Compression and affixing of carton lid

Packing apparatus provides for essentially automatic packing of a cardboard carton at a significantly reduced cost compared to conventional strapping equipment and procedures. The carton preferably used with the packing apparatus includes a cardboard carton lid that is constructed so that the carton may be securely packed and shipped without the necessity for plastic strapping, and using lower strength paperboard than is conventionally provided, and is used with a carton body having side walls. The lid has elongated side panels with first and second parallel lines of weakness (e.g. perforations) formed in them. The bottom, fastening portion, of the side panels is preferably secured to the carton body side walls by cam elements of the apparatus moving the side panels outwardly from the carton side walls, and apparatus for applying adhesive to them while in that position. The carton is packed with nondeformable material such as business forms which extend above the top edge of the carton. The apparatus pushes down on the lid, compressing the material within the carton, to reduce voids in the material, and the components are maintained in the compressed condition as the side panels are adhesively attached to the carton body side walls, without interfering with the ability of the lid to flex at its lines of weakness.

BACKGROUND AND SUMMARY OF THE INVENTION 
Business forms, paper, and many other products are conventionally shipped 
and stored in two piece cartons having a carton body and a top, both of 
cardboard. Since it is highly desirable for the carton lids to be reused 
in such cartons, the carton lid is typically secured to the carton body by 
plastic straps. This is an expensive procedure, however, since there is a 
substantial investment in automatic strapping equipment, since the plastic 
straps are relatively expensive, and since there are significant 
maintenance costs associated with the automatic strappers. Therefore, it 
is highly desirable to provide a carton with a reusable lid that may be 
shipped without plastic strapping, while still securely maintaining the 
carton contents. 
Further, in conventional corrugated cartons, during shipping and handling 
varying amounts of weight and momentum are applied to the carton. This has 
led many users of cartons to build higher cost and higher strength 
corrugated paperboard cartons in order to maintain a rigid box of 
unchanging depth. However, if the box is able to flex to accommodate 
varying amounts of weight and momentum that are applied during shipping 
and handling, lower cost paperboard may be utilized, yet the carton will 
retain its integrity and uniformity throughout its useful life. This is 
especially desirable in the area of packing paper products, such as 
business forms, which tend to expand and contract over time and to settle 
after initial packing since voids are common in the depth dimension. 
It is also necessary, if appropriate production speeds are to be achieved, 
to be able to produce cartons that solve the above mentioned problems with 
automated equipment, rather than requiring hand construction of the 
cartons. 
According to the present invention, an apparatus is provided which effects 
construction of a carton which solves the above mentioned problems in a 
simple and effective manner. According to the present invention the 
expensive strapping equipment necessary for most commercial carton 
packaging systems is eliminated, the cost of materials for packaging are 
greatly reduced, and since the equipment utilized to effect packaging 
according to the invention is much less expensive with a much simpler 
construction, equipment maintenance costs are substantially reduced. For 
example, according to the present invention the apparatus for effecting 
packaging can be about one-fifth the cost of conventional strapping 
equipment, while the operating cost per thousand cartons is less than 
one-tenth, and almost no maintenance is required. 
The invention comprises apparatus for packing and securing a cardboard 
carton. The carton utilized is preferably the carton disclosed in 
copending U.S. application Ser. No. 07/583,371 filed Sept. 17, 1990. 
According to one aspect of the invention, the apparatus comprises: Means 
for providing a compressive force to the lid so that the lid moves 
downwardly toward the carton body top edge. Means for moving the lid 
overlapping side panels away from the carton side walls, and applying 
adhesive thereto and/or to the cooperating portions of the carton side 
walls. And, means for maintaining compressive force on the lid and 
applying inward compressive force to the lid overlapping side panels to 
adhesively bond the overlapping side panels to the side walls. 
