Patent Publication Number: US-2022227514-A1

Title: Adaptable Tooling Methods, System and Apparatuses

Description:
CROSS-REFERENCE TO RELATED CASES 
     This application is a continuation application claiming priority to U.S. application Ser. No. 16/852,077, which was filed on Apr. 5, 2022; and which in turn claims priority to Provisional Application 62/835,095, which was filed on Apr. 17, 2019, the entire contents of which are incorporated herein by reference. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a case former, and more particularly to the tooling of a case former, and its use, that may be readily adjusted in order to allow the case former to produce cases of various sizes and shapes. 
     BACKGROUND OF THE INVENTION 
     Many known case formers rely on a forming cavity, forming head and tooling to fold a case blank having a specific size and configuration into a corresponding case. Some case formers are capable of being reconfigured in order to allow the case former to produce cases of different sizes and shapes, but these known case formers rely on cumbersome mechanisms that are inefficient in terms of cost and use, prone to being misadjusted, and/or require constant monitoring to ensure they remain in alignment during use. 
     There is a need for a mechanism and system that will allow the size of the case forming cavity, and associated tooling, to be adjusted in order to allow the case former to be capable of producing different types of cases as desired by an operator. It is desirable that such a mechanism and system be comparatively less costly than those that are, easily and reliably repeatable for operational personnel, provides consistent results over time, and which has a high tolerance for material variations from suppliers. 
     Embodiments disclosed herein address this need by providing an adjustable case forming cavity having four, rail mounted, moveable corner slide blocks that can be easily reconfigured to accept various shapes and sizes of corrugated cardboard blanks so as to produce any of a wide variety of finished case configurations. The adjustable cavity is utilized with a customizable case gage that ensures each configuration of the corner slide blocks is precisely maintained throughout a forming run, thereby ensuring that cases are formed consistently. When a different case configuration is desired to be produced, the current case gage and forming head are removed, the corner blocks are reconfigured, and a new case gage and head that are tailored to the new blank are locked onto place over the reconfigured cavity, and the case former is ready to produces the new cases. 
     SUMMARY OF THE INVENTION 
     Embodiments shown and described herein are directed to a customizable case former, systems and methods of use. The case former includes a base that supports rail guided slide blocks that define the case forming cavity and provide it with a customizable shape. The case former also includes any number of potential case gages that are each uniquely configured to accept a particular size, shape and pattern of a case blank, which the case former folds and assembles into a particular style of case during its operation. Each case gage is provided with various guide mechanisms, and acts as a template to ensure the case forming cavity is properly sized and shaped to receive a particular blank necessary to form a corresponding particular type of case that is to be formed therefrom. Each case gage is accompanied by a customized forming head that is shaped to correspond to the opening size of the case forming cavity as defined by the case gage template. 
     By reconfiguring the slide blocks upon their respective rails, to match the template of a given case gage and forming head, the case former can be quickly and efficiently reconfigured to accept any of a variety of configurations of case blanks, and thereby produce a corresponding variety of configurations of cases with reliability and consistency. 
     These and other embodiments and their features are shown in the drawings and the following detailed description and claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a exploded isometric view of an embodiment of the case former shown with a first type of case gage, forming head and blank in association with the case former base having slide blocks configured to define a first opening configuration of the case forming cavity. 
         FIG. 2  is an isometric view of the assembled case former shown in  FIG. 1  with the blank shown being received onto the case gage prior to case formation. 
         FIG. 3  is an isometric view of the case gage shown in  FIG. 2  that has been reconfigured with a second type of case gage and forming head to allow the case former to receive a second type of blank. 
         FIG. 4 a -4 g    are top down views of exemplary case gage and forming head embodiments that maybe interchangeably used with the case former base, illustrating a sample of the variety of different template openings that a case gage may be provided with relative to correspondingly configured forming heads. 
         FIG. 5 a    and  FIG. 5 b    are the same isometric view of the case former base shown in  FIGS. 1-3  with the slide blocks shown in different positions to illustrate the manner in which the case forming cavity is reconfigured. 
