Patent Publication Number: US-6336310-B1

Title: Method and apparatus for making compact packages for speadable product

Description:
This application claims the benefit of U.S. Provisional Application Ser. No. 60/099,460, filed Sep. 8, 1999 in the name of the Applicant of the instant application, which is hereby incorporated by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     The present invention relates to the manufacture of a multiplicity of packages for an individual service portion of a spreadable product, and, more specifically, to certain new and useful improvements in the method and apparatus for manufacturing such packages. 
     The innovation of “compact packages for spreadable products” (trademarked as COMPACT REDDIES™) by this applicant as disclosed in U.S. Pat. Nos. 4,700,532 and 4,720,014 has established the product as a staple package of the United States butter and margerine industry for use by institutions, fast food outlets, hospitals, restaurants, government installations, etc. (Butter will hereinafter be used as the generic term for butter, margerine and all similar spreads). 
     While this package is about the lowest cost unit of use butter service that is available, it has been competed with by various imitations as well as small individual plastic peel top cups and fully foil wrapped butter pats (or “pats”) known to the trade as “Continentals”. These cups and “Continientals” have perceive advantage of being sealed or totally enclosed packaging. 
     OBJECTS OF THE INVENTION 
     It is an object of the invention to further significantly reduce the materials cost of compact packages for spreadable products. 
     It is the further object of this invention to create an advanced trouble free manufacturing system and apparatus for the very high speed production of these low cost compact packages (e.g., 1500 units per minute). 
     The invention consists of the novel parts, constructions, arrangements, combinations, steps and improvements herein shown and described. 
     SUMMARY OF THE INVENTION 
     Briefly described, the present invention is directed to a new and improved method and apparatus for making rigid unitized packages formed from channel members unitized by adherence to four sides of the preferably rectangular product encased by the channel members. 
     In an aspect of the present invention there includes a machine for producing small or compact packages for spreadable products a pat of spreadable product on a flanged paperboard mat covered by a rectangle or sheet of greaseproof paper including a pivotal clamp mechanism actuated by a fixed cam which causes the clamp to pivot open to receive a card or mat and then releases the clamp which snaps on that card. The clamping may be actuated by a leaf spring. The pivoted clamp mechanism and the leaf spring are mounted on a flight comprise a clamping flight assembly which is in turn mounted on a roller chain. The roller chains is mounted with a series of flights carrying the actuated pivoted clamps and are capable of transporting the cards through a driven rotary scoring and tucking assembly which simultaneously scores and bends said cards into a channel shape with upright flanges. The rotary and scoring assembly is comprised of a pair of upper grooved wheels having a tucking step alongside the groove which are driven at the same peripheral velocity that the cards are being transported at by said clamping flight assemblies. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a side elevation of a packaging machine construction embodying the present invention; 
     FIG. 1A is an enlarged view in perspective of the bottom card unfolding mechanism of the present invention in which the pre-bent channel-shaped card is reopened and substantially flattened; 
     FIG. 1B is an enlarged perspective view of an individual bottom card illustrating the cared in its partially pre-bent channel shape and partially reopened and substantially flattened; 
     FIG. 2 is a fragmentary view in side elevation of the bottom card feed mechanism and driven scoring rollers of the 
     FIG. 3 is a fragmentary top plan view, partly in section, of the bottom card feed and scoring roller mechanism, taken along line  3 — 3  of FIG. 2; 
     FIG. 4 is a fragmentary sectional view of the driven scoring rollers of the bottom channel fabrication section taken along line  4 — 4  of FIG. 2, illustrating the scoring of a bottom card cut from the bottom card stock supply; 
     FIG. 5 is an enlarged fragmentary perspective view showing the cover channel fabrication section and a portion of the package assembly section of the package machine shown in FIG. 1; 