The means for providing a compressive force preferably comprise a bottom 
conveyor, such as a plurality of rollers, and a top conveyor, such as a 
plurality of rollers that are slanting so as to provide a constantly 
decreasing height so as to effect gradual compression of the carton in the 
vertical dimension. A cam and applicator comprise the means for moving the 
lid overlapping side sections away from the carton side walls and applying 
glue to the carton side wall and/or the overlapping lid side sections. The 
means for maintaining the compressive force may comprise a plurality of 
vertical axis rollers biased horizontally into engagement with the side 
sections of the lid. 
According to another aspect of the apparatus according to the invention, 
the apparatus comprises: Means for providing a compressive force to the 
carton lid so that the lid moves downwardly toward the carton body top 
edge. Means for attaching the lid overlapping side panels to the carton 
side walls; and means for maintaining compressive force on the lid and 
applying inward compressive force to the lid overlapping side panels 
coincident with action by the means for attaching the lid overlapping side 
panels to the carton side walls. The attaching means preferably comprises 
the adhesive applying means described above, but may also comprise means 
for spraying adhesive, or stapling or taping equipment. 
According to another aspect of the apparatus of the invention, apparatus is 
provided comprising means for moving the carton lid overlapping side 
panels away from the carton side walls, and applying adhesive thereto 
and/or to the cooperating portions of the carton side walls, this means 
comprising a wedge shaped cam element for movement between the lid side 
panels and the carton body side wall disposed on each side of the carton 
to cam the side panel away from the carton wall, and an adhesive 
applicator for transferring adhesive to at least one of the interior of 
the side panel or exterior of the carton side wall as it moves therepast; 
and means for applying an inward compressive force to the lid overlapping 
side panels to adhesively bond the overlapping side panels to the side 
walls. 
It is the primary object of the present invention to provide apparatus for 
effectively, simply, and inexpensively packing a carton and attaching the 
lid to the carton. This and other objects of the invention will become 
clear from an inspection of the description of the invention and from the 
appended claims.

DETAILED DESCRIPTION OF THE DRAWINGS 
An exemplary cardboard carton that is acted upon using the apparatus 
according to the present invention is shown generally by reference numeral 
10 in FIG. 1. While the term "cardboard" will be used throughout the 
specification and claims, it is to be understood that such term is used 
only generically, and includes corrugated and non-corrugated cardboard 
and/or paperboard, and all like materials typically used in cartons. The 
carton per se is the subject of copending application Ser. No. 07/583,371 
filed Sept. 17, 1990. 
The main components of the cardboard carton 10 comprise a lid 11 and a body 
12. The body 12 has a bottom 13 (see FIG. 3), a pair of end walls 15, and 
a pair of side walls 14. It also has an open top defined by a top edge 16 
(see FIG. 3). Except for the weight of the cardboard utilized, the bottom 
12 is a conventional carton bottom of the type commonly used for packaging 
paper products, such as business forms, and the like. 
The lid 11 of the carton is preferably significantly different than 
conventional cardboard carton lids. The lid 11 includes a top 18 and a 
pair of end sections or panels 19, the end panels 19 have a top edge 20 
connected to the top panel 18 and a bottom edge 21, the edges 20 and 21 
spaced a first spacing, typically about three inches. The end sections 19 
are substantially perpendicular to the top panel 18. 
The lid 11 also comprises at least one--and preferably two--side panels 22, 
each having a top edge 23 thereof and a bottom edge 24, the spacing 
between the top edge 23 and the bottom edge 24 being a second spacing 
which is significantly greater than the first spacing. The panel 22 is 
also connected to the top panel 18 at the top edge 23 thereof, and is 
generally perpendicular to both the top panel 18 and the side panels 19. 
Although not apparent in the other figures, as can be seen in FIG. 5, the 
end panels 19 preferably have a pair of ears 30 extending from each, and 
pre-fold score lines 31 therein, both of which are conventional. As is 
conventional, the ears 31 are tucked inside the side panels 22 and affixed 
to the side panels 22 with adhesive or other fasteners (e.g. staples). 
