System and method for assembling a package with a flip-top

An automatic packaging machine for forming a latching flip-top box from a blank. A plurality of mandrels are coupled to a conveyor system. Each of the mandrels include a mounting block for coupling the mandrel to the automatic packaging machine, a package-holding assembly operatively connected to the mounting block and being rotatable about a first axis from a first position to a second position, and a flap holder assembly operatively connected to the mounting block. The flap holder assembly is rotatable about a second axis substantially perpendicular to the first axis. A plurality of plows and tucker assemblies sequentially manipulate portions of the blank in order to form portions of the box.

FIELD OF THE INVENTION

The present invention relates generally to automatic packaging machines. More particularly, the present invention relates systems and method for assembling self-latching boxes and/or packages with a flip top.

BACKGROUND OF THE INVENTION

Various types of automatic packaging machines are known and used for assembling paperboard and/or cardboard packages from precut box blanks. These packages can be used to hold a wide variety of items, ranging from chewing gum to candy to office supplies: U.S. Pat. Nos. 4,578,929; 4,548,593; 4,716,714; 4,829,751; 4,856,566; 4,982,556; 5,010,929; 5,072,573; 5,144,790; and 6,195,959 are examples of packaging machines which may be used to load small items into different types of packages.

Conventional automatic packing machines include a conveyor, usually an endless link chain conveyor, which travels through or past a number of work stations extending between a magazine containing package blanks and a product discharge end. Usually, the package blanks are a stack of die cut paperboard or cardboard blanks which are picked up one-at-a-time by vacuum cups and then put into package-forming mandrels carried by the conveyor. Panels and flaps on the bottom of the blank are folded by a series of plows and sealed in order to close the package. A pre-determined amount of product is then placed in the package. Next, panels and flaps forming a top of the package are folded and sealed. Then the package is discharged onto any suitable conveyor, into a shipping carton, or to another device for receiving the completed product containing packaging.

Conventionally, a plow is a strip of metal, or the like, extending along a length of the conveyor and in a location where the panels and flaps are to be folded. First, panels and flaps forming the bottom of the package encounter the plows and then are folded as the conveyor carries the package past the plow. Then, a pre-determined amount of product is placed in the package. Next, panels and flaps forming a top of the package are folded and sealed in a similar manner. Depending upon product packaging needs, the package may or may not be wrapped in a transparent film which is sealed. Finally, the package is discharged onto any suitable conveyor, into a shipping box or another suitable device for receiving the product containing package.

Often, the product presents special considerations which require the packaging machine to perform unique functions as the package is formed and filled. These functions may be performed by special parts which are attached to or positioned near the conveyor. Many examples of such special parts are shown and described in the above-cited patents.

One type of conventional package which is often used for candy and mints is commonly referred to as a “flip-top” box or package. Such a package is made from a single, unitary, die cut blank of thin cardboard stock. A flip-top package has a bottom section which is in the form of a rectangular parallelepiped. The top of the package is in the form of a hood connected to the bottom along a crease line which acts as a hinge. The hood moves away from or over the top of the package in order to open or close it. It is necessary for the packaging machine to first form the blank into the package, then count a specific number of small items, such as candy coated chewing gum, next deposit them in the package, and finally close and seal the package. One such “flip-top” package is shown in prior art FIG.1.

Prior artFIG. 2shows one type of example automatic packaging machine for assembling the type of “flip-top” package of FIG.1. This machine is described in detail in U.S. Pat. No. 6,195,959 and is incorporated herein by reference. This system uses a two-part mandrel which is joined by a single hinge. One of the two hinged parts includes a roller thereon for following a cam track having a quarter turn spiral therein. As the roller follows the spiral causing one hinged part to move through a quarter turn, the flip-top is folded over and formed.

In the conventional “flip-top” package shown inFIG. 1, the hinge of the flip-top joins the flip-top to the entire width of the (longer) major plane of the package. As a result, when the flip-top is opened, the entire top area of the package is exposed. Recently, however, a new type of “flip-top” package has been developed. This new package is shown at98in FIG.3. The package98, like the conventional package ofFIG. 1, includes a flip-top101hingedly connected to an upper portion103of the package. Unlike the conventional package, however, the flip-top's hinge105runs along the (shorter) minor plane of the package, substantially perpendicular to the hinge line of the conventional “flip top” package. Furthermore, the hinge105runs across the middle of the package top, unlike the conventional package. As a result, the new package98has a hole108within a side panel106of the package98instead of having the top entirely open when the flip-top101is “flipped open.”

