Patent Publication Number: US-10759133-B2

Title: Machine for automatically manufacturing customized packaging items

Description:
FIELD OF THE INVENTION 
     The present invention generally finds application in the field of creation of packages and boxes, and particularly relates to a machine for automatically manufacturing customized packaging items, preferably made of corrugated cardboard or the like. 
     BACKGROUND ART 
     Systems or machines are known in the art of packaging, for creating packages having predetermined dimensions, and adapted to contain one or more items to be shipped or stored. 
     These machines can create a package from a sheet of base material, e.g. corrugated cardboard or the like. 
     Particularly, most of these machines can create a substantially box-like package by appropriately shaping a previously cut and creased sheet. 
     Therefore, all of these arrangements suffer from the drawback that the cardboard must be first submitted to a cutting and creasing step, to be carried out in a machine external to the system, often located in other factories or departments. 
     Nevertheless, some systems afford adjustment of certain internal members thereof, to form packages with variable dimensions. 
     EP2697124 discloses an apparatus for creating cardboard containers of variable sizes. This apparatus comprises a forming station with a frame composed of a pair of longitudinal members that slidingly support a plurality of plate-like forming tools, which are designed to delimit the forming area. The forming area has the same size as the package to be created, and the frame also comprises a pair of transverse members that slidingly support the longitudinal members to change the distance therebetween in a predetermined range from minimum to maximum values. By appropriate adjustment of the longitudinal distance between the tools and the transverse distance between the longitudinal members, the dimensions of the forming area may be changed to form packages of variable dimensions. 
     A first drawback of this arrangement is that the distances between the longitudinal members and the tools must be manually adjusted by an operator, which involves long downtimes and a dramatic reduction of throughput. 
     Furthermore, this apparatus has no pressure means for interacting with the cavity and shape the package, whereby the formation of the box requires the installation of pushing systems external to the apparatus and interacting with the die. 
     In view of at least partially obviating these drawbacks, package-forming systems have been developed, that can automatically and autonomously change the dimensions of the box. 
     AU20154060 discloses a system for forming cardboard boxes, which comprises a die having a cubic cavity, delimited by four corner elements that are slidingly mounted to respective straight guides. An actuator is placed at the top of the die, and is able to vertically move between a lifted position, in which it is outside the cavity, to a lowered position in which it is within the cavity. 
     Once the sheet has been cut and creased, it is placed on top of the die when the actuator is in the lifted position, and as the latter is lowered, the sheet is gradually pushed into the die to thereby form a box-like enclosure due to the interaction exerted by the corner elements with its outer surface. 
     Driving means are associated with the corner elements for promoting controlled movement thereof toward or away from each other to change the dimensions of the die. 
     Furthermore, the actuator has a pair of projecting appendices, that can be controllably moved to change the plan projection of the actuator for mating and synchronization thereof with the dimensions of the die. 
     The main drawback of this arrangement is that the cut and creased sheet must be manually placed on the die, whereby the package-forming process is actually semiautomatic. 
     Furthermore, the package must be also manually removed from the die, which will further reduce the throughput of the system. 
     An additional drawback of this arrangement is that the wings of the actuator can be adjusted within a limited range, and as a result the system can create packages whose dimensions are variable within a small adjustment range. 
     Also, an important drawback of this arrangement is that the apparatus can create boxes having an open bottom or an open sidewalk, that are required to be manually closed using adhesive tape or glue, before introducing the material to be packaged therein. 
     Technical Problem 
     In light, of the prior art, the technical problem addressed by the present invention consists in providing a fully automatic machine for creating customized packaging items, that can quickly create boxes of different dimensions, according to the products to be packaged. 
     DISCLOSURE OF THE INVENTION 
     The object of the present invention is to solve the aforementioned technical problem and obviate the above drawbacks, by providing a machine for automatically manufacturing customized packaging items that is highly efficient and relatively cost-effective. 
     A particular object of the present invention is to provide a machine for automatically manufacturing customized packaging in a fully automatic manner. 