         FIG. 6  is an isometric view exploded view of the case former shown in  FIGS. 5 a    and  5   b,  with a case gage shown being positioned over the case forming cavity of the base and prior to being secured to the base and slide blocks. 
         FIG. 7  is an isometric view of the case former shown in  FIG. 6  with a case gage shown positioned over the case forming cavity of the base and locked to each of the slide blocks via locking pins. 
         FIG. 8  is a close up view, isometric view of a slide block such as is shown in  FIGS. 6 and 7 . 
         FIGS. 9 a -9 c    are close-up, isometric views of a portion of the case gage shown in  FIG. 7  and one of the slide blocks, depicted to show the manner in which a slide block is aligned with the case gage opening and locked in place to the case gage via a retaining pin. 
         FIG. 10  is an isometric view of an exemplary side guide of a case gage depicted with a type of blank to illustrate how features of the side guide and blank potentially interact. 
         FIG. 11  is an isometric view of the exemplary side guide shown in  FIG. 10  an equipped with minor support flap carriers. 
         FIG. 12  is an isometric view of the exemplary side guide shown in  FIG. 11  depicted with a type of blank to illustrate how features of the side guide and blank potentially interact. 
         FIG. 13  is an isometric view of an exemplary side guide of a case gage depicted with a type of blank to illustrate how features of the side guide, specifically relief notches, and the blank potentially interact. 
         FIG. 14  is an an isometric view of an exemplary case gage equipped with blank supports. 
         FIG. 15  is an isometric view of the case gage shown in  FIG. 14  and depicted with a type of blank positioned on the case gage to illustrate the manner in which the blank supports support portions of the blank. 
         FIGS. 16-19  are a sequence of isometric views of the case former and blank showing the case forming process. 
     
    
    
     DETAILED DESCRIPTION 
     As mentioned above, embodiments disclosed herein are directed to a customizable case former, and particularly to case former that can be quickly and efficiently converted from forming one type of case to another, and which will form cases with precision and consistency. An embodiment of such a case former and the primary elements that provide it with its customizable case forming functionality are shown in  FIGS. 1-19 . The methods of using such a case former, as well as the accompanying systems of employing customized forming heads and case gages with the case former are likewise illustrated in the drawings and described in greater detail below. 
     Starting with  FIG. 1 , a case former  10  is shown in an exploded view in order to reveal the various components that make up of the case former. As is shown, the case former  10 , includes a case former base  12 , which acts as a housing having an interior  14 . Within the interior  14 , and supported by the base  12  on opposing sides of the interior  14  are a first primary slide rail  16  and a second primary slide rail  18 . The primary slide rails  16  and  18 , support opposing first and second slide rail assemblies  20  and  22  respectively. The slide rail assemblies  20  and  22  are slidingly engaged and movable along the length of the primary slide rails  16  and  18  within the interior  14  of the base housing  12 . 
     Each of the slide rail assemblies  20  and  22  support a secondary slide rails  24  and  26  respectively. For purposes of identification the secondary slide rails will be designated as a left secondary slide rail  24  and a right secondary slide rail  26 . Slidingly mounted to the left secondary side rail  24  are a first pair of slide blocks  30  and  32 . Slidingly mounted to the right secondary side rail  26  are a second pair of slide blocks  34  and  36 . The four slide blocks  30 ,  32 ,  34 , and  36  define the case forming cavity  40  of the case former, and by repositioning them along the secondary slide rails  24  and  26 , and likewise, by repositioning the slide rail assemblies  20  and  22  along the primary slide rails  16  and  18 , the case forming cavity  40  may be re-sized and re-shaped to any degree; limited only by the interior dimensions of the base housing  12 . 