Disposed in the side panels 22 are first and second lines of weakness 25, 
26, preferably formed by perforations (34, 35) that are substantially 
parallel to each other and to top edge 23 and bottom edge 24. Between the 
bottom, second, line of weakness 26 and the bottom edge 24 is a section 27 
of the side panel 22 which has a sufficient dimension to be securely 
attached to the side wall 14 of the carton body 12. Most desirably, the 
first, top, line of weakness 25 is disposed in alignment with the bottom 
21 of the end panels 19 (e.g. about three inches from the top edge 23), 
and the spacing between the lines of weakness 25, 26 is about 1/2 to 1 
inch, and the width of the bottom section 27 (the spacing between second 
line of weakness 26 and bottom edge 24) is about 3/4-11/2 inches. A 
removable strip 28 is provided between the lines of weakness 25, 26. 
The carton lid 11 is also constructed so as to further provide means for 
facilitating grasping of the removable strip 28 to allow tearing of the 
side section at the perforations defining the lines of weakness 25, 26 so 
that the section 27 is detached from the rest of the lid 11. This is 
preferably accomplished--with particular reference to FIGS. 2 and 5--by 
providing a die cut blank 37, having a die cut 38 at the top and bottoms 
thereof, and side die cuts 39 with the removable strip 28, the blank 37 
being provided in substantially the center of the side panel 22. The means 
for facilitating grasping further preferably comprise die cut lines 40, 41 
extending from both sides of the blank 37 and formed at a slight angle 
with respect to the rest of the lines of weakness 25, 26 so as to provide 
enlarged grasping portions 42 in the strip 28. The perforations 34, 35 are 
parallel to each other, and generally in line with the die cut lines 40, 
41, and may have the configuration illustrated in FIGS. 2 and 5, although 
other configurations are also possible, as long as they allow relatively 
ready detachment of the strip 28. 
As seen in FIG. 3, the carton 10 is filled with substantially nondeformable 
(that is non-permanently deformable) material, in the particular case 
illustrated in FIG. 3 a plurality of paper sheets, in the form of 
continuous business forms, multipart business forms (whether continuous or 
detached), or like products. The product extends in a stack upwardly from 
the bottom 13 past the top edge 16 of the carton body 12. The carton is 
then compressed by pushing down on the lid 11--as will be hereafter 
described--to reduce the void volume within the stack of business forms or 
like product, and then adhesive 45--or like fastening means--is utilized 
to affix the bottom sections 27 of the side panels 22 to the carton body 
side walls 14. 
With the above-identified overpacking of the carton 10, and compressing 
thereof, the lines of weakness 25, 26 will inherently form flex areas, so 
that when the carton 10 is subjected to varying loads and momentum during 
shipping and handling, the carton components can flex (see FIG. 4) rather 
than having to be rigid enough to withstand such forces without any 
deformation. This ability to "give" in response to applied forces rather 
than having to be strong enough to resist such forces allows the carton 10 
to be constructed of lower weight paperboard, and does not require the use 
of filler pads. For example, in conventional packaging of business forms, 
200 pound test boxes with or without extra strength 33 pound mediums, and 
corrugated and Styrofoam.RTM. filler pads, are utilized. However for the 
carton 10, there is no need for any fillers, and 125 pound, 150 pound or 
175 pound test corrugated paperboard may be utilized for both the carton 
body and the lid. While more paperboard material (square footage) is 
necessary because of the elongated side panels 22, since the weight is 
less, the cost of the carton 10 will be less than that of a comparable 
conventional carton having the same protecting qualities. 
FIGS. 6 through 8 schematically illustrate apparatus according to the 
invention for packing a cardboard carton, such as the carton 10. The 
apparatus is illustrated generally at 50 in FIGS. 6 and 7, and includes an 
aligning section 51, an encoding section 52, a turning section 53, a 
compressing section or stage 54, an affixing, bonding, or adhesion stage 
55, and a further compression and accumulation stage 56. The apparatus 50 
includes a conventional conveyor 58, such as powered horizontal axis 
rollers, which transport the carton 10 up to the last section 56. The 
carton is conveyed in the direction of arrow 59 in FIGS. 6-8, the carton 
10 first being aligned by the guides 60, and then being encoded by the 
encoding wheel 61, engaging the turning post 62, and then being turned so 
that the elongated (side) panels face in the direction of conveyance 59. 