     FlG.  5 A is a fragmentary bottom plan view taken along lien  5 A— 5 A of FIG. 5, illustrating the entrance of the top cover material web to the scoring rollers of the cover channel fabrication section; 
     FIG. 6 is a fragmentary view in side elevation illustrating the cover channel fabrication section and a portion of the package assembly section shown in FIG. 5; 
     FIG. 7 is a fragmentary sectional view taken along line  7 — 7  of FIG. 6, illustrating the scoring rollers for the cover channel fabrication section; 
     FIG. 8 is a fragmentary top plan view taken along line  8 — 8  of FIG. 6, showing the folding and creasing unit of the cover channel fabrication section which fold the scored edges of the cover material under the moving material web and compresses the folded edges flat onto the web; 
     FIG. 9 is a sectional view taken along line  9 — 9  of FIG. 8, illustrating the scored edges of the cover material folded under and compressed flat onto the material web; 
     FIG. 10 is a fragmentary top plan view, partly sectional, taken along line  10 — 10  of FIG. 6, showing draw rollers which draw the web of cover material from the stock supply, the cutting and cover sheet guide unit, and the accelerating rollers which grip and accelerate the cut and pre-creased cover sheet into the package assembly section; 
     FIG. 11 is a fragmentary sectional view, partly in side elevation, taken along line  11 — 11  of FIG. 10; 
     FIG. 12 is a fragmentary view in end elevation, partly in section, taken along line  12 — 12  of FIG. 11, illustrating an individual pre-creased cover sheet gripped between the high speed driven accelerating rollers of the cover channel fabrication section; 
     FIG. 13 is an enlarged fragmentary side elevational view of the rolling and tucking spool roller of the package assembly section of the machine shown in FIG. 1; 
     FIG. 14 is a fragmentary view in end elevation taken along line  14 — 14  of FIG. 13, illustrating the spool roller rolling the cover sheet into adhering contact with the top of the product pat carried by the bottom channel fabrication and package assembly sections; 
     FIG. 16 is a fragmentary perspective view of the conveyor chain shown in FIG. 15; 
     FIG. 17 is a fragmentary view in side elevation illustrating the tamper and tucking rail guide of the package assembly section and the upper accelerating conveyor chain assembly of the tray loading section of the machine shown in FIG. 1; 
     FIG. 18 is a fragmentary top plan view taken along, line  18 — 18  of FIG. 17, illustrating opposed including plow rails raising the pre-bent sides of the bottom card into a vertical position, thereby forming the bottom card into a channel-shaped configuration, and opposed spring-loaded ball detents pressing the bottom channel sides into adhering contact with the sides of the product and into overlapping contact with the channel sides of the cover channel member adhered to the product; 
     FIG. 19 is a fragmentary view in side elevation taken along line  19 — 19  of FIG. 18; 
     FIG. 20 is a fragmentary sectional view taken along line  20 — 20  of FIG. 19, illustrating the completed package produced by the machine shown in FIG. 1; 
     FIG. 21 is a fragmentary view in end elevation taken along line  21 — 21  of FIG. 17, illustrating an extended finger of the upper conveyor chain assembly of the tray loading section engaging and accelerating a completed package away from the package assembly section and into the tray loading section; 
     FIG. 22 is an enlarged fragmentary view in end elevation of the cover material web guide roller unit shown in FIG. 1; 
     FIG. 23 is a partly sectional, partly elevational view of the web guide unit shown in FIG. 22, the view illustrating the adjustment mechanism for adjusting the lateral position of the flanged web guide roller; 
     FIGS. 24A-24C disclose various views of the scorer-bender assembly with the pivoting clamp assemblies of an alternative embodiment; 
     FIG. 25 is a side elevation view of the scorer-bender assembly with the pivoting clamp assemblies of the alternative embodiment; 
     FIGS. 26A-26B are enlarged views of a pivotal clamp assembly; and 
     FIGS. 27A-27E show various elements of the clamp assembly. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Referring now more particularly to the preferred embodiment of the invention shown in the accompanying drawings, there is illustrated in FIG. 1 a packaging machine, designated generally by reference number a 1 , having a bottom channel fabrication section  2 , a pat forming and deposition section  3 , a cover channel fabrication section  4 , a package assembly section  5 , and a tray loading section  6 . 