This new type of “partial flip-top” package requires several more distinct flaps than the previous packages, which adds a significant amount of complexity to any machine for assembling and filling the packages. In particular, problems arise because the mandrels used in the conventional assembly devices are not properly aligned to fold down the top panels of the package blank to form the flip-top of the package. Several additional steps are therefore required to complete the assembly process. This results in increased complexity and assembly time, diminishing the assembly machine's efficiency.

SUMMARY

It is therefore one object of the invention to provide an improved system and method for assembling a “flip top” package.

It is another object of the invention to provide a system and method for assembling a “flip-top” package where the flip-top of the package is hingedly connected to the top of the package along a hinge line running through the middle of the package top.

It is another object of the invention to provide a system and method for assembling a “flip-top” package that includes a minimal amount of manual labor.

It is still another object of the invention to provide a system and method for assembling a “flip-top” package that can be assembled in a minimal amount of time.

In accordance with the invention and the above examples of objects, a system and method is provided for assembling a “partial flip-top” box or package in a highly efficient manner. In a preferred embodiment, a plurality of mandrels are coupled to an “endless link” chain conveyor. Each mandrel includes a mounting bracket for coupling the mandrel to a rail. The bracket is operatively connected to a package-holding subassembly. The package-holding assembly includes a gripping mechanism for holding the package blank during assembly. The package-holding assembly is rotatable about a first axis relative to the rest of the mandrel. A flap holder subassembly is also operatively connected to the bracket. The flap holder assembly is rotatable about a second axis substantially perpendicular to the first axis. The rotation of the package-holding assembly permits the package blank to be moved into various orientations such that the blank can be quickly and efficiently assembled into a “partial flip-top” package. In one preferred embodiment of the invention, the system and method results in up to 400 partial flip-top packages being assembled per minute.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIGS. 3 and 4show a paperboard package98including a “partial” latching flip-top package flip-top101which is folded, formed, filled, and sealed by an automatic package machine according to one form of the invention. The package98, has the flip-top101hingedly connected to an upper portion103of the package98. The hinge105between the flip-top101and the upper portion103runs along the (shorter) minor plane of the package, substantially perpendicular to where the hinge line would be on a conventional “flip top” package. The hinge105runs across the middle of the upper portion103. The package98includes a hole108within a minor side panel106of the package98instead of having the top entirely open when the flip-top101is “flipped open.” In this new package, the hole108is exposed when the flip-top101is flipped open, as shown inFIG. 4, and the hole108is unexposed when the flip-top101is closed.

FIG. 5shows a paperboard package blank99that is ultimately assembled into the package98shown inFIGS. 3-4. The package blank99includes a first major side100, a second major side102, a first minor side104and a second minor side106. The second minor side106includes a hole108prepunched therein. When the package98is fully assembled and filled, the packaged product is ejected through the hole108. An inner panel110is attached to the edge of the second minor side106opposite the second major side102. According to one particular preferred embodiment, the inner panel110is pre-secured to the inside of the first major side100before the blank99enters the package machine. Preferably glue or some other type of adhesive or adhesion method is used to secure the inner panel106to the first major side100.

The bottom of the package is formed by the combination of a first minor lower flap112, a second minor lower flap114, a first major lower flap116and a second major lower flap118. As is discussed herein, in the most preferred embodiment these flaps are sequentially folded during the assembly process such that the second major lower flap is the outermost flap when the package98is completed, serving as the “bottom” of the package.

A latching panel122is coupled to the top of the second minor side106. The latching panel122is folded downward during the assembly process. When the package98is fully assembled, the latching panel122will come into contact with the underside of the flip-top101, providing a certain degree of resistance and helping to keep the flip-top101in the closed position relative to the rest of the package98. The flexibility of the latching panel122enables it to be released from the flip-top101when the flip-top101is manually opened to the position shown in FIG.4. Yet, the resilience of the latching panel122is such that the flip-top101is again captured when closed.

A first front upper panel124is coupled to the first major side100, and a second front upper panel120is coupled to second major side102. Similarly, a first rear upper panel134is coupled to the first major side100; and a second rear upper panel136is coupled to the second major side102. As will be discussed herein, the first and second front upper panels124and120eventually cooperate to the top portion of the package98between the flip-top101and the rest of the package98, the first and second rear upper panels134and136eventually cooperating to form the top of the package98behind the flip-top101.