     A particular object of the present invention is to provide a machine for automatically manufacturing customized packaging items that has a high hourly throughput, due to minimized adjustment times for its pick-up and forming members. 
     Yet another object of the present invention is to provide an automatic machine that can create a custom enclosure from a pack or coil of base sheet material. 
     A further object of the present invention is to provide a machine that can automatically release the formed packaging items without requiring any manual action by an operator. 
     Another important object of the present invention is to provide a machine for creating custom packaging items with two or more edges joined together. 
     These and other objects, as better explained hereafter, are fulfilled by a machine for automatically manufacturing customized packaging items as defined in claim  1 . 
     Advantageous embodiments of the invention are obtained in accordance with the dependent claims. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Further features and advantages of the invention will be more apparent upon reading of the detailed description of a machine for automated creation of custom packages, which is described as a non-limiting example with the help of the annexed drawings, in which: 
         FIG. 1A  is a perspective view of a machine for automated creation of custom packages according to the invention in a first configuration; 
         FIG. 1B  is a perspective view of a first enlarged detail of  FIG. 1 ; 
         FIG. 2  is a top view of a machine for automated creation of custom packages according to the invention in a second configuration; 
         FIGS. 3 and 4  are perspective views of the machine of  FIG. 1  in two different operating positions; 
         FIGS. 5A and 5B  are perspective views of the machine of  FIG. 1  in a further operating position; 
         FIGS. 6A and 6B  are perspective views of the machine of  FIG. 1  in a further operating position; 
         FIGS. 7 and 8  are perspective views of a second detail of  FIG. 2 , in two different operating positions; 
         FIGS. 9A and 9B  are perspective views of the detail of  FIG. 7  in a further operating position; 
         FIGS. 10 ;  11 A and  11 B are perspective views of the detail of  FIG. 7  in two further operating positions; 
         FIG. 12  is a top view of a plant composed of a plurality of machines for automated creation of custom packages as shown in  FIG. 1  and/or  FIG. 2 . 
     
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Particularly referring to the accompanying figures, a machine for automatic creation of packages I from continuous sheet material, such as corrugated cardboard or the like, is illustrated and generally designated by numeral  1 . 
     The machine  1  is particularly suitable for creating custom packages I, according to user requirements and to the dimensions of the object to be packaged. 
     Furthermore, the machine  1  will be configured to create packages I from a continuous web of material that may be unwound from a coil, or folded in accordion-like pleats, with sheets joined at their edges folded upon themselves. 
     The machine  1  of the invention comprises a cutting and creasing unit  2  for cutting and creasing the continuous web to obtain one or more sheets F of material having a plurality of cuttings and/or bendinglines, generally referenced C and defining respective flaps S. 
     The cutting, unit  2  is designed to change both the dimensions of the sheet F being cut, and the position of the cuttings and bendinglines C according to the package I to be formed. 
     A plate  4  is provided at the exit  3  of the unit  2 , for the sheet F of material to slide thereon once it has been cut and creased. In an alternative configuration of the invention, not shown, a device for customized ink-jet printing of images on one or more faces W of the sheet F of material may be installed between the exit  3  of the cutting and creasing unit  2  and the sliding plate  4 . 
     Conveniently, the machine  1  comprises at least one variable-geometry die-forming unit  5  for forming the cut and creased sheet F and create package I having preset dimensions. 
     In a preferred embodiment of the invention, not shown, the machine  1  may comprise a single cutting and creasing unit  2  and two or more die-forming units  5  placed downstream from the sliding plate  4 , for sequential or simultaneous formation of multiple packages I. 
     The die-forming unit  5  may have a die-forming cavity  6  of variable dimensions, substantially matching those of the package I to be created. 
     Particularly, as best shown in  FIGS. 3 to 6B , the die-forming unit  5  may be adapted to form an erect custom package I from a cut and creased sheet F. 
     In this case, the die-forming cavity  6  will be delimited by a plurality of substantially vertical abutment members  7 , each having a flat outer surface  8  adapted to interact with the sheet F to fold it along its bendinglines C. 