     Positioned above the base  12 , the next primary component of the case former  10  is a case gage  50 . The case gage  50  provides two key functions of the case former, namely, to act as a support and guide to the blanks  100  of corrugated carboard (or other materials) that are fed into the case former and assembled into cases; and to secure the position of the slide blocks  30 ,  32 ,  34  and  36  in order to maintain the precise opening dimensions of the case forming cavity  100  that is necessary for the formation of a given type of case for the duration of a case forming run. 
     The primary component of the case gage  50  is the base plate  52 , which acts as a template for guiding and holding the slide blocks  30 ,  32 ,  34 , and  36  in a given position in order to establish the dimensions of the forming cavity  40  that is required for a given case assembly run. To accomplish this goal, each base plate  52  is provided with an opening  42  that has customized dimensions unique to a given case that is to be formed during the case forming process. The case forming process will be discussed in greater detail below, and is shown in  FIGS. 16-19 . 
     In order to properly act as a template, a case gage  50 , must be properly positioned over the forming cavity  40  and secured to the base  12  before the case forming process begins. Returning to the base housing  12  for a moment, within the base interior  14  are two opposingly positioned, and fixed in place, bracing members  44 . The bracing members  44  each have an upwardly protruding locating pin  46 . Going back to case gage  50 , the base plate  52  of the case cage  50  defines a pair of locating pin openings  54 , that are sized and shaped to receive a locating pin  46  therethrough. The spacing and position of the locating pin openings  54  on every potential base plate  52  (and thus, every case gage  50 ) will be the same from one base plate to another. All of these components work together to provide a guide and securement mechanism whereby a case gage  50  is placed on top of the base  12  in such a manner so that each locating pin opening  54  receives one locating pin  46  therein. This provides an easily utilized, but precise mechanism to align and seat a case gage  50  on to the base  12 . 
     While it is necessary to engage the case gage  50  to the base  12 , it is also necessary to secure the case gage  50  to each of the slide blocks  30 ,  32 ,  34 , and  36  if the base plate  52  is to properly act as a template for establishing and maintaining the proper size and shape of the forming cavity  40  through a given a case assembly run. To accomplish this, each base plate  50  defines four slide block alignment holes  55 , each of which align with a slide block hole  35 . Regardless of the type of base plate  52  and the size and shape of the template opening  42 , the four slide block alignment holes  55  have the same position, relative to the template opening  42 . This ensures that each case cage will fit onto the base  10  with consistency and precise alignment. The manner in which these holes are aligned and secured in place via the use of locking pins  60  is discussed in greater detail below and shown in  FIGS. 9 a   - 9   c.    
     The locking pins  60  may be any sort of elongate fastener having a relatively narrow diameter post  62  as compared to a larger diameter head  64 , such as in the manner of a screw, bolt, or pin. 
     As mentioned above, in addition to acting as the template for the dimensions of the forming cavity  40 , the case gage  50 , also is the guide and support mechanism for the blanks  100  that are to be formed into cases. As such in addition to the base plate  52 , each case gage  50  will also include a pair of side guides  56  that are secured to and positioned above the base plate  52  by spacer  58 . The spacers  58  provide the proper spacing between the case blank  100  and the forming cavity  40  during the forming process of a given case. Like the base plate opening  42 , the various characteristics of the side guides  56  and spacers  58  are fully customizable depending on the type of blank  100  and the case being formed therefrom. Some of these characteristics as well as additional features of the side guides are discussed in greater detail below and shown in  FIGS. 10-15 . 
     The final primary component of note for providing the case former  10  with the capability of being convertible from forming one type of case to another is the forming head  70 . In  FIG. 1 , a forming head  70  is shown that has external dimensions which correspond to the dimensions of the forming cavity  40 , as imposed by the template opening  42  and whose corners are defined by the positions of the slide blocks  30 ,  32 ,  34 , and  36 . For each case gage  50  that has a unique template opening  42 , a correspondingly shaped forming head  70  is provided. The precise relationship between the template opening  42  and forming head  70  are key elements that ensure that a given blank  100  is properly engaged by the slide blocks  30 ,  32 ,  34 , and  36  during the case formation process, and that a given type of case will be formed with precision and repeatability. 