     Bottom Channel Fabrication Section 
     The bottom channel fabrication section  2  includes a suitable supply (not shown) of a relative stiff paperboard, or other equivalent, material which is drawn from the supply in the form of a web  50  by driven rollers  51 ,  51 A which feed the web of paperboard stock in conventional manner under a rotary cutting roller)(not shown) where the paperboard is cut into individual cards  52  of predetermined length and thereafter accelerated by high speed driven rollers under a conveyor chain  53  moving in a direction perpendicular to the movement of web  50 . Advantageously, the aforesaid cutting roller mechanism and high speed accelerating rollers for cutting the paperboard stock and feeding the individual cut cards into the path of the conveyor chain  53  are similar to that shown in FIG. 11, more fully described hereinafter. 
     Conveyor  53  grips and holds each individual card by a suitable clip member  54  (see FIG. 1A) mounted to each of the conveyor platforms  60  and advances the card through drive scoring rollers  55 ,  56  and from there to folder/underfolder unit  57 . 
     As best seen in FIGS. 15 and 16, because card  52  is bent into a narrow channel-shaped configuration in the completed package formed by machine  1 , conveyor chain  53  and platforms  60  must be even slightly more narrow and it is therefore necessary to provide a guiding system to control the path of travel of the conveyor chain to a straight line with no erratic sidewise or up and down movement. To that end, as here embodied, the conveyor chain links  75  are joined by outer shoe links  76  having flat upper and lower surfaces which are slidably mounted in guide tracks  77 ,  77 A. 
     As here preferably embodied, scoring roller  56  is provided with a pair of raised ribs  56 A,  56 B which rotate in closely spaced relationship to anvil wheels  55 A,  55 B of driven roller  55 . As best seen in FIG. 4, as conveyor chain  53  (not shown) passes between through anvil wheels  55 A,  55 B, transporting card  52 , card  52  is compressed between ribs  56 A,  56 B and anvils  55 A,  55 B, forming a pair of opposed parallel score lines  52 A,  52 B adjacent two parallel edges of card  52 . 
     It will be seen that by providing driven anvil roller  55  compressing card  52  against scoring roller  56 , thus positively gripping and driving card  52  therebetween transported by conveyor chain  53 , cards  52  are scored accurately and consistently, ensuring the later formation of the card into a channel which is in true alignment throughout its length. Also, as shown in FIG. 4, ribs  56 A,  56 B are rounded, or may be otherwise suitably blunted so as to compress, rather than pierce or cut, the paperboard material of the card. It has been found that forming the score in this manner is highly advantageous in preventing moisture or oil contained in the enclosed product from being absorbed into the paperboard. 
     As best seen in FIGS. 2 and 3, folder/unfolder unit  57  comprises a pair of opposed rail members  58 ,  59  provided with inwardly and downwardly inclined side walls  61 ,  62  which engage the scored edges of card  52  and bend them gradually downwardly to form card  52  into a channel-lie shape with opposed channel sides  52 C,  52 D. Advantageously, side walls  61 ,  62  are inclined to so as to put a radical bend on the scored edges of card  52 , preferably well beyond 90°, in order to also ensure that card  52  may be later formed into a true channel and fitted closely about the product to be enclosed, as more fully described hereafter. 
     As embodied, folder/unfolder unit  57  also includes a second set of upwardly and outwardly inclined side walls  63 ,  64  which immediately engage and partially re-open the channel sides  52 C,  52 D of card  52 . Alternatively, it has been found that a paperboard material of the thickness desired for card  52  has sufficient stiffness and resiliency to spring back naturally into a partially re-opened position after bending and consequently, that side walls  63 ,  64  may be optionally omitted with satisfactory results. 
     After passing through folder/unfolder unit  57 , conveyor  53  carries the pre-scored, pre-bent and partially unfolded card  52  onto a generally semi-circularly shaped guide member  65  mounted circumferentially about the end sprocket gear driving conveyor  53 . As best seen in FIGS. 1A and 1B, guide  65  gradually widens to further gradually re-open the previously formed channel sides of card  52  and finally delivers the card into a forming block  66  having opposed guide slots  67 ,  68  which spread channel sides  52 C,  52 D of card  52  into a substantially flattened position. 
