Abstract:
A moveable tape head mechanism for a box erecting machine having a fixed guide rail and an adjustable guide rail includes a cradle which carries a tape head, the cradle being horizontally slidable between operational and loading positions to expedite replacement of a tape roll contained thereon. In the operational position, the tape head mechanism is detachably held by a pin in operational alignment with a box flap closure apparatus. The tape head mechanism is moved from the operational positional to the loading position by installing a cover plate over the tape head to compress the rollers into the tape head, disengaging the pin from its corresponding receptacle formed on the flap closure apparatus, and sliding the tape head mechanism under a frame member and outside the perimeter of the box erecting machine. When the tape head is in the loading position, the tape roll is located outside the perimeter of the box erecting machine to facilitate replacement thereof. After the tape roll has been replaced, the tape head mechanism is slid back to the operational position with the pin slidably engaging a ramp surface and returning into engagement with the receptacle, thus automatically realigning the tape head mechanism with the flap closure apparatus.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     The present application is a continuation application claiming priority from U.S. patent application Ser. No. 09/183,480 filed Oct. 30, 1998 now U.S. Pat. No. 6,135,937 entitled MOVEABLE TAPE HEAD FOR BOX ERECTING MACHINE, the disclosures of which are incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     This invention relates generally to box erecting machines and, more particularly, to a moveable tape head for a box erecting machine. Specifically, the invention relates to an adjustable tape head that can be horizontally moved between an operational position internal to the box erecting machine operationally and adjustably aligned with the box folding structure and a loading position outside the perimeter of the box erecting machine to facilitate replacement of the tape roll. 
     2. Background Information 
     Essentially all commercial goods travel through commerce enclosed in some type of packaging. Among the most common types of packaging are boxes (also referred to as carton or cases) of a rectangular solid shape and that are typically manufactured of corrugated cardboard. Such boxes are of innumerable shapes and sizes suited to the specific needs of the packaging application. One such type of box is a parallelepiped carton with inward-turned flaps on at least the bottom thereof. 
     Unassembled parallelepiped cartons are typically cut from a single sheet of material and then formed into a generally tubular configuration having four sides. Each side terminates with a top flap and a bottom flap at opposed ends thereof. The top flaps and bottom flaps are folded inwardly and sealed to form top and bottom sides, respectively. Such boxes are typically shipped from a box manufacturer in a flat configuration as blanks and must be assembled into a three-dimensional box prior to use. Such assembly can be by hand or through the use of a box erecting machine. 
     The flaps of a box are designated in the art as “major” and “minor” depending on their relative length. For instance, in a parallelepiped box having a length, a width, and a height, with the length and width being unequal, the major flaps are the two opposed flaps lying adjacent the longer of the length and width, with the minor flaps being the flaps adjacent the shorter of the length and the width. While many parallelepiped boxes contain bottom-forming flaps and top-forming flaps, some parallelepiped boxes contain only bottom-forming flaps, with the fully assembled box having an open top. 
     Parallelepiped boxes are assembled by first drawing the unassembled, flat box into a generally tubular rectangular shape. The minor flaps are each folded 90 degrees inward, with the major flaps then being folded 90 degrees inward and over the minor flaps. The flaps are then sealed in place using glue, adhesive tape, gummed tape, or other such materials that are known and understood in the relevant art. 
     The bottom flaps of a parallelepiped box often are fully assembled first with the top flaps being left open or unassembled so that the box can be filled with the appropriate contents. After the box has been filled, the final step is to fold and seal the top flaps of the box. The top flaps are sealed in a manner similar to the sealing of the bottom flaps, i.e., folding the minor flaps 90 degrees inward, folding the major flaps 90 degrees inward and over the minor flaps, and then sealing the major flaps in position with glue, adhesive tape, gummed tape, or the like. 
     Such operations often are performed as part of an assembly line operation with the unfolded boxes being loaded into a magazine, each box being opened in turn and the bottom flaps thereof sealed to form a bottom. The boxes are then appropriately filled and the top flaps thereof sealed. 