     In order to change the dimensions of the cavity  6 , the abutment members  7  may be selectively movable in a longitudinal direction L and/or a transverse direction T in a predetermined range of values. 
     Therefore, appropriate positioning of the abutment members  7  will provide a cavity  6  of predetermined dimensions and geometry, e.g. a square or rectangular cavity. 
     In the die-forming unit  5  as shown in  FIGS. 3 to 6A , the abutment members  7  may comprise a lower portion  9 , formed by a plurality of vertical profiles  10  with one or more flat outer surfaces  8  interacting with the cut and creased sheet F. 
     The abutment members  7  may also comprise an upper portion  11  formed by a plurality of rods  12  hinged at the upper end  13  of the profiles  10 . 
     These rods  12  may selectively rotate about a first horizontal rotation axis X between an inoperative lowered position, in which they are substantially horizontal and have coplanar outer surfaces  8  to define a plate  4 ′ for the cut and creased sheet F to lie thereupon, and an operative lifted position in which they are substantially vertical and aligned with their respective profiles  10 , with their outer surface  8  interacting with the sheet F to create the package I. 
     Furthermore, the abutment members  7  may be also vertically movable over a predetermined range, generally about 150 mm. 
     In an alternative configuration of the machine  1 , the die-forming unit  5  may be configured to create folded packages I known as American-type packages. 
     This particular die-forming unit  5  is shown in  FIGS. 7 to 11B , and its cavity  6  is delimited by abutment means  7  consisting of a pair of horizontal plates  14  with a flat top surface  8  adapted to define an abutment for the sheet F and a plurality of motorized actuators  15 , that can selectively rotate relative to a corresponding horizontal rotation axis Y between an inoperative position, in which they do not contact the sheet F, and an operative position in which they interact with the sheet F to fold a flap S thereof into the cavity  6 . 
     For example, a pair of actuators  15  may be provided at the periphery of the cavity  6 , each having a plurality of transversely adjacent longitudinal bars  16 , having a pitch p therebetween that can be adjusted according to the package I to be created. 
     The die-forming unit  5  will further have a plate  4 ′ for the sheet F to be laid thereupon before being introduced into the die-forming cavity  6 . 
     First motor means, not shown, are provided, which are associated with the abutment members  7  to change the longitudinal distance d 1  and the transverse distance d 2  therebetween. 
     If the die-forming unit  5  is of the type as shown in  FIGS. 3 to 6B , the first motor means may promote selective and independent movement of the abutment members  7  in a longitudinal and/or transverse direction, lifting thereof, and rotation of the rods  12  relative to the corresponding rotation axis X. 
     However, if the die-forming unit  5  is of the type as shown in  FIGS. 7 to 11B , the first motor means may promote longitudinal movement of the plates  14  and the actuators  15 , and controlled rotation of the bars  16  about the axis Y. 
     Preferably, the machine  1  may also comprise unloading means  17  for unloading the package I, located at the die-forming station  5 , for automatically releasing the package I once it has been formed. 
     In the die-forming unit  5  as shown in  FIGS. 3 to 6B , the unloading means  17  may comprise one or more vertically movable surfaces  18 , which are designed to lift the erect package I to thereby remove it from the cavity  6  and allow it to be manipulated by an external member. 
     Otherwise, in the alternative configuration of the die-forming unit  5  as shown in  FIGS. 7 to 11B , the unloading means  17  may comprise a single  19  drive roller  19 , frictionally interacting with one of the flaps S of the folded package I to cause it to come out of the cavity  6 . 
     Furthermore, the machine  1  may comprise bonding means  20 , which are adapted to distribute a layer of adhesive A on at least one flap S of the cut and creased sheets F, to promote adhesion with another flap S′ thereof, and thereby form the package I. 
     In the configuration of the machine  1  as shown in  FIGS. 3 to 6B , the bonding means  20  are located upstream from the die-forming unit  5  and comprise a bonding head, not shown, which is placed above the sliding plate  4  to distribute a line of adhesive A on the outermost edges S of the sheet F. 