     It will be understood from the foregoing that upon passing through forming block  66 , the pre-bent and substantially flattened card  52  is ready to receive an individual service portion of a product thereon. Although the present invention is not limited to any particular shape or product material, it is particularly advantageously useful for packaging generally rectangularly-shaped pats of butter or margarine or like product. To that end, for ease of description only, the package formed by the machine and method of the present invention is hereinafter described with reference to a rectangular butter pat but it will be understood the invention is not limited to such usage. 
     Accordingly, while scored card  52  is being held flat by forming block  66 , a rectangularly-shaped pat of butter  70  is advantageously formed and deposited onto the approximate center of card  52  by a suitable forming and feeding drum  72  as is more fully described and illustrated in the aforesaid Redmond U.S. Pat. No. 3,129,546. 
     Advantageously, and as here preferably embodied, butter pat  70  is shaped and sized so that two opposed sides thereof are aligned with and in close overlying relationship to the score lines  52 A,  52 B formed in card  52 . Card  52  is longer than pat  70  to provide end margins adjacent the sides of pat  70  perpendicular to the sides aligned with the score lines. It will be seen that the provision of end margins serves to both create a neat, elongated appearance to the package and provide a surface for gripping when it is desired to open the package and use the contents thereof 
     Finally, it will be understood from the foregoing that the provision of means for scoring, bending and reopening card  52  into a substantially flattened configuration enables a rectangular pat of butter to be deposited onto card  52  without the numerous difficulties of precise placement that would be required if card  52  was in its channel configuration and yet fit snugly and cleanly within the channel walls when later erected. 
     After the butter pat  70  is deposited onto the pre-scored card  52 , conveyer  53  continues to transport the pat-carrying, pre-scored card  52  toward package assembly section  4 . 
     Cover Channel Fabrication Section 
     The cover channel fabrication section  4  includes a suitable stock supply  80  of a relatively thin and flexible top cover material  85 , preferably paper or a “deadfold” foil, or other equivalent material. Advantageously, conventional roll stock brake means  81  engages roll  80  to control unwinding of material  85  and a suitable switch  83  may be provided to detect when roll  80  is used up and stop the machine for reloading. 
     Material  85  is continuously drawn from supply roll  80  over a series of flanged idler guide rollers  86 ,  87 ,  88  which direct the web of material  85  through a pair of opposed scoring rollers  90 ,  91  which form a pair of parallel score lines  85 A,  85 B in material  85  spaced apart a distance approximately equal to score lines  52 A,  52 B in bottom card  52 . 
     In accordance with the invention, means are provided for guiding material web  85  in accurate alignment through scoring rollers  90 ,  91 . To that end, as here preferably embodied, and as best seen in FIGS.  6  and  22 - 23 , flanged guide roller  88  is rotatably mounted in bracket  92  which in turn is mounted for adjustable movement transversely of web  85  by a threaded knob  93  which forces pin  94  toward or away from the machine frame F. 
     Scoring rollers  90 ,  91  are preferably suitably provided with opposed circumferentially extending ridges  90 A,  90 B in mating relationship to circumferentially extending grooves  91 A,  91 B, respectively. It will be seen from the foregoing that the provision of aligned and mating ridges and grooves in scoring, rollers  90 ,  91  results in the formation of ver accurate, consistent, and true score lines in material web  85 . 
     The scored material web  85  is thereafter drawn through a creasing unit  95  including a funnel-shaped former  96  which engages the opposed scored edges  85 C,  85 D of web  85  and folds them under and back onto web  85  whereupon edges  85 C,  85 D are compressed flat onto web  85  by opposed pressure adjustable rollers  97 ,  98 . After folding and flattening of edges  85 C,  85 D, these edges are then passed over a wedge-shaped forming member  100  which again reopens and substantially flattens out edges  85 C,  85 D into a single plane with web  85 , whereupon the pre-creased and substantially flat web  85  passes between the opposed driven draw rollers  105 ,  106  which grip and pull web  85  from the stock supply  80 . 