     When adhesive tape is utilized to seal the flaps of the box, the tape is typically delivered from a large roll attached to a tape head of the type known and understood in the relevant art. Inasmuch as the tape is consumed from the roll, such rolls of tape require periodic replacement. Such replacement can be both time consuming and expensive inasmuch as the assembly line typically must be cleared prior to replacement of the tape roll. Thus, the need exists for a taping mechanism for a box erecting machine wherein the tape roll can be easily replaced with a minimum of downtime and effort. 
     Box erecting machines of the type described above are rather complex and expensive machines that are permanently installed in production lines and are capable of being set up to assemble boxes of different sizes. Such machines typically contain adjustable guide rails that maintain the boxes in proper orientation over the folding and taping structures of the machine. 
     One such type of box erecting machine utilizes a stationary guide rail and an adjustable guide rail that is adjusted to correspond with width of the box being assembled. As is understood in the relevant art, the major flaps of a box are taped, typically in a single operation, at the center of the box width. When the adjustable side rail is adjusted to accommodate a box of a different width, the center line of the box where the folding and taping operations occur is shifted laterally. Thus, a box erecting machine having a fixed guide rail and an adjustable guide rail must additionally contain an adjustment system that permits the box folding and taping structures to correspondingly move with the center line of the box. 
     One reason for designing machinery to contain a fixed guide rail and a moveable guide rail with correspondingly moveable box folding and taping structures is to permit the boxes, as they are assembled, to travel along a fixed, constant “index” line. Inasmuch as the boxes are assembled for the purpose of carrying goods, the goods must, at some point, be loaded into the boxes. Boxes traveling through a production line along a fixed index line are more easily filled than boxes that are delivered centered along a conveyor system because such centered boxes typically require a longer reach by the individual who loads or the machinery that loads the box. Cartons traveling along a common index line can be filled directly from the index line with minimal reach and minimal wasted effort. Additionally, the use of a common index line for filling boxes expedites the setup of automated machinery used to fill the boxes. 
     One type of box erecting machine known in the art is described in U.S. Pat. No. 5,374,326 to Marchetti. The machinery disclosed therein permits boxes to be assembled, but does not provide for the assembly and delivery of boxes along a common, fixed index line. Thus, while the invention disclosed in Marchetti can assemble boxes of different widths, Marchetti does not disclose an invention that can assemble boxes of different widths and deliver the boxes along a common index line. Moreover, Marchetti discloses a box sealing structure that is upwardly removable from a box erecting machine requiring maintenance or reloading to be performed while reaching and leaning over the machine. 
     Other box erecting machines share this drawback. The tape heads are often tucked under the assembly line and are difficult to reach by a person changing the tape roll. The person changing the tape roll is often uncomfortable and off balance, conditions that increase the risk of injury or harm to the machine and to the person. 
     An improved device overcoming the limitations of other devices known in the art would preferably include a tape head mechanism that is horizontally adjustable to correspond with boxes of different widths and is horizontally removable from the box erecting machine for replacement of the tape roll. Such a device would then allow the tape head mechanism to be readily and automatically alignable with the box folding structures of the box erecting machine. Thus, the need exists for a box erecting machine that can assemble boxes of different widths and deliver the boxes along a common index line with the tape roll of the machine being readily replaceable by the user. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, an objective of the invention is to provide a box erecting machine having a tape head mechanism that is adjustable to suit cartons of various widths. 
     Another objective of the present invention is to provide a box erecting machine having a tape head mechanism that is slidably adjustable. 
     Another objective of the present invention is to provide a box erecting machine having a tape head mechanism horizontally moveable between an operational position internal to the box erecting machine and a loading position outside the perimeter of the box erecting machine. 
     Another objective of the present invention is to provide a box erecting machine having a tape head mechanism with a tape roll that is readily replaceable. 
     Another objective of the present invention is to provide a box erecting machine having a tape head mechanism that is detachably alignable with the box folding structures of the machine. 