The flip-top101of the package98is formed by the folding of several sequential panels as is discussed herein. A rear flip-top panel126ais coupled to the first minor side104on one edge and an intermediate flip-top panel127on an opposite edge. A front flip-top panel132is coupled to the intermediate flip-top panel127on an edge of the intermediate flip-top panel127opposite the rear flip-top panel126a. First and second flip-top wing panels126band126c, respectively, are also coupled to the intermediate flip-top panel127on opposite sides thereof. The first flip-top wing panel126bhas a first wing panel128coupled to one edge thereof. Similarly, the second flip-top wing panel126chas a second wing panel130coupled to one edge thereof.

The back of the top portion of the package98is formed by the subsequent folding of a first rear upper panel134and a second rear upper panel136. The first rear upper panel134is connected to the first major side100, and the second rear upper panel136is coupled to the second major side102.

The present invention provides an automatic packaging machine which forms, fills and closes the package shown and described inFIGS. 3-5andFIGS. 12-13, by use of a mandrel200shown inFIGS. 6-11.

The automatic packaging machine comprises a plurality of the mandrels200coupled to a conveyor system. An example of a conventional conveyor system is shown in prior art FIG.2. As shown inFIGS. 6-11, each of the mandrels200comprises a mounting block202that couples the mandrel200to a suitable conveyor, an example of which is shown in prior artFIG. 2, so that the mandrel200is carried by and moves with the conveyor. In one embodiment of the invention, the conveyor comprises a link chain. The mounting block202is operatively connected to a package-holding assembly204. The package-holding assembly204includes a movable gripper206surrounding a guide mechanism208for holding a package blank99during assembly. The gripper206includes a first gripper half210and a second gripper half212, each of which is capable of moving away from each other in order to allow a package blank99to be placed within the guide mechanism208. After the blank is placed within the guide mechanism208first gripper half210and the second gripper half212move towards each other. It is also possible that the first gripper half210can be formed from two pieces, as can the second gripper half212and the guide mechanism208.

Each mandrel200includes a support member214connected to a side of the mounting block202. The package-holding assembly204is rotatably connected to the support member214at a first axis216. A latching member218is attached to the support member214at an end substantially opposite the first axis216. The latching member218is capable of capturing and fixing the position of a bushing220on the package-holding assembly204. When the latching member218releases the bushing220, the package-holding assembly204is capable of rotating about the first axis216, which is substantially vertical according to one preferred embodiment of the invention.

Each of the mandrels200also includes a flap holder assembly222operatively connected to the support member214. The flap holder assembly222is rotatable about a second axis224which is substantially perpendicular to the first axis216. The flap holder assembly222is used primarily to push down the rear flip-top portion126aand also push down the connected portions that comprise the flip-top101towards the rest of the package98.

According to a preferred embodiment shown inFIGS. 14-15, a first tucker assembly400and a second tucker assembly420are used to make additional folds in the package98. Both the first tucker assembly400and the second tucker assembly420are attached to the package machine and strategically located to come into contact with multiple panels.

The first tucker assembly400comprises a first tucker402with multiple flanges408. The first tucker402is coupled to a rotatable shaft404which is operatively connected to a transverse member406, with the transverse member406ultimately connected to the rest of the machine of the present invention. The second tucker assembly420comprises a second tucker422including a pair of slots424and is operatively connected to the rest of the package machine in a manner substantially identical to that of the first tucker402.

The first tucker402is positioned such that the leading edges of two of its flanges408sequentially come into contact with the second front upper panel120and the latching panel122, pushing both panels downward and into the appropriate positions. Similarly, the pair of slots424on the second tucker422sequentially “catch” the first wing panel128and the second wing panel130, folding them inward to their new positions.

The assembly of the package98in a most preferred embodiment is generally as follows and as represented in FIG.18. As discussed above, glue or some other type of conventional adhesion method is used to secure the inner panel106to the first major side100before the package blank99is placed into the machine. The package blank99is moved into the machine by use of a plurality of suction devices (not shown) that “grab” the package blank99and transport it to a mandrel200. Before receiving the package blank99, the first gripper half210and the second gripper half212open, shown at500, to allow the package blank99to enter the guide mechanism208, shown at502. After the package blank99has been inserted into guide mechanism208, the first gripper half210and the second gripper half212close, shown at504.