     The forming head  70  is otherwise a conventional forming head having the capability to selectively apply suction or vacuum to a surface, such as that of a blank  100  during the case forming process, in order to selectively hold the blank, and release the eventual case, to the surface of the forming head during the case forming process. 
     By comparing the manner in which a case former  10  may be configured in two different ways, such as is shown in  FIGS. 2 and 3 , the basic nature of the relationship between the template opening  42 , the position of the slide blocks  30 ,  32 ,  34 , and  36 , and the forming head  70  is illustrated. In a first configuration shown in  FIG. 2 , the case former  10  is provided with a case gage  50  whose base plate  52  defines a template opening  42  such that the slide blocks  30 ,  32 ,  34 , and  36  define a forming cavity  40  having a size which corresponds to that of the forming head  70 . All of which have been selected to assemble a particular type of case from the blank  100  shown. The same is true of the configuration shown in  FIG. 3 , where it will be noted that the case gage  50  has been switched out for one whose template opening  42  is distinctly smaller in size and shape than that of the  FIG. 3  configuration. The smaller template opening  42  dictates the positions of the slide blocks  30 ,  32 ,  34 , and  36 , which are now in much closer proximity to one another, thereby forming a forming cavity  40  of a corresponding smaller size and shape as well. The forming head  70  provided to the configuration shown in  FIG. 3  is likewise, sized and shaped according to the smaller size and shape of the template opening  42 , and corresponds to the formation requirements of a case that is to be formed from the very different type of blank  100 , than that which is being used in configuration of  FIG. 2 . 
     As may be seen in  FIGS. 4 a   - 4   g,  the case former  10  may be provided with a plurality of interchangeable forming head  70  and case gage  50  configurations. In each configuration of the case gage  50 , the base plate  52  may be provided with a unique template opening  42  to which the corresponding forming  70  is designed to operate with for the forming of particular types of cases. 
     While the case gage  50 , and more precisely the opening  42  defined by the base plate  52 , along with a correspondingly sized and shaped forming head  70  are components that provide a basis of the customizability of the case former  10 , via their ability to be readily removed and replaced on the case former  10 , nevertheless, it is the uniquely reconfigurable slide blocks  30 ,  32 ,  34 , and  36  within the base  12 , such as are depicted in  FIGS. 5 a    and  5   b,  that make the use of the various case gages  50  and forming head  70  possible. 
       FIGS. 5 a  and 5 b    show the interior  14  of the base  12  in two different states such as may be observed during the change over from one type of case forming run to another. Having removed the case gage  50  from atop the base  12 , by first removing the locking pins  60  from slide block alignment holes  55  and slide block holes  35 ; and then by lifting the case gage  50  from atop the base  12  and its engagement with the locating pins  46  (see  FIG. 1 ), the interior  14  of the base  12  is made accessible. Once accessed in this manner, the slide blocks  30 ,  32 ,  34 , and  36  may be moved from their previously secured position shown in  FIG. 5 a    to a fully extended position such as is shown in  FIG. 5   b.  This movement is accomplished by sliding each of the slide blocks  30 ,  32 ,  34 , and  36  along the respective secondary rails  24  and  26  (secondary rail  26  is not visible in this view, see  FIG. 1 ) to which they are mounted, and by likewise sliding the slide rail assemblies  20  and  24 , which house the slide blocks and secondary rails, along the primary slide rails  16  and  18 . The slide rail assemblies  20  and  24  and slide blocks  30 ,  32 ,  34 , and  36  may then be slid into new positions within the base interior  14  to effectively reset the size and shape of the forming cavity  40 , as dictated by a new case gage  50  that is placed over the slide blocks  30 ,  32 ,  34 , and  36  and base  12 , and then secured into place by aligning the base plate locating pin openings  54  with the locating pins  46  of the base  12  and by locking pins  60  inserted into the slide blocks  30 ,  32 ,  34 , and  36  through the slide block alignment holes  55  of the base plate  52  in the manner shown in  FIGS. 6 and 7 . 