     Furthermore, the machine  1  may also comprise one or more die cutters, also not shown, which are adapted to interact with one or more flaps S of the sheet F to reduce their dimensions. 
     Preferably, the bonding heads and the die cutter may be housed within the same box-like enclosure  21 , which is secured in cantilever fashion above the sliding plate  4 . 
     In the different embodiment of the die forming unit  5  as shown in  FIGS. 7 to 11B , the bonding means  20  comprise a head for distribution of the adhesive A, not shown, which is mounted at the end  22  of a transversely movable arm  23 , located substantially at the center of the cavity  6 . 
     According to a peculiar aspect of the invention, a multifunctional manipulator  24  is provided, which is adapted to automatically pick up one sheet F at a time from the cutting and creasing unit  2 , and feed it to the die-forming unit  5 . 
     Furthermore, the manipulator  24  is designed to automatically adapt to the dimensions preset in the die-forming unit  5  to interact therewith for forming the package I. 
     Preferably, as better shown in the figures, the manipulator  24  comprises a fixed base  25 , generally placed between two adjacent die-forming stations  5  that are fed by the same cutting and creasing unit  2  and an anthropomorphic motorized arm  26  which is adapted to rotatably support a movable head  27 . 
     The movable head  27  may comprise a plurality of suction cups  28 , as schematically shown in the figures, which are connected to respective suction means, not shown, to promote a gripping action on the sheet F at the exit of the cutting and creasing unit  2  and release thereof into the die-forming cavity  6 . 
     Thus, the machine  1  will create custom packages I in a fully automated manner, without requiring the operator to transfer the cut and creased sheet F to the die-forming unit  5 . 
     Furthermore, the head  27  may comprise a generally longitudinal upper beam  29 , for supporting a plurality of substantially vertical pressure members  30 , which are designed to penetrate the die-forming cavity  6  once the sheet S has been positioned in the die-forming unit  5 . 
     These pressure members  30  can be adjusted both in the longitudinal direction L, substantially parallel to the beam  29 , and in the transverse direction T to adapt to the dimensions of the die-forming cavity  6 . 
     Conveniently, the suction cups  28  may be arranged at the free bottom and  31  of the pressure members  30 . 
     Advantageously, the machine  1  may comprise second motor means  32  associated with the vertical pressure members  30  of the head  27 , to selectively change the longitudinal distance d 3  and the transverse distance d 4  therebetween. 
     Thus, the distances d 3 , d 4  between the pressure members  30  will be controlled to be substantially equal to the dimensions of the cavity  6 , which in turn match those of the package I to be created. 
     The machine  1  may further comprise electronic control means  33 , comprising an interface unit  34  that is designed to be actuated by the user to set the dimensions of the package I. 
     The control means are electrically connected to the cutting and creasing means  2 , for the cuttings and the bendinglines C to be made in the proper positions, with reference to a given preset package I. 
     Furthermore, the electronic control means  33  will be also connected to the first and the second motor means  32  to automatically change the distances d 1 , d 2  of the abutment members  7  and the distances d 3 , d 4  of the pressure members certainty according to the dimensions of the package I. 
     Preferably, the electronic control means  33  may comprise a microprocessor unit  35 , for controlling both the movement of the manipulator  24  and the first and second motor means  32  during formation of the package I in the die forming unit  5 . 
     For example, the microprocessor unit  35  may control the vertical movement of the abutment means  7 , as well as the rotation of the rods  12  and the actuators  15  about their respective rotation axes X, Y. 
     In operation, if the plant  1  is configured to create an erect package I, the sheet F at the exit  3  of the cutting and creasing unit  2  will be picked up by the manipulator  24  and moved into the die-forming unit  5 , as shown in  FIGS. 3 and 5A . 
     Before reaching this unit  5 , the sheet F will be moved by the manipulator  24  below the bonding heads, if applicable, as schematically shown in  FIG. 4 . Thus, the sheet S will reach the die-forming unit  5  in a die-cut state, with a layer of adhesive A on at least one flap. S. 
     In this processing step, the die-forming unit  5  will have the abutment members  7  lowered, with the rods  12  in the inoperative position, to define the plate  4 ′ for the F to lie thereupon F, as well shown in  FIG. 5B . 
