Patent Publication Number: US-2011077138-A1

Title: Apparatus and method for folding blank into a box

Description:
FIELD OF THE INVENTION 
     The present invention relates to boxes, and more particularly, to method and apparatus for folding blanks to form boxes. 
     BACKGROUND OF THE INVENTION 
     Boxes may be made from blanks by folding along fold lines included in the blanks. The blanks may be folded into boxes using an automated process, or manually. 
     Automated processes for folding blanks into boxes typically require the use of machines that are relatively costly and occupy relatively large amounts of space. 
     Folding of blanks into boxes manually typically is a laborious and time consuming process. For example, oftentimes several panels of a blank may need to be folded to obtain a box. In addition, the panels of the blank may need to be folded in a specific sequence to obtain the box. 
     There exists a need for a device that may facilitate quick, easy and inexpensive assembly of boxes by manual folding of blanks. 
     SUMMARY OF THE INVENTION 
     In accordance with an aspect of the present invention, an apparatus may be used to facilitate folding of a blank into a box. The blank may include a base panel attached to opposing first and second side panels and opposing first and second end panels, first and second corner panels attached respectively to opposing edges of the first end panel, and third and fourth corner panels attached respectively to opposing edges of the second end panel. The apparatus may include a base having opposing first and second sides and opposing first and second ends. The apparatus further may include at least one first side panel folding means and at least one second side panel folding means arranged on the first side and the second side of the base, respectively. Each of the at least one first and second side panels means may include folding surfaces that extend upwardly and outwardly from the base for, respectively, engaging and folding the first side panel and the second side panel of the blank. In addition, a first end panel folding means may be arranged on the first end of the base and include a folding surface that extends upwardly and outwardly from the base for engaging and folding the first end panel, and a second end panel folding means may be arranged on the second end of the base and include a folding surface that extends upwardly and outwardly from the base for engaging and folding the second end panel. The at least one second end panel folding means may include a first positioning means for positioning the second end panel prior to folding of the blank. The apparatus also may include first and second corner panel folding means arranged opposite each other on the first and second sides of the base. Each of the first and second corner panel folding means may include a folding surface that extends upwardly and outwardly from the base for engaging and folding, respectively, the first corner panel and the second corner panel of the blank. In addition, each of the first and second corner panel folding means may include a second positioning means for positioning, respectively, the first corner panel and the second corner panel prior to folding of the blank. In addition, the apparatus may include third and fourth corner panel folding means arranged opposite each other on the first and second sides of the base. Each of the third and fourth corner panel folding means may include a folding surface that extends upwardly and outwardly from the base for engaging and folding, respectively, the third corner panel and the fourth corner panel of the blank. The first, second, third and fourth corner panel folding means and the first and second side panel folding means may be adapted such that, when the blank is in an unfolded condition on the apparatus with the first and second corner panels positioned by the first positioning means and the third and fourth corner panels positioned by the second positioning means, and when the blank is pressed in the direction of the base, the first, second, third and fourth corner panels are folded upwardly by the folding surfaces of the respective first, second, third and fourth corner panel folding means so the first and third corner panels overlie inwardly facing surface of the first side panel and the second and fourth corner panels overlie inwardly facing surface of the second side panel as the first and second side panels are folded inwardly by the folding surfaces of the respectively first and second side panel folding means. 
     In accordance with another aspect of the invention, a method is provided for folding a blank into a box. The blank includes a base panel attached to opposing first and second side panels and opposing first and second end panels, first and second corner panels attached respectively to opposing edges of the first end panel, and third and fourth corner panels attached respectively to opposing edges of the second end panel. The method includes positioning the blank horizontally over an apparatus having a plurality of folding surfaces; and pressing the blank downwardly into the apparatus to engage the folding surfaces, such that the first, second, third and fourth corner panels are folded upwardly, and the first and third corner panels are positioned inside the first side panel and the second and fourth corner panels are positioned inside the second side panel as the first and second side panels and the first and second end panels are folded inwardly toward the base. 