When moving in direction 59, the carton 10 (comprising lid 11 and body 12) 
encounters a guide or cam 63 which engages the lid 11 and gradually moves 
it into contact with the upper horizontal axis rollers 65, which--as 
illustrated in FIG. 7--are disposed at an angle with respect to the power 
rollers 58 so that the distance between the rollers 65 and the rollers 58 
is gradually decreased as the carton 10 moves in the direction of 
conveyance 59. This action compresses the carton 10, removing a 
significant amount of the void volume within the carton since the product 
in the carton is above the top edge 16 of the carton body 12 (see FIG. 3). 
While the carton 10 is held in this compressed condition, it engages the 
gluing or adhesion apparatus 66. 
The gluing or adhesion apparatus 66--as seen most clearly in FIG. 
8--preferably comprises a first element 67 having a wedge shape including 
a cam surface 68 which engages the side panel 22 at the bottom section 27 
thereof and cams it outwardly, away from the side wall 14 of the carton 
bottom 12. The bottom section 27 of the side panel 22 then comes in 
contact with the glue applicator 69, which has surfaces 70, 71 thereof 
which respectively engage the inside of the side panel 22, and the 
exterior of the side wall 14. Glue may be applied by one or both of the 
surfaces 70, 71 to the cardboard. In FIG. 8 the surface 70 of applicator 
69 has applied the glue 45 to the interior surface of the side panel 22 
bottom section 27, which is then cammed back into contact with the side 
panel 14 by the element 72 having a wedge shape, including the linear cam 
portion 73. During this entire time, the rollers 75--rotatable about a 
horizontal axis--maintain a compressive force on the lid 11. 
After passing through the affixing stage 55, the carton 10 enters the 
accumulation stage 56 which includes means for maintaining the compressive 
force on the lid and applying an inward compressive force to the side 
panels to adhesively bond the side panels to the side walls of the carton. 
Preferably two rows of vertical axis rollers 76 are provided, with an 
adjustable spacing therebetween and preferably is spaced in such a way--or 
biased by springs or the like--so that they apply an inward force to the 
side panels 22. In the stage 56 the top rollers 75 are continued, and also 
bottom rollers 77 are provided, the rollers 77--unlike the rollers 
58--being nonpowered. In addition to maintaining compression of the lid 11 
on the carton body 12, stage 56 also accumulates cartons. Guides 78, like 
guides 60, also may be provided. Most plants, although utilized 
differently than as described above, have existing apparatus like that in 
stage 56. 
While particular apparatus has been described above, it is to be understood 
that the apparatus described is totally exemplary, and that many other 
inexpensive comparable components can be utilized for performing the same 
functions. For example, the rollers 65, 75 can be spring biased 
downwardly, rods or other pressure bearing devices may be utilized instead 
of the vertical axis rollers 76, etc. Also, while the elements of the 
gluing section 66 are illustrated as supported from above--with supports 
exteriorly of the carton sides and extending downwardly to below the 
elements 67, 69, 72--they can, of course, be supported by legs upstanding 
from the bottom stationary side edges of the conveyor 58. Further, glue 
application in section 55 may be by spraying, extruding, or positively 
flowing onto the cardboard; or replaced by automatic stapling equipment, 
or automatic taping equipment (e.g. using security thread or security 
printed pressure sensitive or gummed tape). 
It will be seen that the apparatus according to the invention is simple and 
relatively inexpensive, yet allows effective automatic packing of a 
carton. While the invention has been herein shown and described in what is 
presently conceived to be the most practical and preferred embodiment 
thereof, it will be apparent to those of ordinary skill in the art that 
many modifications may be made thereof within the scope of the invention, 
which scope is to be accorded the broadest interpretation of the appended 
claims so as to encompass all equivalent structures and apparatus.