     Another objective of the present invention is to provide a box erecting machine having a tape head mechanism that is slidably mounted on horizontal bars. 
     Another objective of the present invention is to provide a box erecting machine that assembles at least the lower half of a carton and includes a moveable tape head assembly. 
     Another objective of the present invention is to provide a box erecting machine that supplies assembled boxes along a common index line, and includes a tape roll that is readily replaceable. 
     These and other objectives and advantages of the invention are obtained by a box erecting machine for erecting a box from a collapsed configuration to a set up configuration, the box erecting machine including a frame defining a structural perimeter of the machine; guides mounted on the frame for guiding the box, the guides defining an operational perimeter of the machine; the operational perimeter extending vertically above the guides; a conveyor device that moves the box through the guides; a tape head selectively movably mounted to the frame; and the tape head being selectively movable between a loading position outside the operational perimeter and an operational position inside the operational perimeter; the loading position being displaced in at least a horizontal direction with respect to the operational position. 
     Other objectives and advantages of the invention are achieved by a box erecting machine for erecting a box from a collapsed configuration to a set up configuration, the box erecting machine including a frame defining a structural perimeter of the machine; substantially parallel guides mounted on the frame for guiding the box through the machine, the guides defining an operational perimeter of the machine; the operational perimeter extending vertically above the guides; a tape head selectively slidably mounted to the frame; and the tape head being slidably moveable between a loading position outside the operational perimeter and an operational position inside the operational perimeter; the loading position being displaced in at least a horizontal direction with respect to the operational position. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The preferred embodiment of the invention, illustrative of the best mode in which applicant has contemplated applying the principles of the invention, is set forth in the following description and is shown in the drawings and is particularly and distinctly pointed out and set forth in the appended Claims. 
     FIG. 1 is a front elevational view of a box erecting machine containing the moveable tape head of the present invention; 
     FIG. 2 is a plan view of the moveable tape head of the present invention in an operational position taken immediately above the tape head; 
     FIG. 3 is a left side elevational section view of the moveable tape head taken along line  3 — 3  of FIG. 2; 
     FIG. 4 is an enlarged view of the encircled portion of FIG. 2; 
     FIG. 5 is a view similar to FIG. 2 with portions removed and with a cover plate installed on the tape head; 
     FIG. 6 is a view taken along line  6 — 6  of FIG. 5 with portions removed and with the cover plate installed on the tape head; 
     FIG. 7 is an enlarged view of the encircled portion of FIG. 5; 
     FIG. 8 is a plan view similar to FIG. 2 with the moveable tape head of the present invention in a loading position; 
     FIG. 9 is a left side elevational section view taken along line  9 — 9  in FIG. 8; and 
     FIG. 10 is an enlarged view of a portion of the tape head mechanism of the present invention similar to FIG.  7  and showing the tape head returning from the loading position to the operational position. 
    
    
     Similar numerals refer to similar parts throughout the specification. 
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The moveable tape head mechanism of the present invention is indicated generally by the numeral  2  in the accompanying drawings. Tape head mechanism  2  is a component of a box erecting machine  4  of the type generally known and understood in the relevant art. Box erecting machine  4  is a machine that assembles boxes from a flat, unassembled configuration to a parallelepiped configuration with an assembled bottom and an open or unassembled top. 
     Box erecting machine  4  includes a frame  6  that carries various components. Box erecting machine  4  includes a magazine  8 , an inlet  10 , and an outlet  12 . Magazine  8  includes a pair of feed trays  7  and a spring bar  9 . Boxes (not shown) in a flat, unassembled configuration are placed in feed trays  7  of magazine  8  and held in place by spring bar  9 . A suction puller  11  pulls a box on demand from magazine  8  and delivers it to inlet  10 . In passing from inlet  10  to outlet  12 , the unassembled box is opened to parallelepiped form and the bottom flaps of the box are folded and taped by structures to be described below to form a box having an assembled bottom. 