     Draw rollers  105 ,  106  thereafter drive the pre-creased web of cover material  85  through cutting means, which comprise a lower stationary knife blade  110  and an upper driven rotating cutting knife  112  held in adjustably mounted cylinder  111  on its circumferential surface, and web  85  is thereafter directed by guides  113  into engagement with driven high speed accelerating rollers  114 ,  115 . As best shown in FIG. 11, the position and timing of cutting knife  112  is set so that the leading end of web  85  is received between and initially slidingly held by accelerating rollers  114 ,  115  just prior to the time that blade  112  rotates into cutting position against stationary blade  110 . Rotation of blade  112  into contact with blade  110  cuts web  85  into individual pre-creased sheets  120  of predetermined length, preferably approximately equal to the length of bottom card  52 , whereupon the cut sheet is instantaneously accelerated forward into the package assembly section  5 , where it is deposited onto butter pat  70 . 
     Advantageously, and as will be understood from the foregoing, the relative timing and speed of cutting knife  112  and accelerating rollers  114 ,  115  are selected so that the individual pre-creased sheets  120  of the top cover material are cut to the desired length and then accelerated forward to a speed coinciding with the speed of travel of the conveyor chain  52  transporting the pre-bent bottom card  52  carrying butter pat  70 . Also, as preferably embodied, the aforesaid accelerating movement is of such speed and timing to create a space between successively cut individual top cover sheets  120  which is identical to the space between the transverse center lines of two succeeding bottom cards carried by the conveyor chain  53 , to thereby deposit the pre-creased top sheet  120  onto the center of the butter pat  70  carried by the bottom card. 
     Package Assembly Section 
     The package assembly section  5  includes a spring-loaded flanged rolling and tucking spool roller  130  mounted directly above and in alignment with the top of the butter pat  70  being transported beneath roller  130  by conveyor  53 . As best seen in FIGS. 13 and 14, the pre-creased cover sheet  120  is rolled into adhering contact with the top surface of butter pat  70  and, simultaneously, the spool flanges  131 ,  132  of roller  130  bend the pre-creased edges of cover sheet  120  downwardly and closely adjacent to or in partial contact with two opposed sides of butter pat  70 , thereby forming cover sheet  120  into a channel-shaped configuration having channel side walls  120 C,  120 D. 
     Advantageously, and as here preferably embodied, conveyor  53  thereafter transports card  52  between opposed longitudinally extending card  52  between opposed longitudinally extending side pressure rails  134 ,  135 , preferably shaped similar to the bottom of a ski, which thereafter guide and compress the aforesaid channel sides  120 C,  120 D of covered sheet  120  against and in generally adhering contact with the sides of butter pat  70 . 
     After the channel-shaped cover sheet  120  is adhered to the top and two opposed sides of butter pat  70 , conveyor  53  passes through a pair of opposed longitudinally-extending plow members  138 ,  139  which raise the pre-scored and pre-bent side edges  52 C,  52 D of the bottom card  52  into a generally upright position to thereby form channel sides which preferably are in substantially adhering contact, or close-fitting relationship, with the sides of butter pat  70  and also are in overlapping contacting relationship with the outer surfaces of the downwardly extending channel sides  120 C,  120 D of the top cover sheet  120 . 
     Advantageously, as best seen in FIGS. 18-20, opposed adjustable rail guide means containing spring-loaded detents  140 ,  141  thereafter press the bottom card channel sides  52 C,  52 D into generally adhering contact with the lower portion of the sides of the butter pat  70  and into close-fitting overlapping contact with the outer surfaces of the top cover channel sides  120 C,  120 D. 
     Finally, as here preferably embodied, immediately following erection of the bottom channel sides  52 D,  52 D into adhering and overlapping contact with the sides of butter pat  70  and the outer surfaces of cover channel sides  102 C,  120 D, tamper  145  finally sizes and shapes the completed package. Advantageously, tamper  145  may be constructed as shown and described in the aforesaid Redmond U.S. Pat. No. 4,449,350. 