     In a further aspect of the invention, an apparatus may be used for folding a blank into a box. The blank may include a base panel attached to opposing first and second side panels and opposing first and second end panels, first and second corner panels attached respectively to opposing edges of the first end panel, and third and fourth corner panels attached respectively to opposing edges of the second end panel. The apparatus includes a base; positioning means extending from the base for positioning the blank over the base in a predetermined position; side panel folding means disposed on opposite sides of the base and including folding surfaces that extend upwardly and outwardly from the base; end panel folding means disposed at opposite ends of said base and including folding surfaces that extend upwardly and outwardly from the base; and corner panel folding means disposed on opposite sides of the base and including folding surfaces that have a greater incline than the incline of the folding surfaces of the side panel folding means, such that, when the blank is positioned over the base of the apparatus by the positioning means and pressed in the direction of the base, the first, second, third and fourth corner panels are folded upwardly to a first extent before the side panels are folded to the first extent. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Other objects and advantages of the present invention will be apparent from the following detailed description of the present preferred embodiments, which description should be considered in conjunction with the accompanying drawings in which like reference indicate similar elements and in which: 
         FIG. 1  is a plan view of an exemplary blank, in accordance with an aspect of the invention, from which the box of  FIG. 8  is constructed. 
         FIG. 2  is a perspective view of an exemplary jig for use in construction of a box using the blank of  FIG. 1 , in accordance with an aspect of the present invention. 
         FIG. 3  is a perspective view of the blank of  FIG. 1  juxtaposed with respect to the jig of  FIG. 2 . 
         FIG. 4  is a perspective view of the blank of  FIG. 1  engaged by the jig of  FIG. 2 , prior to folding of the blank. 
         FIG. 4A  is a cross-sectional view of a portion of the blank and jig as shown in  FIG. 4  at cross-sectional line  4 A- 4 A. 
         FIG. 4B  is a cross-sectional view of a portion of the blank and jig as shown in  FIG. 4  at cross-sectional line  4 B- 4 B. 
         FIG. 5  is a perspective view of the blank and jig combination, with the blank engaged by the jig and being in a partially folded condition. 
         FIG. 6  is another perspective view of the blank and jig combination, with the blank engaged by the jig and being in a partially folded condition. 
         FIG. 7  is a perspective view of the blank in a partially folded condition, as obtained by use of the jig of  FIG. 2 . 
         FIG. 8  is a perspective view of a box constructed from the blank of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     A container  300 , in an assembled condition as shown in  FIG. 8 , may be formed by folding an exemplary blank  10 , which is shown in  FIG. 1  in an unfolded position. The blank  10 , which may be made from corrugated or paperboard material, has a substantially uniform thickness and includes fold lines that define a plurality of panels. The fold lines correspond to scored portions of the blank  10 . 
     Referring to  FIGS. 1 and 8 , in accordance with an aspect of the present invention, the blank  10  includes a rectangular base or bottom panel  12 . Two rectangular end panels  14   a ,  14   b  are attached to longer edges of the bottom panel  12 , and two side panel members are attached to shorter edges of the bottom panel  12 . Each of the side panel members includes an outer side panel  16   a  attached directly to the bottom panel  12  and an inner side panel  16   b  attached to the outer panel  16   a . The longer edge of the panel  16   b  opposite the panel  16   a  includes a tab  17 . In addition, the panel  12  defines an aperture  19  adjacent each of its shorter edges. The apertures  19  have substantially the same dimensions as, and are aligned with, the tabs  17  of the respective adjacent side panels  16   b.    
     The blank  10  further includes corner panels  20   a ,  20   b  attached, respectively, to the shorter edges of the panel  14   a . In addition, the blank  10  includes corner panels  20   c ,  20   d  attached, respectively, to the shorter edges of the panel  14   b.    