     Turning now to the features and functions of the slide blocks  30 ,  32 ,  34 , and  36  themselves, a close up view of a representative slide block is shown in  FIG. 8 . Each slide block  30 ,  32 ,  34 , and  36  is constructed in the same manner, and has the same features and functions. As is shown in  FIG. 8  each slide block is comprised of a minor flap folding post  80 , a first major flap folding plate  82 , a second major flap folding plate  84 , compression cylinders  86  and a bearing block  88 . In addition, as already described above, each slide block defines a slide block hole  35  which is sized to receive a locking pin  60  in the manner shown. 
     The first major flap folding plate  82  and second major flap folding plate  84 , are positioned on either side of the minor flap folding post  80 . This intersection of post  80 , and plates  82  and  84 , is the defining shape of each corner of the case forming cavity  40 . 
     The first major flap folding plate  82  and second major flap folding plate  84  are of the same height, and are both shorter than the minor flap folding post  80 . 
     As their names suggest, the minor flap folding post  80  and major flap folding plates  82  and  84  are the aspects of the slide block that engage particular portions of the blank  100  as the forming head  70  pushes the blank  100  into the forming cavity  42  during the case forming process, such as in the manner shown in  FIGS. 18-21 , for example. The compression cylinders  86  are actuated during the folding process causing the first and second major flap folding plates  82  and  84  to push outward to put the major flaps of the blank  100  into compression (so as to both continue the folding process but also to set any adhesive that was applied to the blank prior to the folding process beginning). The bearing block  88  is that portion of the slide block that is slidingly engaged to the secondary slide rails (specifically the bearing block  88  of slide blocks  30  and  32  are engaged to secondary slide rail  24  of the first slide rail assembly  20 ; and the bearing block  88  of slide blocks  34  and  36  are engaged to secondary slide rail  26  of the second slide rail assembly  22 , such as in the manner shown in  FIG. 1 ) 
     As best depicted in  FIGS. 6 and 7 , in addition to their respective functions related to the folding of a blank into a case, the minor flap folding post  80  and major flap folding plates  82  and  84  also function as the most basic/preliminary guide to the initial installation of a new case gage  50  onto the base  12 . When positioning a new case gage  50  onto the base  12 , the minor flap folding post  80  and major flap folding plates  82  and  84  of each slide block  30 ,  32 ,  34 , and  36  must extend partially through the template opening  42  of the base plate  52 . As such, the slide blocks  30 ,  32 ,  34 , and  36  may be roughly slide into position to allow the template opening  42  of the base plate  52  to be placed over all four slide blocks  30 ,  32 ,  34 , and  36 . Once all four slide blocks  30 ,  32 ,  34 , and  36  are contained within the confines of the template opening, the case cage  50  can be manually manipulated so that the base plate locating pin openings  54  receive the locating pins  46  of the base  12 . 
     The subsequent, and more precise alignment of the slide blocks  30 ,  32 ,  34  and  36  with the template opening  42  is accomplished by sliding each slide block as necessary so that the slide block alignment holes  55  of the base plate  52  line up with the slide block holes  35  such as in the manner shown in  FIGS. 9 a  and 9 b   . Once the holes  35  and  55  are in alignment, such as is shown in  FIG. 9 b   , a locking pin  60 , such as is shown in  FIG. 9 c   , is passed through the alignment holes  55  of the base plate  52  and received into the slide block hole  35  of each slide block  30 ,  32 ,  34  and  36 . In this manner, the case gage  50  is secured to each of the slide blocks  30 ,  32 ,  34 , and  36  in a quick and easily repeatable manner, without sacrificing precision. 
     The forming head, and the posts and plates of the slide blocks, are not the only structures that contact the blank and are of significance to the case forming process. As shown in  FIGS. 10-15 , the side guides  56  of the case gage  52  (see  FIG. 1 ) also have structural and functional properties that impact the blank folding and case forming process. 