     The completed packages in accordance with the invention are thereafter transported and deposited by conveyor  53  onto spaced side rails  147 ,  148 , where they are pushed forward by an overhead conveyor chain assembly  150  having rotatably mounted finger members  151  which engage and accelerate the completed packages away from the package assembly section  4  and into the tray loading section  5 . 
     Tray Loading System 
     Although not forming a part of the present invention, the completed packages preferably are thereafter suitably transported by conveyor  150  to a tray loading station  5 , e.g., as shown and described in my aforesaid U.S. Pat. No. 3,631,652, where they may be advantageously automatically loaded into narrow elongated boxes or trays  155 , known as “boats”, and the loaded boats automatically transported to a platform or table  56  from which they may be manually placed into shipping containers. 
     It will be seen from the foregoing general and detailed descriptions that the objects of the invention specifically enumerated herein are accomplished by the invention as here embodied. 
     Thus, the method and apparatus of the present invention are capable of manufacturing rigid unitized packages enclosing and adhered on four sides to an individual service portion of butter, margarine or similar product at speeds of on the order to 1,500-1,800 packages per minute, and yet the finished packages are of improved quality in appearance and consistency of production. Also, the method and apparatus of the present invention, by prescoring and pre-bending each of the top and bottom channel members forming the package enclosure, produce a finished package having unusually sharply defined corners which give an improved crispness and neatness to the appearance of the package. Pre-scoring and pre-bending of the package components also permits a package to be produced which substantially completely encases the product and yet does not require the use of any external adhesive, thereby further enhancing the speed, efficiency and economy of production of the packages, while reducing materials costs by nearly one-third. 
     An alternative embodiment as disclosed in FIGS. 24A-27E is now discussed. 
     The package of U.S. Pat. No. 4,720,014, issued Jan. 19, 1988, hereby incorporated by reference, is comprised of a lower channel member, the mat made of ten millionths of an inch (0.010″) thick paperboard made greaseproof and water resistant by various means. A rectangular butter or margerine pat centrally deposited and located between the upright flanges of the channel. Over the pat, a piece of greaseproof paper roughly 3 mils thick folded into an inverted channel whose flanges contact and run down the side of the pat within the upright flanges of the lower ten mil paperboard member. In the United States, the most popular size is 90 pats per pound. These pats contain very close to 5 gms. of product each. Ninety of the mats cost approximately 6 plus cents to as high as 8 cents making them the most expensive single packaging component of compact packages for spreadable products. 
     A unique new fluorocarbon paperboard coating has been developed by the 3M Corporation (FC-845) which renders it greaseproof and moisture resistant at very low cost. 10 mil. board treated with FC-845 encountered problems in running on the machine of U.S. Pat. No. 4,720,014, issued Jan. 19, 1988, to Redmond, hereby incorporated by reference. It would be advantageous to utilize this paperboard for the mats particularly in reduced gauges, such as 5 mil. which has all the necessary qualities and yields important cost reductions. However, a problem encountered was that the spring steel clips used in the machine to hold the 10 mil. mats while being transported by the conveyor mounted on the conveyor chain as described above damaged the thinner 5 mil. mats and required continual adjustment to make them acceptable. 
     Therefore, an aspect of the present invention is a system that would not damage the mats since it would open to capture the mat and close to clamp it. This is implemented using a small pivoted clamp (pc) actuated by a fixed cam. Since the machine runs about 25 units per second and the pivoted clamps are very small, bearings could not be reasonably used for the pivot shaft. The pivoted clamp instead may be made of delrin since the delrin would act as its own bearing when drilled for the pivot shaft. 