     In addition, the blank  10  includes a rectangular cover or top panel  32  having lengthwise and widthwise dimensions that are slightly less than those of the bottom panel  12 . The top panel  32  is attached at its longer edges, respectively, to the end panel  14   b  and a rectangular end panel  14   c , and is attached at its shorter edges, respectively, to side flap panels  26   a  and  26   b . The flap panels  26   a ,  26   b  are trapezoidally shaped and have lengthwise and widthwise dimensions that are slightly less than the corresponding lengthwise and widthwise dimensions of the panels  16   a ,  16   b . The end panel  14   c  has lengthwise and widthwise dimensions that are slightly less than the corresponding lengthwise and widthwise dimensions of the panel  14   a . In addition, side flap panels  28   a ,  28   b  are attached, respectively, to the opposing shorter edges of the panel  14   c.    
     In accordance with an aspect of the present invention, a jig  100 , as shown in  FIG. 2 , may be provided for assembling the container  300  from the blank  10 . Referring to  FIG. 2 , in an exemplary embodiment of the jig  100 , which may be made of wood or plastic material, includes a substantially rectangular base  102  having a flat top surface  107 , and parallel exterior ends  103   a ,  103   b  that are longer than parallel exterior sides  105   a ,  105   b . The base  102  further includes parallel interior end walls  106  and parallel interior side walls  108 , which are parallel to the ends  103  and sides  105 , respectively, and define a rectangular central aperture  104 . The length of each of the end walls  106  is substantially equal to the longer dimension of the panel  12 , and the length of each of the side walls  108  is substantially equal to the shorter dimension of the panel  12 . 
     Along the end  103   b  of the base  102  are two upstanding end guides  110  that are parallel to the sides  105  of the base  102 . In addition, along the end  103   a  of the base  102  are two upstanding end guides  114  that are parallel to the sides  105  of the base  102  and, respectively, oppose the two guides  110 . The end guides  110  have inwardly facing edges  111  that extend vertically beginning at the top edge of the end wall  106  which is adjacent the end  103   b , and desirably orthogonal to the surface  107 . In addition, the end guides  110  include edges  112  that extend from the edges  111  and are inclined upwardly and extend outwardly with respect to the aperture  104 . The end guides  110  further include top edges  113  that extend from the edges  112  and are substantially parallel to the surface  107  of the base  102 . Similar to the guides  110 , the guides  114  have inwardly facing edges  117  that extend vertically beginning at the top edge of the wall  106  which is adjacent the end  103   a , and desirably orthogonal to the surface  107 . Further, the guides  114  include edges  118  that extend from the edges  117  and are inclined upwardly and extend outwardly with respect to the aperture  104 . The edges  111  and  112  of the guides  110  face the edges  117  and  118  of the opposing guides  114 . In one embodiment, the edges  112 ,  118  are at about a forty-five degree angle with respect to the surface  107  of the base  102 . 
     In addition, referring to  FIGS. 4 and 4A , each of the edges  118 , at an uppermost portion, terminates in a lip  119  that is parallel to the surface  107  of the base  102 . Further, an edge extension  120  extends upwardly from, and desirably perpendicular to, the lip  119 . The lips  119  are spaced the same distance from the surface  107  as the edges  113  of the guides  110 . The lip  119  and the edge extension  120  of the guide  114 , in combination, serve to position the blank  10 , as discussed below. In addition, the edges  111 ,  112  of the guides  110 , and the edges  117 ,  118  of the guides  114 , form folding surfaces that may engage the blank  10 , in the manner explained below. 
     Each of the sides  105  of the base  102  includes a pair of upstanding side guides  130  that are parallel to the ends  103  of the base  102 . In a desired embodiment, the guides  130  on the side  105   a  are disposed to oppose the guides  130  on the side  105   b . Each of the side guides  130  has an inwardly facing edge  131  that extends vertically from the top edge of the adjacent wall  108 , and desirably is orthogonal to the surface  107 . In addition, each of the side guides  130  includes an edge  132  that extends from the edge  131  and is inclined upwardly and outwardly with respect to the aperture  104 . In one embodiment, the edges  132  are at about a forty-five degree angle with respect to the surface  107  of the base  102 . The side guides  130  further include top edges  133  that extend from the edges  132 , are parallel to the surface  107  of the base  102  and spaced the same distance from the surface  107  as the edges  113  of the guides  110 . The edges  131 ,  132  of the guides  130  form folding surfaces that may engage the blank  10 , in the manner explained below. 