     Boxes are pushed through box erecting machine  4  from inlet  10  in the direction of outlet  12  by a push bar  13  (FIG. 1) that advances the box a given distance, rotates upwardly through an angle of approximately 90 degrees, and is then retracted toward inlet  10  where it is lowered to its original position for pushing another box through box erecting machine  4 . Push bar  13  is depicted in FIG. 1 in the upward, non-retracted position. 
     Boxes being pushed through box erecting machine  4  pass between and are held in rectangular alignment by a fixed guide rail  14  and an adjustable guide rail  16  parallel and spaced apart from fixed guide rail  14 . Fixed guide rail  14  is fixedly attached to frame  6 . In accordance with the objective of the invention, the edge of fixed guide rail  14  facing adjustable guide rail  16  provides an index line  15  against which all boxes passing through box erecting machine  4  are aligned. 
     An operational perimeter is defined between imaginary planes extending vertically from the surfaces of guide rails  14  and  16  facing one another, the planes being substantially parallel with each other. Folding and taping operations that are performed on boxes occur inside the operational perimeter. The operational perimeter of box erecting machine  4  thus varies with the position of adjustable guide rail  16 . 
     Adjustable guide rail  16  is selectively lockable by the action of a pair of locking levers  20  that selectively lock a pair of lock bars  22  that are each fixedly attached to adjustable guide rail  16  and slide through a hole in frame  6 . Adjustable guide rail  16  is adjusted by releasing locking levers  20 , adjusting adjustable guide rail  16  to the desired position between minimum inward and maximum outward limiting positions depending upon the width of the box to be assembled and engaging locking levers  20  to lock adjustable guide rail  16  in the desired position. 
     Guide rails  14  and  16  align boxes over a flap closure apparatus  18  and tape head mechanism  2 . Both the folding operation carried out by flap closure apparatus  18  and the taping function performed by tape head mechanism  2  are performed at the center of the width of the box as it passes between guide rails  14  and  16 . Inasmuch as fixed guide rail  14  remains fixed and adjustable guide rail  16  is adjusted to suit the width of the particular box being assembled, flap closure apparatus  18  and tape head mechanism  2  must be centered between guide rails  14  and  16  prior to operation of box erecting machine  4 , as is set forth more fully below. 
     Flap closure apparatus  18  includes a fold plate  26 , a pair of deflection bars  28 , and a locking plate  30  attached to a mounting plate  19 . A crank assembly  23  includes a threaded centering crank  24  rotatably mounted to frame  6  and operating threadably with a cooperatively threaded block  25  attached to mounting plate  19 . In other embodiments not shown, locking plate  30  could be directly attached to block  25 . Crank assembly  23  adjusts and centers flap closure apparatus  18  between guide rails  14  and  16  by rotation of centering crank  24 . Fold plate  26  (FIG. 1) folds the leading flap of the box inwardly as the box passes fold plate  26 . Deflection bars  28  are a pair of elongated bars that extend generally upwardly and inwardly in the downstream direction from inlet  10  toward outlet  12 . After the leading flap of the box has been folded inwardly (i.e., rearwardly) by fold plate  26 , the flaps parallel with rails  14  and  16  contact deflection bars  28  and are folded inward thereby toward one another. As is known in the art, box erecting machine  4  has an additional mechanism (not shown) that folds the trailing flap of the box immediately after its removal from magazine  8  by suction plate  11  and prior to its being pushed in the downstream direction over flap closure apparatus  18  by push bar  13 . 
     In passing over flap closure apparatus  18 , the flaps of the box have been folded such that the leading and trailing flaps (minor flaps) are folded inward with the flaps adjacent rails  14  and  16  (major flaps) folded inward over them. With the bottom flaps folded as such, the box is then directed to tape head mechanism  2  for the taping operation. 