After the package blank99is placed within the guide mechanism208, the mandrel200moves along a conveyor. At step506, the first minor lower flap112comes into contact with a first plow (not shown), folding the first minor lower flap112inward. The second minor lower flap114is then folded inward by a second plow (not shown), shown at step508. The first major lower flap116then comes into contact with a third plow (not shown), folding the first major lower flap116inward at510. A glue or some other type of adhesive is then applied to the exposed side of the first major lower flap116, shown at step512. Immediately thereafter, a fourth plow (not shown) folds the second major lower flap118onto the first major lower flap116, shown at514.

At this stage, the bottom of the package98is completely assembled. At step516, a cam on the machine acts against the mandrel200, causing the latching member218to disengage from the bushing220and causing the package-holding assembly204to rotate approximately ninety degrees about the first axis216from the position shown inFIGS. 6-7to the position shown inFIGS. 9-10.

Once the package-holding assembly204has been rotated ninety degrees, the mandrel200reaches the first tucker assembly400. At step518, one of the flanges408of the first tucker402comes into contact and folds down the second front upper panel120. This is followed at step520by another of the flanges408of the first tucker402coming into contact with the latching panel122, folding it downward and outward from the center of the package98. This moves the latching panel122into a loosely folded position where it is later caught by the panels on the flip-top101, thereby creating a latching condition. Glue or another type of adhesive is then placed on the exposed surface of the second front upper panel120, shown at522. This is followed at step524by a fifth plow (not shown) coming into contact with and folding down the first front upper panel124onto the exposed surface of the second front upper panel120.

At step526, the flap holder assembly222is rotated approximately ninety degrees about the second axis224. This action causes the front flip-top panel132to fold downward towards the rest of the package98. Simultaneously, first and second side members230and232on the flap holder assembly222come into contact with the first and second flip-top wing panels126band126c, respectively, causing them to fold inward (if necessary, a small spacer233can be used to achieve a precise alignment and positioning of the first and/or second flip-top wing panels126band126c).

The mandrel200then reaches the second tucker assembly420. The slots424on the second tucker422then sequentially grab and fold the first wing panel128and the second wing panel130inward, shown at steps528and530. At step532, glue or another type of adhesive is then applied to the exposed surfaces of the first and second wing panels128and130. It is also possible to locate the glue or another type of adhesive on the underside of the front flip-top panel132. A sixth plow300is then used at step534to fold the front flip-top panel132downward and secure it to the exposed sides of the first and second wing panels128and130. This effectively forms the lid101of the package98.

At step535, the package-holding assembly204is rotated back about the first axis216from the second position to the first position. The next step of the process, represented at536, involves the package-holding assembly204rotating back to its original position. This can be accomplished by the use of a cam or other conventional system known to those skilled in the art. At step538, a seventh plow302contacts and folds downward a first rear upper panel134. At step540, glue or another type of adhesive is applied to the exposed side of the first rear upper panel134. This is followed at step542by an eighth plow (not shown) contacting and folding downward the second rear upper panel136onto the exposed surface of the first rear upper panel134. At step544, the completed package98is discharged from the mandrel200, where any suitable means is provided to carry the box98away for disposition.

As discussed above, a series of plows are provided for making a series of strategic folds in the package98.FIGS. 16 and 17illustrate how two exemplary plows operate to fold individual panels. InFIG. 17, the sixth plow300is used to fold the front flip-top panel132. InFIG. 16, the seventh plow302is used to fold down the first rear upper panel134. A series of other plows (not shown) are used through the assembly process to make other folds in a manner that is known to those skilled in the art. According to a preferred embodiment of the invention, all of the plows remain stationary during the assembly process, while each individual mandrel200moves the packages98into contact with the plows.

At one stage during the package assembly process, the product to be packaged is deposited into the partially-completed package98. In one preferred embodiment of the invention, this occurs between steps514and516, when the bottom of the package98has been completely assembled; but the top of the package98remains open. However, it is possible that the filling of the package could occur at some other time. The filling process is performed automatically by methods known by those skilled in the art.

Using the preferred system described herein, up to about 400 packages can be assembled per minute, while maintaining a fully automated system.

It should be understood that the above description of the invention and the specific examples and embodiments, while indicating the preferred embodiments of the present invention, are given by demonstration and not limitation. For example, it is possible to use different types of tuckers and plows in various orders to complete the assembly of the package98. Many changes and modifications within the scope of the present invention may therefore be made without departing from the spirit of the invention, and the invention includes all such inventions and modifications.