     Further, a pair of upstanding corner guides  150  is disposed on the base  102  opposite to each other. One of the guides  150  is between the end  103   a  and the guide  130  which is adjacent to the end  103   a  and the side  105   b , and between the side  105   b  and the guide  114  which is adjacent to the side  105   b . The other of the guides  150  is between the end  103   a  and the guide  130  which is adjacent to the end  103   a  and the side  105   a , and between the side  105   a  and the guide  114  which is adjacent to the side  105   a . Further referring to  FIG. 4B , each of the guides  150  includes an edge  152  extending from the surface  107  of the base  102 , with a slight incline toward the adjacent side  105  of the base  102 , to a rounded edge  154 , which interconnects the edge  152  to an edge  156 . In one embodiment, the edge  152  is substantially perpendicular to the surface  107 , and the edge  156  is substantially parallel to the surface  107 . In addition, each of the guides  150  includes an edge  158  extending upwardly from, and desirably perpendicular to, the edge  156 , and an edge  160  extending from the edge  158 . The edges  156  of the guides  150  are spaced the same distance from the surface  107  of the base  102  as the edges  113  of the guides  110 . The edges  152 ,  154  of the guides  150  form folding surfaces that may engage the blank  10 , in the manner explained below. In addition, the edges  156  and  158  of the guide  150 , in combination, may serve to position the blank  10 , as discussed below. 
     Further, the blank  10  includes a second pair of upstanding corner guides  170  disposed on the base  102  opposite to each other. One of the guides  170  is between the end  103   b  and the guide  130  which is adjacent to the end  103   b  and the side  105   b , and between the side  105   b  and the guide  110  which is adjacent to the side  105   b . The other of the guides  170  is between the end  103   b  and the guide  130  which is adjacent to the end  103   b  and the side  105   a , and between the side  105   a  and the guide  110  which is adjacent to the side  105   a . Each of the guides  170  includes an edge  172  extending upwardly from the surface  107 , with a slight incline toward the adjacent side  105  of the base  102 , to a rounded edge  173 , which interconnects the edge  172  to an edge  174 . In one embodiment, the edge  172  is substantially perpendicular to the surface  107 . The edge  174  extends from the edge  172 , is substantially parallel to the surface  107  of the base  102  and is spaced the same distance from the surface  107  as the edges  113  of the guides  110 . The edges  172 ,  172  of the guides  170  form folding surfaces that may engage the blank  10 , in the manner explained below. 
     Further, the base  102  includes a pair of opposing, rectangular cutouts  180 , desirably extending only partially through the base  102 . The cutouts  180  are disposed between the pairs of guides  130  on the respective sides  105 , and are in communication with the aperture  104  at the walls  108 , respectively. 
     To assemble the blank  10  into a box, a user may position the blank  10  horizontally above the jig  100 , as shown in  FIGS. 3 and 4 . Further referring to  FIGS. 4A and 4B , the blank  10  may be initially positioned such that the corner panels  20   a  and  20   b  of the blank  10  rest on the surface of the edges  156  and contact the surfaces of the edges  158  of the opposing guides  150 , respectively. In addition, the side panel  14   a  may rest on the surfaces of the lips  119  and contact the surfaces of the edges  120  of the guides  114 . Further, the panels  16   a ,  16   b  may rest on the surfaces of the edges  133  of the guides  130 , the panels  20   c ,  20   d  may rest on the surfaces of the edges  174  of the guides  170 , and the panel  14   b  and the panel  32  may rest on the surfaces of the edges  113  of the guides  110 . Consequently, in such position of the blank  10 , the blank  10  rests on the jig  100  with the panel  12  superposed over the aperture  104 . 