     Tape head mechanism  2  includes a tape head  32 , a cradle  34  in which tape head  32  is mounted, a handle  35  attached to cradle  34 , and a pair of collars  36  attached to cradle  34 . In accordance with the features of the invention, a bar  38  slides through each of collars  36 , thus permitting collars  36  and, in turn, cradle  34  and tape head  32 , to be slidably adjustable along bars  38 . Bars  38  are fixedly attached to brackets  40  which are, in turn, fixedly attached to and extend outwardly from frame  6 . Thus, as is shown in FIGS. 3,  6 , and  9 , and in accordance with the features of the present invention, brackets  40  permit bars  38  to extend outwardly from and beyond the perimeter of frame  6 . Brackets  40  each terminate in a butt plate  42 . Tape head mechanism  2  additionally includes a pin assembly  44  and a cover plate  56 , both of which are more fully described below. 
     Tape head  32  is a conventional tape head of the type known and understood in the relevant art. Tape head  32  may, for instance, be an ACCUGLIDE® II Taping Head manufactured by the Minnesota Mining and Manufacturing Co. of Minneapolis, Minn., although other tape heads may be used without departing from the spirit of the present invention. Tape head  32  has a spool for carrying a tape roll  33  and additionally includes a plurality of rollers  62  that press the tape from tape roll  33  into adhesive contact with the box. As is understood in the relevant art, rollers  62  are biased to the upward position shown in FIG.  1  and can be pressed inward into tape head  32  by an appropriately applied downward compressive force. 
     Cradle  34  of tape head mechanism  2  is formed of a pair of parallel, rectangular plates  37  separated by collars  36 . Collars  36  are elongated hollow substantially cylindrical bodies, each formed with a substantially cylindrical hole therein. Each collar  36  is slidingly disposed on one of bars  38 . As indicated hereinbefore, and in accordance with the features of the present invention, cradle  34 , and thus tape head  32  installed in cradle  34 , are horizontally slidable along bars  38 . 
     As indicated hereinbefore, the taping operation occurs centrally between guide rails  14  and  16 , and collars  36  of tape head mechanism  2  permit cradle  34  and tape head  32  to slidably move along bars  38 . Pin assembly  44  is employed to align cradle  34  in an operational position with flap closure apparatus  18 . Pin assembly  44  includes a pin  46 , a pull knob  48  connected to pin  46 , a sleeve  50  through which pin  46  telescopes, and a spring  52  for biasing pin  46  toward a receptacle  54  formed on locking plate  30 . 
     In operation, pin  46  is received in receptacle  54  of locking plate  30 , thus holding cradle  34  and tape head  32  of tape head mechanism  2  in operational alignment with flap closure apparatus  18 , and thus defining the operational position for tape head mechanism  2  depicted in FIGS. 1-7. 
     Cradle  34  and tape head  32  may be moved horizontally from the operational position depicted in FIG. 3 to a loading position outside the perimeter of box erecting machine  4  (FIGS. 8 and 9) at which point cradle  34  contacts and is retained by butt plates  42 . With tape head  32  in the loading position depicted in FIGS. 8 and 9, tape roll  33  lies outside the perimeter of box erecting machine  4  and can be readily replaced. In accordance with the features of the present invention, in such position tape roll  33  can be more readily replaced than if tape head  32  and tape roll  33  were centered in box erecting machine  4  because tape head  32  is accessible and easy to work with. 
     As can be seen in the dashed lines of FIG. 1, rollers  62  of tape head  32  protrude above the lower edge of a frame member  6 ′. Frame  6 , including frame member  6 ′, define a structural perimeter of box erecting machine  4 . 
     Roller  62  also protrude above adjustable guide rail  16  as shown in FIG.  3 . In moving between the operational position and the loading position, cradle  34  and tape head  32  of tape head mechanism  2  must pass underneath adjustable guide rail  16  and frame member  6 ′. A cover plate  56  is thus used to press rollers  62  downward and into the interior of tape head  32 . As is best shown in FIG. 6, cover plate  56  includes an upper plate  58  and a lower plate  60  connected by an intermediate plate  61 . Lower plate  60  is substantially parallel with upper plate  58 . When lower plate  60  is slipped underneath the lower edge of one of plates  37  of carriage  34 , upper plate  58  depresses rollers  62  into tape head  32 , thus permitting cradle  34  and tape head  32  to have clearance sufficient to slidably pass underneath guide rail  16  and frame member  6 ′. The upward biasing of rollers  62 , as is understood in the relevant art, causes a compressive force upward on upper plate  58 , thus causing lower plate  60  to engage the lower edge of plate  37  and be held in place thereon. Furthermore, intermediate plate  61  is sized to snugly fit on plate  37 . 