     Beginning with  FIG. 10 , a side guide  56  is shown equipped with a broad support surface  51 , which is useful in handling a blank  100  that has particularly large flaps  103 . The side guide  56  is also equipped with a stop block  53 , which acts to properly position the blank  100  over the forming cavity  40  (see  FIG. 1 ). The stop block  53  may be repositioned along the length of the side guide  56 . 
     Moving on to the side guide  56  embodiment shown in  FIG. 11 , in this embodiment the stop block  53  is in a fixed position relative to the support surface  51 . The embodiment shown is provided with a one ore more convex (relative to the blank and support serface) flap support members  57 , which act to catch and support particularly large minor flaps  105  that are not supported by the support surface  51  (due to the particular configuration of the blank  100 ), as the blank it is advanced into position along the side guide and over the case forming cavity  40  (see  FIG. 1 ) such as in the manner shown in  FIG. 12 . 
     In the side guide embodiment show in  FIG. 13 , here the side guide  56  is provided with a pair of recesses  59  that aid in the formation of very shallow cases  102 , by necessitating that the flaps  103  of the case be run through the recesses  59  such as in the manner shown. 
     In the embodiment shown in  FIGS. 14 and 15 , rather than providing the side guides  56  with additional structures to support the blank  100 , the case gage  50  is provided with blank support members  90  which act to support those portions of blanks that are not supported by the support surface  51  of the side guides  56 , due to the particular configuration of the blank. 
     As one of ordinary skill will understand and recognize, when the case former described herein is in use, a given blank  100  may be advanced/shuttled/pushed into the former by various mechanisms. The process of forming a case from a blank  100  that has been advanced into the case former, and properly positioned over the case forming cavity  40 , and under the forming head  70 , via the side guides  56  is shown sequentially in  FIGS. 16-19 . 
     As shown in  FIG. 16 , the advancing blank  100  enters the former  10  by a path defined by the slide rails  56 . The advancement of the blank is stopped by the stop blocks  56  which are also positioned to ensure that the blank  100  is properly aligned over the case forming cavity  40 , and under the forming head  70 . At or before this time, adhesive, such as hot melt adhesive, is applied to the blank at selected points of the blank surface (not shown). 
     Next, as shown in  FIG. 17 , the forming head  70  will move down in a vertical direction (the forming head is supported and actuated by conventional means that will be recognized and understood by one of ordinary skill) whereupon it will engage the blank  100 , and while applying vacuum to the blank  100 , begin pushing the blank  100  into the case forming cavity  40 . As this occurs, the minor flap folding post  80  is the first aspect of the slide blocks  30 ,  32 ,  34 , and  36  to contact the blank  100 , due to its greater height than that of the folding plates  82  and  84 . Once in contact with the blank  100 , the minor flap folding post  80  will exert a force on the minor flaps  103  of the blank to begin their folding prior to the folding of the major flaps  105 . 
     Next, as shown in  FIG. 18 , when the forming head (no longer visible) reaches its final forming position within the forming cavity  40 , the compression cylinders  86  (see  FIG. 8 ) are activated to actuate the first and second major flap folding plates  82  and  84  causing them to push outward and against all of the flaps  103  and  105  of the blank that are adjacent thereto, causing the overlapping layers of the blank (and any adhesive present thereon) to be compressed together. 
     Finally, as shown in  FIG. 19 , after an accepted amount of time (to set any adhesive present) the compression cylinders  86  (see also  FIG. 8 ) are deactivated, allowing the first and second major flap folding plates  82  and  84  to pull back. The forming head  60  (not visible, see  FIG. 16 ), still applying vacuum to the newly formed case  102  is moved vertically upward from within the case forming cavity  40 . Application of vacuum is ceased and the case  102  is released from the forming head and passed out of the case former  10 . 
     The many features and advantages of the invention are apparent from the above description. Numerous modifications and variations will readily occur to those skilled in the art. Since such modifications are possible, the invention is not to be limited to the exact construction and operation illustrated and described. Rather, the present invention should be limited only by the following claims.