     Another problem that was overcome in the present invention is that the system of scoring and bending up the flanges as discussed above was accomplished in two separate operations. A scoring operation followed by a tucking operation where the 5 mil. mats were driven through fixed tuckers which at the high operating speed, often damaged or crumpled the mats. It was discovered by the Applicant while working with this system that the scoring system could be made to both score and bend the system in a single operation which eliminated the need for fixed tuckers of a single power driven rotary system which would both score and bend the paperboard mats in a single operation eliminating the need for fixed tuckers. 
     These two systems, the cam actuated delrin card clamps and the power driver rotary scorer bender, made feasible the utilization of 5 mil. paperboard mats at the very high operating speeds required. 
     For even thinner gauges of paper or other materials, the clamps might have to be opened mechanically to release the finished units. When necessary, this can be accomplished by various means such as adding a driven reciprocating tamper which presses on the roller of the delrin pivoted clamp to open it in timed relationships with the removal of the finished package by mechanical means. 
     FIGS. 24A-24C disclose various views of the scorer-bender assembly  200  with the pivoting clamp assembly  217  according to the present invention. The scorer-bender assembly is comprised of a pair of upper grooved roller dies  210  with outer flanges which in cooperation with a pair of lower thin flanged roller dies  211  create a score and simultaneously bend a pair of edge flanges in the mat member. Also shown is a conveyor chain  212  which conveys the mat through the machine. Flights  217  are mounted on the conveyor chain  212  and includes tiny cam operated pivoting clamps  218  which open to precut cards or mats fed in by a card feeder. The pivoting clamps  218  on the flights  217  are opened by cam pressure and pick the cards or mats on the fly as they travel. After passing the end of the cam they instantly close down on the card actuated by a stainless steal leaf spring  231 . The cards are then, after passing over rails with spring resistance members, transported through the unique rotary scoring and bending assembly of the present invention which simultaneously scores and bends up longitudinal side flanges to create a channel shaped member from the flat paperboard card. 
     FIG. 25 illustrates a side elevation view of the scorer-assembly and pivoting clamps  218  of the present invention. Reference numeral  215  shows a score depth adjuster for optimizing the scoring. Pivoting clamps  218  are shown in both an open position and a closed position. Reference numeral  221  illustrates a flight opening cam which periodically opens and closes pivoting clamps  218 . 
     FIGS  26 A- 26 B illustrate a detailed view of a pivoting clamp assembly  217 . FIG. 26A shows the pivoted delrin clamp assembly  218  in open position for engaging or releasing mat  227  and FIG. 26B shows the pivoted delrin clamp assembly  218  clamping mat  227  in a closed position. Reference numeral  223  indicates a cam follower roller and reference numeral  225  indicates a delrin clamp member. Reference numeral  229  indicates a stainless steel flight body and reference numeral  231  indicates the leaf spring. FIGS. 27A-27E show the elements of the delrin clamp assembly  218  in detail. 
     A method of operation of the alternative embodiment is discussed. A card receiving and conveying pivotal clamp assembly  218  is mounted on a flight  217  which in turn is mounted on the roller chain  212 . The roller chain  212  is mounted on a series of the flights  217  which carry the actuated pivoted clamps  218 . The pivoting clamps  218  are actuated by fixed cams which cause the clamps  218  to pivot open to receive cards or mats  227 . The cams then release and the clamps  218  are actuated by leaf springs  231  which then snap shut on the cards  227 . 
     The roller chain  212  is capable of transporting the cards  227  through the driven rotary scoring and tucking assembly  200  which simultaneously scores and bends the cards into a channel shape with upright flanges. The rotary scoring and tucking assembly  200  is comprised of a pair of upper grooved wheels  210  having a tucking step alongside the groove  210   a  (shown in FIG.  24 C). The upper grooved wheels are driven at the same peripheral velocity that the cards are being transported at by the clamping assemblies  218 . 
     More specifically, this embodiment discloses a new system for handling paperboard or mat in a variety of gauges ranging from 0.010″ and more to 0.004 inches thick and less. 
     The invention in its broader aspects is not limited to the specific embodiments herein shown and described but departures may be made therefrom within the scope of the accompanying claims, without departing from the principles of the invention and without sacrificing its chief advantages.