     In order to move cradle  34  and tape head  32  from the operational position to the loading position, cover plate  56  is first installed onto cradle  34 , thus compressing rollers  62  into tape head  32  and below frame member  6 ′. Pull knob  48  of pin assembly  44  is pulled in a direction away from receptacle  54  of locking plate  30  thus releasing tape head  32  from operational alignment with flap closure apparatus  18  and permitting cradle  34  and tape head  32  to slide along bars  38  to the loading position. In accordance with the features of the present invention, in returning cradle  34  and tape head  32  from the loading position to the operational position, cradle  34  is simply slid back into alignment with flap closure apparatus  18  until pin  46  engages receptacle  54 . 
     As is best shown in FIG. 10, locking plate  30  has an angled ramp surface  64  that is engaged by pin  46  to depress pin  46  prior to the engagement of pin  46  in receptacle  54 . Inasmuch as pin  46  is biased toward locking plate  30  by spring  52 , it is understood that in returning cradle  34  to the operational position, cradle  34  is simply slid toward locking plate  30  where pin  46  engages ramp surface  64  and is translated thereby, with pin  46  ultimately returning into engagement with receptacle  54 . Cover plate  56  is then removed from tape head  32 , thus permitting rollers  62  to return to their original position. 
     In accordance with the features of the present invention, the slidable nature of tape head mechanism  2  permits tape roll  33  to be replaced outside the perimeter of box erecting machine  4  with minimal effort, and with less effort than would be required if tape roll  33  were mounted centrally within box erecting machine  4 . Inasmuch as box erecting machine  4  is typically used in a mass-production environment, tape roll  33  is of an appropriate large size to reduce as much as possible the required frequency of changing tape roll  33 . Such large tape rolls are of a standard size and are known and understood in the relevant art to be bulky and difficult to replace. It is also known that threading the tape of tape roll  3  into tape head  32  is a difficult task, especially when tape head  32  is disposed under or within box erecting machine  4 . The positioning of tape roll  33  outside the perimeter of box erecting machine  4  when in the loading position thus allows tape roll  33  to be replaced with relative ease. 
     In accordance with other features of the present invention, pin assembly  44  further expedites the replacement of tape roll  33  by obviating the need to separately align tape head  32  between guide rails  14  and  16  in the operational position. Once tape roll  33  has been replaced, cradle  34  is slid along bars  38  with pin  46  engaging ramp surface  64  and returning with the biasing effect of spring  52  to engage receptacle  54 . As such, once flap closure apparatus  18  has been centered between guide rails  14  and  16  by adjusting centering crank  24 , cradle  34  can be repeatedly slid between operational and loading positions and tape roll  33  can be repeatedly replaced without the need to separately align tape head  32  between guide rails  14  and  16 , thus resulting in significant cost and time savings. 
     Accordingly, the improved moveable tape head for box erecting machine invention is simplified, provides an effective, safe, inexpensive, and efficient device that achieves all the enumerated objectives, provides for eliminating difficulties encountered with prior devices, and solves problems and obtains new results in the art. 
     In the foregoing description, certain terms have been used for brevity, clearness, and understanding; but no unnecessary limitations are to be implied therefrom beyond the requirement of the prior art, because such terms are used for descriptive purposes and are intended to be broadly construed. 
     Moreover, the description and illustration of the invention is by way of example, and the scope of the invention is not limited to the exact details shown or described. 
     Having now described the features, discoveries, and principles of the invention, the manner in which the moveable tape head for box erecting machine invention is constructed and used, the characteristics of the construction, and the advantageous new and useful results obtained; the new and useful structures, devices, elements, arrangements, parts, and combinations are set forth in the appended Claims.