. 1).

In the exemplary embodiment, upper plow assembly108includes a first tuck flap folder224and a second tuck flap folder226. First and second tuck flap folders224and226are aligned generally across from one another, and are positioned generally vertically below back end186of frame members180and182. In the exemplary embodiment, each tuck flap folder224and226includes a contact portion228coupled to an actuating mechanism230, such as, for example, a pneumatic cylinder. Actuating mechanism230is operatively coupled to a controller (not shown). Tuck flap folders224and226are oriented such that each contact portion228is configured to contact a corresponding blank tuck flap26(shown inFIG. 1). As such, tuck flaps26associated with rear top lid panel24(shown inFIG. 1) do not interfere with or contact end panel folding plows210or212as container is directed from forming station104(shown inFIG. 2) to operator loading station114(shown inFIG. 2).

FIG. 6is a perspective view of lower plow assembly110(shown inFIG. 2). Lower plow assembly110forms a portion of forming station104(shown inFIG. 2). Specifically, lower plow assembly110facilitates forming a portion of container from blank10. Lower plow assembly110includes a first frame member260and an opposite second frame member262. Frame members260and262extend substantially parallel with respect to one another from a front end264to a back end266. Lower plow assembly110includes a plurality of rear side panel folding plows268extending from frame members260and262. In the exemplary embodiment, rear side panel folding plows268are variably positionable and moveable along frame members260and262to facilitate forming multiple sized blanks10(shown inFIG. 1).

In the exemplary embodiment, each rear side panel folding plow268includes a first portion270, a second portion272, a third portion274, a first radius portion276extending between first and second portions270and272, respectively, and a second radius portion278extending between second and third portions272and274, respectively. In the exemplary embodiment, first portion270is coupled to and extends substantially vertically upward from a respective arm280. Second portion272extends obliquely with respect to first portion270and generally extends outwardly and upwardly with respect to lower plow assembly110. Third portion274extends obliquely with respect to second portion272and generally extends outwardly and upwardly with respect to lower plow assembly110. The position of rear side panel folding plows268with respect to frame members260and262is variably selected by altering the attachment position of arm280with respect to frame members260and262to facilitate forming multiple sized blanks10. Moreover, the orientation of rear side panel folding plows268is variably selected in a predetermined configuration such that an inner surface282of each rear side panel folding plow268is configured to contact blank rear side panel20(shown inFIG. 1).

In the exemplary embodiment, lower plow assembly110includes a front side panel folding plow284extending from frame member262. In the exemplary embodiment, front side panel folding plow284is stationary with respect to frame member262. In the exemplary embodiment, front side panel folding plow284includes a first portion286, a second portion288, a third portion290, a first radius portion292extending between first and second portions286and288, respectively, and a second radius portion294extending between second and third portions288and290. In the exemplary embodiment, first portion286is coupled to and extends substantially vertically upward from a respective arm296. Second portion288extends obliquely with respect to first portion286and generally extends outwardly and upwardly with respect to lower plow assembly110. Third portion290extends obliquely with respect to second portion286and generally extends outwardly and upwardly with respect to lower plow assembly110. The orientation of front side panel folding plow284is variably selected in a predetermined configuration such that an inner surface298of front side panel folding plow284is configured to contact blank front side panel18(shown inFIG. 1).

Lower plow assembly110also includes a folding plow actuating mechanism300coupled to front side panel folding plow284. Actuating mechanism300facilitates adjusting the position of front side panel folding plow284between a loading position and an unloading position. In the loading position, as shown inFIG. 6, the front side panel folding plow284is in a substantially upright, or vertical, position, similar to the position illustrated inFIG. 6. As such, front side panel folding plow284facilitates forming the container when in the loading position. In the unloading position, front side panel folding plow284is in a substantially horizontal position (not shown) such that the formed container can be transferred from forming station104. In the exemplary embodiment, actuating mechanism300is a pneumatic cylinder operatively coupled to a controller (not shown) for controlling the position of front side panel folding plow284. In one embodiment, the controller is coupled to a photo-detection eye302positioned along frame member260to determine the presence or absence of a container in the line of sight of eye302. Eye302transmits a signal to the controller relating to the presence of the container, and the controller operates actuating mechanism300accordingly. For example, in one embodiment, when the absence of a container is detected by eye302, a signal is transmitted to the controller to activate actuating mechanism300to move front side panel folding plow284into the loading position.