     Referring to  FIG. 5 , the blank  10  may then be pressed downwardly at the panel  12 , which causes the corner panels  20   a ,  20   b ,  20   c ,  20   d  to fold upwardly and inwardly. Simultaneously, the side panels  16   a  begin to fold and the side panels  16   b  begin to lift, and also the end panels  14   a ,  14   b  to begin to fold upwardly and inwardly. In accordance with an aspect of the invention, the panels  20   a ,  20   b ,  20   c ,  20   d  are caused to be folded first to a greater extent, from the start of folding of the panels of the blank  10 , in relation to the folding of the panels  16   a ,  16   b , because of the positions of the surfaces of the edges  154 ,  152  and  173 ,  172  of the respective guides  150  and  170 , in relation to the positions of the surfaces of the edges  132  of the guides  130 . Consequently, the panels  20   a - 20   d  are folded so that the panels  20   a - 20   d  at least partially overlie the inwardly facing surfaces of the side panels  16   b , as the side panels  16   b  are folded. 
     As the blank  10  is pressed further downwardly into the jig  100 , the panel  12  enters the aperture  104 . Also, the inclined folding surfaces  112 ,  118  continue to fold and lift the end panels  14   a ,  14   b , and the end panels  14   a ,  14   b  are received in the aperture  104  at the corresponding walls  106 . Further, the inclined folding surfaces  132  continue to fold and lift the side panels  16   a , and the side panels  16   a  are received in the aperture  104  at the corresponding walls  108 . As the panel  12  continues to move downwardly into the aperture  104 , the vertical folding surfaces  131  of the guides  130  lift the side panels  16   a  into vertical positions at right angles to the surface  107 , and the vertical folding surfaces  111 ,  117  lift the end panels  14   a ,  14   b  into vertical positions at right angles to the surface  107 , as shown in  FIG. 6 . At this point in the assembly of the box  300 , the panels  20   a ,  20   b ,  20   c ,  20   d  overlie the inwardly facing surfaces of the panels  16   a  and are at least partially within the aperture  104 . 
     Still referring to  FIG. 6 , the side panels  16   a  and the end panels  14   a ,  14   b  are engaged within the aperture  104 , such that they are held in a vertical position and the blank  10  is a partially folded position. Then, the side panels  16   b  may be folded by hand inwardly, in the direction of the aperture  104 , to provide that the panels  16   b  are substantially parallel with and overlie the inwardly facing surfaces of the corresponding side panels  16   a  and the tabs  17  of the panels  16   b  may be inserted into the respective apertures  19 . The partially folded blank  10 , which corresponds to a partially assembled box  300 , may then be removed manually from the jig  100 , as shown in  FIG. 7 . 
     Assembly of the box  100  may be completed by initially manually folding the panels  28   a ,  28   b  toward inwardly facing surface of the panel  14   c  so the panels  28   a ,  28   b  are perpendicular to inwardly facing surface of the panel  14   c . Then, the panel  14   c  may be manually folded inwardly so that the panel  14   c  is perpendicular to inwardly facing surface of the panel  32 . Then, the panels  26   a ,  26   b  may be manually folded toward inwardly facing surface of the panel so that the panels  26   a ,  26   b  are perpendicular to the inwardly facing surface of the panel  32  and contact the folded panels  28   a ,  28   b . The panel  32  and the folded panels  14   c ,  26   a ,  26   b ,  28   a ,  28   b  may then be inserted into the box  10 , such that the panel  14   c  overlies the inwardly facing surface of the panel  14   a  and the panels  26   a ,  26   b  overlie the inwardly facing surfaces of the respective panels  16   b.    
     Thus, an apparatus in accordance with aspects of the present invention permits manual construction of boxes from blanks, such as the exemplary blank described above, inexpensively, accurately and quickly. 
     Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.