     Also, the manipulator  24  will place the sheet F on the die-forming unit  5 , so that the portion designed to form the bottom wall of the package I will be centered relative to the cavity  6 . 
     Then, the manipulator  24  will promote the controlled descent of the head  27  so that, by the action of the pressure members  30 , the sheet F will progressively penetrate the cavity  6 , as shown in  FIGS. 6A and 6B . 
     As the head  27  moves downwards, the first motor means will promote the rise of the abutment members  7  and the controlled rotation of the rods  12  from the inoperative position to the operative position, to thereby cause the sheet F to be folded along the foldline C to form the erect package I. 
     Also, during forming, the flap S with the adhesive A will overlap another flap S′ of the sheet F to form an erect package I with the side walls and the bottom wall closed. 
     At the end of the forming step, the suction cups  28  will release the package I so formed and the manipulator  24  will move to a position external to the die-forming unit  5  and be ready to pick up a new sheet F at the exit  3  of the cutting and creasing unit  2 . 
     Then, as the movable surfaces  18  of the unloading means  17  are lifted, the erect package I will be removed from the die-forming cavity  6 . 
     If the plant  1  is configured to create a folded package I, the latter will be picked up by the manipulator  24 , due to the adhesion of the suction cups  28 , at the exit of the cutting and creasing unit  2 , and will be placed on the plate  4 ′, as shown in  FIG. 7 . 
     If needed, the manipulator  24  may promote a 90° rotation of the sheet F before placing it on the die-forming unit  5 . 
     Then, the manipulator  24  will promote the controlled descent of the head  27  so that, upon the action of the pressure members  30 , the sheet F will progressively penetrate the cavity  6  until it abuts the top surface  8  of the horizontal plates  14 , as shown in  FIG. 8 . 
     Now, the suction cups  28  will release the sheet F and the manipulator  24  will move to a position external to the die-forming unit  5  and be ready to pick up a new sheet F at the exit  3  of the cutting and creasing unit  2 . 
     Then, the first rotor means will promote controlled rotation of an actuator  15  about its rotation axis Y from the inoperative position to the operative position, so that the corresponding flap S of the sheet F may be folded into the cavity  6  and over the portion that lies on the horizontal plates  14 , as shown in  FIGS. 9A and 9B . 
     Later, as best shown in  FIG. 10 , the movable arm  23  that supports the bonding head will be actuated, to distribute the adhesive A on the outer face W of the flap S so folded. 
     Now, the first motor means will promote the rotation of the other actuator  15  about its rotation axis Y from the inoperative position to the operative position, for a different flap  5 ′ of the sheet F to be folded and adhered to the previously folded flap S coated with the adhesive A, as best shown in  FIG. 11A . 
     Finally, the drive roller  19  will be rotated about its axis Z to promote removal of the folded package I and pressing of the two flaps S, S′ so bonded. 
     As shown in  FIG. 12 , a modular plant  36  may be provided, for automated production of custom packages I from sheet material. Such plant  36  has a plurality of machines  1  as described above, arranged in side-by-side relationship, each having a cutting and creasing unit  2 , a manipulator  24  and two or more die-forming units  5  for forming the package. 
     Therefore, the plant  36  will greatly increase the overall throughput, as it will simultaneously provide multiple custom packages, each created by a single machine. 
     The machine of the invention is susceptible of a number of changes and variants, within the inventive concept disclosed in the appended claims. All the details thereof may be replaced by other technically equivalent parts, and the materials may vary depending on different needs, without departure from the scope of the invention. 
     While the machine has been described with particular reference to the accompanying figures, the numerals referred to in the disclosure and claims are only used for the sake of a better intelligibility of the invention and shall not be intended to limit the claimed scope in any manner. 
     INDUSTRIAL APPLICABILITY 
     The present invention may find application in industry, because it can be manufactured on an industrial scale in factories for production of machines designed for processing of semirigid sheet products, such as cardboard or the like, or for production of package-forming machines.