FIG. 7is a perspective view of transfer assembly112(shown inFIG. 2). Transfer assembly112facilitates transferring a formed container from forming station104to operator loading station114(shown inFIG. 2). Specifically, transfer assembly112includes a container support assembly320to facilitate supporting panels of the formed container. Container support assembly320is moveable along a linear path of travel between an extended position and a retracted position. In the retracted position, container support assembly320is located proximate forming station104. In the extended position, as shown inFIG. 7, container support assembly320is located proximate loading station114. In the exemplary embodiment, transfer assembly112includes an actuating mechanism322to facilitate transferring container support assembly320along the path of travel. In one embodiment, actuating mechanism322is a pneumatic band cylinder. Actuating mechanism322is operatively coupled to a controller (not shown) that controls the operations of actuating mechanism322.

In the exemplary embodiment, support assembly320includes a front side panel containment bar324, an end panel containment bar326, and a rear side panel containment bar328. In the exemplary embodiment, rear side panel containment bar328is moveable in the direction of arrow “A”. Specifically, rear side panel containment bar328is moveable between an extended, or supporting position, and a non-extended, or non-supporting, position, as shown inFIG. 7. In the extended position, rear side panel containment bar328contacts rear side panel20(shown inFIG. 1) of container. As such, rear side panel containment bar328facilitates supporting rear side panel20during transfer of container from forming station104to operator loading station114. In the non-extended position, rear side panel containment bar328is positioned away from the container, which is located in the forming area, such that rear side panel containment bar328does not interfere with the forming process of the container. Once activated, rear side panel containment bar328moves to the extended position, and transfer assembly112is ready to transfer the container from forming station104to loading station114. In one embodiment, rear side panel containment bar328is extended and retracted by a pneumatic cylinder operatively coupled to a controller (not shown). Rear side panel containment bar328is then de-activated such that support assembly320can be returned to forming station104.

As further shown inFIG. 6, container packing system100(shown inFIG. 2) includes an end panel containment assembly330coupled to a frame member332. In one embodiment, frame member332is coupled to lower plow assembly frame member260. Frame member332is selectively positionable to facilitate positioning end panel containment assembly330. Specifically, end panel containment assembly330is positioned to contact end panel14(shown inFIG. 1) of the container when the container is transferred to loading station114by transfer assembly112. As such, end panel containment assembly330and container support assembly320(shown inFIG. 7) facilitate supporting each sidewall of the container during the packing of the container by operator (shown inFIG. 2). In the exemplary embodiment, end panel containment assembly330includes an actuating mechanism334to facilitate providing a biasing force against end panel14of the container when the container is positioned at loading station114. In one embodiment, end panel containment assembly330is spring loaded.

FIG. 8is a perspective view of loading station114(shown inFIG. 2). In the exemplary embodiment, loading station114includes a guard340having a flat top surface342. As illustrated inFIG. 2, guard340surrounds transfer assembly112, specifically container support assembly320, to protect operator116(shown inFIG. 2) when transfer assembly112is transferred from the retracted position to the extended position. Loading station114also includes a deck344for supporting the container while operator116is loading or packing the container with items. Once the container is loaded, operator116closes the container. A front guide rail346extends along deck344to guide the container as operator116manually transfers the closed container out of loading station114. In the exemplary embodiment, guide rail346includes a photo-detector eye348positioned along guide rail346to determine the presence or absence of a container in the line of sight of eye. Eye348transmits a signal to the controller relating to the presence or absence of the container. A rear guide rail350extends substantially perpendicularly with respect to front guide rail346along a portion of deck344. In the exemplary embodiment, the position of rear guide rail350along deck344is variably selectable to accommodate multiple size containers.

In the exemplary embodiment, prior to operation of container packing system100, operator116loads a stack of blanks10(shown inFIG. 1) in blank hopper assembly102. During operation, blank pick mechanism106ascends to attach to a single blank10in blank hopper assembly102. Blank pick mechanism106then descends through forming station104, and as blank10descends through forming station104, blank10is formed into a container. In the exemplary embodiment, blank10is sequentially formed into the container as blank is directed through forming station104. Specifically, as blank10begins to descend, minor flaps16(shown inFIG. 1) contact and are folded by minor flap folding plows192,194,196, and198. As blank10is further descended, end panels14(shown inFIG. 1) contact and are folded by end panel folding plows210and212. As blank10is further descended, side panels18and20(shown inFIG. 1) contact and are folded by side panel folding plows268and284. As such, each of the panels are sequentially folded along respective fold axis to form the container. Additionally, when the container is within forming station104, end panel folding plows210and212and rear side panel folding plows268maintain contact with respective panels of the container. As such, adhesive is not required for the container to maintain form. Front side panel folding plow284may be in contact with front side panel18when the container is in forming station104, however, front side panel folding plow284must be in the unloading position before the container is transferred from forming station104. Additionally, even when front side panel folding plow284is in the unloading position, front side panel18of the container is supported. Specifically, front side panel18is supported by container support assembly320.

When the container is in the fully formed state, container support assembly320of transfer assembly112is positioned along respective portions of the container. Specifically, front side panel18is in contact with front side panel containment bar324, and an end panel14is in contact with end panel containment bar326. Additionally, once container is in the fully formed state, a controller transmits a signal to pneumatic cylinder to extend rear side panel containment bar328. Once extended, transfer assembly112is ready to transfer the container from forming station104to loading station114. In the exemplary embodiment, operator116operates a switch (not shown) to activate the transfer assembly112. In one embodiment, the switch is a foot switch. Once activated, transfer assembly112guides the container to the operator loading station114. As the container is transferred, end panels14and side panels18and20are fully supported such that the container retains a formed shape. In the fully extended position, one of end panel14is in contact with end panel containment assembly330.

Once the container is transferred to loading station114, the absence of a container is sensed by photo-detection eye348, and a signal is sent to a controller relating to a demand for another container. A corresponding signal is transmitted from the controller to blank pick mechanism106to retrieve another blank10. As such, a container is readily available for operator116when a demand is requested.

When the container is at loading station114, operator116loads or packs the container with items for packaging. In one embodiment, the items are delivered to operator116by a conveyor system (not shown). Once the container is loaded, operator116folds tuck flaps26into the container and directs top lid panels22and24towards container, thereby closing the container. Once the top lid panels22and24are properly positioned, the container does not require additional external support from container support assembly320. Once packaged and closed, the container is manually transferred from loading station114. In one embodiment, the container is transferred from loading station114to a container sealing station (not shown) where an adhesive, such as packaging tape, is applied to the top lid panels22and24to seal the container from opening. Additionally, because blank10has a single, solid bottom panel12, adhesive is not required to seal bottom panel12. As the container is transferred from loading station114, end panel containment assembly330is moved to allow the container to pass from loading station114. Additionally, when the container is transferred, photo-detection eye348detects the absence of a container. A signal relating to the absence of a container is transmitted to a controller (not shown) and a corresponding signal is transmitted from the controller to transfer assembly112. Specifically, rear side panel containment bar328is transferred to the non-extended position, and transfer assembly112transfers support assembly320to the retracted position. Once in the retracted position, support assembly320is configured to support the respective panels of the next container in forming station104.

FIG. 9illustrates an exemplary folding progression400of blank10formed through a sequential forming process. In the exemplary embodiment, minor flaps16are inwardly folded along fold axis between minor flaps16and end panels14. End panels14are then inwardly folded along fold axis between end panels14and bottom panel12. Side panels18and20are then inwardly folded along fold axis between side panels18and20and bottom panel12. Tuck flaps26are then inwardly folded along fold axis between tuck flaps26and top lid panels22and24. Top lid panels22and24are then inwardly folded along fold axis between top lid panels22and24and side panels18and20.

The container formed by such a process and from such a blank10provides a rigid container having additional vertical support due to the additional panels, such as, minor flaps16and tuck flaps26, along end panels14and side panels18and20. As such, the container can support additional weight, or layers of containers, stacked on top of the container. Additionally, the container formed by such a process and from such a blank10provides a stable container having a solid bottom panel12. As such, additional assembly time, personnel, and materials are not required to secure the bottom panel12prior to packing the container. Moreover, by using a container packing system, such as system100, additional assembly time and personnel are not required to form the container prior to packing the container, as system100automatically provides a container in a formed state and holds the container in the formed state until operator116secures the container.

The above-described container packing system100for forming a container for packing operates in a cost-effective and reliable manner. The container is formed from a blank10having a single bottom panel12and a plurality of flaps for forming the side walls and the top walls. The packing system100includes a forming station104for folding the major and minor flaps of the blank10in a sequential order such that a container is formed and presented to an operator for loading of items therein. Additionally, the packing system100includes a plurality of containment bars that retain the container in a formed state while the operator is loading the container. As a result, a packed container may be formed and loaded in a reliable and cost-effective manner.

Exemplary embodiments of container packing systems100are described above in detail. The packing systems100are not limited to the specific embodiments described herein, but rather, components of each packing system100may be utilized independently and separately from other components described herein. For example, each packing system100component can also be used in combination with other packing system100components.